Grab_System_ Bauer GB34

Instr ns truct uctio ion n Manual nual GRAB SYS SYSTE TEM M

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BAUER Maschinen GmbH P.O. Box No. 12 60 • D-86522 Schrobenhausen, Germany Telephone +49 8252 97-0 • Fax +49 8252 97-1359

PREFACE

US UK

If you are not familiar with the language used in this operating manual you must not operate the equipment. If you cannot read this operating manual or understand its contents, you must contact the customer service servi ce department of BAUER Maschinen GmbH and order a manual in a language you understand. Telephone +49 8252 97-2586 Fax +49 8252 97-2587 E-Mail [email protected]

Ако не разбирате езика, използван използван в това Ръководство за експлоатация, не трябва да пускате пус кате машината/съоръжението машината/съоръжението в експлоатация. В такъв случай се свържете със сервиз на BAUER Maschinen GmbH и поръчайте разб ираем за Вас език. BG Ръководство за експлоатация на разбираем Телефон +49 8252 97-2586 Факс +49 8252 97-2587 E-Mail [email protected] 如果您无法理解该操作手册所使用语言，禁止运行该设备/机器。请联系 BAUER Maschinen GmbH 客户服务部，订购您所能够理解的语言版本的操作手册。

CN

CZ

电话传真电子邮件

+49 8252 97-2586 +49 8252 97-2587 [email protected]

Pokud nerozumíte jazyku tohoto návodu k obsluze, nesmíte přístroj přístr oj / zařízení uvést do provozu. V takovém případě kontaktujte zákaznický servis společnosti BAUER Maschinen GmbH a objednejte si návod k obsluze v jazyce, který je pro vás srozumitelný. srozumitelný. Telefon +49 8252 97-2586 Telefax +49 8252 97-2587 E-Mail [email protected]

GB 34 / 2010

I

DE

Sollten Sie die in dieser Betriebsanleitung verwendete Sprache nicht verstehen, darf das Gerät / die Anlage von Ihnen nicht in i n Betrieb genommen werden. Kontaktieren Sie bitte in i n so einem Fall den Kundendienst der BAUER Maschinen GmbH und bestellen Sie eine Betriebsanleitung in einer für Sie verständlichen Sprache. Telefon +49 8252 97-2586 Telefax +49 8252 97-2587 E-Mail [email protected]

DK

Hvis du ikke forstår sproget, der er brugt i denne betjeningsvejledning, betjeningsvejledning, må du ikke tage udstyret/anlægget i brug. Kontakt i dette tilfælde kundeservice hos BAUER Maschinen GmbH, og bestil en brugsanvisning br ugsanvisning på et sprog, som du forstår. Telefon +49 8252 97-2586 Fax +49 8252 97-2587 E-Mail [email protected]

ES

En caso de no comprender el idioma utilizado en el presente manual de usuario, no podrá poner en funcionamiento funcionamiento el aparato apar ato / equipo. En ese caso, póngase por favor en contacto con el servicio de atención al cliente de BAUER Maschinen GmbH y solicite un manual de instrucciones que esté en su idioma. Teléfono +49 8252 97-2586 Fax +49 8252 97-2587 E-Mail [email protected]

EE

Kui see kasutusjuhendis on keeles, mida te ei oska, on teile selle masina/seadme masina/seadme kasutamine keelatud. Palun võtke sellisel juhul ühendust BAUER Maschinen GmbH klienditeenindusega ja tellige endale kasutusjuhend, mis on teile arusaadavas keeles. Telefon Faks E-post

FI

+49 8252 97-2586 +49 8252 97-2587 [email protected]

Jos et ymmärrä tässä käyttöohjeessa käytettyä kieltä, et saa ottaa laitetta / laitteistoa käyttöön. Ota tässä tapauksessa yhteyttä BAUER Maschinen GmbH -yhtiön asiakaspalveluun ja tilaa sieltä sellainen käyttöohje, jonka kieltä ymmärrät. Puhelin +49 8252 97-2586 Faksi +49 8252 97-2587 Sähköposti [email protected]

GB 34 / 2010

II

FR

Si vous ne comprenez pas la langue l angue utilisée dans ce manuel d'instructions, vous ne devez pas mettre en service l'appareil/l'installation. Dans ce cas, veuillez contacter le service après -vente de BAUER Maschinen GmbH et commandez u manuel d'utilisation rédigé dans une langue compréhensibles compréhensibles pour vous. Téléphone +49 8252 97-2586 Télécopie +49 8252 97-2587 E-Mail [email protected]

GR

Εάν δεν καταλαβαίνετε τη γλώσσα που π ου χρησιμοποιείται χρησιμοποιείται στο παρόν εγχειρίδιο οδηγιών, δεν επιτρέπεται να τεθεί σε λειτουργία ο εξοπλισμός. Στην περίπτωση αυτήν επικοινωνήστε με το κέντρο σέρβις της BAUER Maschinen GmbH και παραγγείλετε ένα εγχειρίδιο οδηγιών σε μια γλώσσα που καταλαβαίνετε. Τηλέφωνο +49 8252 97-2586 Φαξ +49 8252 97-2587 E-Mail [email protected]

Ako jezik upotrijebljen u ovim uputama za uporabu ne razumijete, razumijete, uređaj / postrojenje ne smijete stavljati u pogon. U takvom slučaju stupite u kontakt k ontakt sa servisnom službom tvrtke BAUER Maschinen GmbH i naručite upute za HR uporabu na jeziku koji razumijete. Telefon +49 8252 97-2586 Telefaks +49 8252 97-2587 E-pošta [email protected]

HU

Amennyiben nem érti a jelen használati útmutató nyelvét, akkor nem helyezheti üzembe a készüléket / berendezést. Ezért ilyen esetben lépjen kapcsolatba a BAUER Maschinen GmbH ügyfélszolgálatával és rendelje meg a használati útmutatót olyan nyelven, amelyet megért. Telefon Fax E-Mail

IT

+49 8252 97-2586 +49 8252 97-2587 [email protected]

Se non si comprende la lingua utilizzata in queste istruzioni d'uso, non è consentito mettere in funzione l'apparecchio / l'impianto. l 'impianto. In questo caso, contattando il Servizio Assistenza BAUER Maschinen GmbH, è possibile ordinare le istruzioni d'uso in una lingua a scelta. Telefono +49 8252 97-2586 Telefax +49 8252 97-2587 E-Mail [email protected]

GB 34 / 2010

III

LU

Falls Dir d'Sprooch déi an dëser Betribsuleedung benotzt gëtt net verstitt, dann dierft Dir den Apparat / d'Anlag net a Betrib Betri b huelen. Kontaktéiert an esou engem Fall de Konnendéngscht vun der BAUER Maschinen GmbH a bestellt eng Betribsuleedung an enger Sprooch déi Dir verstitt. Telefon +49 8252 97-2586 Telefax +49 8252 97-2587 E-Mail [email protected]

LV

Ja jūs šajā lietošanas instrukcijā lietoto valodu nesaprotat, jūs nedrīkstat sākt šīs ierīces/iekārtas ekspluatāciju. Šajā gadījumā lūdzam jūs sazināties ar firmas BAUER Maschinen GmbH klientu apkalpošanas centru un pasūtīt lietošanas instrukciju, kas ir iespiesta jums saprotamā valodā. Tālrunis +49 8252 97-2586 Fakss +49 8252 97-2587 E-pasts [email protected]

MT

Jekk mintix familjari mal-lingwa użata f'dan il -manwal ta' tħaddim, ma għandekx tħaddem dan l -apparat. Jekk ma tistax taqra dan il-manwal ta' tis tax tifhem il-kontenut tieg ħu, għandek tħaddim jew inkella jekk ma tistax tikkuntattja lid-dipartiment tas-servizz tal-klijenti ta' t a' BAUER Maschinen GmbH u għandek tordna ma nwal f'lingwa li tifhem. Telefon Fax E-Mail

+49 8252 97-2586 +49 8252 97-2587 [email protected]

NL

Als u de taal t aal van deze gebruiksaanwijzing niet machtig bent, mag het apparaat / de installatie niet door u in gebruik genomen worden. Neemt Neemt u s.v.p. in dat geval contact op met de klantenservice van BAUER Maschinen GmbH en bestel daar een gebruiksaanwijzing in een voor u verstaanbare taal. Telefoon +49 8252 97-2586 Fax +49 8252 97-2587 E-Mail [email protected]

NO

Dersom du ikke frostår det språket som brukes i denne bruksanvisningen, må du ikke betjene apparatet/anlegget. Ta i så fall kontakt med kundeservice hos BAUER Maschinen GmbH og bestill en bruksanvisning på et språk du forstår. Telefon +49 8252 97-2586 Telefaks +49 8252 97-2587 E-post [email protected]

GB 34 / 2010

IV

PL

PT

Jeśli nie rozumieją Państwo języka, w którym który m napisana została instrukcja obsługi, to nie mogą Państwo uruchamiać urządzenia/instalacji. W takim s erwisem firmy BAUER Maschinen przypadku należy skontaktować się z serwisem GmbH i zamówić instrukcję instrukc ję w języku przez Państwa rozumianym. Telefon +49 8252 97-2586 Telefaks +49 8252 97-2587 E-Mail [email protected] Se não entender o idioma utilizado utili zado neste manual de instruções, não pode colocar a máquina/unidade em funcionamento. Neste caso, contacte o serviço de assistência da BAUER Maschinen GmbH e encomende um manual num idioma que entenda. Telefone Fax E-Mail

+49 8252 97-2586 +49 8252 97-2587 [email protected]

RO

Dacă nu înţelegeţi limba utilizată în acest ac est manual de utilizare, aparatul / instalaţia nu trebuie pusă în funcţiune. Vă rugăm să contactaţi în î n acest caz serviciul pentru clienţi al BAUER Maschinen GmbH şi să comandaţi un manual de utilizare în limba dumneavoastră. Telefon +49 8252 97-2586 Telefax +49 8252 97-2587 E-Mail [email protected]

RU

Если вы не понимаете язык, на котором написана данная инструкция по эксплуатации, ввод устройства / установки в эксплуатацию запрещается. В этом случае свяжитесь с отделом обслуживания компании BAUER Maschinen GmbH и закажите инструкцию по эксплуатации на языке, который вам понятен. Тел. +49 8252 97-2586 Факс +49 8252 97-2587 E-Mail [email protected]

SE

Förstår du inte språket i den här bruksanvisningen får du inte använda apparaten/anläggningen. Kontakta i så fall f all BAUER Maschinen GmbHs kundtjänst och beställ en bruksanvisning på ett språk du förstår. Telefon +49 8252 97-2586 Telefax +49 8252 97-2587 E-Mail [email protected]

GB 34 / 2010

V

SK

Ak by ste nerozum ner ozumeli eli jazyku, v ktorom je napísaný tento návod na obsluhu, nesmiete prístroj / zariadenie zari adenie uvádzať do prevádzky. V takomto prípade kontaktujte, prosím, zákaznícku službu firmy BAUER Maschinen GmbH a objednajte si návod na obsluhu v jazyku, ktorému ktorému rozumiete. Telefón +49 8252 97-2586 Fax +49 8252 97-2587 Email [email protected]

SI

Če jezika, uporabljenega v teh navodilih za uporabo, ne razumete, ne smete aparata / naprave poganjati. V takšnem primeru stopite v stik s servisno službo podjetja BAUER Maschinen GmbH in naročite navodila za uporabo v jeziku, ki ga razumete. Telefon +49 8252 97-2586 Telefaks +49 8252 97-2587 E-pošta [email protected]

TR

Bu kullanım kılavuzunda kullanılan dili anlayamadığınız taktirde, cihaz / sistem sizden geri alınmayacaktır. Bu gibi bir durumda, BAUER Maschienen GmbH ile temasa geçin ve sizin anlayabileceğiniz dilde bir kullanım kılavuzu sipariş edin. Telefon +49 8252 97-2586 Telefaks +49 8252 97-2587 E-Mail [email protected]

UA

Якщо ви не розумієте мову, якою написана ця інструкція з експлуатації, введення пристрою / установки в експлуатацію забороняється. У такому випадку зверніться до відділу обслуговування компанії BAUER Maschinen напис ану мовою, яка вам GmbH та замовте інструкцію з експлуатації, написану зрозуміла. Тел. +49 8252 97-2586 Факс +49 8252 97-2587 E-Mail [email protected]

GB 34 / 2010

VI

This Instruction Manual is written for use by operating and maintenance personnel. personnel. Before the first use of this equipment equipment PLEASE

Manual" l" and the First, take your time and read the " Instructio n Manua enclosed booklet entitled "Safety Information". These two documents shall always be kept at the equipment to be accessible accessible for review at any time. Instruct ion Manual" Manual" gives you a detailed description of the equipment, guidelines The " Instruct for transport and initial start-up as well as comprehensive instructions instructions for the operation of the equipment, equipment, trouble shooting tips and information related to maintenance.

Technical data, weights and measurements are accurate as of the day this Instruction Manual is printed. Due to the continuous technical advancements made, there may be minor deviations between the technical data, weights and measurements measurements contained in the Instruction Manual and the equipment as actually built and delivered. These minor deviations are, however, inconsequential and do not change in any material way nor do they invalidate the contents of this Instruction Manual. The equipment as delivered to you may have options that might not be pictured in the photographs or described in the text t ext contained in this Instruction Manual exactly as they appear on your equipment. This is i s due to the individualization of the equipment based on the wishes and orders of the individual customers and no claims of any kind shall be based on such deviations. The equipment shall only be used for f or the authorized purposes listed in the t he Instruction Manual. The manufacturer shall have no liability li ability whatsoever for the improper or unauthorized use of the equipment, operator errors err ors or mistakes or improper respectively insufficient maintenance. Safety Inform Inform ation" contains the directions and related The enclosed booklet entitled " Safety Safety Information" must be information for the safe use of the equipment. The " Safety followed at all times.

Also, pay attention to and follow all the instructions contained in the attached documents (Appendix ___) of the component manufacturers.

GB 34 / 2010

VII

Instruct ion Manual" Manual" was written and published by The " Instruct BAUER Maschinen GmbH • Postfach 12 60 • D-86522 Schrobenhausen, Schrobenhausen, Germany

Copyright 2010, BAUER Maschinen GmbH The information contained in this manual and/or any of its parts, sub-parts or chapters, is the intellectual property pr operty of BAUER Maschinen GmbH and is protected by domestic and international copyright and other intellectual property laws. The information contained herein is provided for the operation, service, maintenance and troubleshooting of the equipment described herein. Any duplication, reproduction, translation, micro filming, storage in electronic or magnetic form, processing as electronically or magnetically stored media, copying or dissemination of these materials and/or the information contained herein, or any part thereof, except for the internal use of BAUER Maschinen GmbH or its authorized external suppliers, consultants or agents, without the prior written consent of BAUER Maschinen GmbH, is hereby strictly prohibited. All rights and remedies are hereby expressly reserved. Violators will be prosecuted. BAUER Maschinen GmbH shall have no liability whatsoever arising ari sing from or connected in any way to the so prohibited use of the information contained herein by any person or entity, wherever located. BAUER Maschinen GmbH reserves the right to change, delete or otherwise alter or modify any information contained herein, or the equipment itself, at any time and for any reason, with or without notice.

GB 34 / 2010

VIII

TABL TAB L E OF CONTEN CONTENTS TS PREFACE .................................................................... ......................................................................................................... ......................................................................... ...................................... .. I TABL E OF CONTENTS CONTENTS...................................................................... ........................................................................................................... ................................................... .............. IX ABOUT THE MANUAL .............. ....... .............. .............. ............... ............... .............. .............. .............. ............... ............... .............. .............. .............. .............. ............... ............. ..... XIII NAMEPLATES ......................................................................... .............................................................................................................. ............................................................ .......................XV AFTER SAL ES SERVICE............... ........ .............. .............. .............. ............... ............... .............. .............. .............. .............. ............... ............... .............. .............. .............. ......... XVI WARRANTY TERMS TERMS........................................................................................ .......................................................................................................................... ..................................XVII WARRANTY WARRANTY CLAIM CLAIM................................................................................................ ............................................................................................................................. ............................. XIX PERSONALANFORDERUNG / STAFF REQUEST......................................................................... ............................................................................... ...... XX REGISTRIERUNG BETREIBER UND GERÄT/ OWNER AND EQUIPMENT REGISTRATION ............ XXI 1 1.1 1.1.1 1.2 1.2.1 1.2.1.1 1.2.1.2

DESCRIPTION DESCRIPTION ...................................................... ........................................................................................... ............................................................1 .......................1 - 1 INTENDED INTENDED AND AUTHORIZE AUTHORIZED D USE .............................................. ................................................................................1 ..................................1 - 1 Änderungsantrag / Change request ..................................................................... ....................................................................................1 ...............1 - 3 COMPONEN COMPONENTS TS ............................................................................. ................................................................................................................. ....................................1 1-4 Basic Basic Rig / Grab Equipment Equipment..................................................................... ...............................................................................................1 ..........................1 - 4 Componen Components ts Overview Overview........................................................................ .......................................................................................................1 ...............................1 - 4 Componen Components ts Descriptio Description n .............................................................. ................................................................................................... ......................................1 .1 - 5

2 2.1 2.2 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.5 2.5.1 2.5.2 2.5.2.1 2.6 2.7

SAFETY ................................................................. ...................................................................................................... ...........................................................2 ......................2 - 1 GENERAL SAFETY REQUIREMENTS ..............................................................................2 - 1 EQUIPMENT EQUIPMENT SAFETY SAFETY .......................................... .............................................................................. .............................................................2 .........................2 - 1 MAJOR HAZARDS HAZARDS ........................................................... ................................................................................................ .................................................2 ............2 - 1 SAFETY SAFETY DEVICES DEVICES ..................................................... .......................................................................................... .......................................................2 ..................2 - 2 Emergen Emergency cy Stop .................................................... ........................................................................................ ............................................................2 ........................2 - 2 Pilot Control Control Safety Safety Stick..................................................................... ....................................................................................................2 ...............................2 - 2 Fire Extinguis Extinguisher her...................................................................... .......................................................................................................... ..........................................2 ......2 - 2 Medical Medical Box........................................................................ ............................................................................................................ ...............................................2 ...........2 - 3 Emergen Emergency cy Exit ............................................................................................... .................................................................................................................2 ..................2 - 3 Limit Switches Switches.................................................................... ......................................................................................................... ................................................2 ...........2 - 4 STABILITY STABILITY ................................................................................................. ........................................................................................................................2 .......................2 - 5 Stability Stability Guidelin Guidelines es ................................................................................................ ............................................................................................................2 ............2 - 5 Stability Stability With W ith Grab Equipment Equipment ......................................................................................... ...........................................................................................2 ..2 - 6 Travellin Travelling g With Equipme Equipment nt ............................................................................................... .................................................................................................2 ..2 - 7 RISK OF ROPE BREAKING WHEN ADJUSTING BOOM ..................................................2 - 8 PERMISSIBL PERMISSIBLE E WIND SPEED SPEED........................................................................ ............................................................................................2 ....................2 - 9

3 3.1 3.1.1 3.2 3.3

TECHNICAL TECHNICAL DATA ............................................................................. ...........................................................................................................3 ..............................3 - 1 DIMENSIONS DIMENSIONS ...................................... .......................................................................... ......................................................................... ..........................................3 .....3 - 1 With Grab Equipme Equipment nt (MDSG) (MDSG)...................................................................... ...........................................................................................3 .....................3 - 1 EQUIPMENT EQUIPMENT DATA...................................................................... ........................................................................................................... .....................................3 3-2 GRAB OPERATING OPERATING RANGE RANGE ........................................................................ .............................................................................................3 .....................3 - 3

GB 34 / 2010

IX

3.3.1 3.4 3.4.1 3.5 3.6 3.7

MDSG ....................................................................................... ........................................................................................................................... ........................................3 ....3 - 3 ROPE SPECIFICAT SPECIFICATIONS IONS ................................................ .................................................................................... ..................................................3 ..............3 - 4 Main Rope Rope .............................................................. ................................................................................................... ...........................................................3 ......................3 - 4 NOISE EMISSION EMISSION .......................................... ............................................................................... ...................................................................3 ..............................3 - 5 TEMPERATURE TEMPERATURE CONDITION CONDITIONS S .............................................................. .........................................................................................3 ...........................3 - 5 EXPOSURE EXPOSURE TO VIBRATION VIBRATIONS S...................................................................... ...........................................................................................3 .....................3 - 5

4 4.1 4.2 4.3 4.4

CONTROLS CONTROLS AND INDICATORS INDICATORS ........................................................................ .......................................................................................4 ...............4 - 1 OPERATOR'S OPERATOR'S CAB .................................................................................................... ...........................................................................................................4 .......4 - 1 CONTROL CONTROL PANEL .............................................................................. ............................................................................................................4 ..............................4 - 2 CONTROL CONTROL PANEL 2............................................................................ 2..........................................................................................................4 ..............................4 - 3 MONITOR MONITOR UNIT ............................................................................ ................................................................................................................ ....................................4 4-4

5 5.1 5.2 5.2.1 5.2.2 5.3 5.3.1 5.3.2 5.4 5.4.1 5.4.2 5.4.2.1 5.5 5.5.1 5.5.2 5.6 5.6.1 5.6.1.1 5.6.2 5.7 5.8 5.8.1 5.8.2 5.8.2.1 5.8.2.2 5.8.2.3 5.8.3 5.8.3.1 5.8.3.2

OPERATION OPERATION ........................................................................................ .....................................................................................................................5 .............................5 - 1 TRAVELLIN TRAVELLING G AND STEERING STEERING ........................................................ .........................................................................................5 .................................5 - 1 UPPER CARRIAGE CARRIAGE SWING SWING .............................................................. ..............................................................................................5 ................................5 - 2 Swing Swing Brake Brake ............................................................................................... ......................................................................................................................5 .......................5 - 2 Swing Swing Control Control .......................................................................... ............................................................................................................... ..........................................5 .....5 - 3 ADJUSTING THE OPERATING RADIUS ...........................................................................5 - 4 Increasing / Reducing the Operating Radius ......................................................................5 - 4 Raising / Lowering the Boom in Rigging Mode ...................................................................5 - 4 TRAVELLIN TRAVELLING G WITH W ITH THE RIG .......................................................... ...........................................................................................5 .................................5 - 5 Travelling on Level Ground ................................................................................................5 - 5 Travelling Up or Down Gradients .......................................................................................5 - 5 With Raised Mast and Without Work Equipment ................................................................5 - 5 OPERATING OPERATING THE WINCH....................................................................... ................................................................................................. ..........................5 5-6 Winding In and Unwinding the Main Winch Rope ...............................................................5 - 6 Operating the Main Winch in Rigging Rigging Mode.............. ...... ............... .............. .............. .............. ............... ............... .............. .............. ........5 .5 - 6 OPERATING OPERATING MODES MODES......................................................................... ........................................................................................................5 ...............................5 - 7 Rope Rope Grab Mode ..................................................................... ......................................................................................................... ..........................................5 ......5 - 7 Free-Fa Free-Fallll Operatio Operation n ............................................... .................................................................................... .............................................................5 ........................5 - 8 Hydraulic Hydraulic Grab Grab Mode Mode .............................................................. .................................................................................................. ...........................................5 .......5 - 9 OPERATING THE AUTOMATIC ROPE TENSIONING FACILITY ....................................5 - 10 OPERATING SPECIAL GRAB FUNCTIONS ....................................................................5 - 11 Moveable Moveable Suspen Suspension sion * ...................................................................... ...................................................................................................5 .............................5 - 11 Flap Control Control........................................................................ ............................................................................................................ .............................................5 .........5 - 12 Y Axis Axis Flap Control Control ........................................................... ................................................................................................ ...............................................5 ..........5 - 12 X Axis Flap Control Control *..................................................................... ........................................................................................................5 ...................................5 - 13 Retracting Retracting All Flaps Flaps........................................................................ ..........................................................................................................5 ..................................5 - 13 Turning Turning Device Device ........................................................................ ............................................................................................................. ........................................5 ...5 - 14 Rotating Rotating the Grab Manually......... Manually............................................. ......................................................................... .................................................5 ............5 - 14 Rotating the Grab in Automatic Mode ...............................................................................5 - 15

6 6.1 6.1.1 6.1.2 6.1.3 6.1.3.1 6.1.3.2 6.1.4 6.1.4.1 6.1.4.2 6.1.4.3

START-UP / SHUT-DOWN SHUT-DOWN...................................................................... ................................................................................................6 ..........................6 - 1 START-UP START-UP ......................................................................... ............................................................................................................. ...............................................6 ...........6 - 1 Initial Initial Start-Up Start-Up.................................................................... ........................................................................................................ ................................................6 ............6 - 1 Visual Inspection Before Start-Up ......................................................................................6 - 1 Daily Start-Up Start-Up .................................................................... ........................................................................................................ ................................................6 ............6 - 2 Starting Starting the Equipmen Equipmentt ....................................................................... ......................................................................................................6 ...............................6 - 2 Selecting Selecting an Operatin Operating g Mode......................................................................... .............................................................................................6 ....................6 - 3 Safety Tests before Starting Work ......................................................................................6 - 4 Checking the Emergency Emergency STOP STOP............... ....... ............... .............. .............. .............. ............... ............... .............. .............. .............. .............. ..........6 ...6 - 4 Checking the Pilot Control Safety Stick ..............................................................................6 - 4 Checking the Hoist Limit Switch (HS 1) ..............................................................................6 - 4

GB 34 / 2010

X

6.1.4.4 6.2 6.2.1 6.2.2

Checking the Winch Free-Fall Function ..............................................................................6 - 5 SHUT-DO SHUT-DOWN WN .................................................................... ........................................................................................................ ................................................6 ............6 - 6 Daily Shut-Dow Shut-Down n ...................................................................... .......................................................................................................... ..........................................6 ......6 - 6 Shutting Down for a Longer Period.....................................................................................6 - 6

7 7.1 7.2 7.3 7.4 7.5 7.5.1 7.5.2 7.6 7.7 7.7.1 7.7.1.1 7.7.1.2 7.8 7.9 7.10 7.10.1 7.11 7.12 7.13 7.13.1 7.14 7.14.1 7.14.2 7.15 7.15.1 7.15.2 7.16 7.17

RIGGING RIGGING / DE-RIGGING DE-RIGGING......................................................................... ...................................................................................................7 ..........................7 - 1 GUIDELINES FOR RIGGING AND DE-RIGGING ..............................................................7 - 1 WAX REMOVAL REMOVAL...................................................................... .......................................................................................................... ..........................................7 ......7 - 2 EXTENDING EXTENDING THE CRAWLERS CRAWLERS.................................................................... .........................................................................................7 .....................7 - 3 MOUNTING THE COUNTERWEIGHT ...............................................................................7 - 4 ASSEMBLIN ASSEMBLING G THE BOOM...................................................................... ................................................................................................7 ..........................7 - 5 Mounting Mounting the Boom Boom Top...................................................................... .....................................................................................................7 ...............................7 - 5 Assemblin Assembling g the Boom Boom Sections Sections..................................................................... ..........................................................................................7 .....................7 - 6 ASSEMBLY INSTRUCTIONS: SPRING ACCUMULATORS ...............................................7 - 8 ASSEMBLING THE MDSG SYSTEM ...............................................................................7 - 11 Installing the MDSG System on the Base Machine ...........................................................7 - 11 Assembly: Assembly: Version Version 1 ..................................................................... ........................................................................................................7 ...................................7 - 12 Assembly: Assembly: Version Version 2 ..................................................................... ........................................................................................................7 ...................................7 - 17 INSTALLIN INSTALLING G THE CABLE CABLE DRUM....................................................................... ....................................................................................7 .............7 - 20 HYDRAULIC HYDRAULIC CONNECTI CONNECTIONS ONS ............................................................................. .........................................................................................7 ............7 - 21 INSTALLIN INSTALLING G THE MAIN ROPE .................................................................... .......................................................................................7 ...................7 - 24 Reeving Reeving the Main Main Rope.......... Rope.............................................. ......................................................................... ......................................................7 .................7 - 24 INSTALLIN INSTALLING G THE ROPE SWIVEL...................................................................... ...................................................................................7 .............7 - 26 INSTALLIN INSTALLING G THE GRAB......................................................................... ................................................................................................. ........................7 7 - 27 RAISING RAISING THE BOOM BOOM ................................................. ..................................................................................... .....................................................7 .................7 - 28 Attaching Attaching Retainin Retaining g Clamps Clamps ......................................................... ............................................................................................. ....................................7 7 - 28 DISASSEMBLING THE EQUIPMENT ..............................................................................7 - 29 Disassemb Disassembling ling the Grab...................................................................... ...................................................................................................7 .............................7 - 29 Disassembling MDSG Equipment ....................................................................................7 - 29 LOWERING LOWERING THE BOOM ................................................................................................. .................................................................................................7 7 - 30 Removing Removing Retaining Retaining Clamps Clamps......................................................................... ............................................................................................7 ...................7 - 30 Lowering Lowering the Boom Boom ..................................................... .......................................................................................... .....................................................7 ................7 - 30 REMOVING THE COUNTERWEIGHT .............................................................................7 - 31 RETRACTING RETRACTING THE CRAWLERS CRAWLERS........................................................................ .....................................................................................7 .............7 - 32

8 8.1 8.2 8.3 8.4 8.5 8.6

TRANSPORT TRANSPORT ............................................................................................. ....................................................................................................................8 .......................8 - 1 SAFETY GUIDELINES FOR TRANSPORT.............. ...... ............... .............. .............. .............. ............... ............... .............. .............. ........8 .8 - 1 MEASURES TO TAKE FOR TRANSPORT ........................................................................8 - 2 DRIVING ON / OFF A LOW LOADER ................................................................................8 - 3 LIFTING LIFTING POINTS POINTS..................................................................... ......................................................................................................... ..........................................8 ......8 - 4 TYING DOWN DOWN ..................................................................................... ...................................................................................................................8 ..............................8 - 5 TRANSPORT TRANSPORT DATA ............................................................... .................................................................................................... ...........................................8 ......8 - 6

9 9.1 9.2 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6

MAINTENANCE MAINTENANCE .............................................................................................. ................................................................................................................9 ..................9 - 1 SAFETY GUIDELINES FOR MAINTENANCE ....................................................................9 - 1 MAINTENAN MAINTENANCE CE INTERVALS INTERVALS .......................................................................................... ............................................................................................9 ..9 - 1 MAINTENAN MAINTENANCE CE PLAN ................................................................................... ......................................................................................................9 ...................9 - 2 Entire Equipment Equipment ..................................................................... ......................................................................................................... ..........................................9 ......9 - 2 Attachments Attachments ....................................................................... ........................................................................................................... ...............................................9 ...........9 - 3 Work Equipme Equipment nt ............................................................................ ................................................................................................................ ....................................9 9-6 Upper Upper Carriage Carriage ................................................ ..................................................................................... ..................................................................9 .............................9 - 7 Underca Undercarriag rriage e............................................................................................. ....................................................................................................................9 .......................9 - 8 Optional Optional Equipme Equipment nt .................................................................................................... ...........................................................................................................9 .......9 - 9

GB 34 / 2010

XI

9.4 9.5 9.6 9.6.1 9.6.2 9.6.3 9.6.3.1 9.7 9.7.1 9.7.2 9.8 9.8.1 9.8.2 9.8.3 9.8.4 9.8.4.1 9.8.4.2 9.9 9.10 9.10.1 9.10.2 9.10.2.1 9.10.2.2 9.10.3 9.10.4 9.10.4.1 9.10.4.2 9.11

MAINTENANCE DURING LONGER LONGER PERIODS OF STANDSTILL STANDSTILL .............. ....... .............. ............... ............... .......9 9 - 10 LUBRICATIO LUBRICATION N PLAN ........................................................................................... ......................................................................................................9 ...........9 - 11 HYDRAULIC HYDRAULIC SYSTEM SYSTEM ....................................................................... ....................................................................................................9 .............................9 - 12 Hose Hose Assemblies Assemblies ................................................... ....................................................................................... ..........................................................9 ......................9 - 12 Hydraulic Hydraulic Cylinders Cylinders....................................................................... ..........................................................................................................9 ...................................9 - 13 Filter Replace Replacement ment........................................................................ ...........................................................................................................9 ...................................9 - 14 Replacing Replacing the Line Filters Filters......................................................................... ................................................................................................. ........................9 9 - 14 WINCHES WINCHES .................................................................... ........................................................................................................ ...................................................9 ...............9 - 16 Checking Checking the Oil Level Level ............................................................ ................................................................................................ .........................................9 .....9 - 16 Changin Changing g the Gear Oil .............................................................................. .....................................................................................................9 .......................9 - 17 WIRE ROPE ACCESSOR ACCESSORIES IES ......................................... .............................................................................. .................................................9 ............9 - 18 Rope Rope Swivel Swivel ....................................................................... ........................................................................................................... .............................................9 .........9 - 18 Rope Rope Hold-Dow Hold-Down n Rollers Rollers..................................................................... ..................................................................................................9 .............................9 - 18 Rope Fasteners, Thimbles and Sockets ...........................................................................9 - 19 Rope Rope Sheaves Sheaves ............................................................................... .................................................................................................................9 ..................................9 - 20 Greasing Greasing Rope Sheaves Sheaves ..................................................................... ..................................................................................................9 .............................9 - 20 Checking Checking Rope Rope Sheaves.................... Sheaves........................................................ ......................................................................... ..........................................9 .....9 - 21 MDSG LUBRICATIO LUBRICATION N PLAN........................................................................ ...........................................................................................9 ...................9 - 22 CRAWLER CRAWLER TRACK ASSEMBLIES ASSEMBLIES...................................................................... ...................................................................................9 .............9 - 23 Visual Visual Inspection Inspection................................. ...................................................................... ......................................................................... ........................................9 ....9 - 23 Crawler Crawler Tracks Tracks ........................................................................ ............................................................................................................. ........................................9 ...9 - 24 Checking Checking the Track Track Tension.......... Tension.............................................. ......................................................................... ...............................................9 ..........9 - 24 Adjusting the Track Tension .............................................................................................9 - 24 Checking Checking the Mounting Mounting Bolts.................................................................... ............................................................................................9 ........................9 - 26 Travel Travel Gear .............................................................................. .................................................................................................................. .......................................9 ...9 - 27 Checking Checking the Oil Level Level ........................................................... ................................................................................................ ..........................................9 .....9 - 27 Changin Changing g the Oil...................................................................... .......................................................................................................... ........................................9 ....9 - 27 BOLTED BOLTED CONNECTI CONNECTIONS ONS ............................................................................................... ...............................................................................................9 9 - 28

10 10.1 10.1.1 10.1.2 10.1.3 10.1.3.1 10.1.3.2 10.1.3.3 10.1.3.4 10.1.3.5 10.1.3.6 10.1.3.7 10.2 10.2.1 10.3 10.4

LUBRICANTS / TABLES TABL ES ........................................................................ ................................................................................................1 ........................10 0- 1 LUBRICANTS LUBRICANTS ............................................ ................................................................................ ......................................................................1 ..................................10 0-1 General General ......................................................................... ............................................................................................................. ..................................................10 ..............10 - 1 Lubrican Lubricantt Table........................................................................ ............................................................................................................ ........................................10 ....10 - 2 Lubrican Lubricantt Guide ....................................................................... ........................................................................................................... ........................................10 ....10 - 4 Gear Oils, Petroleu Petroleum m - CLP.................................. CLP...................................................................... ............................................................1 ........................10 0-4 Gear Oils, Petroleum – API ..............................................................................................10 - 5 Gear Oils, Synthetic – CLP PG ........................................................................................10 - 6 Hydraulic Oils, Petroleum – HVLP(D) ...............................................................................10 - 7 Engine Oils, Petroleum – API CI-4 ...................................................................................10 - 8 Gear Oils, Synthetic – CLP HC ........................................................................................10 - 9 Greases Greases,, Petroleu Petroleum m – KP2N KP2N ...................................................................................... .......................................................................................... ....10 10 - 10 OPERATING OPERATING FLUIDS FLUIDS ......................................................................... .................................................................................................... ...........................10 - 11 Coolants Coolants ........................................................................ ............................................................................................................ ................................................ ............10 - 11 BOLT TORQUE TORQUE VALUES VALUES .............................................................................................. ..............................................................................................10 - 12 CONVERSION CONVERSION TABLE ....................................................................... .................................................................................................. ...........................10 - 14

GB 34 / 2010

XII

ABOUT AB OUT THE MANUA MA NUAL L THIS MANUAL IS MADE FOR Equipment model: mod el: Serial number: num ber: Constructi Constr ucti on year: year: Date of 1st operatio operat ion: n:

Grab System / GB 034 034 0583 0583 / 0119 0119 2010 2010 .. / .. / .... ....

THIS THIS MANUAL WAS PUBL ISHED ISHED IN 04.2010

THE CHAPTERS OF OF THIS MANUAL 1 2 3 4 5 6 7 8 9 10

DESCRIPTION SAFETY TECHNICAL TECHNICAL DATA CONTROLS AND INDICATORS INDICAT ORS OPERATION START-UP / SHUT-DOWN RIGGING / DERIGGING TRANSPORT MAINTENANCE LUBRICANTS LUB RICANTS / TAB TABLES LES

APPENDIX

G:\...\0583_Grab_System_en_0000661694.docx

GB 34 / 2010

XIII

SYMBOLS USED IN THIS THIS MANUAL DANGER! "Danger!" is used to identify an immediate immedi ate hazard hazard . Serious Serious i njury or loss of life will result if the instructions i nstructions given in the manual are ignored or incorrectly followed.

WARNING! "Warning!" is used to identify a potential pot ential hazard. hazard. Serious Serious i njury or loss of life can result if the instructions given in the manual are ignored or not correctly followed.

CAUTION

NOTE

GB 34 / 2010

"Caution" is used to identify a hazard that can result in moderate injury and / or damage to the equipment if the instructions given in the manual are ignored or not correctly followed.

"Note" is used to highlight an operation, assembly or maintenance procedure. In general, observance of the information here will facilitate the work.

XIV

NAMEPLATES Nameplates Nameplates on the th e equipm ent Component

Location

Nameplate

Total equipment

Bauer Maschinen GmbH D - 86522 Schrobenhausen Made in Germany

nächstePrüfung

Gerätetyp type Baujahr year of manufacture

2 1 2 3 1

1 1 0 1

9

2001

4

5

8 7 6

Sachkundigenprüfung expert test

CE - Zeichen CE sign

Bau - Nr. serial No Rückzugkraft pulling force max. Druck max. pressure Gesamtgewicht total weight Motorleistung engine power

Trägergerät base carrier Inv. - Nr. Inv. No Vorschubkraft kN pushingpower Betriebsdruck bar workingpressure Arbe Arbeitspa itspannung kg working voltage Frequenz kW frequency

kN bar V Hz

B0000551.wmf BK786502.wmf

GB 34 / 2010

XV

AFTER AF TER SAL SA L ES SERVICE How to r each each th e After Sales Sales Serv Service ice

Fax

+ 49 8252 97-2586 + 49 8252 97-2587

E-mail

[email protected]

Phone

NOTE

Whenever you consult the After Sales Service, please give the following information so that your inquiry can be dealt with accurately and more quickly:

Equipment description – Name of model: – Serial number: – Operating hours: Description of damage – Date (DD.MM.YY): – Cause of damage (if known): – Course of events leading leading to damage: For possible check-backs – Contact person; Telephone / Fax: Description of site – Name of site: – Address (post code, town, town, street): – Route description for a mechanic mechanic (as necessary):

GB 34 / 2010

XVI

WARRANTY TERMS If a warranty agreement was concluded concluded with the client, the following terms shall apply to warranty procedures: Warranty Warranty p eriod:

The contractual agreement is principally principally decisive for the warranty period; if no agreement on the warranty period was concluded, the warranty shall be valid for 12 months from the time of commissioning.

Commencement:

The warranty officially comes into effect when the equipment is put into initial operation at the Client's, a process which must be recorded in the "Commissioning "Commissioning Certificate" and verified by the signatures of both the Client and a representative of BAUER. In any event, the warranty shall come into effect no later than 1 week after delivery.

Warranty Warranty terms and conditions:

- Original BAUER spare spare parts must be used throughout throughout the warranty period. - Components and operating operating systems must not be dismantled dismantled or repaired at any time during the warranty period without proper authorisation. - Any faults must be notified to BAUER in in writing on the appropriate " Warranty Warranty Claim" Claim" form within 24 hours of their occurrence. - The Client or Operator of the BAUER equipment equipment agrees to carry out all services throughout the warranty period within the specified service intervals in full compliance with the instruction manual. - Any work (servicing, repairs, repairs, etc.) carried out on the equipment equipment must be recorded in the Maintenance and Repair Log provided for this purpose with each item of equipment.

Warranty Warranty exclusio ns:

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

GB 34 / 2010

XVII

A) Liabi Li abi lilitities es and an d Respo Res pons ns ibil ib il it ies of BA BAUER UER

– BAUER will supply supply spare parts required required for carrying carrying out repairs to BAUER BAUER equipment equipment under warranty to the Client. – Spare parts will be delivered c.i.f. c.i.f. (cost, insurance, freight) to the Client. – If necessary, BAUER will will also provide provide personnel personnel for carrying our repairs repairs under warranty. 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, Schrobenhausen, Germany. Transport costs for redeliveries will be paid by BAUER Maschinen GmbH (after sales service).

NOTE

– Redeliveries / deadlines deadlines Concerning requested redeliveries, the following deadlines are valid from the date of arrival of the new parts on the jobsite in the assignm a ssignment ent country until arrival of the damaged parts in Schrobenhausen. Schrobenhausen. – Redeliveries Redeliveries via air freight: freight: – Redeliveries via via sea freight:

4 weeks 4 months

If the damaged parts, which are redelivered via sea freight, are not redelivered in time due to the jobsite situation, situation, the after sales service has to be informed correspondingly, correspondingly, at the latest 6 weeks before expiry of the deadline. Concerning redeliveries redeliveries via air a ir freight, an extension of the deadline is principally not possible. In case requested redeliveries are not returned within the agreed time period, the corresponding corresponding open amounts according to the sales invoice have to be paid by the respective customer. B) Liabilities and Responsib Responsib ilit ies of the Client Client

– Any customs duties duties payable in the country of destination destination for a consignment consignment of spare parts supplied under warranty shall be carried by the Client. – Local transport to a final destination destination (construction site) in connection connection with a warranty claim shall also be the responsibility of the client. – Full and meticulous meticulous compliance compliance with all operating operating instructions and observance observance of proper operating procedures for all equipment. – Full compliance compliance with the specified specified and necessary necessary service schedule. schedule. – Entering and maintaining maintaining full and comprehensive comprehensive records in the Maintenance Maintenance and Repair Repair Log.

GB 34 / 2010

XVIII

To:

BAUER Maschinen GmbH After Sales Service Department P.O. Box 12 60 86522 Schrobenhausen, Germany Phone +49 8252 97-2586 Fax +49 8252 97-2587

From (Customer, Agent): Phone:

Fax:

Total number of pages of claim:

WARRANTY CLAIM 1. Product specifications

Serial Equipment: number: Current location of the t he equipment, postal address: Date of commissioning:

Constr. year:

Operating hours:

Date of damage:

2. Descrip tion of damage

Please describe damaged parts and state their material number: Descript Descript ion Material Material no.

Serial Serial number

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

3. Delivery Delivery of n ew parts parts and repair

Replacement of damaged parts from customer's cu stomer'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 Replacem ent work by customer, custome r, agent? Yes No Estimated Estim ated working time (hrs): Estimated additional additional costs:

Date

Name of claim ant (please print)

Signature

Company

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

3 0 0 2 / 1 0 2 . 5 9 3 . 0 1 9

Subject to warranty? If yes, give order number: Further reports: Further actions: Return of damaged parts by: Estimated working time (hrs):

Yes No If no, give reasons:

(Signed by authorised BAUER employee)

An: BAUER Maschinen GmbH

Abteilung Kundendiens K undendienstt Postfach 12 60 D-86522 Schrobenhausen Tel. +49 8252 97-2586 Fax +49 8252 97-2587 E-Mail [email protected]

PERSONALANFORDERUNG / STAFF REQUEST REQUEST Von Firma / Company:

Besteller / Ordered by:

Tel.: Fax:

Bestell-Nr. / Order no.:

E-Mail:

Gerät /

Ausrüstung /

Equipment:

Attachment:

Betriebsstd. /

Bau-Nr. / Serial no.:

Working hours:

Standort des Geräts / Location of machine:

Ansprechpartner Baustelle / Contact person jobsite:

Baustellentelefon / Jobsite phone no.:

Zielflughafen / Airport of destination: destination: Datum des gewünschten Einsatzes / Date of requested assignment: Gewünschtes Personal / Requested staff:

Mechaniker mechanic

Elektriker electrician

Einweiser operator

Voraussichtliche Dauer / Estimated Estimated duration: Auszuführende Arbeiten / Works to be carried out:

Besonderheiten / Special requirements:

Ersatzteile / Spare parts:

Kommunikation auf der Baustelle / Communication Communication on jobsite: deutsch/German

englisch/ English

Datum / Date: BAUER Maschinen GmbH • D-86529 Schrobenhausen

Landessprache/ Language of country

Unterschrift Unterschrift / Signature: •

Tel. +49 82 52/97-0

sra

910.097.1+2BMA

08/2008

An/ To:

BAUER Maschinen GmbH Abteilung Kundendienst/ After Sales Service Service Depar Departmen tmentt Postfach/P.O. Box 12 60

86522 Schrobenhausen, Germany Phone: +49 8252 97-2586 Fax: +49 8252 97-2587 E-mail: [email protected]

REGISTRIERUNG REGISTRIERUNG BETREIBER UND GERÄT/ GERÄ T/ OWNER AND EQUIPMENT REGISTRATION Wir möch ten dem Betreiber jederzeit jederzeit eine optimale Dienstleistung Dienstleistung bezüglich bezüglich Kundeninform ationen ationen bieten können. Wir bit ten deshalb jeden jeden neuen Betreiber, sich und sein Gerät Gerät über di eses eses Formul ar bei bei der BAUER Maschinen GmbH registrieren zu lassen./ We would l ike to off er the equipment equipment owner an optimum servic e as as regards regards cu stomer information at all all times. For this r eason, eason, we would ask each new owner to register hi mself and his equipm ent with BA UER UER Maschin Maschin en GmbH by fill ing out t his for m.

1. Gerätedaten/Equipment Data

Gerät/

Baunummer/

Betriebsstunden/

Equipment:

Serial number:

No. of operating hours:

2. Betreiberdaten/Owner Information Current ow ner of the equipment, including address: Aktu Ak tu eller B etreiber etr eiber d es Gerätes mit m it Ansc An schr hrifift/ t/ Current

Firma/Company: Abteilung/Department : Ansprechpartner/Contact person: Postfach/P.O. Box: Straße/Street: Land/ Country: Tel./Tel.: Fax/Fax: E-Mail/E-mail:

Datum/ Date

Name des Aus stellers (in Blockbuchstaben)/ Blockbuchstaben)/

Unterschrift/

Firma/

Signature

Company

Name of i ssuer (in capital letters)

BAUER Maschinen GmbH • 86522 Schrobenhausen

•

Tel. +49 8252 97-0

shj

910.847.1+zhBMA

11/2009

DESCRIPTION

1

DESCRIPTION

1.1

INTENDED A ND AUTHORIZED USE

The equipment shall only be used for f or the following operations: Operation Grabbing work with hydraulic grab and mechanical hose drum system Grab applications with hydraulic grab and turning device

Abbreviation

Authorized use?

MDSG

yes

TG

yes

Authorized use means use in strict compliance with and strict adherence to all directives, mandates, precautions and prohibitions contained in this Instruction Manual as well as in all additional manuals and documents supplied herewith. Everything contained in the Instruction Manual refers to and applies only to the t he equipment as first delivered to the original purchaser including all original attachments attachments and factory installed options as of the day of delivery. Any modification of the equipment or its attachments or factory installed i nstalled options made after delivery might render r ender the equipment unsafe and therefore invalidates this equipment shall no t be used after any any such mo difi cations Instruction Manual. The equipment are made made unless s uch use us e aft after er modif modif ication has been been approved approved in writ ing by BAUER Maschi Maschi nen GmbH as as set f ort h below. The manufacturer disclaims any liability of any kind arising from or connected with the so prohibited and unauthorized use of the equipment equipment in any way unless such use after modifi mod ifi cation has been appr approved oved in wri ting tin g by BAUER Maschi Maschi nen GmbH. GmbH.

GB 34 / 2010

1-1

DESCRIPTION

After modification of the equipment, the original attachments or factory installed options as of the day of delivery, the equipment is not authorized for any use whatsoever and wherever unless or until an authorization is first given by BAUER Maschinen GmbH in writing. To obtain such an authorization, a Change Request as shown below must be submitted to BAUER Maschinen GmbH. The authorization to use the equipment after any modification of the equipment, the original attachments or factory installed options can only be given by BAUER Maschinen GmbH after submission and review of a properly completed Change Request. No other person, entity or organization, including but not limited any government entity located anywhere, shall have the right ri ght to give such an authorization. Neither any agents, distributors, importers, dealers or subsidiaries of BAUER Maschinen GmbH shall have the right to or are able to give such a valid authorization. Only the corporate headquarters of BAUER Maschinen GmbH can issue a valid authorization after submission of a properly completed Change Request. The equipment described in this Instruction Manual is only intended for and therefore shall only be used in the country for which it was ordered by the original purchaser. All contractual agreements between the manufacturer and the original purchaser with respect to the requirements and restrictions of use and operation of the equipment in a country other than the one the equipment was ordered for are binding on any and all subsequent purchasers. Any use of the equipment in any country other than the country for which it was ordered by the original purchaser is unauthorized use and strictly prohibited unless the prior written authorization of BAUER Maschinen GmbH GmbH has been requested and received. Any use of the equipment in the United States of America is only allowed if the equipment was first ordered for and delivered for use within the United States of America or if the equipment has been expressly approved and authorized in writing for use within the United States of America by BAUER Maschinen GmbH. Any use of the t he equipment other than the use authorized and described in this Instruction Manual shall constitute unauthorized and strictly prohibited use and is hereby expressly forbidden. The same applies if the t he equipment is used as a crane, for levelling purposes or for the t he transport of people. These uses are expressly unauthorized and hereby strictly prohibited. The manufacturer shall not be liable for any injuries or damages of any kind which are caused by, directly or indirectly, or are in any way, shape or form connected to, or arising from any unauthorized use described herein or any use that is i s not expressly authorized in this Instruction I nstruction Manual.

GB 34 / 2010

1-2

DESCRIPTION

An/ To:

BAUER Maschinen GmbH Abteilung Abteil ung Kundendienst Postfach 12 60 D-86522 Schrobenhausen

Tel. Fax E-Mail

+49 8252 97-2586 +49 8252 97-2587 [email protected] kvt@bau er.de

Von (Eigentümer, Betreiber)/From (owner, user): Tel.: Fax: E-Mail: Gesamtseitenzahl dieses Antrages/Total number of pages of this request:

1.1.1 1.1.1

Änderung santrag / Change Change request

für/for Gerät/Equipment Gerät/Equipm ent Ausrüstung/Attachment Ausrüstung/Att achment 1. Grunddaten/Equipment Grunddaten/Equipment specifications

Anbauteil/factory Anbauteil/f actory installed install ed option

BetriebsBaunummer/ Baujahr/ stunden/ Serial Year of Operating Equipment/ number.: manufacture manufacture : hours: Plant: Aktueller Standort des G Gerätes erätes/der /der Anlage mit Anschrift/ Anschrift/ Current location of the equipment/plant with complete address: Datum der Kommissionierung/Da Kommissionierung/Date te of commissioning (first use): Anbauteile (original)/Factory installed options (OEM): Bezeichnung/Description Materialnumm er/Material er/Material number numb er Baunumm er/Serial er/Serial number num ber Gerät/Anlage

Ausrüstung (original)/Attachment (OEM): Bezeichnun g/Designatio n Materialnumm er/Material er/Material number numb er

2. Änderungsdaten/Change data für/for Gerät/Equipment Gerät/Equipment Ausrüstung/Attachment Ausrüstung/Attachment Änderungsbeschreibung/Descri Änderungsbeschr eibung/Description ption of changes

m j b 9 0 0 2 / 5 0 A M B 2 + 1 . 8 1 8 . 0 1 9

Baunumm er/Serial er/Serial number num ber

Anbauteil/Factory Anbauteil/Factory installed option ggf. Angebotsnr. BAUER/BAUER BAUER/B AUER offer no (if applicable) applicabl e)

Es wird hiermit ausdrücklich erklärt und bestätigt, dass sich das Gerät zum aktuellen Zeitpunkt im Originalzustand (Auslieferungzustand) befindet und ausschließlich mit BAUER-Originalkomponenten bestückt ist. Das Gerät befindet sich in einem technisch einwandfreien Zustand./ It is herewith explicitly declared and confirmed that the equipment is presently in its original condition (as delivered) and contains only genuine original BAUER OEM components. The equipment is in a technically flawless condition. Eigentümer bittet um technische Überprüfung des Gerätes./ The owner requests a technical inspection of the equipment.

Name/Na Name/Name me

Unterschr ift/Signatur ift /Signatur e

Datum/Date

3. BAUER-int BAUER-intern ern (wird von B AUER ausgefüll t) / For internal int ernal use of BAUER (to be filled in by BA UER) UER) Antrag erhalten am/Request received on: Antrag weitergeleitet an/ VT Name: Datum/Date: EK Name: Datum/Date: Request forwarded to: PM Name: Datum/Date: Datum/Dat e: andere/other andere/other Name: Datum/Date: Name KVT-Mitarbeiter/Name of KVT employee:

GB 34 / 2010

1-3

DESCRIPTION

1.2

COMPONENTS

1.2.1 1.2.1

Basic Basi c Rig / Grab Equip ment

1.2.1.1 Components Overview Basic Rig 7

1 Boom (top / bottom / turning point) 2 Swing mechanism mechanis m 3 Travel gear 4 Counterweight 5 Hoist winch 6 Hoist rope 7 Boom head ("masthead") 8 Boom cylinder 9 Upper carriage 10 Undercarriage

1 21

8 20

Grab equipment (MDSG)

20 21 22 23

Hose drum system Double spring accumulator Electric cable reel Hydraulic hose guide

6 5 9

22 2 10

4 3 G0040509.wmf

GB 34 / 2010

1-4

DESCRIPTION 1.2.1.2 Components Description

Basic rig components description table Component

Descrip Descrip tion / function

Boom

Consists of a top and bottom part, and is mounted on the bottom end with a turning point so that it is able to move on the base machine.

Boom cylinders

Used for raising/lowering/adjus raising/lowering/adjusting ting the boom, and provide support for it.

Boom head *

Guides the grab hoist rope using us ing rope sheaves.

Hoist winch with hoist rope

Hoist equipment for the grab.

Upper carriage

Houses the engine, hydraulic system and controls. controls.

Swing mechanism

Enables the rotation of the upper carriage to both sides.

Undercarriage

The undercarriage carries the upper carriage and enables travelling with the equipment, from one spot to the next.

Travel gear

For driving the undercarriage undercarria ge crawlers.

Counterweight

Gives the equipment stability.

* Also referred to as a "masthead" " masthead"

GB 34 / 2010

1-5

DESCRIPTION

Table: Components description, grab equipment (MDSG) Component

Descript Descript ion / funct ion

Hose drum system (MDSG) (Mechanical Drum System Grab)

Two drums for holding h olding and guiding the hydraulic hoses required for the grab supply, and the associated spring accumulators for mechanical reeling/unreeling reeling/unreeling of the hoses (see below).

Double spring accumulator

Mounted on the boom and flange-connected to the hose drums. The sets of springs housed in the two tubes are tensioned and relieved of tension by a wire rope connected to the relevant hose drum.

Electric cable and reel

The electric cable transfers data from the grab to the base machine. In automatic mode, the cable is automatically wound onto/unwound from the cable drum to ensure that data transfer can continue uninterrupted.

GB 34 / 2010

1-6

SAFETY

2

SAFETY

2.1

GENERAL SA SAFETY FETY REQUIREMENTS

● It is fundamental that the national accident accident prevention codes be observed where this equipment is used. ● In addition, the "Safety Information" Information" book supplied supplied with this equipment equipment must be read and understood. It contains general safety requirements requirements and such that have been compiled by the manufacturer especially for this type of equipment. ● Also, the safety messages given given in the instruction manual of the equipment equipment must be followed.

2.2

EQUIPMENT SA SAFETY FETY

The safety built into this equipment is state-of-the-art and complies with all valid EC requirements. Equipped safety devices guarantee the highest possible safety standard.

2.3

MAJOR MAJ OR HAZARDS HAZA RDS

– In grab applications, the equipment equipment is operated with heavy tools. Being hit by a moving tool can cause severe or even fatal injuries. – The stability of the equipment must must not be compromised. Exceeding Exceeding the rig's capacity or operating with faulty limit switches can make the equipment fall violently causing severe personal injury or even loss of life. – Never remove equipped safety devices devices nor render them out of order. – Be observant of oil spills from the hydraulic hydraulic system. Oil spraying with high pressure pressure from a leak in i n the hydraulic system can cause severe burns and poisoning. – The cooling system gets very hot from operation. Coming Coming into contact with components containing coolant can cause burns. – Engine, gear and hydraulic oils get very very hot during operation. Touching Touching a component containing such oil can cause burns. – Be sure the equipment is properly shut down down before you begin a maintenance, maintenance, repair or cleaning job on it. Set all controls to Off, stop the engine and interrupt the power supply by setting the battery main switch to Off position. – To prevent abuse and unauthorised unauthorised starting of the equipment, equipment, shut it down, remove the ignition key and lock l ock the cab whenever you leave the equipment unattended.

GB 34 / 2010

2-1

SAFETY

2.4

SAFETY DEVICES

2.4.1 2.4.1

Emergency Emergenc y Stop

In an an emergency!! Press the Emergency STOP button (1)!! All equipment functions will promptly come to a stop.

1

To re-start, pull the depressed Emergency STOP button.

BK786504.wmf

2.4.2 2.4.2

Pilot Control Contro l Safety Safety Stick

With the safety stick (1), the operator must shut off the pilot control before leaving the driver's seat. With the stick in the "Off" position, all hydraulic functions are blocked.

1.2 1.1

Pilot control On: Stick moved to position (1.1) Pilot control Off: Stick moved to position (1.2) BK786505.wmf

2.4.3 2.4.3

Fire Exting uisher

Machines with an engine power of < 200 kW are equipped with o ne fire extinguisher. Machines with an engine power of > 200 kW are equipped with t wo fire extinguishers. Their location in or on the machine is identified with a decal (see fig.). Personnel must re-read the instructions i nstructions provided on fire extinguisher from time ti me to time to ensure that they are able to operate them correctly.

GB 34 / 2010

B0000506.wmf

2-2

SAFETY 2.4.4 2.4.4

Medi Medical cal Box

A First Aid medical box is found in the operator’s cab. Its location is identified with a decal (see fig.).

B0000562.wmf

2.4.5 2.4.5

Emergency Emergenc y Exit

Whenever the normal exit from the cab is blocked, the operator can use the emergency hammer (see fig.) to smash a window. The hammer is found in the upper corner behind the operator’s seat.

BS756504.wmf

GB 34 / 2010

2-3

SAFETY 2.4.6 2.4.6

Limit Lim it Switches Switch es

Table of limit switches Name HS 1

Function

Switches off the "Wind in rope" function for the hoist winch in order to prevent a collision with the boom head.

HS 1

GO0755002.wmf

GB 34 / 2010

2-4

SAFETY

2.5

STABILITY

2.5.1 2.5.1

Stabilit y Guidelines

Load capacity charts are calculated in compliance with the European standard DIN 996. WARNING!

Tipping hazard! The conditions listed in the following must be observed to guarantee the stability of the rig. Conditions for operation: – The angles and main rope loads specified in the load capacity capacity charts are maximum values and must not be exceeded for safety reasons. The specified loads apply only when not combined with one another or used on an altered setup of equipment. If heavier equipment is attached or the centre of gravity is at a higher point, the stability will need to be recalculated. – Machine on firm, horizontal and even surface. surface. Observe national national standards and guidelines regarding soil and working platform conditions. – When a load is attached to the rope, the upper upper carriage must only be swung swung slowly (max. 3 rpm). – No diagonal pull.

The pulling forces of the winch and the current centre of gravity (position of the equipment) are factors which also affect stability. The loads given in the load capacity charts take into consideration the most adverse position of the components.

NOTE

Conditions fo r on-site travelling: travelling:

CAUTION

Risk of accident if driver does not have an all-round view from the cab! The driver of the rig must be assisted by a person giving hand signals during travel.

– Machine on firm, horizontal and even surface. surface. Observe national national standards and guidelines regarding soil and working platform conditions. – Upper carriage in line with undercarriage. – Equipment and moveable moveable loads must be kept as close close to the ground as possible. possible. – Set the boom to its minimum permissible permissible operating radius. – No abrupt movements. movements.

GB 34 / 2010

2-5

SAFETY 2.5.2 2.5.2

Stabilit y With Grab Equipment −

Valid only for

−

Conditions Conditions for operation

− − −

Counterweight Counterweight 12.40 t − Width of track shoes DHG/SF 800 grab 15.40 t Machine on firm, firm, horizontal and and even working working platform Max. upper carriage swing speed: 3 rpm No diagonal pull

700 mm

Do not exceed the specified maximum values for the angles and loads! The specified loads apply only when not combined with one another or used on an altered setup of equipment. equipment.

CAUTION

Permissible Operating Range

Permissible operating radius during operation: Max. min. Max. rope force

4.50 m

≙ Boom

angle 79.4° /

3.50 m ≙ Boom angle 83.6° Permissible operating radius

Loading condition

in metres

Boom angle

Grab above trench

185.07 KN

4.50

79.4°

Grab at final depth

156.96 KN

4.50

79.4°

Chisel recovery 4.75 78.4° 338.25 KN Note: Specified capacities for the recovery do not meet EN 996 requirements and are therefore for information purposes only. BAUER Maschinen GmbH does not assume liability for recovery operations! operations!

Ground pressure in kPa

Grab above trench

Lengthwise Crosswise Max.

306 184 345

Grab at final depth


229 157 254

Grab recovery


786 263 860

Definition: Boom operating radius Recovery

GB 34 / 2010

→

→

Distance between centre of slewing ring and centre of trench Raising a grab grab stuck in in the trench.

2-6

SAFETY

2.5.2 2.5.2.1 .1 Travelli Travelli ng With Equipment WARNING!

Tipping hazard! Travelling too fast with a load, travelling with a l oad across terrain with an excessively steep incline, and swinging the load l oad may lead to the equipment tipping over and cause serious injury as a result. with a load at the lowest speed speed setting. • Only travel with boom angle angle before travelling up and down down slopes. • Set the boom • Only travel with with the load over terrain whose whose working platform platform inclination does not exceed the values listed in the table below. • Move the control lever smoothly and carefully. carefully.

Working platform inclination [α] Upper carriage position in relation to crawlers Position of hook load Permissible boom operating radius Permissible boom angle [ β]

Working platform angled upwards Max. -5° (upwards)

Working platform angled downwards Max. 3° (downwards)

Lengthwise

Lengthwise

Facing upwards

Facing downwards

4.50 m - 3.70 m

3.70 m - 3.50 m

79.4° - 82.8°

82.8° - 83.6°

GO01085000.wmf

GB 34 / 2010

2-7

SAFETY

2.6

RISK OF ROPE BREAKING BREA KING WHEN ADJUSTIN ADJ USTING G B OOM

Adjusting the boom will change the length of the rope. r ope. Before adjusting the boom (for rigging or derigging purposes, or in order to make it more suitable for the application), you must make sure that enough rope has been unwound to prevent additional pulling forces from being exerted on it as a result of the boom being adjusted. To prevent a dangerous situation developing where where the rope breaks as a result of its tension increasing in an uncontrolled manner, any rope r ope ends that are attached att ached to fix points must be released. WARNING!

Accident risk! Excessive strain on the ropes may cause them to break, which could lead to serious injuries as a result. • Make sure sure the rope is long enough. enough.

L0000530.wmf

GB 34 / 2010

2-8

SAFETY

2.7

PERMISSIBLE PERMISSIBL E WIND SPEED

The place to measure the wind speed is at the masthead: Max. Max. permissible wind speed speed for equipment operation

m/s 20

km/h 72

miles/h 45

Beaufort 8

Barrier effect

ktn 39

250 (N/m²)

WARNING!

Tipping hazard! Shut down the equipment before the value is exceeded.

● ● ● ● ●

Set the suspended suspended grab down down on the ground. Lower movable components components as close to the ground as possible. Adjust the upper carriage carriage in line with the undercarriage undercarriage and interlock them. Set the mast mast to the minimum minimum operating radius. Extend the ground prop of the mast, mast, if so equipped.

Table of wind forces f orces and speeds Wind force Beaufort Beaufort English 0 calm 1 light air 2 light breeze

3

gentle breeze

4 5

moderate breeze fresh breeze

6

strong breeze

7

near gale

8

gale

9

strong gale

GB 34 / 2010

Wind speed Wind effects m/s km/h 0 - 0.2 less than 1 Smoke rises straight in the air, sea is calm-glassy Smoke drifts but vanes remain still, sea is rippled 0.3 - 1.5 1-5 Wind can be felt on your face, leaves rustle, sea 1.6 - 3.3 6 - 11 has wavelets 3.4 - 5.4 12 - 19 Leaves and thin twigs move, pennants stretch, wave crests begin to break 5.5 - 7.9 20 - 28 Dust and paper lift, twigs and branchlets sway, waves are growing in length, scattered white-caps 8 - 10.7 29 - 38 Small trees begin to sway, waves are whitecapped all over the sea Sturdy branches move, wires sing, umbrellas are 10.8 - 13.8 39 - 49 hard to handle, sea is rough, crests break Whole trees swaying, working towards the wind is 13.9 - 17.1 50 - 61 difficult, sea is very rough, foam on crests 17.2 - 20.7 62 - 74 Branches break off, walking outdoor is extremely difficult, waves are high, spray from crests 20.8 - 24 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

2-9

TECHNICAL DATA

3

TECHNIC TECHNICAL AL DATA

3.1

DIMENSIONS

3.1.1 3.1.1

With Grab Equip ment (MDSG) (MDSG)

Dimensions in [mm] 16331 15808

13846

0 0 7 6

7211

5128

0 0 8 5

° 6 . 3 8

1391 0 0 2 1

0 0 8 2

0 4440 5360 3500 - 4350

GB 34 / 2010

R 3450

GU00745000.wmf

3-1

TECHNICAL DATA

3.2

EQUIPMENT DATA DA TA

Base machine Upper carriage Type Serial number

Hyundai BH 70 175

Engine Type Serial number Output Speed

Cummins C8.3-C 73034489 194 kW 2200 rpm

Undercarriage Type Serial number Width over crawlers Length of crawlers Width of track pads

UW 65 DH 1318 2980 - 4,380 mm 5,430 mm 700 mm

Main winch

Type Serial number Pulling force (1st layer, reeved) Rope speed (reeved) ("lifting" with a load of 80 kN)

4066 WF 08 / 0 69418 170 kN 34 m/min

Working weight

With: DHG-SF 800 grab

GB 34 / 2010

approx. 73.0 t

3-2

TECHNICAL DATA

3.3

GRAB OPERATING RANGE

3.3.1

MDSG

Excavation depth (D): 50 m Working radius: Mast inclination:

4,500 mm / 3,500 mm 79.4° - 83.6°

T

G0030514.wmf

GB 34 / 2010

3-3

TECHNICAL DATA

3.4

ROPE SPECIFICATIONS WARNING!

Accident risk! Ropes breaking can cause serious accidents. installed in hoist hoist winches must have a minimum • Ropes installed breaking load which is at least three times the pulling force. safety factors must comply with with the standards • The ropes' safety required for the equipment equipment and must be observed. 3.4.1

Main Rope Rop e

Techni Technical cal data:

Finished length Diameter

159 m 26.00 mm

Characteristics:

Lay and direction Rotation characteristics Rope end characteristics

GB 34 / 2010

Regular lay, right (sz) Non-rotating Pointed - Pointed

3-4

TECHNICAL DATA

3.5

NOISE EMISSION

1. Insi Insi de Cab (door closed)

Measurement in acc. with ISO 6394: Sound-pressure level in cab

LPA =

78.8 dB(A)

2. Outside

Measurements in acc. with DIN 45635 P.33: Average sound-pressure level Sound-power level

3.6

LPA = 80.3 dB(A) LWA = 111.6 dB(A)

TEMPERATURE CONDITIONS

The equipment can be used at outdoor temperatures ranging from -20° to +40° C (-4 to +104 F). For use at temperatures outside the specified range the manufacturer must be consulted.

3.7

EXPOSURE TO VIBRA TIONS

The operator’s exposure to vibration acceleration during operation with this equipment is less than 0.5 m/s2.

GB 34 / 2010

3-5

CONTROLS AND INDICATORS

4

CONTROL CONTROL S AND INDICATORS

4.1

OPERATOR'S OPERATOR'S CAB 1

P

1.1 2.1

8.1 1.2 2.2 30.4

30.3 30.2 30.6

3 4 5 6 7

34 33 32 31 30.5 30.1

P

8.3 8.5 8.7

8.4 8.6 8.8 8.2

20 10 11 12 13

GO01015001.wmf

1.1 1.2 2.1 2.2 3 4 5 6 7 8.1 8.2 8.3 8.4 8.5 8.5 8.5 8.5 8.5 8.6 8.6 8.6 8.6

Left crawler travel forward Left crawler travel reverse Right crawler travel forward Right crawler travel reverse Free-fall / freewheel release Not used Not used Horn Not used Unwind rope Wind in rope Close grab shovel Open grab shovel + Retract all flaps + Retract Y+ flaps + Retract Y- flaps + Retract X+ flaps * + Retract X- flaps * + Extend Y+ flaps + Extend Y- flaps + Extend X+ flaps * + Extend X- flaps *

10 11 12 13

Ignition Igniti on on/off Set diesel engine speed Emergency STOP Adjust track gauge of undercarriage

20

Hydraulic Hydrauli c pilot control On / Off

30.1 30.2 30.3 30.4 30.5

Increase operating radius (short stroke) Reduce operating radius (short stroke) Swing upper carriage left Swing upper carriage right Rigging mode selected: Increase operating radius (long stroke) 30.6 Rigging mode selected: Reduce operating radius (long stroke) 31 Not used 32 Activate Activat e diesel engine idle speed / activate selected diesel engine speed 33 Not used 34 Diesel engine speed 110% for 8 seconds

*) Not supplied with this version

GB 34 / 2010

4-1


4.2

CONTROL CONTROL PANEL

1

P

P

GO01055002.wmf

1 2 3 4 5 6 7 8 9 10 11

Indicator: Indicat or: Rope grab selected Selection Selecti on switch: Rope grab / hydraulic grab Indicator: Indicat or: Hydraulic grab selected Rigging mode (override winch stroke limit) Warning display: Free-fall oil filter filt er contaminated Control Y+ flaps * Control Y- flaps * Indicator: Indicat or: Normal winch operation Selection Selecti on switch: Normal winch operation / free-fall winch operation Indicator: Indicat or: Free-fall winch operation Potentiometer: Set automatic rope tensioning facility

12 Button with indicator: Automatic rope tensioning facility On / Off 13 Not used 14 Not used 15 Button with indicator: Release free fall 16 Retract all all grab steering flaps * 17 Button with indicator: Automatic winding of E cable roller On / Off 18 Button with indicator: indicator : Release swing brake 19 Button with indicator: Apply swing brake 20 Not used 21 Not used

* With grab flaps control system

GB 34 / 2010

4-2


4.3

CONTROL PA PANEL NEL 2

Position speichern

Au Autom tomatik atik Ein

Greiferdrehen links rechts

4 12 20

5 6 13 14 21 22

MEM

1 9 17

2 10 18

3 11 19

7 15 23

8 16 24 LN184716501.wmf

1-18 19

Not used Save the current grab position as end point 20 Select: Turn to end points saved for grab 21 Grab turns left and indicator shows: End point reached 22 Grab turns right and indicator shows: End point reached 23-24 Not used

GB 34 / 2010

4-3


4.4

MONITOR UNIT

For more detailed information, i nformation, please see the additional documentation in the appendix.

GB 34 / 2010

4-4

OPERATION

5

OPERATION

5.1

TRAVELLING TRAVEL LING AND STEERING

CAUTION

Risk of shortening the service life of crawler components due to incorrect loading! The main direction of travel should always be - as shown - following the direction of the arrow (2); the front idlers (1) facing forward and the travelling drive (3) at the back. During operation, the front idler (1) should bear the main load. Position the undercarriage accordingly.

CA00005000.wmf

B0000552.wmf

CAUTION

Risk of damaging the crawler components! components! The crawlers installed on the equipment are designed for standard operation with grab loads. This equipment should not travel over longer distances! Suitable and designated means of transport must be used to reposition the machine!

NOTE

GB 34 / 2010

5-1

OPERATION

5.2

UPPER CARRIAGE CARRIA GE SWING

5.2.1 5.2.1

Swing Brake Brak e

The swing brake serves to arrest the upper carriage against rotation during operation.

CAUTION

Risk of damaging components! The swing brake may be applied only when the upper carriage has come to a stop. WARNING!

Risk of getting crushed or hit! Before swinging the upper carriage, check the danger zone is free. The rear-view mirror (and tail camera camera if equipped) must must be clean at all times. To apply the swi ng brake: ● Press button (19). The indicator light in the button will light up. To release the swi ng brake: br ake: ● Press button (18). The indicator light in the button will light up.

1

P

P

GO01055002.wmf

GB 34 / 2010

5-2

OPERATION 5.2.2 5.2.2

Swing Contro l

Upper Upper carriage swing to left: ● Release swing brake. ● Move control control lever (30) (30) to left (30.3) from centre. Upper Upper carriage swing to rig ht: ● Release swing brake. ● Move control control lever (30) (30) to right (30.4) from centre.

30.3

30.4

GO01055003.wmf

Letting the lever return to centre makes the swing slowly come to a stop using hydraulics. A quicker stop can be implemented by carefully moving the lever in the opposite direction.

GB 34 / 2010

5-3

OPERATION

5.3

ADJUSTING ADJ USTING THE OPERATING RADIUS RAD IUS

Please refer to the "STABILITY" section for the permissible operating radius. r adius.

5.3.1 5.3.1

Increasing / Reduci Reduci ng the Operatin Operating g Radius Radius

CAUTION

Risk of damaging the hoist rope! Please pay particular attention to the information in the "OPERATING THE WINCH" section!

1

30.1

P

P

30.2

GO01055002.wmf

Reducing Reducing the operating radius (raising) Move the left control lever backwards (30.2)

5.3.2 5.3.2

GO01055004.wmf

Increasing the operating radius (lowering) Move the left control lever forwards (30.1)

Raisi Raisi ng / Lowering Loweri ng the Boom in Rigging Riggi ng Mode

To raise or lower the boom, the hoist limit switch must remain re main deactivated (= rigging mode) whilst the raising / lowering functions are being carried out with the control lever: •

Press and hold button button (4) on the control control panel, and move move the left control lever lever (30) as shown (see above).

CAUTION

GB 34 / 2010

Risk of damaging the boom! Immediately after the boom is raised, it must be fastened to the bottom (long stroke) of the mast cylinder using clamps.

5-4

OPERATION

5.4

TRAVELLING TRAVEL LING WITH THE RIG

5.4.1 5.4.1

Travelli Travelli ng on Level Ground

CAUTION

● ● ● ● ● ●

Risk of accident if driver does not have an all-round view from the cab! The driver of the rig must be assisted by a person giving hand signals during travel.

Provide an obstacle-free travel path. path. Adjust the upper carriage in line with the undercarriage undercarriage and apply the swing swing brake. Lower the equipment and movable movable loads as close to the ground as possible. possible. Set the boom to its minimum minimum permissible operating operating radius. Travel on firm and level surfaces only. Avoid making making abrupt movements.

5.4.2 5.4.2

Travelli Travelli ng Up or Down Gradients

5.4.2 5.4.2.1 .1 With Raised Mast Mast and Without Work Equipment

Tipping hazard! Observe all instructions found in sect. "Travelling over level ground"! CAUTION

CAUTION

GB 34 / 2010

Tipping hazard! It is prohibited to travel up/down gradients of more more than 5° and also to traverse gradients!

5-5

OPERATION

5.5

OPERATING THE WINCH

CAUTION

5.5.1 5.5.1

Risk of damaging the rope, r ope, mast and components! Before using the winch, please read r ead the entire "OPERATING MODES" section carefully. Do not allow the rope to become slack AT ALL when lowering the load. A slack rope on the drum could lead to the load sliding down in an uncontrolled manner and the rope being damaged beyond repair! When unwinding the rope from the winch, always remember that, for safety reasons, the rope must remain wound around the drum at least three times! Particular care must be taken when operating the winch in rigging mode, as the hoist limit switch is deactivated!

Winding In In and Unwindi ng the Main Main Winch Rope Rope

1

8.1

P

P

8.2

GO01055002.wmf

Rope grab / hydraulic grab mod e

Set selection switch (9) to the "Raise winch" position

GO01055005.wmf

Unwinding rope (lowering grab)

Winding in rope (raising grab)

Move the right control lever forwards (8.1)

Move the right control lever backwards (8.2)

The speed of the winch is controlled by moving the control lever: the further the control lever is moved, the quicker the process. 5.5.2 5.5.2

Operati Operating ng the Main Main Winch in Rigging Riggi ng Mode

Due to the mast inclination, the hoist limit switch must remain re main deactivated (= rigging mode) whilst the winding in / unwinding functions for the main winch rope are carried out with the control lever: button (4) on the control control panel, and move move the right control lever (5) (5) as • Press and hold button shown (see above).

GB 34 / 2010

5-6

OPERATION

5.6

OPERATING MODES

The GB has been designed for use in the following two operating operati ng modes: – Rope grab mode – Hydraulic grab mode The key difference between the modes lies in i n how the winch functions when each of them is activated. The following section outlines each of the operating modes in terms of their functions. However, both operating modes have the following in i n common: •

• • •

Button 17 must must be pressed before operating the the winch in order order to activate automatic automatic winding of the elec. cable roller → This causes the LED in the button to light up. Open the grab shovels using using the control control lever on the right (8.4). Close the grab shovels using using the control control lever on the right (8.3). To avoid damaging the the main rope, it should should be kept tensioned whilst whilst the grab shovels are being closed during operation: To close the grab shovels, move the right-hand control lever to the left (8.3). To keep the main rope r ope tensioned, move the right-hand control lever downwards (8.2) (see graphic on the right).

8.3

GO01055010.wmf

5.6.1

Rope Rop e Grab Mode Mod e

1

P

P

GO01055002.wmf •

Set selection switch (2) to the "Rope grab" grab" position.

Once rope grab mode has been selected, the following winch functions can be used: – Raising / lowering load using right control control lever (as described) – Lowering load in free-fall mode using right right foot pedal

GB 34 / 2010

5-7

OPERATION 5.6.1.1 5.6.1.1 Free-Fall Free-Fall Operatio n

CAUTION

Risk of damaging the equipment! The load on the rope must not exceed 50% of the maximum pulling force for the winch.

1

8.1

P

P

8.2

GO01055002.wmf

GO01055006.wmf

Switching o n, activating activating and triggering f ree-fa ree-fallll operation: • • • • •

• •

Select "Rope "Rope grab" grab" mode mode (as described). Press button 17 until the LED in it lights up. Set selection switch (9) to the "Free fall" fall" position. Press foot pedal (3) all all the way down → Free-fall operation switched on. Free-fall operatio n activated (LED in button lights Press and hold button (15) → Free-fall up). Release button (15) → Load is held by foot on pedal! You can control control the free-fall speed by applying applying more more or less pressure to the pedal.

Interrupting Interrupting free-fall free-fall operation bri efly and reactivating reactivating it: • •

Move the right control control lever backwards backwards (8.2) → Free-fall operation deactivated. Press foot pedal pedal (3) all the way down down and press button (15) briefly briefly → Free-fall operation reactivated.

Stopping and switchi ng off free-fall free-fall operation: •

Set selection switch (9) to the "Raise winch" winch" position again. again.

GB 34 / 2010

5-8


Hydraulic Hydraul ic Grab Mode

1

P

P

GO01055002.wmf

• •

Set selection switch (2) to the "Hydraulic grab" grab" position. position. Press button 17 until the LED in it lights up.

Once hydraulic grab mode has been selected, the following winch function can be used: – Raising / lowering load using right control control lever (as described).

GB 34 / 2010

5-9

OPERATION

5.7

OPERATING THE AUTOMATIC AUTOMA TIC ROPE TENSIONING FACILITY FACIL ITY

This facility prevents the rope from becoming slack when the grab reaches the ground. As soon as a certain residual winch pulling force (which has been predefined) is i s no longer present, the winch will stop unwinding the rope.

1

P

P

GO01055002.wmf

Switching the automatic rope tensioning facility on/off •

Press button 12 → LED in button (12) does not light up = Automatic rope tensioning tensioning facility activated → LED in button (12) lights up = Automatic rope tensioning facility deactivated

Adju Ad just st ing in g the th e aut omat om atic ic ro pe tens t ensio io ning ni ng f acil aci l it y •

Set the potentiometer potentiometer (11) to to the required residual winch pulling pulling force. The settings are as follows: 0 = Residual winch pulling force of 0 to 10 = Residual winch pulling force of 2 to

GB 34 / 2010

5 - 10

OPERATION

5.8

OPERATING SPECIAL GRAB GRA B FUNCTIONS

5.8.1 5.8.1

Moveable Suspensio Suspens ion n*

The moveable suspension for the grab enables the grab gr ab to be tilted along the y axis. Axis definition +

1

-X

P

P

+X

-Y

GO01055007.wmf

BTS0180F001.wmf

Tilt grab in "y+" direction: Press button 20 and move control lever to pos. 8.7. Tilt grab in "y-" direction: dir ection: Press button 21 and move control lever to pos. 8.7.

8.7

8.8

GO01055008.wmf


GB 34 / 2010

5 - 11


Flap Control Contr ol

The flap control for the grab enables the grab to be tilted along the y axis and the x axis. Axis definition +

1

-X

P

P

+X

-Y

GO01055007.wmf BTS0180F001.wmf

5.8.2.1 Y Axis Flap Control Extend Y+ flaps. Press button 6 and move control lever to pos. 8.6. Retract Y+ flaps. Press button 6 and move control lever to pos. 8.5.

8.5

8.6

Extend Y- flaps. Press button 7 and move control lever to pos. 8.6. Retract Y- flaps. Press button 7 and move control lever to pos. 8.5.

GB 34 / 2010

GO01055009.wmf

5 - 12

OPERATION 5.8.2.2 5.8.2.2 X Axis Flap Cont rol ro l * Extend X+ flaps. Press button 13 and move control lever to pos. 8.6. Retract X+ flaps. Press button 13 and move control lever to pos. 8.5.

8.5

8.6

Extend X- flaps. Press button 14 and move control lever to pos. 8.6. Retract X- flaps. Press button 14 and move control lever to pos. 8.5.

GO01055009.wmf


5.8.2.3 Retracting All Flaps

Retract all flaps. Press button 16 and move control lever to pos. 8.5. 8.5

8.6

GO01055009.wmf

It is recommended that you retract all flaps before raising the grab out of the trench. NOTE

GB 34 / 2010

5 - 13


Turning Turn ing Device

The turning device for the grab enables the grab to be rotated about its longitudinal axis. 5.8.3.1 Rotating the Grab Manually

8.7

8.8

Position speichern

Automa tomatik Ein

Greifer drehen links rechts

MEM

22

23

24

GO01055008.wmf

25

26

27

28

29

GO098501.wmf

The grab can be positioned anywhere within its turning range. Precondition: The "Automatic" function (25) is deactivated → LED (25) is not lit. •

•

Press and hold down down button (26) and move move the control lever to position (8.7) or (8.8) (8.8) to rotate the t he grab counterclockwise. Press and hold down down button (27) and move move the control lever to position (8.7) or (8.8) (8.8) to rotate the t he grab clockwise. − The grab only rotates as long as the button is held down. when a previously saved saved end position position is reached − The LED (26) / (27) only lights up when (see the section entitled "Saving the grab end position").

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5 - 14

OPERATION 5.8.3 5.8.3.2 .2 Rotating t he Grab Grab in Automatic Aut omatic Mode Saving Saving the reference axis

Axis definition +Y

-X

8.7

+X

-Y

8.8

Position speichern

Autom omatik Ein


MEM

22 GO01055008.wmf

23

24

25

26

27

28

29

GO098501.wmf

BTS0180F001.wmf

Precondition: The "Automatic" function (25) is deactivated → LED (25) is not lit. Define which reference axis the grab rotation is to start from. Procedure for defining the reference axis: •

Press button (27) and move move the control lever to position (8.7) or (8.8) (8.8) until the grab is aligned in the X direction.

•

Saving the X axis axis as the reference reference axis: axis: Once the grab is in position, the keyoperated switch in the switch cabinet should be briefly set to (1). When the reference axis has been saved, reset the key-operated switch to (0).

LQ1094011.jpg

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5 - 15

OPERATION Saving Saving t he grab end positio n

8.7

8.8

Position speichern

Automatik Ein


MEM

22

23

24

25

26

27

28

GO01055008.wmf

29 GO098501.wmf

Precondition: The "Automatic" function (25) is deactivated → LED (25) is not lit. •

•

Press button (26) (26) / (27) and move the control lever to position position (8.7) or (8.8) until the required end position is reached. Press button (24) to save the end position. position. The current position is saved as an end end position along with its counterpart at the other end of the range, which is saved automatically.

The save procedure is complete when LED (26) or (27) lights up, depending on which end position has been reached. Rotating the grab • •

•

Press button (25) → LED (25) lights up. Press and hold down down button (26) and move move the control lever to position (8.7) or (8.8) (8.8) to move to the left end position. Press and hold down down button (27) and move move the control lever to position (8.7) or (8.8) (8.8) to move to the right end position.

LED (26) or (27) lights up, depending on which end position has been reached.

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5 - 16

START-UP / SHUTDOWN

6

START-UP STA RT-UP / SHUT-DOWN

6.1

START-UP

6.1.1 6.1.1

Initi al Start-Up

The initial start-up s tart-up of the equipment concerns both the manufacturer and the future user, the customer. In general, the job required here will be carried out jointly in a training held at the manufacturer's or in a briefing on the construction site. Even before the first fir st rigging operations are begun, the operator of the equipment must be familiar with all the control elements elements and their capabilities.

6.1.2 6.1.2

Visual Inspecti on Before Start-Up Start-Up

A visual inspection and thorough check are required before putting the equipment into operation:

● ● ● ● ●

Inspect the entire equipment equipment for loose connections connections and missing missing pins or bolts. Check all components for wear. Check all electric lines for damage. damage. Look for leaks and fluid spills. Check that all contained contained oils and fluids have have the proper proper level.

GB 34 / 2010

6-1

START-UP / SHUTDOWN 6.1.3 6.1.3

Daily Start-Up

6.1.3 6.1.3.1 .1 Starting the t he Equip Equip ment

CAUTION

● ● ● ●

Risk of damaging the equipment! Observe instructions in the instruction i nstruction manual of the base machine!

Set the battery main switch switch to "On" position. position. Set all control control elements elements to "0" position. Pull the Emergency STOP button. Start the engine engine by turning the ignition key. key.

CAUTION

CAUTION

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

Risk of damaging the control! When starting with the aid of an external power source, first fir st switch off main fuse F1 (BAUER part)!

● Move the pilot control control safety stick to the "On" position.

GB 34 / 2010

6-2

START-UP / SHUTDOWN 6.1.3.2 Selecting an Operating Mode Selecting the maximum engine power

After restarting the engine, select operating mode "M". NOTE

● Press button (1). Indicator "H" lights up. ● Press button (2). The "Heavy duty work mode" indicator lights up. ● Press button (3). Indicator "M" lights up.

BK00004000.jpg

NOTE

GB 34 / 2010

For more details, please consult the additional operator's manual supplied by the manufacturer.

6-3

START-UP / SHUTDOWN 6.1.4 6.1.4

Safety Safety Tests before Starting Work WARNING!

Severe accident hazard! Faulty safety devices are dangerous. All safety devices must be tested prior to starting work, and any faults found must be repaired by skilled personnel/After Sales Service personnel. The equipment may be put to work only when all safety devices are in proper working order. Initial Initial sit uation: – Diesel engine is running.

6.1.4.1 6.1.4.1 Checking Checki ng the th e Emergency STOP

● Press the EMERGENCY EMERGENCY STOP button. → All control elements must be deactivated and the diesel engine must come to a stop.

6.1.4 6.1.4.2 .2 Checki Checking ng the Pilot Cont rol Safety Stic Stic k

● Move the safety stick stick of the pilot control control to "Off" position. → All hydraulic functions must be disabled. di sabled. The diesel engine remains on.

6.1.4 6.1.4.3 .3 Checki Checking ng the th e Hois Hois t Limit Lim it Switch Swi tch (HS 1)

● Activate the winch, wind in the rope and slowly slowly lift the attached load (approx. 100 kg) kg) towards the hoist limit switch contactor weight. → The winch must come to an immediate stop.

GB 34 / 2010

6-4

START-UP / SHUTDOWN 6.1.4 6.1.4.4 .4 Checki Checking ng the t he Winch Winch Free-Fa Free-Fallll Funct ion

Initial situation: "Rope grab" mode selected (2). The winch free-fall function must be checked daily before each new work shift, to ensure it is working correctly.

1

8.1

P

P

8.2

GO01055002.wmf

•

Set selection selection switch switch (9) to the "Free fall " position. → Free-fall operation must remain deactivated.

•

Press button (15); → Free-fall operation must not b e triggered triggered.

•

Press pedal (3) (3) all the way way down and release button (15). → Free-fall operation must be triggered (the load will be held by the pedal).

GB 34 / 2010

GO01055006.wmf

6-5

START-UP / SHUTDOWN

6.2

SHUT-DOWN

6.2.1 6.2.1

Daily Shut-Dow n

● Park the machine machine on firm level ground. ● Set the boom to its minimum minimum permissible operating operating radius. ● Stop the equipment equipment or moveable loads and and use lifting equipment equipment to secure them in an upright position. ● Adjust the upper carriage in line with the crawlers. crawlers. ● Set all control control elements elements to "0" position. ● Move the safety stick stick of the pilot control control to "Off" position. ● Stop the engine.

CAUTION

Risk of damaging the engine! If the engine has been operating with a high load, let it run idle for about 5 minutes before stopping, to allow the temperature of coolant and oil drop and stabilize.

● When leaving the the equipment, equipment, lock the operator's cab. ● Set the battery main switch switch to "Off" position. position.

6.2.2 6.2.2

Shutting Shuttin g Down for a Long er Perio Period d

Fuel tank

● Before longer periods of standstill, fill up fuel tank completely with fuel for for protection against corrosion.

GB 34 / 2010

6-6

RIGGING / DERIGGING

7

RIGGING / DE-RIGGING

7.1

GUIDELINES FOR RIGGING AND DE-RIGGING

● Have assembly assembly work carried out by qualified qualified personnel only. only.

CAUTION

Severe accident hazard! The operator must be familiar with all the control elements and their capabilities before he starts rigging ri gging operations. WARNING!

Danger of falling! Personnel working on the mast or on the upper carriage must wear the prescribed fall protection equipment.

● The equipment must must only be mounted on even and horizontal horizontal ground with the necessary load-bearing capacity. ● Check all components for damage. damage. ● Steel components which which are subjected to heavy loads (e.g. the undercarriage, upper upper carriage, boom, auxiliary boom, supporting boom, kinematic triangle, tri angle, mast sections, masthead, winch trestles and the connection between between the piston eyes and the hydraulic cylinders and piston rods) should undergo visual inspection prior t o mounting to check for fissures. ● Before starting assembly, assembly, inspect the equipment equipment for a film of protecting protecting wax. All such wax must be removed (see Chapter Wax Removal). ● For lifting and loading, loading, use only the lifting slings forming part of the basic outfit. ● Attach lifting slings only to provided provided lifting eyes. eyes.

CAUTION

Tipping hazard! During rigging operations, the upper carriage must be in line with the undercarriage and be interlocked with it. i t.

● Select rigging mode: Button (4) on the control panel.

GB 34 / 2010

7-1

RIGGING / DERIGGING

7.2 •

WAX REMOVAL REMOVAL

Prior to putting into service, remove all all protecting wax wax with with a hot water water jet at a temperature of 90 – 95° C (approx. 200° F).

NOTE

CAUTION

GB 34 / 2010

Alternatively, the equipment can be washed down with a cold water detergent. The treatment must be repeated until all the equipment is totally free of wax.

Risk of damaging components! Detergents used must not be harmful to seals etc. Check the detergents for their areas of application prior to use.

7-2

RIGGING / DERIGGING

7.3

EXTENDING THE CRAWLERS CRAWL ERS

CAUTION

Tipping hazard! The crawlers must be extended as soon as the machine has been unloaded from the transporting vehicle and before rigging operations are begun.

First extend the left crawler:

NOTE

The photo shows the left crawlers, with the front idler (1) at the front and the drive (2) at the rear.

BG594460.jpg

● Remove the locking bar bar between the upper carriage and undercarriage. ● Release the retainers (2) and remove remove all the pins (1) from locking position "A". ● Use the button to extend the crawlers (this moves the crawlers forwards and backwards). backwards). ● Reinsert the pins (1) in locking position "B" and secure them with retainers (2). BV737516.jpg

GB 34 / 2010

7-3

RIGGING / DERIGGING

7.4

MOUNTING THE COUNTERWEIGHT COUNTERWEIG HT WARNING!

Tipping hazard! The machine must be fitted with the appropriate counterweight before rigging operations are begun. The counterweight(s) must remain unchanged and installed as long as the machine is rigged. ri gged. WARNING!

Severe accident hazard! No person must stand on or under a counterweight while it is being mounted. Persons working on the upper carriage must wear a fall protection belt secured to the upper carriage (red painted loop).

CAUTION

Risk of damaging components! Counterweights consisting of several parts are to be transported in upright position. For further information please refer to the documentation supplied with the base machine.

NOTE

GB 34 / 2010

7-4

RIGGING / DERIGGING

7.5

ASSEMBLING THE BOOM

7.5.1 7.5.1

Mounting the Boom Boo m Top

• • • •

Align the boom top and the top section section of the boom with the lifting equipment. equipment. Use four pins to mount mount the boom top on the top section of the boom. Secure the pins with cotter cotter pins. Establish an electrical connection.

GAALM074.wmf

GB 34 / 2010

7-5

RIGGING / DERIGGING 7.5.2 7.5.2

Assembling Assembl ing the Boo m Secti Secti ons

● Set the top section section of the boom down horizontally on a firm and level level surface, in front of the bottom section of the boom.

CAUTION

Risk of damaging components! Clean flange faces and locating pins and check for damage.

● Move the base machine machine up to the top section section of the boom. boom. WARNING!

Squashing hazard, shearing hazard and hitting hazard! Avoid getting limbs in between the mast sections. Minor backstay cylinder movements can lead to major movements movements of the t he mast sections. During the assembly operations, the operator must keep the person working at the mast in view at all times.

● Move the boom cylinder to align the bottom section of the boom (3) with the top section of the boom (1), until the holes for the assembly assembly pins (2) are ar e lined up. 1

2

3

B0000567.wmf

● Install the pins and secure. secure. ● Retract the boom cylinder to raise the bottom section section of the boom until the flange faces meet.

CAUTION

GB 34 / 2010

Risk of damaging components! Take care the locating pins are properly in place!

7-6

RIGGING / DERIGGING

● Bolt the top section of the the boom (7) to the bottom section of the boom (6) as illustrated here. 7

1 2 3 4 5 6 7

Hex head bolt Washer Tension bush Hex nut Lock nut Lower mast section Upper mast section

12

3

6

24 5 B0000568.wmf

● Remove transport supports. ● Establish hydraulic hydraulic connections between the boom sections. ● Establish electrical connections between the boom sections. To do this, remove plug (1) from transport socket (2) and plug it into a different boom section. BM400462.jpg

GB 34 / 2010

7-7

RIGGING / DERIGGING

7.6

ASSEMBLY ASSEMBL Y INSTRUCTIO INSTRUCTIONS: NS: SPRING SPRING ACCUMULATORS

Spring accumulator components: components: 1

9 2

5 3

4

8 6

7

GM000506.wmf

1 2 3 4 5

Cap Top insert Top Spring tube Set of springs

●

Arrange the the spring spring tubes tubes next to one another and screw screw them in place. MDSG 35 MDSG 40 MDSG 50

GB 34 / 2010

6 7 8 9

Insert Spring tube Butt Bottom insert (slot hole)

6.00 m 7.82 m 9.36 m

7-8

RIGGING / DERIGGING

● Attach the end of the the wire rope to the top top using pins.

GM000501.wmf

● Guide the other end of the wire rope through the spring tube. ● Push the first set of springs into the spring tube tube and then place the insert in after it.

GM000502.wmf

● Repeat the process until all the sets of springs are arranged next to one another another (when you reach the last set of springs, place the butt provided in after it i nstead of the insert). MDSG 35 MDSG 40 MDSG 50

4 5 6

GM000503.wmf

GB 34 / 2010

7-9

RIGGING / DERIGGING

● Screw the "bottom insert" (slot hole) hole) to the spring spring tube.

GM000504.wmf

● Push the installation tube over the sets of springs above it (this can only be done with type MDSG 50 or above). ● Using appropriate pulling pulling equipment (pulling force force of 1000 kg) kg) and the wire rope, rope, pull the set of springs in until the t he "top insert" can be put in place. During the pulling process, stay out of the hazardous areas at the ends of the spring tubes! CAUTION

GM000505.wmf

NOTE

The springs will now be pretensioned to such an extent that they are able to tension t ension the hydraulic hoses. Always remember that, when the hoist rope is not bearing any loads, the entire spring force is supported by the retaining plate (see arrow).

● The set of springs is now pretensioned and and ready for operation. operation. ● Repeat the process with the second spring spring accumulator. accumulator.

GB 34 / 2010

7 - 10

RIGGING / DERIGGING

7.7

ASSEMBLING ASSEMB LING THE MDSG SYSTEM

7.7.1 7.7.1

Installi Instal ling ng the th e MDSG MDSG System Syst em on the Base Machine Machin e

There are 2 different versions of the equipment that can be installed: Versi Version on 1: The hydraulic hose drum is separate from the set of springs. Versi Version on 2: The hydraulic hose drum is installed with the set of springs.

Initial situation: Mast installed.

● Set the boom boom down down on the ground.

CAUTION

GB 34 / 2010

Accident risk! All persons must vacate the area inside and beneath the boom when the MDSG equipment is being mounted on the boom.

7 - 11

RIGGING / DERIGGING 7.7.1.1 Assembly: Version 1

Position the mast as shown in the image: • •

Mount the auxiliary frame frame for the hose drum system on the bottom part of the boom. Mount the auxiliary frame frame for the spring accumulator accumulator on the top part part of the boom. boom.

AAAAA081.wmf

Follow the procedure outlined below: •

•

Use an auxiliary crane crane to raise the hose hose drum onto the auxiliary frame, and connect the drum and frame using pins. Secure the pins.

AAAAA082.wmf

GB 34 / 2010

7 - 12

RIGGING / DERIGGING

•

Use the auxiliary crane crane to position the spring spring accumulator accumulator on the hose drum system (as shown in the image) and secure it in place using pins.

AAAAA083.wmf •

Attach the spring accumulator accumulator to the auxiliary frame of the hose drum drum system. system. The spring accumulator base plate is flange-connected flange-connected to the t he retaining plate on the auxiliary frame. Make sure the base plate is in the correct position (the slot hole on the plate must be horizontal, as shown in view "A"). Do not fasten the end of the wire rope to any of the hose drums. ns c View "A"

Ansicht "A" View "A"

AAAAA084.wmf

GB 34 / 2010

7 - 13

RIGGING / DERIGGING

•

Mount the hose guides guides at the points points provided for them.

AAAAA085.wmf

•

Establish hydraulic connections connections (SAE (SAE 1 1/2" coupling) coupling) to the connection connection plate plate rotary lead-through in such a way that they will be unaffected by any axial or radial f orces.

AAAAA042.wmf

GB 34 / 2010

7 - 14

RIGGING / DERIGGING

•

Connect the hydraulic hydraulic hose to the connection connection plate of the the hose drum (SAE 1 1/4" coupling) and wind it in:

AAAAA048.wmf

GB 34 / 2010

7 - 15

RIGGING / DERIGGING

•

Attach the wire rope from the spring accumulator accumulator to the appropriate lifting point (see arrows below).

GR517431.jpg •

Turn the hose drum until the rope rope has been wound wound around the drum drum 3 times.

•

Carefully unwind unwind the hydraulic hydraulic hose from the hose drum and lead it through through the hose guide and hose guide wheels on the t he boom head.

CAUTION •

The drum is tensioned and must be secured to prevent it from winding the hose back in whilst you are unwinding it.

The procedure is the same for both drums.

G00005007.wmf

NOTE

GB 34 / 2010

Connecting the hose wheels to the sets of springs increases the retraction force when the hydraulic hoses are being unwound from the drum. Make sure that the hose drum is secured to prevent it from winding the hose back in whilst you are unwinding it.

7 - 16

RIGGING / DERIGGING 7.7.1.2 Assembly: Version 2

Position the mast as shown in the image:

● Mount the hose drums drums plus the spring accumulators accumulators on the auxiliary auxiliary frame (see arrows).

GO030511.wmf

GO0404007.jpg

GB 34 / 2010

7 - 17

RIGGING / DERIGGING

•

Mount the hose guides at the points provided provided for them on the mast. mast.

AAAAA085.wmf

•

Establish hydraulic connections connections (SAE (SAE 1 1/2" coupling) coupling) to the connection connection plate plate rotary lead-through in such a way that they will be unaffected by any axial or radial f orces.

AAAAA042.wmf

GB 34 / 2010

7 - 18

RIGGING / DERIGGING

•

Connect the hydraulic hydraulic hose to the connection connection plate of the the hose drum (SAE 1 1/4" coupling) and wind it in.

AAAAA048.wmf

● Guide the loose ends of the hydraulic hydraulic hoses through the hose hose guide and hose guide wheel.

CAUTION •

The drum is tensioned and must be secured to prevent it from winding the hose back in whilst you are unwinding it.

The procedure procedure is the same same for both drums. drums.

G00005007.wmf

NOTE

GB 34 / 2010

Connecting the hose wheels to the sets of springs increases the retraction force when the hydraulic hoses are being unwound from the drum. Make sure that the hose drum is secured to prevent it from winding the hose back in whilst you are unwinding it.

7 - 19

RIGGING / DERIGGING

7.8

INSTALLING THE CABLE CAB LE DRUM

Once the MDSG equipment has been installed, the t he cable drum needs to be put in place. Installing Installing the cable drum: •

Set the cable cable drum down in the correct position. position.

•

Position the mast mast above the cable drum as shown in the image.

•

Slowly lower the boom until the cable drum can can be connected to to the boom. boom.

•

Connect the cable drum drum to the hydraulic supply.

•

Establish an electrical electrical connection to the cable cable drum and depth indicator. indicator.

•

Guide the loose end of the the electric cable cable through the guide sheave. sheave.

GO030505.wmf

GB 34 / 2010

7 - 20

RIGGING / DERIGGING

7.9

HYDRAULIC HYDRAUL IC CONNECTIONS

Table for MDSG hydraulic connections Connection

Function

1

Open grab

2

Close grab

GO0304001.jpg

GB 34 / 2010

7 - 21

RIGGING / DERIGGING

Table for hydraulic connections to the hoist winch Connection

Function

1

Lower grab

2

Raise grab

3

Free fall control

4

Leak oil

5

Winch control

GN012031.tif

GO030506.wmf

GB 34 / 2010

7 - 22

RIGGING / DERIGGING

Table for hydraulic connections to the boom Connection

Function

1

Retract boom cylinder (long distance)

2

Extend boom cylinder (long distance)

3

Elec. cable drum down

4

Elec. cable drum up

5

Elec. cable drum, leak oil

6

Elec. cable drum, pilot oil

7 8

Extend boom cylinder (long distance)

9

Retract boom cylinder (short distance)

GO0304000.jpg

GAALM083.wmf

GB 34 / 2010

7 - 23

RIGGING / DERIGGING

7.10 INSTALLING INSTAL LING THE MAIN ROPE 7.10.1 7.10.1 Reevin Reeving g the Main Main Rop Rope e

The main rope is drawn in when the mast is down. Main winch in operating position. • • •

Press and hold the rigging mode button. Switch off the automatic rope tensioning facility. Remove rope guard guard pins pins (1) (1) from the boom and masthead. masthead.

1

1 GO01055013.wmf •

Use the right control lever to unwind unwind the main rope.

CAUTION

Risk of damaging components! Pulling in the main rope incorrectly can subject both it and the ropeguiding components to excessive wear. • Pull in the main rope in accordance accordance with with the position of the pulley block on the masthead.

Version 1: Position of the pulley block rotated 90° about the longitudinal axis of the grab

GO01055012.wmf

Version 2: Position of the pulley block parallel to the longitudinal axis of the grab

GO01055011.wmf

GB 34 / 2010

7 - 24

RIGGING / DERIGGING

3 2 1 GR517508.WMF

Version 1: Position of the pulley block rotated 90° about the longitudinal axis of the grab

NOTE • •

• • • •

If the grab is wide enough to install the pulley block in the standard position on the grab, reeve the main rope as described below. This position exerts the least wear on the rope.

Place the rope sheaves in position 2. Insert the main rope into the hose guide guide wheels at position position 2 and unwind it until the rope ends reach the contactor weights of the hoist limit switch. Attach and secure the rope guard pins. no t guide the main rope through the contactor weight of the hoist limit switch. Do not Thread the rope into the pulley block. Attach the rope to the boom. boom.

Versi Version on 2: Position of the pulley block parallel to the longitudinal l ongitudinal axis of the grab

NOTE • •

• • • • •

no t wide enough to install the pulley block in the standard If the grab is not position on the grab, the main rope will need to be reeved as described below.

Place the rope sheaves in position 1. Insert the main rope into the guide wheels wheels in position position 1 and and unwind unwind it until until the rope ends reach the contactor weights of the hoist limit switch. Attach and secure the rope guard pins. Guide the main rope rope through through the contactor weight of the hoist limit switch. switch. Thread the rope into the pulley block. Guide the main rope rope through through the contactor weight of the hoist limit switch switch again. Attach the rope to the boom. boom.

GB 34 / 2010

7 - 25

RIGGING / DERIGGING

7.11 INSTALLING INSTAL LING THE ROPE SWIVEL

CAUTION

Severe accident hazard! Always attach the reeved hoist rope to the top fix point with a r ope swivel. Use only the genuine BAUER Maschinen GmbH rope swivel. The rope swivel must be designed for the max. pulling force of the winch used.

● Install the rope swivel swivel as shown shown in the figure figure below. Risk of damaging components! Mount the rope swivel in the right position. The lube nipple must face up. CAUTION

● Following installation, lubricate the the rope swivel swivel and test whether it rotates freely.

1 6 5

1 2 3 4 5 6

Hoist rope Pin Lube nipple Hex head bolt Lock washer Washer

2 4

3

B0000572.wmf

GB 34 / 2010

7 - 26

RIGGING / DERIGGING

7.12 7.12

INSTALLING THE GRAB

G00005008.wmf •

•

• • •

Once the MDSG equipment and cable drum have been installed, position position the grab grab in front of the base machine or approach the grab using the base machine. The grab must must be positioned in front of the base machine machine such that the the cover of the hydraulic box in the grab is facing upwards. Lower the boom and position position it in front of the grab as shown shown above. above. Install the pulley block on the grab. Secure the hose drums drums to prevent them winding the hoses in unintentionally. unintentionally.

CAUTION

Injury hazard! Hose drums are tensioned. Before unwinding hydraulic hoses from the hose drums, secure the drums to prevent them t hem from winding the hoses back in unintentionally.

GO01025003.png • • • •

•

Pull the hydraulic hoses to the grab grab and connect them (1). * Unwind the electric cable cable from the drum and connect it to the grab (2). * Fasten the the hydraulic hydraulic hoses hoses in place using the the clamps provided. When the boom is raised following this this (see the the section entitled "Raising the Boom"), Boom"), make sure that the grab is not raised along with it. it . To raise the grab, move move the boom (once raised) to its operating operating position position and raise the grab using the hoist winch.

*) The positions of the connections on the grab depend on the equipment being used and may vary.

GB 34 / 2010

7 - 27

RIGGING / DERIGGING

7.13 RAISING THE B OOM WARNING!

Squashing hazard, shearing hazard and hitting hazard! Minor backstay cylinder movements can lead to major movements movements of the t he mast sections. During the assembly operations, the operator must keep the person working at the mast in view at all times.

CAUTION

Danger of being injured by falling parts! Remove all loose objects from the boom.

● Press the button for rigging rigging mode and move the left control control lever backwards smoothly to retract the boom cylinder (long stroke). The boom is now raised.

7.13 7.13.1 .1 Attachi ng Retaining Retaining Clamps Clamps

CAUTION

Tipping hazard! These clamps must be attached as soon as the boom has been raised.

● Attach the retaining retaining clamps (1) to the boom boom cylinder once it has been retracted (long stroke). ● Push O-ring (2) up over the retaining clamps clamps and insert it in groove (3). ● Using a rubber rubber hammer, hammer, knock locking ring ring (4) down onto the two retaining clamps.

4 3 1

3 1

2

BK331531.wmf

GB 34 / 2010

7 - 28

RIGGING / DERIGGING

7.14

DISASSEMBLING DISASSEMB LING THE EQUIPMENT

7.14.1 7.14.1 Disassembl Disass embling ing the Grab • • • •

Place the the grab grab down in front of the the base machine. Close the ball cocks for the grab supply supply on the base base machine. machine. Lower the boom (if necessary). Secure the hose drums to prevent them winding the hoses hoses in.

CAUTION

Risk of injury! The hose drums are tensioned. t ensioned. Before disconnecting hydraulic hoses from the grab, secure the drums to prevent them from winding the hoses back in.

•

Disconnect the hydraulic hoses from the grab.

•

Remove the pins from the cable guide roller roller on the boom head.

•

Disconnect the electric cables cables from the grab and wind them in.

•

Detach the hoist rope from the top fix point. point.

•

Remove the pins from the rope guide pins.

•

Wind in the hoist rope until it reaches the boom head.

•

Move the base machine away from the grab.

7.14.2 7.14.2 Disassembl Disass embling ing MDSG MDSG Equip ment •

Lower the boom boom (see the "LOWERING "LOWERING THE BOOM" section).

•

Remove the hose guide from the boom.

•

Wind in the hydraulic hoses and electric cables.

•

Disconnect the electric cables from the base machine. Disconnect the hydraulic hoses from the base machine. Use the auxiliary crane crane to secure secure the hose drum drum and remove it from the auxiliary frame on the boom. Set the hose drum down onto a suitable transport transport rack. rack. Repeat the procedure for the second hose drum. Remove the auxiliary frame from the boom.

• •

• • •

GB 34 / 2010

7 - 29

RIGGING / DERIGGING

7.15 LOWERING THE BOOM BO OM 7.15 7.15.1 .1 Removi Removing ng Retaining Retaining Clamps Clamps

● Using a hammer, knock the locking ring (4) off the both retaining clamps (1). ● Remove the O-ring (2) from the groove (3) in the clamp. ● Remove the retaining clamps clamps from the boom cylinder.

4 3 1

3 1

2

B0000671.wmf

7.15 7.15.2 .2 Lowering Low ering the Boom

● Adjust the upper carriage carriage in line with the undercarriage undercarriage so that that the boom is positioned on the same side as the front idlers of the undercarriage.

CAUTION

There is a risk that the boom could collide with the undercarriage and any parts attached to it. The upper carriage must be in the correct position.

● Unwind the main rope and place place it on the ground beside the base machine. machine. ● Press the button for rigging rigging mode and move the left control control lever forwards smoothly smoothly to extend the boom cylinder (long stroke). The boom is now lowered. l owered.

GB 34 / 2010

7 - 30

RIGGING / DERIGGING

7.16

REMOVING THE COUNTERWEIGHT COUNTERWEI GHT WARNING!

Risk of getting crushed or hit! No person must stand on or under a counterweight while it is being mounted. Avoid getting limbs in between machine and counterweights. Persons working on the upper carriage must wear a fall protection belt secured to the upper carriage.

CAUTION

Risk of damaging components! Counterweights consisting of several parts are to be transported in upright position. During their intermediate inter mediate storage, the counterweights must be secured against tipping. For further information please refer to the documentation supplied with the base machine.

NOTE

GB 34 / 2010

7 - 31

RIGGING / DERIGGING

7.17 RETRACTING THE CRAWLERS CRAWL ERS Begin with t he right crawler.

NOTE

The picture shows the left crawler: The front idler (1) is on the front side, the drive (2) is at the back. BG594461.jpg

● Clean and grease grease the sliding sliding surfaces (3) on the crawlers and beams.

BV737445.jpg

● Release the retainers (2) and remove remove all the pins (1) from locking position "B". ● Use the button to retract the crawlers (this moves the crawlers forwards and backwards). backwards). ● Reinsert the pins (1) in locking position "A" and secure them with retainers (2).

BV737516.jpg

GB 34 / 2010

7 - 32

TRANSPORT

8

TRANSPORT

8.1

SAFETY GUIDELINES FOR TRANSPORT

● Only use hoisting equipment equipment and lifting slings slings that have sufficient sufficient bearing capacity. capacity. WARNING!

Severe accident hazard! 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 i ndividual components are painted RED.

CAUTION

The hoist rope must be vertical at all times, ti mes, to prevent swinging. If the load begins to swing, set it down immediately and readjust until the rope is vertical again.

● Arrest and secure secure movable movable parts of the the equipment. equipment. ● Check the work platforms platforms are safely latched to to the upper carriage. ● Put accessories to be stored safely safely away so they will will not be an obstacle to traffic on the roads or on a construction site and will not be interfered inter fered with by accident or abuse. ● Additionally cover up and secure sharp edges, projecting points points and cutting blades. ● The driver of the transporting vehicle vehicle is responsible for checking checking each time before he starts to drive that all the equipment, the machine and accessories, accessories, are restrained from movement and properly tied down to the deck of the vehicle. ● The haulier in charge is responsible for for the transport of the equipment, equipment, the machine machine and accessories. ● The hauler should should be informed of the transport transport dimensions, the weights and the route. ● A road permit permit must be obtained.

GB 34 / 2010

8-1

TRANSPORT

8.2

MEASURES TO TAK TAKE E FOR TRANSPORT

MACHINE Before loading:

The machine must be in transport position before it may be driven or lifted by a cr ane on the low-loading truck: The machine is in its transport position, if – – – – – – – –

all of the equipment has been removed removed from the boom. the boom has been lowered. the top section of the boom has been removed. the bottom section of the boom has been removed (if necessary). necessary). the upper carriage is in line with the crawlers and locked to the undercarriage. the crawlers are retracted. the beam extensions (if so equipped) equipped) have been removed. removed. the counterweights have been removed removed (if necessary). necessary).

After Af ter l oad i ng: ng :

● ● ● ● ● ●

Underpin the lower mast mast section with transport supports and secure. secure. Move the safety stick stick of the pilot control control to the "Off" position. Stop the engine engine and remove remove the ignition ignition key. Lock the operator's operator's cab and and remove the key. Put the battery main switch switch to the "Off" position. position. Tie the machine safely safely down to the deck of the transporting vehicle. vehicle.

EQUIPMENT

● Take the dimensions dimensions and weight weight of the MDSG equipment equipment into consideration consideration when transporting it.

GB 34 / 2010

8-2

TRANSPORT

8.3

DRIVING ON / OFF A LOW L OADER .

.

3. 6.

10.

10.

9.

9.

7.

7. 4. 5. 2.

1. max.40° 9 8

9

10

?

?

10A

? BK786512.wmf

1 2 3 4 5 6

Battery main switch "ON" Unlock "EMERGENCY-STOP" "EMERGENCY-ST OP" Move pilot control safety stick to "Off" Start engine Adjust engine speed Move pilot control safety stick to "ON"

GB 34 / 2010

7 Lift bottom section of boom with left left control control lever 8 Travel forwards by pushing both levers forwards 9 Travel in reverse by pulling both levers backwards 10 Lower bottom section of boom with left control lever

8-3

TRANSPORT

8.4

LIFTING POINTS

Lifting points on the machine are marked in green and have a hook symbol. The lifting points for the individual components are marked in red.

BK1162502.wmf

GB 34 / 2010

8-4

TRANSPORT

8.5

TYING DOWN WARNING!

Severe accident hazard! Attach the lashing chains only at the designated lashing points. Lashing chains must have sufficient load-bearing capacity.

Tying points

– On blue undercarriages, the points points provided for tying down down are painted YELLOW. – On yellow undercarriages, the points points provided for tying down are painted painted BLUE. – In addition, tying points bear a hook symbol symbol and show the max. permissible pulling pulling force. To tie down

● Tie the equipment down down on the transporting vehicle in the professional professional manner and in compliance with national directives. Principally, the haulier in charge is responsible for tying down the equipment properly. Example Example of tying -down points

CI439400.jpg

GB 34 / 2010

8-5

TRANSPORT

8.6

TRANSPORT TRANSPORT DATA

Dimensions Dimensions in [mm]

0 1 9 2

5 5 9 2

0 6 3 0 1 7 8

2200

2325

6935 12715

3455

0 0 4 3

5 6 7 1 0 4 8

0 0 2 1

4440 5360 6700

700 3200 - 4400 R 3450 GU035501.wmf

Weights Component

Weight Weight in [t]

Machine with bottom section of boom and counterweights Counterweights Boom head with guide wheels

47.2 6.2 + 6.2 1.6

Machine

Equipment

Top section of boom with MDSG equipment

GB 34 / 2010

7.6

8-6

MAINTENANCE

9

MAINTENANCE

9.1

SAFETY GUIDELINES FOR MAINTENANCE MAIN TENANCE

● Have maintenance carried out by the after sales service only or by skilled skilled personnel authorised by the after sales service. ● Only use genuine genuine BAUER Maschinen Maschinen GmbH spare parts. parts. ● Observe the "Safety Information" leaflet supplied with the equipment. equipment. ● Carry out maintenance maintenance at the prescribed intervals. intervals. ● Also observe the other other manufacturers' service service instructions for components components of the equipment.

9.2

MAINTENANCE MAINTENA NCE INTERVALS INTERVAL S

The maintenance for this equipment is organised into the following intervals: – – – – – – –

Every Ever y 10 hour ho urss o f o perat per atio ion n or o r d ail y Every Ever y 50 hour ho urss o r o p erat io n or o r w eekly eekl y Every Ever y 250 hour ho urss o f o perat per atio ion n or o r mo m o nthl nt hlyy Every Ever y 500 hour ho urss o f o perat per atio ion n or o r every ev ery t h r ee mo nths nt hs Every Ever y 1000 hou h ours rs o f o perat per atio ion n or o r yearl y earlyy Every Ever y 2000 hou h ours rs o f o perat per atio ion n or o r yearl y earlyy Every Ever y 3000 hou h ours rs o f o perat per atio ion n or o r every ev ery t w o years. year s.

The specified intervals are based on the operating hours meter of the base machine. NOTE

Normally the intervals are cumulative, cumulative, meaning that when the 1000 hours maintenance is due, the 10, 50, 250 and 500 hours services will also have to be carried out again. If the equipment equipment is used under extremely wet and dusty conditions, it may be necessary to service more often.

CAUTION

GB 34 / 2010

Loss of the equipment warranty! Maintenance carried out on the equipment must be entered into the "Maintenance and Repair Log" supplied. In case of a warranty claim, BAUER shall have the right to consult the log.

9-1

MAINTENANCE

9.3

MAINTENANCE PLAN PL AN

9.3.1 9.3.1

Entire Equipment

Entire equipment table Compon ents

Maintenance int erval Operation

y h l i 0 a 1 d

y l h k 0 e 5 e w

y l h h 0 t 5 n 2 o m

s h h t 0 n 0 o 5 m 3

h l y 0 r 0 a 0 e 1 y

h l y 0 r 0 a 0 e 2 y

h y s r r a 0 e 0 v e 0 e y 3 2

Note

Entire equipment Visual inspection - Missing or damaged parts - Load-bearing steel components (e.g. the undercarriage, upper carriage, boom, auxiliary boom, supporting boom, kinematic triangle, mast sections, masthead, winch trestles and the connection between the piston eyes and the hydraulic cylinders and piston rods) should undergo visual inspection prior to mounting to check for fissures and other damage. - Missing or loose bolts / bolted connections. - Missing or damaged safety devices, such as fire extinguisher, first-aid kits, warning signs - Leaks Check Check for pro per function of: - Controls and indicators - Safety devices devices such as emergency STOP, pilot control safety stick, limit switches, hoist limit switches - Free-fall Free-fal l function Inspection by competent engineer engineer

X X

X X

X X X

X X

*Only during running-in period

GB 34 / 2010

9-2

MAINTENANCE 9.3.2

Attachments

Table Attachment Compon ents


y h l i 0 a 1 d

y l h k 0 e 5 e w

y l h h t 0 n 5 o 2 m

s h h t 0 n 0 o 5 m 3

h l y 0 r 0 a 0 e 1 y

h l y 0 r 0 a 0 e 2 y

h y s r r a 0 e 0 v e 0 e y 3 2

Note

Boom head

- Check that the connecting bolts and screws for the mast, if provided, are firmly screwed in; tighten screws - Replace the connecting bolts for the boom, if these are being used Boom Boom - Lubricate guide rails - Check that the connecting pins and bolts between the boom components are firmly inserted (if these are being used); tighten bolts - Replace connecting bolts between the boom components, if these are being used Boom pivot point - Lubricate the boom pivot point - Lubricate mounting bolts - Replace flange bolts

X*

10000 hrs

X X*

5000 hrs

X X 10000 hrs


GB 34 / 2010

9-3

MAINTENANCE



y h l i 0 a 1 d

Winches - Check oil level Main winch

y l h k 0 e 5 e w

y l h h t 0 n 5 o 2 m

s h h t 0 n 0 o 5 m 3

h l y 0 r 0 a 0 e 1 y

h l y 0 r 0 a 0 e 2 y

h y s r r a 0 e 0 v e 0 e y 3 2

Note

X

- Change oil Main winch

X*

- Lubricate counter bearings Main winch

X

X

- Ensure that mounting bolts of the winch trestles are firm, tighten bolts - Replace mounting bolts of the winch trestles

X* 10000 hrs

Cylinders

- Clean piston rods - Check tightness of cylinder - Lubricate joints Bearings and bearing bearing pins - Lubricate all bearings and bearing pins that are equipped with lube nipples

X X X X


GB 34 / 2010

9-4

MAINTENANCE



y h l i 0 a 1 d

y l h k 0 e 5 e w

y l h h t 0 n 5 o 2 m

s h h t 0 n 0 o 5 m 3

h l y 0 r 0 a 0 e 1 y

h l y 0 r 0 a 0 e 2 y

h y s r r a 0 e 0 v e 0 e y 3 2

Note

Wire rope and accessories Ropes, rope fasteners, thimbles and sleeves - Inspect for wear and damage Rope swivel - Lubricate - Check if bolts are secure - Check slew function Rope hold-down rollers - Check parallel position position to cable drum - Inspect for wear and damage Rope sh eaves eaves - Inspect for wear, damage, and if bearing gap is exceeded - Check sheaves are free to rotate - Check if bolts are secure - Check groove radii for deviation and edge formation - Put grease grease in lube nipples, where fitted: - Rope sheaves with friction bearing - Rope sheaves with roller bearings Rope roller brackets - Ensure that mounting bolts of the turning blocks are firm, tighten bolts - Replace mounting bolts of the turning blocks

X

X X X X X

X X X X

X

X

X*

10000 hrs


GB 34 / 2010

9-5

MAINTENANCE 9.3.3 9.3.3

Work Equipment

Table Equipment Compon ents


y h l i 0 a 1 d

y l h k 0 e 5 e w

y l h h t 0 n 5 o 2 m

s h h t 0 n 0 o 5 m 3

h l y 0 r 0 a 0 e 1 y

h l y 0 r 0 a 0 e 2 y

h y s r r a 0 e 0 v e 0 e y 3 2

Note

MDSG Visual inspection: - Missing or damaged parts - Missing or loose pinned/bolted/screwed connections Lubrication points - Lubricate rotary lead-through Gear bearings - Hose drum system bearings Function check: - Displays/indicators Displays/i ndicators and control equipment - Safety devices devices such as hoist limit switches Inspection by competent engineer engineer

X X*

X

X X X X X X X


GB 34 / 2010

9-6


Upper Carriage

Upper carriage table Compon ents


y h l i 0 a 1 d

y l h k 0 e 5 e w

y l h h t 0 n 5 o 2 m

s h h t 0 n 0 o 5 m 3

h l y 0 r 0 a 0 e 1 y

Engin e

Observe separate engine manual!!

Cooli ng system

Observe separate engine manual!!

h l y 0 r 0 a 0 e 2 y

h y s r r a 0 e e 0 v 0 e y 3 2

Note

Pump distributor g ear ear

- Check oil level - Change oil

X X*

X

Hydraulic Hydraulic system Hydraulic tank - Check oil level - Change oil - Take oil sample and check oil Hose assemblies - Have them inspected for damage damage by an expert Filter element replacement

-

X X* X X

Pilot control filters Return-flow filters Leak-oil filters Free-fall filters Tank breather breather filter Suction filter Breather filter

Pressure accumulators - Check preload pressure Oil cooler - Clean - Check for damage

X

X* X* X* X*

X X X X X

X*

Or if contamination is indicated (on screen or filter) X

X

X*

X X

X

Swing m echanism echanism

- Grease external slewing ring teeth - Lubricate ball bearing race and rotor bearing - Tighten up screws

X X*

X X*

X


GB 34 / 2010

9-7

MAINTENANCE

Upper carriage table Compon ents


y h l i 0 a 1 d

y l h k 0 e 5 e w

y l h h 0 t 5 n 2 o m

s t h h 0 n 0 o 5 m 3

h l y r 0 a 0 e 0 y 1

h l y r 0 a 0 e 0 y 2

h y s r r a 0 e 0 v e 0 e y 3 2

h l y 0 r 0 a 0 e 2 y

h y s r r a 0 e 0 v e 0 e y 3 2

Note

Counterweight

- Check all fastening elements are applied and firm Electrical system

X

Batteries - Check electrolyte electrolyt e level - Check cable connections Fuses - Check fuses Filters - Replace air filter filt er on wiring cabinet

X X X

X


9.3.5

Undercarriage

Undercarriage maintenance table Compon ents

Maintenance int erval

Operation

y h l i 0 a 1 d

y l h k 0 e 5 e w

y l h h t 0 n 5 o 2 m

s h h t 0 n 0 o 5 m 3

h l y 0 r 0 a 0 e 1 y

Note

Crawler track assemblies Visual inspection - Missing or damaged parts - Carry out out a visual inspection of load-bearing steel components (e.g. centre bridge and crawlers) to check for fissures and other damage. - Perform a visual check of the crawler drive wheels, tread rollers and travel gear to ensure they are firmly attached; tighten if necessary Travel gear - Check oil level - Change oil Crawler tracks - Check chain tension - Check that the mounting bolts bolts for the crawler track shoes are firm Telescopic guide - Clean and grease

X X

X

X X*

X

X X

X


GB 34 / 2010

9-8

MAINTENANCE

9.3.6 9.3.6

Optional Equipment

Optional equipment table Compon ents


y h l i 0 a 1 d

y l h k 0 e 5 e w

y l h h t 0 n 5 o 2 m

s h h t 0 n 0 o 5 m 3

h l y 0 r 0 a 0 e 1 y

h l y 0 r 0 a 0 e 2 y

h y s r r a 0 e 0 v e 0 e y 3 2

Note

Ai r con c on diti di ti on ing in g

- Operate the air conditioning system - Clean air filters (optional) - Clean condenser

X

2 - 3 weeks X

X


GB 34 / 2010

9-9

MAINTENANCE

9.4

MAINTENANCE MAINTENA NCE DURING LONGER PERIODS OF STA STANDSTILL NDSTILL

Engine

● Every 2 to 3 weeks, start the diesel diesel engine and let it run in the medium rpm range for about 1 hour.

CAUTION

Risk of damaging the engine! If it is i s not possible to start the engine during the standstill, preservation measures must be taken. Please refer to the diesel engine instruction manual.

Air Ai r c ondi on di t io ning ni ng

● Every 2 to 3 weeks, weeks, turn the air air conditioning on (if fitted) for a short short time. Slewing Slewing r ing

● Preserve the slewing ring ring teeth. ● From time to time during the standstill, remove remove dust and inspect the surface of teeth, slewing ring and drive dri ve pinion for the onset of corrosion; clean and grease as required. Undercarriage telescoping guidance

● Preserve telescopic telescopic guides with grease.

GB 34 / 2010

9 - 10

MAINTENANCE

9.5

LUBRICATION LUBRICA TION PLAN PLA N 5 5 6

7

2

3/4 2 1 2 8

G0030509.wmf

Every 10 operating hour s: 6 7 8

Rope swivel Pulley block Gear ring (outside)

Every 50 operating hours : 1 3/4 8 8

Every 250 250 operating hour s: 2 Boom cylinder joint 5 Boom head rope sheaves

Every 1000 1000 operating operating hours:

Main winch bearing MDSG gear Slewing ring bearing Undercarriage cylinder joints

Observe the instructions in the manual supplied by the base machine manufacturer. NOTE

GB 34 / 2010

9 - 11

MAINTENANCE

9.6

HYDRAULIC HYDRAUL IC SYSTEM

9.6.1 9.6.1

Hose Assembl Ass emblies ies

Inspection ● Hose lines must must be inspected at least least once a year by an expert. expert. Replace the hose lines if the inspection reveals the following:

– Damage in the outer layer down to the core of the hose (e.g. abrasion, cuts or cracks). – The outer layer of the hose is brittle (cracks in the sleeving). – The hose line is no longer in its natural shape, both with and without pressure pressure applied and while it is bent (e.g. ( e.g. layers separating, bubbles forming). forming). (See also DIN 20066 Part 4.) – Leaks. – Damage or deformation of hose end end fittings (tightness impaired); minor damage damage to the surface does not require replacement. – Hose slips out of end fitting. – Corrosion on the end fitting, impairing the function and stability. stability. – The hose is not assembled assembled in compliance with instructions. – The storage and service life are exceeded. Storage and service life ● Hoses and hose assemblies assemblies must be stored in a cool, dry and dust-free environment. environment. Avoid exposure to direct sunlight or UV radiation.

Storage and service life: Storage time Service life (including storage time)

Hose

Hose assembly

2 years

2 years 6 years

Re-use Generally, hoses that have been in service as part of a hose assembly ought not to be re-used in a new hose assembly as they will no longer meet the requirements.

If a hose is re-used despite this, evidence must have been obtained to show that it is suitable for use and will function correctly with the fitting in i n question.

GB 34 / 2010

9 - 12

MAINTENANCE 9.6.2 9.6.2 •

Hydraulic Cylinders Cylind ers

Every 10 operating hours or daily, and every time time before starting up again after a longer period of rest, clean all cylinders and check them for tightness.

CAUTION

Risk of causing damage damage to the t he piston rods! Do not clean cylinder piston rods with a water jet, sharp tool, caustic lye or an abrasive. Severe accident hazard! 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). pins).

On cylinders that are kept kept extended xtended d uring rest:

Risk of corrosion damage in corrosion-supporting environments! environments! The tasks specified below must be carried carri ed out without fail. CAUTION •

•

Once or twice a week, rub down down piston rods with hydraulic oil, or repeatedly repeatedly retract and extend the rods. Before a longer standstill, standstill, preserve preserve piston rods with an acid-free grease.

GB 34 / 2010

9 - 13


Filt er Replacement

9.6.3 9.6.3.1 .1 Replaci Replacing ng the Li ne Filters

The element for the line filters must be replaced after the first 250 operating hours or one month. Following this, the filter element will need to be replaced every 1000 or 2000 operating hours (see maintenance plan for upper carriage) or whenever it is indicated i ndicated that the element is contaminated (optional; warning lamp, error message or display on filter). WARNING!

Serious injury hazard! Before replacing a filter element, depressurise the hydraulic system and allow it to cool down (see the base machine machine manual).

NOTE

When the hydraulic oil is cold, the contamination indicator may light up for a short while.

Line filter: 1 2

Free-fall filter, pos.1 (Bauer component) component) Pilot oil filter, pos. 2 (Hyundai component)

3 4

Leak oil filter, pos. 3 (Bauer component) Return-flow filter in hydraulic tank (Hyundai component) component)

5 6

Suction filter in hydraulic tank (Hyundai component) Breather filter on hydraulic tank (Hyundai component)

BM00995002.wmf

GB 34 / 2010

9 - 14

MAINTENANCE Replaci Replacing ng a filter filt er element element

● Place a suitable suitable container underneath underneath the filter filter housing and unscrew the bottom (3). ● Remove the filter filter element (2) from the top (1) of the housing, and dispose of it along with hazardous waste. ● Clean the top and bottom of the housing. housing. ● Install a new filter element in the the top of the housing. ● Screw the bottom to the top and tighten.

1 2

3 B0000623.wmf

GB 34 / 2010

9 - 15

MAINTENANCE

9.7

WINCHES

9.7.1 9.7.1

Checking Checki ng the th e Oil Level

All equipped winches must be checked for proper pr oper level of gear oil every 50 operating hours or weekly, and whenever the equipment is started up again after a longer standstill.

CAUTION

Danger of oil spray! Check the oil level only when the winch is off.

Winches Winches with dips tick

● Position winch so that the tube (2) is in an upright position. ● Unscrew the dipstick dipstick (1). ● Dry the dipstick with a clean clean and lint-free cloth. ● Reinsert the stick completely. ● Pull the stick out again again and read it. ● If the oil has sunk to the MIN mark, mark, top up with new oil and check again. The MAX mark must not be exceeded. ● Clean the sealing sealing faces, check seal seal for damage damage and wear, replace if necessary. ● Reinsert the dipstick dipstick and screw screw it down down tight.

1 max. min.

2 3 B0000574.wmf

Winches Winches with s ight g lass

The oil level can be checked in any position of the winch. ● If the oil level level has reached reached the lower limit (min. = 20 mm below the winch centre line), add oil through one of the screw plugs (2), then recheck the oil level. Make sure the oil level does not exceed the upper limit ("max." = winch centre line). ● Clean the sealing sealing faces, check seal seal for damage damage and wear, replace if necessary. ● Reinsert the screw plug and screw screw it down down tight.

GB 34 / 2010

max. min.

20 mm

1 B0000846.wmf

9 - 16


Changing Changin g the th e Gear 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.

CAUTION

Danger of oil spray! Change oil only when the winch is off.

Winches Winches with dips tick

● Position winch that the tube (2) is in an upright position. ● Unscrew the dipstick dipstick (1). ● Remove the drain drain screw (3) and drain the gearbox. ● At low outdoor temperatures, flush the empty empty gearbox with a warmed-up part of the new oil. ● Clean the sealing sealing faces, check seal seal for damage damage and wear, replace if necessary. ● Screw in the drain screw. screw. ● Fill in new gear oil. oil. ● Check the oil oil level. ● Reinsert the dipstick dipstick (1) and screw it down down tight.

1 max. min.

2 3 B0000574.wmf

Winches Winches with s ight g lass

The gear oil can be changed in almost any winch position.

● Unscrew one of the screw screw plugs (2). (2). ● Unscrew one of the screw screw plugs (1) and drain the gear oil. ● At low outdoor temperatures, flush the empty empty gearbox with a warmed-up part of the new oil. ● Clean the sealing sealing faces, check seal seal for damage damage and wear, replace if necessary. ● Reinsert the screw plug (1). ● Fill in new gear oil. oil. ● Check the oil oil level. ● Reinsert the screw plug (2) and tighten.

GB 34 / 2010

max. min.

20 mm

1 B0000846.wmf

9 - 17

MAINTENANCE

9.8

WIRE ROPE ACCESSORIES

9.8.1 9.8.1

Rope Swivel

Every 10 operating hours or daily:

● Lubricate the rope swivel (2) until until grease comes comes out of the side of the housing. ● Check that the rope swivel swivel can rotate freely. Conduct the test manually, with no load suspended from the swivel. If the rope swivel will not rotate r otate properly after it has been lubricated, repair or replace it with a new one. ● Check mounting mounting bolts (1 and and 3) are firmly firmly in place. Retighten them as required. Replace the bolts with new ones if they are worn out or demonstrate excessive play.

1 2

3 B0000576.wmf

If the rope swivel is damaged, replace it immediately! CAUTION

9.8.2 9.8.2

Rope Hold-Down Hold -Down Rollers Roll ers

Every 50 operating hours or weekly:

● Check rope hold-down rollers for wear wear and whether they are working correctly. ● Check the roller roller is parallel to the cable cable drum. ● Check the mounting mounting bolts are firmly in place. place. ● Adjust the tension screws until all the tension tension springs are equal. Do not tension worn-out springs too much but replace them with new ones. B0000509.wmf ● Re-align or replace replace protecting bars that are bent. ● Replace the centre pins, sleeves and spacers if they demonstrate demonstrate excessive play. ● If grooves have been been created in a roller, reface the roller (by turning it on a lathe), or replace it with a new one. Refaced rollers have a diminished diameter, so the prestressing of the tension springs must be adjusted accordingly.

GB 34 / 2010

9 - 18


Rope Fasteners, Fasteners, Thimbl es and Sockets


● Check whether the wire wire rope is firmly in place place in the fitting. ● With poured rope fittings, fittings, inspect for broken wires wires and corrosion directly directly where the rope exits the fitting. ● With swaged-on rope fittings, fittings, inspect for broken broken wires next to the fitting, cracks in the sleeve and whether the rope grips the material firmly.

CAUTION

GB 34 / 2010

Danger of rope breaking! br eaking! If a defect is found on a rope r ope fitting, cut off the rope end and re-fit it.

9 - 19

MAINTENANCE 9.8.4

Rope Rop e Sheaves

CAUTION

Risk of damaging the rope! r ope! Sluggish or seized rope sheaves subject the rope to excessive wear and abrasion and make the load distribute unevenly on the rope structure. Repair or replace sluggish or seized rope sheaves, if greasing will not do.

9.8.4.1 9.8.4.1 Greasing Rop e Sheaves Sheaves Rope sheave type

Maint Maintenance enance interval int erval

Maint Maintena enance nce inst ructio ruc tio ns

Rope sheaves with friction bearings 10 operating hours / daily

BM659821.jpg

Rope sheaves with roller bearings 1000 operating hours/ yearly

CAUTION

Risk of damaging the bearing seal! Greasing while rope sheave is rotating. Press grease in slowly to prevent squeezing out bearing seal.

BM659822.jpg

Rope sheaves greased by the central lubrication system

Automatic

BM659823.jpg

GB 34 / 2010

9 - 20

MAINTENANCE 9.8.4.2 9.8.4.2 Checking Checki ng Rope Sheaves Sheaves Operation

Maint Maintenance enance interval int erval

Check whether the rope sheaves are free to rotate.

250 operating hours/ monthly

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

250 operating hours/ monthly

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

1000 operating hours/ yearly

GB 34 / 2010

Maint Maintena enance nce inst ructio ruc tio ns

Re-machine the groove, or replace the rope sheave with a new one, if the groove no longer complies.

9 - 21

MAINTENANCE

9.9

MDSG LUBRICATION LUBRICA TION PLAN PLA N

Lubricate MDSG equipment every 50 h or weekly.

1

Rotary lead-through

2

Gear bearings

3

Hose drum bearings

Lubricate the gear wheels.

GR517419.jpg

GB 34 / 2010

9 - 22

MAINTENANCE

9.10 9.10

CRAWLER TRACK ASSEMBLIES WARNING!

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

9.10 9.10.1 .1 Visual Inspecti on


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

Track shoes (1) Track links (2) Carrier rollers (3) Front idlers (4) Track guide (5) Tread rollers (6) Crawler drive wheels (7) Travel gear (8)

8

7

6

5 B0000676.wmf

NOTE

GB 34 / 2010

On machine with crawlers extended, the crawler telescoping surfaces should be kept corrosion protected with grease.

9 - 23


Crawler Tracks

9.10.2. 9.10.2.1 1 Checking Checki ng the Track Tensi Tensi on

Check the track tension every 10 operating hours or daily. - , m 2-3 cm

● Thoroughly clean clean each crawler and and its sliding surfaces. ● Travel forward a short distance with with the machine and then stop it. ● Measure the sag sag over a length of 1 1.5 m (see fig.). The distance between the measuring rod and track (see fig.) should be roughly 2 - 3 cm in the centre. Otherwise, the track tension will need to be readjusted.

1 - 1,5 m 2-3 c m

1 - 1,5 m 2 - 3 c m

B0000680.wmf

9.10 9.10.2. .2.2 2 Adjus ting ti ng the Track Track Tensio Tensio n Tightening the Track

● Remove cover plate plate (5) and clean the grease nipple (2). (2).

3 2 5 1 3 4 B0000725.wmf

● Put a high-pressure grease grease gun to the the grease nipple. ● Work the grease gun until the proper proper track tension is obtained. obtained. ● Check the chain tension again after a short travel forward forward and backward, backward, and top up with more grease as necessary. ● Reinstall the cover plate.

GB 34 / 2010

9 - 24

MAINTENANCE

To Loosen t he Track Track

3 2 5 1 3 4 B0000725.wmf • •

Remove the cover plate. Unscrew the safety valve valve (1) by approx. approx. 3 revolutions (SW (SW 41) until excessive grease grease escapes at the spot identified with (4). WARNING!

Risk of injury i njury from pressurised grease! Unscrew the safety valve with great care only. • • • •

Retighten the safety valve when when the proper proper track tension tension is obtained. Check the track tension again again after a short short distance forward forward and backward. backward. Clean the nipple nipple and surroundings surroundings so they are free of grease. Reinstall the cover plate. WARNING!

Risk of injury i njury due to pretensioned spring element (compressible silicone oil at 1500 to 2000 bar)! If the spring elements are defective, replace them completely with new ones. Do not attempt to repair, for safety safet y reasons.

GB 34 / 2010

9 - 25

MAINTENANCE 9.10 9.10.3 .3 Checki Checking ng the Mounting Bolts • •

Visually check if the mounting mounting bolts are are firmly in place. Retighten loose bolts.

4

3

6 BK587502.wmf

BK587440.jpg

BM564683.jpg

Bolt torque value Ma [Nm]

Maint Maintenance enance interval inter val in operating hours

570 ± 30

50

Carrier rollers (2)

280

250

Track guide (3)

560

250

Tread rollers (4)

280

250

Crossbeam (5)

---

---

Crawler drive wheels (6)

560

250

Travel gear (7)

560

250

Telescopic cylinder mounting

560

250

Slewing ring (8)

755

After the first 250 and then every 2000

Bolted connection

Track shoes (1)

GB 34 / 2010

9 - 26

MAINTENANCE 9.10.4

Travel Trav el Gear

9.10.4. 9.10.4.1 1 Checking Checki ng the Oil Oil Level

Check the oil level l evel every 250 operating hours or monthly. •

•

•

•

Move machine until oil drain plug (2) on crawler drive wheel is at its lowest position. Unscrew inspection/filler screw (1) together with seal (if equipped). The oil must reach the lower edge of the filler hole. Top up the oil if necessary. Clean inspection/filler screw and sealing surfaces on housing. Replace with new seals as necessary. Reinstall the inspection/filler screw with a new seal and screw tight.

1

3 2 B0000514.wmf

9.10.4.2 Changing the Oil

The gear oil must be changed after the first 250 operating hours or after one month. Subsequent oil changes are due every 1000 operating hours or once a year at least. •

•

•

•

•

•

• •

Move machine machine until oil drain plug (2) on crawler drive wheel is at its lowest position. Unscrew inspection/filler screw (1) together together with seal (if equipped). Place an oil collecting container underneath the drain. Unscrew the drain plug (2) and let the oil out. Clean screw and plug plug and sealing surfaces on housing. Reinstall drain drain plug with new new seal and screw tight. Refill with new new oil to the the proper level. Reinstall the inspection/filler screw screw with a new seal and screw tight. ti ght.

GB 34 / 2010

1

3 2 B0000514.wmf

9 - 27

MAINTENANCE

9.11

BOLTED BOL TED CONNECTIONS

● After the first 250 operating operating hours, retighten all all bolted connections connections described in the following. Generally, you should apply the prescribed torque on these bolts to tension them ("torque pretension method"). NOTE Bolted connections on the boom

● After every 5000 hours of ordinary operation, replace replace all of the elements elements used in the the bolted connections. WARNING!

Severe 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 on the boom pivot point, boom top, winch and rope guide trestles trest les and masthead masthead

● After every 10000 hours hours of ordinary operation, operation, replace all of the elements used in the bolted connections. WARNING!

Severe accident hazard! Replace the elements of bolted connections every time components are mounted or reassembled and whenever the connections have been excessively stressed from rig tipping or improper i mproper handling.

GB 34 / 2010

9 - 28

LUBRICANTS / TABLES

10

LUBRIC LUB RICANTS ANTS / TAB TABLES LES

10.1 LUBRICANTS 10.1.1 General

● Observe instructions given given in the supplied "Safety Information" book on this subject. subject. ● Use only oils and greases prescribed prescribed or suitable for the application application in question. question. ● Before changing to another kind of lubricant, check it is compatible with the previous previous one used. ● The lubricants used must must be fresh.

CAUTION

NOTE

GB 34 / 2010

Risk of damaging components! A damage resulting from non-observance of lubricant i nstructions in this manual will not be covered by the equipment warranty.

The lubricants listed in the lubricant tables of this manual are suitable for ambient temperatures from -20° C to + 40° C (-4° F to +104° F). Information on applications below -20° C and above +40° C can be ordered from the BAUER after sales service.

10 - 1

LUBRICANTS / TABLES 10.1.2 10.1.2 Lub ricant ri cant Table

The following table lists the lubricants with which the equipment is filled when leaving the factory.

NOTE

Quantities given in the table serve as a guide only. Decisive are the specifications found on the nameplates of the respective parts and the actual fill level found when checking. Alternative lubricants are listed on the following pages.

Initial lubricant fill table Appl Ap pl icati ic ation on

Gear Gear oil , petroleum Swing gear Travel gear

Gear Gear oil , synthetic

Main winch

GB 34 / 2010

Specif Spec if icati ic ation on Viscosit y grade

Producer

Name of product

Qty. [ litres ]

API

SAE 85W-140 SAE 85W-140

SHELL SHELL

Shell SAE 85W-140 Shell SAE 85W-140

ISO VG 220

ARAL

Degol PAS 220

7.0 2 x 12.0

CLP HC

9.0

10 - 2

LUBRICANTS / TABLES

Appl Ap pl icati ic ation on Hydraulic oil, petroleum Hydraulic Hydrauli c oil

Specif Spec if icati ic ation on

API CI-4

Greases, petroleum

KP2N-20 NLGIclass 2

Adhesive spray Gear ring

GB 34 / 2010

Producer

Name of product

Qty. [ litres ]

ISO VG 46

Mobil

DTE 25

210.0

SAE 15W-40

SHELL

Rimula Super

19.0

ARAL

Aralub HLP 2

If require d

CASTROL

Molub

HVLPD

Engine oil, petroleum Engine oil

Roller bearing / friction bearing

ISO viscos ity grade / description

Multi-purpose grease on lithium soap base

10 - 3

LUBRICANTS / TABLES 10.1 10.1.3 .3

Lubricant Lub ricant Guide

10.1.3. 10.1.3.1 1 Gear Gear Oils, Oil s, Petr Petrol oleum eum - CLP CLP

Table Gear oils, petroleum - CLP Appl Ap pl ic ation ati on

Specification DIN 51517/ DIN 51502

Gear oil, petroleum

CLP Viscosity grade ISO-VG / DIN 51519 at 40° C in mm 2/s

Producer VG 100

VG 150

VG 220

Description

MOBIL

ARAL Degol BG 100 SHELL OMALA 100 BP Energol GR-XP 100 Mobilgear 627

ARAL Degol BG 150 SHELL OMALA 150 BP Energol GR-XP 150 Mobilgear 629

BP Energol GR-XP 220 Mobilgear 630

AVIA

Avilub RSX 100

Avilub RSX 150

Avilub RSX 220

CASTROL

Alpha SP 100 NL Gear Compound 100 Spartan EP 100



TEXACO

Giran 150 EP Lubricant HD 150 Meropa 150

Giran 220 EP Lubricant HD 220 Meropa 220

TOTAL

Carter EP 150

Carter EP 220

ARAL SHELL BP

CHEVRON ESSO FINA GULF

ARAL Degol BG 220 SHELL Omala 220

KLÜBER

Unimoly Oil 100

Unimoly Oil 150

Unimoly Oil 220

ELF

Reductelf SP 100

Reductelf SP 150

AGIP

Blasia 100

Blasia 150

Reductelf SP 220 Renep Compound 106 Blasia 220

DEA

Falcon 100

Falcon Fal con 150

Falcon 220

FUCHS

PANOLIN

GB 34 / 2010

Mecano ISO 220

10 - 4

LUBRICANTS / TABLES 10.1.3. 10.1.3.2 2 Gear Gear Oils, Oil s, Petr Petrol oleum eum – API API

Table of gear oils, petroleum – API Appl Ap pl ic ation ati on

Specification DIN 51502

Gear oil, petroleum

API GL-5 / MIL-L-2105 B Viscosity grade SAE / DIN 51511

Producer SAE 90

SAE 85W-90

Description ARAL

Gear oil HYP 90

SHELL

Shell Spirax MB 90

BP

Energear Hypo 90

MOBIL

Mobilube HD-A 90

AVIA CASTROL

ESSO GEAR OIL GX-D 90

FINA GULF

Energear Hypo 85W-90 Mobilube HD 85W-90

AVIA HYPOID 90 EP Castrol EPX 90

CHEVRON ESSO

Gear oil HYP SAE 85W-90

RPM Universal Gear Lubricants SAE 80W-90 ESSO GEAR OIL GX-D 85W-90 FINA PONTONIC MP 85W-90

Gulf Multi-Purpose Gear Lubricant SAE 90

TEXACO TOTAL KLÜBER ELF FUCHS AGIP DEA PANOLIN

GB 34 / 2010

TRANSELF TYP B SAE 90 Fuchs Titan Gear Fuchs Titan Gear Hypoid 90 8090 MC Agip Rotra MP Daegear EP-B SAE 85W90 Panolin Super Duty Panolin Super Duty SAE 90 SAE 80W-90

10 - 5

LUBRICANTS / TABLES 10.1.3. 10.1.3.3 3 Gear Gear Oils, Oil s, Synthetic Synthet ic – CLP PG

Table of gear oils, synthetic – CLP PG Appl Ap pl ic ation ati on


Gear oil, synthetic

CLP PG Viscosity grade ISO-VG / DIN 51519 at 40° C in mm 2/s

Producer VG 100

VG 150

VG 220

Description

MOBIL

ARAL Degol GS 150 SHELL Tivela WA BP Enersym SG-XP 150 Mobil Glygoyle 22

ARAL Degol GS 220 SHELL Tivela WB BP Enersym SG-XP 220 Mobil Glygoyle 30

AVIA

Avilub VSG 150

Avilub VSG 220

ARAL SHELL BP

CASTROL CHEVRON Circulation oil 220

ESSO

S

FINA GULF TEXACO TOTAL

ELF

Klübersynth GH 4-220 Syntherma P 270

FUCHS

Renodiol PGP 220

KLÜBER

Klübersynth GH 4-150

AGIP DEA PANOLIN

GB 34 / 2010

10 - 6

LUBRICANTS / TABLES 10.1.3. 10.1.3.4 4 Hydraul ic Oils, Oil s, Petr Petrol oleum eum – HVLP(D) HVLP(D)

Table of hydraulic oils, petroleum – HVLP(D) Appl Ap pl ic ation ati on


Hydraulic oil, petroleum

HVLP(D) Viscosity grade ISO-VG / DIN 51519 at 40° C in mm 2/s

Producer VG 32

VG 46

VG 68

Description AGIP

Agip Arnica 32

DEA

ARAL Vitam HF 32 Avia Fluid HVI 32 / Avia Arctic 32 BP Bartran V 32 Hyspin AWH-M 32 Mechanism LPS 32 Astron Z HLP 32

ELF

ARAL AVIA BP CASTROL CHEVRON

Agip Arnica 46

Agip Arnica 68

ARAL Vitam VF 46 ARAL Vitam VF 68 Avia Fluid HVI 46 / Avia Arctic 46 BP Bartran V 46

Avia Fluid HVI 68 / Avia Arctic 68 BP Bartran HV 68

Hyspin AWH-M 46

Hyspin AWH-M 68

Mechanism LPS 46 Mechanism LPS 68 Astron Z HLP 46

Astron Z HLP 68

Hydrelf DS 32

Hydrelf DS 46

Hydrelf DS 68

ESSO

Univis N 32

Univis Univi s N 46

Univis Univi s N 68

FINA

Hydran HV 32 Renolin MR 32 MC Mobil DTE 13 M

Hydran HV 46

Hydran HV 68

FUCHS MOBIL

Renoli Renolin MR 1025 1025 MC Renol Ren olin in MR 68 MC Mobil DTE 15 M

Mobil DTE 16 M

SHELL SHELL TELLUS OIL TD46 TELLUS OIL T68

TEXACO

SHELL Tellus Oil T32 Rando HD-Z 32

Rando HD-Z 46

Rando HD-Z 68

TOTAL

Equivis Equivi s ZS 32



SHELL

GB 34 / 2010

10 - 7

LUBRICANTS / TABLES 10.1.3. 10.1.3.5 5 Engine Engi ne Oils, Petro leum – API CI-4

Table of engine oils, petroleum – API CI-4 Appl Ap pl ic ation ati on


Engine oil, petroleum

API CI-4 Viscosity grade SAE / DIN 51511

Producer SAE 5W-40

SAE 10W-40

SAE 15W-40

Description AGIP ARAL AVIA

Aral Plus Turboral SAE 15W-40 Avia Multi HDC Plus 15W-40

BP CASTROL CHEVRON

Chevron Delo 400 Multigrade SAE 15W-40

DEA ELF ESSO FINA FUCHS GULF

Fina Universal Plus XL SAE 15W-40 Titan Truck Plus SAE 15W-40 Gulf Super Duty Select SAE 15W-40

KLÜBER MOBIL PANOLIN Q8 SHELL

Mobil Delvac MX SAE 15W-40 Q8 T 750 SAE 15W-40 Shell Rimula Super SAE 15W-40

TEXACO TOTAL

GB 34 / 2010

10 - 8

LUBRICANTS / TABLES 10.1.3. 10.1.3.6 6 Gear Gear Oils, Oil s, Synthetic Synthet ic – CLP HC

Table of gear oils, synthetic – CLP HC Appl Ap pl ic ation ati on


Gear oil, synthetic

CLP HC Viscosity grade ISO-VG / DIN 51562 at 40° C in mm 2/s

Producer VG 100

VG 150

VG 220

Description ARAL AVIA

ARAL Degol PAS 100 AVIA Synthogear Synthogear EP 100

BP CASTROL

Tribol 1710 / 100

DEA

Renolin Unisyn CLP 100

KLÜBER MOBIL OPTIMOL SHELL TEXACO TOTAL TRIBOL

GB 34 / 2010

ARAL Degol PAS 220 AVIA Synthogear Synthogear EP 220 BP Enersyn EP-XF 220 Tribol 1710 / 220

Intor HCLP 150

ESSO FUCHS

ARAL Degol PAS 150 AVIA Synthogear Synthogear EP 150 BP Enersyn EP-XF 150 Tribol 1710 / 150

Tribol 1710 / 100

Intor HCLP 220 Spartan Synthetic EP 220 Renolin Unisyn Renolin Unisyn CLP 150 CLP 220 Klübersynth Klübersynth EG 4-150 EG 4-220 Mobilgear Mobilgear SHC XMP 150 SHC XMP 220 Optigear Synth A 220 SHELL OMALA SHELL Omala HD 150 HD 220 Pinnacle Pinnacle EP 150 EP 220 Carter EP/HAT 150 Carter EP/HAT 220 Tribol 1710 / 150

Tribol 1710 / 220

10 - 9

LUBRICANTS / TABLES 10.1.3. 10.1.3.7 7 Greases, Petr Petrol oleum eum – KP2N

Table of greases, petroleum – KP2N Appl Ap pl ic ation ati on


Greases, petroleum

KP2N-20

Description Producer Description ARAL SHELL BP MOBIL AVIA CASTROL CHEVRON ESSO FINA GULF TEXACO TOTAL KLÜBER ELF FUCHS AGIP DEA PANOLIN

GB 34 / 2010

Multipurpose grease on lithium soap base Aralub HLP 2 Retinax EP 2 Energrease LS-EP 2 Mobilux EP 2

Beacon EP 2 Marson EPL 2A

Epexa 2 Renolit MP Agip GR MUEP 2 Glissando EP 2 EP Grease 2

10 - 10

LUBRICANTS / TABLES

10.2 OPERATING FLUIDS 10.2.1 Coolants

CAUTION

GB 34 / 2010

Risk of damaging the engine cooling system due to coolant gelling and slime growth! Only use CAT ELCTM (Caterpillar Extended Life Coolant). Never mix different types t ypes of coolants. Do not use any other additives. Observe the additional documentation provided by the coolant manufacturer.

10 - 11

LUBRICANTS / TABLES

10.3

BOLT BOL T TORQUE VALUES VAL UES

CAUTION

Bolt torque values given in the following tables are valid only for slightly oiled bolted connections and where the Spare Parts List does not prescribe other torque values.

Bolts Bol ts with wi th Coarse-Pitc Coarse-Pitc h Metri Metri c Thread Thread

Strength classes as per DIN/ISO 898 8.8 Coarse-pitch metric thread M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36

GB 34 / 2010

10.9

12.9

Bolt torque values MA [Nm] 2.8 5.5 9.5 23 46 79 125 195 280 390 530 670 1000 1350 1850 2350

4.1 8.1 14 34 68 117 185 280 390 560 750 960 1400 1900 2600 3300

4.8 9.5 16.5 40 79 135 215 330 460 650 880 1120 1650 2250 3000 3900

10 - 12

LUBRICANTS / TABLES Bolts with Fine-Pitch Metric Thread

Strength classes as per DIN/ISO 898 8.8 Fine-pitch metric thread M 8x1 M 10x1 M 10x1.25 M 12x1.25 M 12x1.5 M 14x1.5 M 16x1.5 M 18x1.5 M 20x1.5 M 22x1.5 M 24x2 M 27x2 M 30x2 M 33x2 M 36x3

GB 34 / 2010

10.9

12.9

Bolt torque values MA [Nm] 24.5 52 49 87 83 135 205 310 430 580 730 1070 1490 2000 2500

36 76 72 125 122 200 300 440 620 820 1040 1500 2120 2800 3500

43 89 84 150 145 235 360 520 720 960 1220 1800 2480 3300 4100

10 - 13

LUBRICANTS / TABLES

10.4 CONVERSION CONVERSION TAB LE Measures for power N 1 10-5 9.81 9.81⋅103 9.81⋅10-3

dyn 105 1 9.81⋅105 9.81⋅108 981

kp

Mp

p

1.02⋅10-4 1.02⋅10-9 10-3 1 10-6

0.102 1.02⋅10-4 1 103 10-3

102 1.02⋅10-2 103 106 1

Measures for energy and operating efficiency J 1 10-7 9.81 3.60⋅106 4187 1.6⋅10-19

erg

kpm

107 1 9.81⋅10-7 3.60⋅1013 4.19⋅1010 1.6⋅10-12

0.102 1.02⋅10-8 1 3.67⋅105 427 1.63⋅10-20

kWh 2.78⋅10-7 2.78⋅10-14 2.72⋅10-6 1 1.16⋅10-3 4.45⋅10-26

kcal 2.39⋅10-4 2.39⋅10-11 2.34⋅10-3 860 1 3.83⋅10-23

ev 6.24⋅1018 6.24⋅1011 6.12⋅1019 2.25⋅1025 2.61⋅1022 1

Measures Measures for o utput W 1 103 981 735.5 4187 1.16

kW 10-3 1 9.81⋅10-3 0.7355 4.19 1.6⋅10-3

kpm /s 0.102 102 1 75 427 0.119

PS 1.36⋅10-3 1.36 1.33⋅10-2 1 5.69 1.58⋅10-3

kcal/s 2.39⋅10-4 0.239 2.34⋅10-3 0.1757 1 2.78⋅10-4

kcal/h 0.86 860 8.43 632 3600 1

Measures Measures for pressure at 1 1.033 1.02 1.02⋅10-5 1.36⋅10-3 0.070

atm 0.968 1 0.987 9.87⋅10-6 1.32⋅10-3 0.0680

bar 0.981 1.0133 1 10-5 1.33⋅10-3 0.0689

N/m2 98100 101330 105 1 133 0.145

Torr 736 760 750 75⋅10-4 1 51.72

Psi 14.22 14.69 14.5 14.5⋅10-5 19.28⋅10-3 1

Measures for length in 1 12 36 0.03937 39.37 39370

GB 34 / 2010

ft 0.08333 1 3 3281⋅10-6 3.281 3281

yd 0.02778 0.3333 1 1094⋅10-6 1.094 1094

mm 25.4 304.8 914.4 1 1000 106

m 0.0254 0.3048 0.9144 0.001 1 1000

km 10-6 0.001 1

10 - 14

Grab_System_ Bauer GB34

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