Instruction manual for BG25

Instruction Manual BG 25

BK000513.wmf

Translation of the original instruction manual

Keep this manual also for future use! BAUER Maschinen GmbH P.O. Box 12 60  D-86522 Schrobenhausen  Germany Phone: +49 8252 97-0  Fax: +49 8252 97-13 59

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 department of BAUER Maschinen GmbH and order a manual in a language you understand. Telephone Fax E-Mail

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

Ако не разбирате езика, използван в това Ръководство за експлоатация, не трябва да пускате машината/съоръжението в експлоатация. В такъв случай се свържете със сервиз на BAUER Maschinen GmbH и поръчайте BG Ръководство за експлоатация на разбираем за Вас език. 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

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 / zařízení uvést do provozu. V takovém případě kontaktujte zákaznický servis společnosti BAUER Mas chinen GmbH a objednejte si návod k obsluze v jaj a-

CZ

zyce, který je pro vás srozumitelný. Telefon Telefax E-Mail

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

I

DE

Sollten Sie die in dieser Betriebsanleitung verwendete Sprache nicht verstehen, darf das Gerät / die Anlage von Ihnen nicht in Betrieb genommen werden. Kontaktieren Sie bitte in so einem Fall den Kundendienst der BAUER Maschinen GmbH und bestellen Sie eine Betriebsanleitung in einer für f ür Sie verständlichen Sprache. Telefon Telefax E-Mail

DK

Hvis du ikke forstår sproget, der er brugt br ugt i denne betjeningsvejledning, må du ikke tage udstyret/anlægget i brug. Kontakt i dette tilfælde t ilfælde kundeservice hos BAUER Maschinen GmbH, og bestil en brugsanvisning på et sprog, som du forstår. Telefon Fax E-Mail

ES

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

Kui see kasutusjuhendis on keeles, mida te ei oska, on teile selle 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]

En caso de no comprender el idioma utilizado en el presente manual de usuario, no podrá poner en funcionamiento el aparato / equipo. En ese caso, póngase por favor en contacto con el servicio de atención al cliente de BAUBA UER Maschinen GmbH y solicite un manual de instrucciones que esté en su idioma. Teléfono Fax E-Mail

EE

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

+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]

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

II

FR

Si vous ne comprenez pas la langue utilisée dans ce manuel d'instructions, d'i nstructions, 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 pour vous. Téléphone Télécopie E-Mail

GR

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

Εάν δεν καηαλαβαίνεηε η γλώζζα ος σπζιμοοιείηαι ζηο απόν εγσειπίδιο οδγιών, δεν ειηπέεηαι να ηεεί ζε λειηοςπγία ο εξολιζμόρ. Σην επίηωζ αςηήν εικοινωνήζηε με ηο κένηπο ζέπβιρ ηρ BAUER Maschinen GmbH και απαγγείλεηε ένα εγσειπίδιο οδγιών ζε μια γλώζζα ος καηαλαβαίνεηε. Τλέθωνο +49 8252 97-2586 Φαξ +49 8252 97-2587 E-Mail

[email protected]

Ako jezik upotrijebljen u ovim uputama za uporabu ne razumijete, ureĎaj / postrojenje ne smijete stavljati u pogon. U takvom slučaju stupite u kontakt sa servisnom službom tvrtke BAUER Maschinen GmbH i naručite upute za up o-

HR

rabu na jeziku koji razumijete. Telefon Telefaks E-pošta

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]

+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. In questo caso, contattando il Servizio Assistenza BAUER Maschinen GmbH, è possibile ordinare le istruzioni d'uso in una lingua a scelta. Telefono Telefax E-Mail

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

III

LU

Falls Dir d'Sprooch déi an dëser Betribsuleedung Betr ibsuleedung benotzt gëtt net verstitt, dann dierft Dir den Apparat / d'Anlag net a Betrib huelen. Kontaktéiert an esou engem Fall de Konnendéngscht vun der BAUER Maschinen GmbH a bestellt eng Betribsuleedung an enger Sprooch déi Dir verstitt. Telefon Telefax E-Mail

LV

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

Fakss E-pasts

MT

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

Als u de taal van deze gebruiksaanwijzing gebruiksaanwijzing niet machtig bent, mag het apparaat / de installatie niet door u in gebruik genomen worden. 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 Fax E-Mail

NO

+49 8252 97-2587 [email protected]

Jekk mintix familjari mal-lingwa użata f'dan il -manwal ta' tħaddim, ma għa ndekx tħaddem dan l -apparat. Jekk ma tistax taqra dan il-manwal ta' tħaddim jew inkella jekk ma tistax tifhem il-kontenut tiegħu, għandek tikkuntattja lid dipartiment tas-servizz tal-klijenti ta' BAUER Maschinen GmbH u għandek tordna manwal f'lingwa li tifhem. Telefon Fax E-Mail

NL

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

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

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. f orstår. Telefon Telefaks E-post

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

IV

PL

Jeśli nie rozumieją Państwo języka, w którym napisana została instrukcja o bsługi, to nie mogą Państwo uruchamiać urządzenia/instalacji. W takim prz ypadku należy skontaktować się z serwisem firmy BAUER Maschinen GmbH i zamówić instrukcję w języku przez Państwa rozumianym. Telefon Telefaks E-Mail

PT

Se não entender o idioma utilizado 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

RO

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

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

SE

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

Dacă nu înţelegeţi limba utilizată în acest manual de utilizare, aparatul / instalaţia nu trebuie pusă în funcţiune. Vă rugăm să contactaţi în acest caz serviciul pentru clienţi al BAUER Maschinen GmbH şi să comandaţi un m anual de utilizare în limba dumneavoastră. Telefon Telefax E-Mail

RU

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

[email protected]

Förstår du inte språket i den här bruksanvisningen får du inte använda apparaten/anläggningen. Kontakta i så fall BAUER Maschinen GmbHs kundtjänst och beställ en bruksanvisning på ett språk du förstår. Telefon Telefax E-Mail

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

V

SK

Ak by ste nerozumeli jazyku, jazyku, v ktorom je napísaný tento návod na obsluhu, nesmiete prístroj / zariadenie uvádzať do prevádzky. V takomto prípade ko ntaktujte, prosím, zákaznícku službu firmy BAUER Maschinen GmbH a obje dnajte si návod na obsluhu v jazyku, ktorému rozumiete. Telefón Fax Email

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

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

SI

jeziku, ki ga razumete. Telefon Telefaks E-pošta

TR

UA

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

Bu kullanım kılavuzunda kullanılan dili anlayamadığınız taktirde, cihaz / sistem sizden geri alınmayacaktır. Bu gibi bir durumda, BAUER Maschinen GmbH ile temasa geçin ve sizin anlayabileceğiniz dilde bir kullanım kılavuzu sipariş edin. Telefon Telefaks E-Mail

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

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 GmbH та замовте інструкцію з експлуатації, написану мовою, яка вам зрозуміла. Тел. +49 8252 97-2586 Факс +49 8252 97-2587 E-Mail

[email protected]

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

VI

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

First, take your time and read the "Instruction Manual" and the enclosed booklet entitled "Safety Information". These two documents shall always be kept at the equipment to be accessible for review at any time. The "Instruction Manual" gives you a detailed description of the equipment, guidelines for transport and initial start-up as well as comprehensive instructions for the operation of the equipment, trouble shooting tips and information related to maintenance. Technical data, weights and measurements are accurate as of the day this Instruction Manual is printed. Due to the continuous technical advancements made, there may be minor deviations between the technical data, weights and measurements contained in the Instruction Manual and the equipment as actually built and delivered. These minor deviations are, however, inconsequential and do not change in any material way nor do they invalidate the contents of this Instruction Manual. The equipment as delivered to you may have options that might not be pictured in the photographs or described in the text contained in this Instruction Manual exactly as they appear on your equipment. This is due to the individualization of the equipment based on the wishes and orders of the individual customers and no claims of any kind shall be based on such deviations. The equipment shall only be used for the authorized purposes listed in the Instruction Manual. The manufacturer shall have no liability whatsoever for the improper or unauthorized use of the equipment, operator errors or mistakes or improper respectively insufficient maintenance. The enclosed booklet entitled "Safety Information" contains the directions and related information for the safe use of the equipment. The "Safety Information" must be followed at all times. Also, pay attention to and follow all the instructions contained in the attached documents (Appendix ___) of the component manufacturers.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

VII

The "Instruction Manual" was written and published by BAUER Maschinen GmbH  Postfach 12 60  D-86522 Schrobenhausen, Germany Copyright 2009, BAUER Maschinen GmbH The information contained in this manual and/or any of its parts, sub-parts or chapters, is the intellectual property of BAUER Maschinen GmbH and is protected by domestic and international copyright and other intellectual property laws. The information contained herein is provided for the operation, service, maintenance and troubleshooting of the equipment described herein. Any duplication, reproduction, translation, micro filming, storage in electronic or magnetic form, processing as electronically or magnetically stored media, copying or dissemination of these materials and/or the information contained herein, or any part thereof, except for the internal use of BAUER Maschinen GmbH or its authorized external suppliers, consultants or agents, without the prior written consent of BAUER Maschinen GmbH is hereby strictly prohibited. All rights and remedies are hereby expressly expressly reserved. Violators will be prosecuted. BAUER Maschinen GmbH shall have no liability whatsoever arising from or connected in any way to the so prohibited use of the information contained herein by any person or entity, wherever located. BAUER Maschinen GmbH reserves the right to change, delete or otherwise alter or modify any information contained herein, or the equipment itself, at any time and for any reason, with or without notice.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

VIII

TABLE OF CONTENTS PREFACE .................................................................. ........................................................................................................................................ .................................................................................... .............. I TABLE OF CONTENTS .................................................................... .............................................................................................................................. .......................................................... IX ABOUT THE MANUAL MANUAL ............................................................................................................................. ............................................................................................................................. XIV NAMEPLATES .......................................................................................................................................... .......................................................................................................................................... XVI AFTER SALES SERVICE ........................................................................................................................ ........................................................................................................................ XVII WARRANTY TERMS .............................................................................................................................. WARRANTY .............................................................................................................................. XVIII DEFECTS LIABILITY CLAIM ..................................................................................................................... ..................................................................................................................... XII PERSONALANFORDERUNG PERSONALANFORDERUNG / STAFF REQUEST .......................................................... ................................................................................. ....................... XIII REGISTRIERUNG BETREIBER UND GERÄT/

............. ............. XIV OWNER A ND EQUIPMENT REGISTRATION REGISTRATION

1 1.1 1.2 1.2.1 1.2.1.1 1.2.1.2

DESCRIPTION ....................................................................................................................... .......................................................................................................................1 - 1 EQUIPMENT APPLICATIONS ............................................................................................... ...............................................................................................1 - 1 COMPONENTS ..................................................................................... ...................................................................................................................... ................................. 1 - 4 Basic Rig / Kelly Equipment ................................................................... .................................................................................................... ................................. 1 - 4 Components Overview ........................................................................................................... ...........................................................................................................1 - 4 Components Description ........................................................................................................ ........................................................................................................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 2.4.7 2.5 2.5.1 2.5.2 2.5.2.1 2.5.2.2 2.5.3 2.5.3.1 2.5.3.2 2.6

SAFETY............................................................... .................................................................................................................................. ...................................................................2 - 1 GENERAL SAFETY REQUIREMENTS ................................................................................. 2 - 1 EQUIPMENT SAFETY ........................................................................................................... ........................................................................................................... 2 - 1 MAJOR HAZARDS ..................................................................... ................................................................................................................. ............................................2 - 1 SAFETY DEVICES ........................................................................................... ................................................................................................................. ...................... 2 - 2 Emergency Stop ..................................................................................................................... .....................................................................................................................2 - 2 Pilot Control Safety Stick ............................................................................................. ........................................................................................................ ........... 2 - 2 Fire Extinguisher ............................................................. ..................................................................................................................... ........................................................2 - 3 Medical Box ............................................................................................................................ ............................................................................................................................2 - 3 Emergency Exit............................................................... Exit....................................................................................................................... ........................................................2 - 3 Limit Switches.................................................................. ......................................................................................................................... .......................................................2 - 4 Fall Protection Equipment * .................................................................................................... ....................................................................................................2 - 5 STABILITY .................................................................................. .............................................................................................................................. ............................................2 - 6 Guidelines for f or Stability ............................................................... ............................................................................................................ .............................................2 - 6 Stability for BG 25 # 2254 - Kelly BK 25/394/4/56 .................................................................2 - 7 Load Capacity Chart ............................................................................................................... ...............................................................................................................2 - 7 Weights / Centres of Gravity - Drilling Distance 3.39 m ......................................................... ......................................................... 2 - 8 Stability for BG 25 # 2254 - Kelly BK 25/394/4/40 .................................................................2 - 9 Load Capacity Chart ............................................................................................................... ...............................................................................................................2 - 9 Weights / Centres of Gravity - Drilling Distance 3.39 m ....................................................... ....................................................... 2 - 10 PERMISSIBLE WIND SPEED ............................................................... .............................................................................................. ............................... 2 - 11

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

IX

3 3.1 3.1.1 3.2.1 3.2 3.3 3.3.1 3.4 3.4.1 3.5 3.5.1 3.5.2 3.5.3 3.6 3.7 3.8 3.9

TECHNICAL SPECIFICATIONS ........................................................... ............................................................................................ ................................. 3 - 1 DIMENSIONS ........................................................................................ ......................................................................................................................... ................................. 3 - 1 Kelly Equipment BK 25/394/4/56 ................................................................................. ............................................................................................ ........... 3 - 1 Kelly Equipment BK 25/394/4/40 ................................................................................. ............................................................................................ ........... 3 - 2 EQUIPMENT SPECIFICATIONS ........................................................................................... ........................................................................................... 3 - 3 ROTARY DRIVE SPECIFICATIONS ................................................................... ...................................................................................... ................... 3 - 5 Rotary Drive, constant ............................................................................................................ ............................................................................................................3 - 5 DRILLING SPECIFICATIONS ................................................................................................ ................................................................................................3 - 6 Kelly equipment ...................................................................................................................... 3 - 6 ROPE SPECIFICATIONS SPECIFICAT IONS ...................................................................................................... 3 - 7 Main Rope .............................................................................................................................. .............................................................................................................................. 3 - 7 Auxiliary Rope Rope .................................................................. ......................................................................................................................... .......................................................3 - 8 Crowd Ropes .............................................................................. .......................................................................................................................... ............................................3 - 9 NOISE EMISSION ................................................................................. ................................................................................................................ ............................... 3 - 10 TEMPERATURE CONDITIONS ............................................................ ........................................................................................... ............................... 3 - 10 EXPOSURE TO VIBRATION ............................................................................................... ...............................................................................................3 - 11 EXHAUST GAS EMISSION .................................................................. ................................................................................................. ............................... 3 - 11

4 4.1 4.2 4.3 4.4

CONTROLS AND INDICATORS ........................................................................................... ........................................................................................... 4 - 1 CAB ........................................................................................................................................ ........................................................................................................................................ 4 - 1 BASE MACHINE CONTROL CONSOLE ............................................................................... ...............................................................................4 - 2 CONTROL PANEL ................................................................................................................. ................................................................................................................. 4 - 3 MONITOR UNIT ..................................................................................................................... .....................................................................................................................4 - 4

5 5.1 5.1.1 5.2 5.2.1 5.2.2 5.3 5.3.1 5.3.2 5.3.2.1 5.3.2.2 5.4 5.5 5.5.1 5.5.2 5.5.2.1 5.6 5.6.1 5.7 5.7.1 5.7.2 5.8 5.8.1 5.9

OPERATION .......................................................................................................................... .......................................................................................................................... 5 - 1 TRAVEL ........................................................................... .................................................................................................................................. .......................................................5 - 1 To Travel and Steer ........................................................ ................................................................................................................ ........................................................5 - 1 UPPERCARRIAGE SW ING ................................................................................................... ...................................................................................................5 - 2 Swing Brake..................................................................... Br ake............................................................................................................................ .......................................................5 - 2 Swing Control .................................................................. ......................................................................................................................... .......................................................5 - 3 MAST REPOSITIONING .................................................................................. ........................................................................................................ ...................... 5 - 4 Mast Auto Reset to Vertical .............................................................................. .................................................................................................... ...................... 5 - 5 Mast Repositioning by Manual Control ........................................................................... ................................................................................... ........ 5 - 6 To Adjust the Mast Inclination ................................................................................................ ................................................................................................ 5 - 6 To Adjust the Drill Distance .................................................................................................... ....................................................................................................5 - 8 MAST PROP CONTROL * ..................................................................................................... ..................................................................................................... 5 - 9 TRAVELLING W ITH THE T HE RIG ............................................................................................. ............................................................................................. 5 - 10 Travelling over Level Ground................................................................................................ 5 - 10 Travelling Up and Down Slopes ........................................................................................... ........................................................................................... 5 - 11 With Raised Mast without Drilling Equipment .............................................................. ....................................................................... ......... 5 - 11 ROTARY DRIVE CONTROL ............................................................................ ................................................................................................ .................... 5 - 12 Kelly Application (Rotary Drive, constant)............................................................................. 5 - 12 WINCH CONTROL ......................................................... ............................................................................................................... ......................................................5 - 14 Lifting / Lowering............................................................. ................................................................................................................... ......................................................5 - 14 To Operate with Freewheel .................................................................................................. ..................................................................................................5 - 16 DEPTH MEASURING CONTROL CONT ROL ......................................................... ........................................................................................ ............................... 5 - 17 To Reset the Depth Measuring.............................................................. ............................................................................................. ............................... 5 - 17 CROWD CONTROL ................................................................... ............................................................................................................. ..........................................5 - 18

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

X

5.9.1 5.9.2 5.10 5.11

Manual Control of the Crowd ................................................................................................ ................................................................................................5 - 19 To Use the Main W inch in Combination with Crowd ............................................................ ............................................................ 5 - 20 USING THE ENGINE DIAGNOSTIC SYSTEM ........................................................... .................................................................... ......... 5 - 21 CENTRAL LUBRICATION CONTROL * .......................................................... .............................................................................. .................... 5 - 22

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 6.2 6.2.1 6.2.2

START-UP / SHUT-DOWN .............................................................................. .................................................................................................... ...................... 6 - 1 START-UP ....................................................................... .............................................................................................................................. .......................................................6 - 1 Initial Start-Up ................................................................................................... ......................................................................................................................... ...................... 6 - 1 Visual Inspection before Starting ........................................................... ............................................................................................ ................................. 6 - 1 Daily Start-Up .................................................................. ......................................................................................................................... .......................................................6 - 2 Starting the Equipment ................................................................................................... ........................................................................................................... ........ 6 - 2 Selecting the Engine Operating Mode .............................................................. .................................................................................... ...................... 6 - 3 Safety Tests before Starting to W ork ..................................................................................... ..................................................................................... 6 - 4 Checking the Emergency STOP............................................................ STOP ............................................................................................. ................................. 6 - 4 Checking the Pilot Control Safety Stick .................................................................................. .................................................................................. 6 - 4 Checking the End Limiters.......................................................... Limiters ...................................................................................................... ............................................6 - 5 SHUT-DOWN ......................................................................................................................... ......................................................................................................................... 6 - 6 Daily Shut-Down ..................................................................................................................... ..................................................................................................................... 6 - 6 Shut-Down for a Longer Period ................................................................................... .............................................................................................. ........... 6 - 6

7 7.1 7.2 7.3 7.4 7.5 7.5.1 7.5.2 7.5.3 7.5.3.1 7.5.3.2 7.5.4 7.5.5 7.5.6 7.6 7.6.1 7.6.1.1 7.6.1.2 7.6.1.3 7.6.1.4 7.6.2 7.7 7.7.1 7.7.1.1 7.7.1.2 7.8 7.8.1 7.8.2 7.8.3 7.8.3.1 7.8.3.2 7.8.4

RIGGING / DE-RIGGING ....................................................................................................... .......................................................................................................7 - 1 GUIDELINES FOR RIGGING AND DE-RIGGING .................................................................7 - 1 WAX REMOVAL ............................................................. ..................................................................................................................... ........................................................7 - 2 EXTENDING THE CRAWLERS ............................................................ ............................................................................................. ................................. 7 - 3 MOUNTING THE COUNTERWEIGHT ..................................................................................7 - 4 MOUNTING THE MAST ............................................................ ......................................................................................................... .............................................7 - 7 Mounting the Trestle .............................................................................. ............................................................................................................... ................................. 7 - 7 Assembling the Mast Sections ......................................................................... ............................................................................................... ...................... 7 - 8 Installing the Ropes .............................................................................................................. ..............................................................................................................7 - 10 Installing the Main and Auxiliary Ropes ............................................................ ................................................................................ .................... 7 - 10 Installing the Upper Crowd Rope ........................................................... .......................................................................................... ............................... 7 - 11 Mounting Crowd Stroke Limiters ..........................................................................................7 - 12 Raising the Mast ......................................................................... ................................................................................................................... ..........................................7 - 13 Mounting Retaining Clamps ................................................................................................. 7 - 14 ASSEMBLY OF WORK ATTACHMENTS ...................................................................... ............................................................................ ......7 - 15 Assembly of Kelly Equipment ................................................................ ............................................................................................... ............................... 7 - 16 Mounting the Rope Swivel .......................................................... .................................................................................................... ..........................................7 - 16 Mounting the Rotary Drive .................................................................................................... ....................................................................................................7 - 17 Mounting Kelly Guidance * ......................................................... ................................................................................................... ..........................................7 - 18 Mounting the Kelly .......................................................................................................... ................................................................................................................ ...... 7 - 20 Mounting Casing Oscillator * ................................................................. ................................................................................................ ............................... 7 - 22 DISASSEMBLY OF WORK ATTACHMENTS ............................................................. ...................................................................... ......... 7 - 23 Disassembly of Kelly Equipment .......................................................................................... 7 - 24 Removing the Kelly......................................................... ............................................................................................................... ......................................................7 - 24 Removing the Rotary Drive................................................................................................... Drive................................................................................................... 7 - 24 DISASSEMBLING THE T HE MAST ............................................................................................. .............................................................................................7 - 25 Removing the Retaining Clamps .......................................................................................... ..........................................................................................7 - 25 Lowering the Mast ................................................................................................................ ................................................................................................................ 7 - 25 Removing the Ropes ........................................................................................ ............................................................................................................ .................... 7 - 26 Removing the Main and Auxiliary Rope ............................................................ ................................................................................ .................... 7 - 26 Removing the Upper Crowd Rope ......................................................... ........................................................................................ ............................... 7 - 27 Disassembling the Mast ....................................................................................................... ....................................................................................................... 7 - 28

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

XI

7.8.5 7.9 7.10

Lowering the Trestle ............................................................................................................. .............................................................................................................7 - 29 REMOVING THE COUNTERWEIGHT ................................................................................ 7 - 30 RETRACTING THE T HE CRAW LERS ........................................................................................ ........................................................................................ 7 - 33

8 8.1 8.2 8.3 8.4 8.5 8.6

TRANSPORT ......................................................................................................................... ......................................................................................................................... 8 - 1 SAFETY GUIDELINES FOR TRANSPORT ................................................................... ........................................................................... ........ 8 - 1 MEASURES TO TAKE FOR TRANSPORT T RANSPORT ........................................................................... ...........................................................................8 - 2 DRIVING ON / OFF A LOW LOADER .................................................................................... .................................................................................... 8 - 3 LIFTING POINTS ................................................................................................................... 8 - 4 TRANSPORT DATA ................................................................... ............................................................................................................... ............................................8 - 5 TYING DOWN ........................................................................................................................ ........................................................................................................................ 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 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 9.9 9.9.1 9.9.2 9.9.3 9.9.4 9.9.4.1 9.9.4.2 9.10 9.10.1 9.10.2 9.10.2.1 9.10.2.2 9.10.3 9.10.3.1 9.10.3.2 9.10.4 9.10.5

MAINTENANCE MAINTENANCE ..................................................................................................................... 9 - 1 SAFETY GUIDELINES FOR MAINTENANCE ............................................................ ....................................................................... ........... 9 - 1 MAINTENANCE INTERVALS ............................................................... ................................................................................................ ................................. 9 - 1 MAINTENANCE PLAN ........................................................................................................... ...........................................................................................................9 - 2 Entire Equipment .................................................................................................................... ....................................................................................................................9 - 2 Components ........................................................................................................................... ........................................................................................................................... 9 - 3 Work Equipment ............................................................. ..................................................................................................................... ........................................................9 - 6 Uppercarriage ........................................................................................ ......................................................................................................................... ................................. 9 - 7 Undercarriage ........................................................................................ ......................................................................................................................... ................................. 9 - 9 Optional Equipment Equipm ent .............................................................................................................. ..............................................................................................................9 - 10 LUBRICATION PLAN ..................................................................................................... ........................................................................................................... ...... 9 - 11 MAINTENANCE DURING LONGER PERIODS OF STANDSTILL ST ANDSTILL ......................................9 - 12 HYDRAULIC SYSTEM ......................................................................................................... 9 - 13 Hose Assemblies ............................................................ .................................................................................................................. ......................................................9 - 14 Hydraulic Cylinders ............................................................................................................... ...............................................................................................................9 - 15 Filter Replacement ............................................................................................................... 9 - 16 Replacing the Line Filters ..................................................................................................... ..................................................................................................... 9 - 16 WINCHES............................................................................................................................. WINCHES.............................................................................................. ............................... 9 - 17 Checking the Oil Level............................................................... .......................................................................................................... ...........................................9 - 17 Changing Gear Oil ...................................................................... ................................................................................................................ ..........................................9 - 18 REPLACING THE UPPER CROWD CROW D ROPE ................................................................... ......................................................................... ......9 - 19 WIRE ROPE ACCESSORIES ............................................................... .............................................................................................. ............................... 9 - 24 Rope Swivel..................................................................... .......................................................................................................................... .....................................................9 - 24 Rope Hold-Down Rollers ...................................................................................................... ...................................................................................................... 9 - 24 Rope Fasteners, Thimbles and Sockets ..............................................................................9 - 25 Rope Sheaves ............................................................................................................. ...................................................................................................................... ......... 9 - 26 Greasing Rope Sheaves ...................................................................................................... ...................................................................................................... 9 - 26 Checking Rope Sheaves ....................................................................... ...................................................................................................... ............................... 9 - 27 ROTARY DRIVE ............................................................. ................................................................................................................... ......................................................9 - 28 Routine Inspection ...................................................................... ................................................................................................................ ..........................................9 - 28 Checking the Oil Level............................................................... .......................................................................................................... ...........................................9 - 29 Main Gear ................................................................................... ............................................................................................................................. ..........................................9 - 29 Planetary Gears .............................................................. .................................................................................................................... ......................................................9 - 30 Changing the Oil ......................................................................... ................................................................................................................... ..........................................9 - 31 Main Gear ................................................................................... ............................................................................................................................. ..........................................9 - 31 Planetary Gears .............................................................. .................................................................................................................... ......................................................9 - 33 Oil Sampling ..................................................................................................... ......................................................................................................................... .................... 9 - 35 Hollow Shaft Mounting Bolts ........................................................................................ ................................................................................................. ......... 9 - 36

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

XII

9.10.6 9.10.6.1 9.10.6.2 9.10.7 9.10.8 9.10.9 9.11 9.11.1 9.11.2 9.11.2.1 9.11.2.2 9.11.3 9.11.4 9.11.4.1 9.11.4.2 9.12 9.13

Kelly Driver and Guide Flange F lange ............................................................... .............................................................................................. ............................... 9 - 37 Checking the Mounting Bolts ................................................................................................ ................................................................................................9 - 37 Checking Driver Strips for Wear ............................................................ ........................................................................................... ............................... 9 - 38 Cardan Joint ......................................................................................................................... ......................................................................................................................... 9 - 39 Sledge Sliding Strips................................................................... ............................................................................................................. ..........................................9 - 39 Greasing the Shaft Seal Ring ........................................................................... ............................................................................................... .................... 9 - 40 CRAWLER TRACK ASSEMBLIES........................................................ ASSEMBLIES....................................................................................... ............................... 9 - 41 Routine Inspection ...................................................................... ................................................................................................................ ..........................................9 - 41 Crawler Tracks T racks ..................................................................................................................... 9 - 42 To Check the Track Tension ....................................................................................... ................................................................................................ ......... 9 - 42 Adjusting Crawler Track Tension ......................................................................................... .........................................................................................9 - 43 Checking Mounting Bolts ........................................................... ...................................................................................................... ...........................................9 - 45 Crawler Drive Gears ............................................................................................................. .............................................................................................................9 - 46 Checking the Oil Level............................................................... .......................................................................................................... ...........................................9 - 46 Changing the Oil ............................................................. ................................................................................................................... ......................................................9 - 46 CENTRAL LUBRICATION SYSTEM MAINTENANCE * ...................................................... ...................................................... 9 - 47 BOLTED CONNECTIONS.......................................................... CONNECTIONS.................................................................................................... ..........................................9 - 48

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 10.2.2 10.3

LUBRICANTS LUBRICANTS / TABLES ...................................................................... ..................................................................................................... ............................... 10 - 1 LUBRICANTS ........................................................................................ ....................................................................................................................... ............................... 10 - 1 General .................................................................................................. ................................................................................................................................. ............................... 10 - 1 Lubricant Table ........................................................................... ..................................................................................................................... ..........................................10 - 2 Lubricant Guide .................................................................................................................... .................................................................................................................... 10 - 4 Gear Oils, Synthetic – CLP HC............................................................................................. 10 - 4 Gear Oils, Petroleum – ATF ................................................................................................. .................................................................................................10 - 5 Hydraulic Oils, Petroleum – HVLP(D)............................................................... ................................................................................... .................... 10 - 6 Hydraulic Oils, Biodegradable on Synthetic Basis – HVLP HC ............................................10 - 7 Hydraulic Oils, Biodegradable – HEES - Saturated Esters...................................................10 - 8 Engine Oils – API CI-4 ............................................................... .......................................................................................................... ...........................................10 - 9 Greases, Petroleum – KP2N .............................................................................................. ..............................................................................................10 - 10 BOLT TORQUE VALUES........................................................... ................................................................................................... ........................................10 - 11 Bolts with coarse-pitch metric thread................................................................... .................................................................................. ............... 10 - 11 Bolts with fine-pitch metric thread.......................................................... ....................................................................................... ............................. 10 - 12 CONVERSION TABLE ....................................................................................................... .......................................................................................................10 - 13

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

XIII

ABOUT THE MANUAL THIS MANUAL IS MADE FOR Equipment model: Construction number: Construction year: Date of 1st operation:

BG 25 2254 2010 .. / .. / ....

Certification:

CE

THIS MANUAL WAS PUBLISHED IN 02.2011

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

DESCRIPTION SAFETY TECHNICAL TECHNICAL SPECIFICATIONS CONTROLS AND INDICATORS OPERATION START-UP / SHUT-DOWN RIGGING / DE-RIGGING TRANSPORT MAINTENANCE LUBRICANTS / TABLES

APPENDICES

G:\...\2254_BG25_en_0000498763 _V01

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

XIV

SYMBOLS USED IN THIS MANUAL DANGER! "Danger!" is used to identify an immediate hazard that can result in serious injury or loss of life if the instructions given in the manual are ignored or not correctly followed.

WARNING! "Warning!" is used to identify a potential hazard that can result in serious injury or loss of life if the instructions given in the manual are ignored or not correctly followed.

CAUTION

NOTE

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

XV

NAMEPLATES Nameplates on the equipment Assembly

Location

Nameplate Bauer Maschinen GmbH

Total equipment

D - 86522 Schrobenhausen Made in Germany Gerätetyp type nächstePrüfung

Baujahr year of manufacture

Rückzugkraft pulling force

1 2 1 2 3

1 1 0 1

Trägergerät base carrier Bau - Nr. serial No

4

max. Druck max. pressure

2001 5

8 7 6

9

Gesamtgewicht

total weight Sachkundigenprüfung expert test

CE - Zeichen CE sign

Motorleistung engine power

Inv. - Nr. Inv. No kN bar kg kW

Vorschubkraft pushing power Betriebsdruck working pressure Arbeitspannun itspannung working voltage Frequenz frequency

kN bar V Hz

B0000551.wmf BK786502.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

XVI

AFTER SALES SERVICE How to reach the Service Centre Phone

+49 8252 97-25 86

Fax

+49 8252 97-25 87

E-Mail

[email protected]

Whenever you consult the Service Centre, please give the following information so your inquiry can be dealt with more quickly.

NOTE Equipment description - Name of model: - Construction number: - Number of operating hours:

Description of damage - Date (DD.MM.YY): - Cause of damage (if identifiable): - Course of events leading to damage:

For possible check-backs - Name of person to contact, phone / fax:

Description of site - Name of site: - Address (post code, town, street): - Route description for a mechanic (as necessary):

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

XVII

WARRANTY WARRA NTY TERMS T ERMS As far as a warranty agreement was was concluded with with the client the following following terms apply to warranty procedures:

Warranty period:

The contractual agreement is principally decisive decisive for the warranty period; as far as no agreement on the warranty period was concluded the warranty is valid valid for 12 months from f rom the time of commissioning.

Commencement:

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

Warranty conditions:

- Original BAUER BAUER spare parts must be used throughout throughout the warranty period. - Components and and 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 BAUER in writing on the appropriappropriate "Warranty Claim" form within 24 hours after their occurrence. - The Client or Operator of the BAUER equipment agrees to carry out all services throughout the warranty period within the specified service intervals in full compliance with the Instruction Manual. - Any work (servicing, (servicing, 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 exclusions:

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

XVIII

A) Liabilities and Responsibilities of BAU BAUER ER

– BAUER will will supply spare parts required required for carrying out repairs repairs to BAUER equipment under warranty to the Client. – Spare parts will will be delivered c.i.f. (cost, insurance, freight) to the Client. Client. – If necessary, BAUER will also also provide personnel for carrying carrying our repairs repairs under warranty. warranty.

NOTE

Any defective parts replaced replaced under warranty warranty shall become the property property of BAUER. BAUER shall determine whether whether defective parts are to t o be returned to their factory at Schrobenhausen, Germany. Transport costs for f or redeliveries will will be paid by BAUER Maschinen GmbH (after sales service).

– Redeliveries / Deadlines

Concerning requested redeliveries redeliveries the following deadlines are valid from the date of arrival of the new parts on the jobsite in the assignment country until arrival of the damaged parts in Schrobenhausen.

– Redeliveries Redeliveries via air freight: – Redeliveries Redeliveries via sea freight:

4 weeks 4 months

If the t he damaged parts, which are redelivered via sea freight, are not redelivered redelivered in time due to the jobsite situation, the after sales service department has to be informed correspondingly, respondingly, at the latest 6 weeks before expiry of the deadline. Concerning redeliveries redeliveries via air freight, f reight, an extension of the deadline is principally not possible. In case requested redeliveries are not returned within the agreed time period, the corresponding open amounts according to the sales invoice have to be paid by the respective customer.

B) Liabilities and Responsibilities of the Client

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

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

XIX

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:

DEFECTS LIABILITY CLAIM 1. Product specifications Equipm Equ ipment: ent: Constr. no.: Current location of the equipment, postal address: Date of commissioning:

Constr Con str.. year:

Operating Operating hours:

Date of damage:

2. Description of damage Please describe damaged parts and state their material number Name of damaged part Material no.

Construction no.

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

3. Delivery of new parts and repair Replacement of damaged parts from customers own stock? Replacement of damaged parts by ordering from after sales service? Shipment (by courier, air or sea freight): Delivery address: Information for a proforma invoice: Replacement work by customer, agent? Yes No Estimate Estimated d working working time (hrs): (hrs): Estimated Estim ated additional addition al costs:

Date

3 0 0 2 / 1 0 2 . 6 9 3 . 0 1 9

Name of claimant (please print)

4. For internal use only (to be filled in by BAUER) BAUER) Subject to warranty? Yes If yes, give order number: Further reports: Further actions: Return of damaged parts by: Estimated working time (hrs):

Signature

Company

No If no, give reasons:

(Signed by authorized BAUER employee)

An:

BAUER Maschinen GmbH Abteilung Kundendienst Postfach 12 60 86522 Schrobenhausen Tel. +49 8252 97-2586 Fax +49 8252 97-2587 E-Mail [email protected]

PERSONALANFORDERUNG / STAFF REQUEST Von Firma / Company :

Besteller / Ordered by:

Tel.: Fax:

Bestell-Nr. / Order no.:

E-Mail:

Gerät /

Ausrüstung / Attachment:

Equipment :

Betriebsstd. / Working hours:

Bau-Nr. / Serial no.: Standort des Geräts / Location of machine:

Ansprechpartner Baustelle / Contact person jobsite:

Baustellentelefon / Jobsite phone no.:

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

Mechaniker mechanic

Elektriker electrician

Einweiser operator

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

Besonderheiten / Special requirements :

Ersatzteile / Spare parts:

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

Datum / Date:

englisch/English

Landessprache/Language

of

Unterschrift / Signature:

BAUER Maschinen GmbH  86529 Schrobenhausen  Tel. 0 82 52/97-0

sra

910.097.1+2BMA

08/2008

An/ BAUER Maschinen GmbH To: Abteilung Kundendienst/ After Sales Service Dept. Postfach/P. O. Box 12 12 60

86522 Schrobenhausen, Germany Tel.: +49 8252 97-2586 Fax: +49 8252 97-2587 E-Mail: [email protected]

REGISTRIERUNG BETREIBER UND GERÄT/ OWNER A ND EQUIPMENT REGISTRATION REGISTRATION Wir möchten dem Betreiber jederzeit eine optimale Dienstleistung bezüglich Kundeninformationen bieten können. Wir bitten deshalb jeden neuen Betreiber, sich und sein Gerät über dieses Formular bei der BAUER Maschinen GmbH registrieren zu lassen./ W e w o u l d l i k e t o o f f e r t h e e q u i p m e n t o w n e r a n o p t i m u m s e r v i c e a s r eg eg a r d s c u s t o m e r i n f o r m a t i o n at all times. F o r t h i s r e as as o n , w e w o u l d a s k e ac ac h o w n e r t o r e g i s t er er h i m s e l f a n d h i s e q u i p m e n t w i t h B A U E R M as as c h i n e n G m b H b y f i l l i n g o u t t h i s f o r m .

1. Gerätedaten/ Equipm ent

Data Data

Gerät/ Equipment:

Baunummer/ Serial number:

Betriebsstunden/ No. of operating hours:

2. Betreiberdaten/ O w n e r i n f o r m a t i o n Aktueller Betreiber des Gerätes mit Anschrift/C u r r e n t

: owner of the equipm ent, including address

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

Datum/ Date

Name des Ausstellers (in Blockbuchstaben)/

Unterschrift/

Firma/

Signature

Company

Name of issuer

(in capital letters)

BAUER Maschinen GmbH  86522 Schrobenhausen, Germany  Tel. +49 8252 97-0

shj

910.847.1+2BMA

11/2009

DESCRIPTION

1

DESCRIPTION

1.1

EQUIPMENT APPLICATIONS APPLICATIONS

The equipment shall only be used for the following operations: Operation

Abbreviation

Authorized use?

Drilling with Kelly equipment Drilling with Continuous Flight Auger equipment Drilling with Front Of Wall equipment

Kelly

Yes

CFA

No

FOW

No

Drilling with dual rotary drive equipment

DKS

No

Piling with vibrator equipment Drilling with High Pressure Injection equipment Drilling with Full Displacement equipment

No HPI

No

FDP

No

Drilling with soil stabilization equipment

CSV

No

Authorized use means use in strict compliance with and strict adherence to all directives, mandates, precautions and prohibitions contained in this Instruction Manual as well as in all additional manuals and documents supplied herewith. Everything contained in the Instruction Manual refers to and applies only to the equipment as first delivered to the original purchaser including all original attachments and factory installed options as of the day of delivery. Any modification of the equipment or its attachments or factory installed options opti ons made m ade after delivery might render the equipment unsafe and therefore invalidates this Instruction Manual. The equipment shall not be used after any such modifications are made unless such use after modification after modification has been approved in writing by BAUER Maschinen GmbH as set forth below. The manufacturer disclaims any liability of any kind arising or connected with the so prohibited and unauthorized use of the equipment in any way unless such use after modification has been approved in writing w riting by BAUER Maschinen GmbH.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

1-1

DESCRIPTION

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

1-2

DESCRIPTION

An/ To:

BAUER Maschinen GmbH Tel. +49 8252 97-2586 Abteilung Kundendienst Fax +49 8252 97-2587 Postfach 12 60 E-Mail [email protected] D-86522 Schrobenhausen Von (Eigentümer, Betreiber)/From (owner, user):

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

Änderungsantrag Änderungsantrag / Change request für/for Gerät/Equipment

Ausrüstung/Attachment

Anbauteil/factory installed option

1. Grunddaten/Equipment specifications Gerät/Anlage Equipment/ Baunummer/ Plant: Serial number.: Aktueller Standort des Gerätes/der Anlage Anlag e mit Anschrift/ Current location of the equipment/plant with complete address: Datum der Kommissionierung/Date of commissioning (first use):

Baujahr/ Year of manufacture :

Betriebsstunden/ Operating hours:

Anbauteile (original)/Factory installed options (OEM): Bezeichnung/Description Materialnummer/Material number

Baunummer/Serial number

Ausrüstung (original)/Attachment (OEM): Bezeichnung/Designation Materialnummer/Material number

Baunummer/Serial number

2. Änderungsdaten/Change data für/for Gerät/Equipment Ausrüstung/Attachment Änderungsbeschreibung/Description Änderungsbeschreibung/Descripti on of changes

Anbauteil/Factory installed option ggf. ggf. Ange Angebot botsnr snr.. BAUER/ BAUER/BAU BAUER ER offer offer no (if applic applicab able) le)

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

Name/Name

Unterschrift/Signature

Datum/Date

3. BAUER-intern (wird von BAUER ausgefüllt) / For internal use of BAUER (to be filled in by BAUER) Antrag erhalten am/Request received on: Antrag weitergeleitet an/ VT Name: Datum/Date: Request forwarded to: EK Name: Datum/Date: PM Name: Datum/Date: andere/other Name: Datum/Date: Name KVT-Mitarbeiter/Name of KVT employee:

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

1-3

DESCRIPTION

1.2

COMPONENTS

1.2.1

Basic Rig / Kelly Equipment

1.2.1.1 Components Overview Basic Rig 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Boom Boom cylinders Swing mechanism Crawler drives Counterweight Main winch Main rope Auxiliary winch Auxiliary rope Wedge * Masthead tilting cylinder * Kinematic triangle * Mast (upper section / lower lower section) Mast prop * Mast pivot Masthead Mast extension (intermediate) * Mast extension (lower) * Backstay cylinders Uppercarriage Rope swivel Crowd rope tensioning cylinder Supporting boom * Supporting trestle Undercarriage Crowd sledge Crowd ropes (upper/lower) (upper/lo wer) Thrust rod * Crowd winch Crowd cylinder *

Kelly equipment 40 41 42 43 44 45 46

Drilling tool Rotary drive Casing drive adapter Shock absorber Cardan joint Kelly drivers Kelly bar

9 16 21

22 46 13

45 43 41 44

26

42 19 40

27 29 6 8 24

13 15 14 2 1 25

20 5 3 4 BK000514.wmf

*) does not exist with this version

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

1-4

DESCRIPTION

1.2.1.2 Components Description Table Basic rig components description

Component

Description / Function Is a movable link from the machine to the mast Boom pivot. Are movable connections of the boom to the maBoom cylinders chine. They enable adjustment of the machine's distance to the bore. Enables rotation of the uppercarriage to both Swing mechanism sides. Crawler drives Drive the two crawlers forward and reverse. Counterweights Render stability to the equipment. Main winch with main rope Is used as a hoist for the Kelly. Auxiliary winch with with auxiliary rope Is used for rigging operations and load handling. Wedge Allows changing the distance from mast to bore. Kinematic triangle (H) Enables parallel repositioning of the mast. Mast (upper (upper section section / lower section) Provides guidance for the crowd sledge. Supports the rig during withdrawal of the drilling Mast prop tool. Mast pivot Is a swivel link between the mast and the boom. Masthead Houses sheaves which guide ropes over the mast. Mast extension (intermediate) Enables use of longer drilling tools. Mast extension (lower) Allows the crowd sledge sledge be positioned positioned further down. Are movable supports of the mast. They raise and Backstay cylinders lower the mast and allow adjustment of the inclination of the mast. Uppercarriage Houses the engine, hydraulic system and controls. Rope swivel Prevents rope twist. Crowd rope tensioning cylinder (S) Stresses the crowd ropes. Supporting boom (H) Enables parallel repositioning of the mast. Supporting trestle (V) Is a mount for the backstay cylinders. Carries the rig and moves it from f rom one drilling spot Undercarriage to the next. Runs up and down the mast while carrying the roCrowd sledge tary drive and drilling tool. Crowd ropes (upper / lower) (S) Transfer force from crowd winch to crowd sledge. Thrust rod (Z) Is a distance keeper for the crowd cylinder. Crowd winch (S) Generates the crowd forces. Crowd cylinder (Z) Generates the crowd forces. Z) for rig fitted with cylinder crowd S) for rig fitted with rope crowd

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

V) for mast lowering to the front H) for mast lowering to the rear

1-5

DESCRIPTION

Table Kelly equipment components description

Component

Description / Function

Drilling tool

Erodes and conveys soil.

Rotary drive

Generates rotary movement and torque for the drilling tool and/or casing tube. Its final gear is driven by planetary gears which take power from hydraulic motors.

Casing drive adapter

Serves as a connector between the cardan joint and the casing tube and transfers the torque.

Shock absorber

Absorbs shocks from the Kelly bar.

Cardan joint

Transfers torque from rotary rotar y drive to casing drive adapter and prevents torsional stress.

Kelly driver

Transfers torque from rotary drive to Kelly bar.

Kelly bar (Kelly)

Consists of telescoping tubes the total length of which determines the achievable depth of the bore. It transfers torque from the rotary drive to the drilling tool.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

1-6

SAFETY

2

SAFETY

2.1

GENERAL SAFETY REQUIREMENTS

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

2.2

EQUIPMENT SAFETY

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

2.3

MAJOR HAZARDS

- In drilling applications, the equipment operates with rotating tools. Being caught by a -

-

-

-

rotating part is mortal. In vibrator vibrator applications, the equipment equipment operates with high-frequency oscillating oscillating tools. Getting knocked down by a component thereof is mortal. The stability of the equipment equipment must not not be endangered. endangered. Exceeding Exceeding the rig's capacity capacity or operating with faulty end-limiters can make the equipment fall violently causing severe personal injury or even loss of life. Never remove equipped safety devices devices or render them out of order. Be observant observant of oil spills from the hydraulic system. If there is a spill, find the cause and repair it. Oil spraying with high pressure from a leak in the hydraulic system can cause severe burns and poisoning. The cooling system gets gets very hot from operation. Coming in touch with with components containing coolant can cause burns. Engine, gear and hydraulic oils get very hot from operation. Touching a component containing such oil can cause burns. Be sure the equipment is properly shut down before you begin a maintenance, repair or cleaning job on it: Set all controls to OFF, stop the engine and set the battery main switch to OFF position. To prevent abuse and unauthorised starting of the equipment, equipment, shut it down, down, remove the ignition key and lock the cab whenever you leave the equipment unattended.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2-1

SAFETY

2.4

SAFETY DEVICES

2.4.1

Emergency Stop

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

1 0

1

To re-start, pull the depressed Emergency STOP button. BK1478505.wmf

2.4.2

Pilot Control Safety Stick 1.2 1.2

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.

1.1 1.1

Pilot control ON: Stick moved to position (1.1) Pilot control OFF: Stick moved to position (1.2)

BK786505.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2-2

SAFETY

2.4.3

Fire Extinguisher

Machine with an engine power of < 200 kW is equipped with one fire extinguisher / Machine with an engine power of > 200 kW has two fire extinguishers. Their location in or on the machine is identified with a decal (see fig.). Personnel must recapitulate the text on fire extinguishers from time to time to be familiar with their use. B0000506.wmf

2.4.4

Medical Box

A First Aid medical box is found in the op-

erator’s cab. Its location is identified with a decal (see fig.).

B0000562.wmf

2.4.5

Emergency Exit

Whenever the normal exit from the cab is blocked, the operator can use the equipped emergency hammer (see fig.) to smash a window. The hammer is found in the operator's cab

beside the operator’s seat.

BS756504.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2-3

SAFETY

2.4.6

Limit Switches

Table Limit switches

Name ES 2* ES 2.1*

Function Limits mast inclination to left.

HS 2

Initial situation: - ES 2 out of order Switches off engine when max. permissible mast inclination to left is obtained.

ES 3

Enables the Rigging Mode when boom cylinders are fully extended.

ES 4*

Limits mast inclination to right.

ES 4.1*

HS 1

Initial situation: - ES 4 out of order Switches off engine when max. permissible mast inclination to right is obtained.

Initial situation: - boom cylinders fully extended ES 10* - inclinometer out of order Limits mast inclination forward or backward for drilling operations.

HS 1

Stops lifting by the main winch before load may hit the masthead.

HS 2*

Stops lifting by the t he auxiliary winch before load may hit the masthead.

ES 3 BK000515.wmf

*) optional

With switch ES 2.1 or ES 4.1 activated, the engine can be restarted by holding the by-pass button depressed while turning the ignition on.

NOTE

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2-4

SAFETY

2.4.7

Fall Protection Equipment * WARNING! Danger of falling! When climbing the mast ladder, the provided fall protection equipment must be used. Personnel climbing the ladder must wear a body harness secured by lanyards to a fall protection slide and by a lifeline, at all times! The person in question must be familiar with the fall protection equipment.

1 2 3 4 5 6 7 8

Shoulder straps, orange red Ring for attaching a lifeline Buckles for shoulder strap positioning Waist strap with wide support for the back D-rings for attaching lanyards Rings for attaching a seat support Seat support, blue Leg straps, blue

1 2 3 4 5

6 7 8 B0000793.wmf

How to don Slip on the orange-red shoulder straps like a jacket, with the lifeline ring r ing to the back. Pull the free end of the waist strap through the twin-buckle at the other end and return through the inner buckle. Step into the loose hanging leg straps; pull them through the crotch and through the corresponding rings and secure using the twin-buckle, like with the waist strap. The seat support must be in position under the buttocks.

How to use The body harness (DIN 7478 sec. A) may be used only in conjunction with a fallf allpreventing slide and lanyards (DIN 23326) or a lifeline (DIN 7471) together with a falldamping device. The harness including all accessories must be checked for good workwor king order before put to use. Never use damaged equipment. Safe anchoring points must be provided above the user’s position. Possible fall height must be kept at minimum using rope shorteners. Never work with slack lanyards or lifeline. Be careful caref ul that lifeline and ring (2) are in proper position at all times. Lanyards must be snapped on directly to D-rings (5) on harness. *) Not used in this version

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2-5

SAFETY

2.5

STABILITY

2.5.1

Guidelines for Stability

Rig capacity charts are calculated in compliance with the European standard DIN EN 791 (issue 1995).

WARNING! Rig tipping hazard! The conditions listed in the following f ollowing must be observed in order that the stability of the rig is guaranteed.

Conditions for operation:

– Rig angles and and loads on main rope, auxiliary auxiliary rope and crowd crowd given in the capacity

– – – –

charts are maximum values which must not be exceeded for safety reasons. The specified loads apply only when not combined and not used on an altered setup of equipment. Mounting attachments which are heavier or have a higher centre of gravity (like e xchanging a Kelly with CFA equipment) requires a new calculation of the rig's stability. Machine on firm, horizontal and even even surface. National safety codes and guidelines observed concerning the soil and working platform conditions. Upper carriage held stationary with with crowd and main rope load. Slow swing swing of upper carriage carriage with load load on auxiliary rope. No diagonal pull. Pulling and pushing forces of the winches / crowd cylinder and the present centre of gravity (position of the work attachments) are factors

which have additional influence on the rig’s stability. NOTE

The loads given in the capacity charts take into consideration the most m ost adverse position of the components.

Conditions for onsite travelling:

– Firm and even even travel surface. surface. National standards and guidelines observed observed regarding – – – –

ground, soil and surface conditions. Upper carriage carriage in line with undercarriage. Work attachments and movable loads kept as close to the ground as possible. Mast vertical. No abrupt movements.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2-6

SAFETY 2.5.2

Stability for BG 25 # 2254 - Kelly BK 25/394/4/56

2.5.2.1 Load Capacity Chart Valid only for

Conditions for operation

Mast extension --- m --- t Counterweight Counterweight 6.20 + 6.20 t Kelly BK 25/394/4/56 10.10 t 1.90 t Casing drive adapter  1,500 mm 2.30 t Drilling tool  1,350 mm Crowd sledge stopper mounted (max. stroke: 8,120 mm)

Max permissible load / max ground pressure** Min. drilling distance*: -- m Max. drilling distance*: distance*: 3.39 m

B0000689.wmf B00005003.wmf B00005002.wmf

Auxiliary rope

8.0 t 430 kPa

Main rope

20.0 t 380 kPa

Crowd

26.0 t 470 kPa

α=° β=° γ=° δ=° α=° β=° γ=° δ=° α=° β=° γ=° δ=°

α = 6° β = 3° γ = 0° δ = 110° α = 6° β = 3° γ = 4° δ = 110° α = 6° β = 3° γ = 4° δ = 110°

Auxiliary rope

α=° β=° γ=°

α = 6° β = 3° γ = 0°

4.0 t 590 kPa

Main rope

α=° β=° γ=°

α = 6° β = 3° γ = 4°

20.0 t 480 kPa

Crowd

α=° β=° γ=°

α = 6° β = 3° γ = 4°

26.0 t 610 kPa

Auxiliary rope

Main rope

Crowd

Max. working platform inclination / max. ground pressure **

8.0 t 750 kPa

20.0 t 480 kPa

26.0 t 610 kPa

5° / 340 kPa

*) Drilling distance = centre distance from machine to drilling tool **) Max. value of ground pressure as calculated in conformance with DIN EN 791 (1995 issue)

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2-7

SAFETY 2.5.2.2 Weights / Centres of Gravity - Drilling Distance 3.39 m Valid only for

Drilling dis-

3.39 m

Weight [kN]

Xres [m]

Zres [m]

Completely equipped drilling rig

822.10

0.68

5.05

Undercarriage with connections to CO

204.00

0.00

0.55

Upper carriage with BAUER attachments, with crowd sledge, with counterweights, without work equipment, without undercarriage, without KDK

424.10

-0.22

4.66

50.00

3.21

11.24

19.00 101.00 23.00 1.00

3.39 3.39 3.39 3.39

9.20 12.30 2.80 19.50

Component

B0000919.wmf

B0000920.wmf

B0000921.wmf

Rotary drive KDK 250 K with Kelly driver Casing drive adapter Ø 1500 mm Kelly BK 25/394/4/56 Drilling bucket Ø 1350 mm Swivel B0000922.wmf

Undercarriage Length of crawler tread Track gauge, extended Width of track shoes

Dimensions [m] A S B

4.62 3.68 0.70

Z

X

A

B

X

S

B0000929.wmf

*) Drilling distance = centre distance from machine to drilling tool

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2-8

SAFETY 2.5.3

Stability for BG 25 # 2254 - Kelly BK 25/394/4/40

2.5.3.1 Load Capacity Chart Valid only for

Conditions for operation

Mast extension --- m --- t Counterweight Counterweight 6.20 + 6.20 t Kelly BK 25/394/4/40 7.70 t 1.90 t Casing drive adapter  1,500 mm 2.30 t Drilling tool  1,350 mm Crowd sledge stopper mounted (max. stroke: 8,120 mm)

Max permissible load / max ground pressure** Min. drilling distance*: -- m Max. drilling distance*: distance*: 3.39 m

B0000689.wmf B00005003.wmf B00005002.wmf

Auxiliary rope

8.0 t 390 kPa

Main rope

20.0 t 370 kPa

Crowd

26.0 t 420 kPa

Auxiliary rope

Main rope

Crowd Auxiliary rope Main rope

Crowd

α=° β=° γ=° δ=° α=° β=° γ=° δ=° α=° β=° γ=° δ=° α=° β=° γ=° α=° β=° γ=° α=° β=° γ=°

α = 6° β = 3° γ = 0° δ = 120° α = 6° β = 3° γ = 4° δ = 120° α = 6° β = 3° γ = 4° δ = 120° α = 6° β = 3° γ = 0° α = 6° β = 3° γ = 4° α = 6° β = 3° γ = 4°

Max. working platform inclination / max. ground pressure ***

8.0 t 690 kPa 20.0 t 490 kPa 26.0 t 570 kPa 5.0 t 560 kPa 20.0 t 490 kPa 26.0 t 570 kPa 5° / 310 kPa

*) Drilling distance = centre distance from machine to drilling tool **) Max. value of ground pressure as calculated in conformance with DIN EN 791 (1995 issue)

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2-9

SAFETY 2.5.3.2 Weights / Centres of Gravity - Drilling Distance 3.39 m Valid only for

Drilling dis-

3.39 m

Weight [kN]

Xres [m]

Zres [m]

Completely equipped drilling rig

798.10

0.60

5.14

Undercarriage with connections to CO

204.00

0.00

0.55

Upper carriage with BAUER attachments, with crowd sledge, with counterweights, without work equipment, without undercarriage, without KDK

424.10

-0.22

4.66

50.00

3.21

11.24

19.00 77.00 23.00 1.00

3.39 3.39 3.39 3.39

9.20 14.30 6.80 19.50

Component

B0000919.wmf

B0000920.wmf

B0000921.wmf

Rotary drive KDK 250 K with Kelly driver Casing drive adapter Ø 1500 mm Kelly BK 25/394/4/40 Drilling bucket Ø 1350 mm Swivel B0000922.wmf

Undercarriage Length of crawler tread Track gauge, extended Width of track shoes

Dimensions [m] A S B

4.62 3.68 0.70

Z

X

A

B

X

S

B0000929.wmf

*) Drilling distance = centre distance from machine to drilling tool

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2 - 10

SAFETY

2.6

PERMISSIBLE WIND SPEED

The place to measure the wind speed is at the masthead:

Max. permissible wind speed for equipment operation m/s km/h miles/h Beaufort 20 72 45 8

Barrier effect ktn 39

250 (N/m²)

WARNING! Rig tipping hazard! Shut down the equipment before the value is exceeded.     

Remove attached drilling tool(s) and suspended load. Lower movable components as close to the ground as possible. Adjust the uppercarriage uppercarriage in line with the undercarriage undercarriage and interlock them. Set the mast into the minimum working range. Extend the mast prop (if equipped) to the ground.

Table of wind forces and speeds Wind force Beaufort English 0 calm 1

light air

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

2

light breeze

1.6 - 3.3

6 - 11

Wind can be felt on your face, leaves rustle, sea has wavelets

3

gentle breeze

3.4 - 5.4

12 - 19

Leaves and thin twigs move, pennants stretch, wave crests begin to break

4

moderate breeze

5.5 - 7.9

20 - 28

Dust and paper lift, twigs and branch lets sway, waves are growing in length, scattered white-caps

5

fresh breeze

8 - 10.7

29 - 38

Small trees begin to sway, waves are whitecapped all over the sea

6

strong breeze

10.8 - 13.8

39 - 49

Sturdy branches move, wires sing, umbrellas um brellas are hard to handle, sea is rough, crests break

7

near gale

13.9 - 17.1

50 - 61

Whole trees swaying, walking towards the wind is difficult, sea is very rough, foam on crests

8

gale

17.2 - 20.7

62 - 74

Branches break off, walking outdoor is extremely difficult, waves are high, spray from crests

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

9

strong gale

20.8 - 24.4

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2 - 11

TECHNICAL TECHNICAL SPECIFICATIONS

3

TECHNICAL SPECIFICATIONS

3.1

DIMENSIONS

3.1.1

Kelly Equipment BK 25/394/4/56

Dimensions in [mm]

4620

BK22545001.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

3-1


3.2.1

Kelly Equipment BK 25/394/4/40

Dimensions in [mm]

4620

BK22545000.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

3-2


3.2

EQUIPMENT SPECIFICATIONS SPECIFICATIONS

Base Machine Uppercarriage Type

Hyundai R 305

Engine Type Serial number Output Speed

Cummins QSC 8.3 21911488 224 kW 2000 rpm

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

UW 75 BH 9161 3000 - 4400 mm 5360 mm 700 mm

Mast Inclination During operation without work equipment forward backward to left to right

6° 4° 3° 3°

During operation with work equipment See load capacity chart

Operating Range See load capacity chart

Working Weight With: Kelly BK 25/394/4/56 Kelly BK 25/394/4/40

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

82.50 tonnes 80.00 tonnes

3-3


Main winch Type Serial number

77 WH 102/13 72810

Pulling force (1st layer) Rope diameter Rope length Rope speed ("lifting" with a load of 80 kN)

200 kN 28 mm 88 m 87 m/min

Auxiliary winch Type Serial number

4.22 1000328 1028

Pulling force (1st layer) Rope diameter Rope length Rope speed ("lifting" with a load of 10 kN)

80 kN 20 mm 50 m 55 m/min

Crowd winch Type Serial number

4.261001908 623

Max. stroke of crowd sledge Max. pushing force at crowd sledge Max. pulling force at crowd sledge Rope diameter Length of upper/lower upper/lower rope without mast extension Crowd speed: "Fast crowd up" "Fast crowd down" "Slow crowd up" "Slow crowd down"

8,145 mm (with Kelly-system) 260 kN 260 kN 24 mm 65 / 60 m

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

21.4 m/min 21.4 m/min 5.9 m/min 5.9 m/min

3-4


3.3

ROTARY DRIVE SPECIFICATIONS SPECIFICATIONS

3.3.1

Rotary Drive, constant

Pth = 205 kW Qth = 2 x 250 l/min i = 26.18 hi h tor ue

low tor ue 200

260 245 240

175

220 151 150

200 191 ]180 m N k [ 160 M

] m N k [125 M

e u q r o T

e u q r o T100

118

140

/ t n e m o m75 h e r D

/ t120 n e m o 100 m h e r D

80

50

60 45 40

25

20 0 0

5

7 9

10

15

20

25

30

35

37

0

40

Drehzahl n [1/min] / S p e e d n [ r p m ]

BK832507.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

0

11 14 10

20

30

37

40

50

[r p m ] Drehzahl n [1/min] / S p e e d n [r

BK832508.wmf

3-5


3.4

DRILLING SPECIFICATIONS SPECIFICATIONS

3.4.1

Kelly equipment L1

A

Dimensions [mm] L1 L2 L3 A max. Hd Bore diameter [mm] uncased cased

L2

Casing length without CO with CO L3

20767 12131 4011 16666 8452

1700 1400

Hw – 0.5 m Hw – 1.5 m

Hd Hw

Drilling depth / Kelly specifications

Kelly type

BK 25/394/4/56 BK 25/394/4/40

B T

W

A [m] 16.71 12.71

B [m] 59.47 43.47

B1 [m] 59.12 43.12

Hw [m] 1.85 5.85

locked Kelly without with CO CO T [m] T [m] 57.31 55.81 41.31 39.81

unlocked Kelly without with CO CO T [m] T [m] 57.66 56.16 41.66 40.16

Weight [t] 10.05 7,70

Notice:

Drilling depth specifications are based on min. operating radius of mast. With max. operating radius the drilling depth increases by 0.456 m.

A: A max.: B / B1: T: Hw: Hd: L1: L2: L3: W: CO:

Length of retracted Kelly Max lifted length of Kelly Length of extended Kelly unlocked / locked Max. possible drilling depth Maximum height to drilling tool Maximum height to casing drive adapter Highest possible position of Kelly lifting eye Highest possible position of Kelly driver upper edge Lowest possible position of Kelly driver upper edge Length of drilling tool: 2.20 m BAUER Casing Oscillator

BS756510.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

3-6


3.5

ROPE SPECIFICATIONS SPECIFICATIONS

3.5.1

Main Rope WARNING! Accident risk! Ropes breaking can cause serious accidents. Ropes installed in hoist winches must have a minimum breaking load which is at least three times the winch pull force.

The ropes' safety factors must comply with the standards required for the equipment and must be observed.

Technical data: Finished length Diameter

88 m 28.00 mm

Characteristics: Lay and direction Rotation characteristics Rope end characteristics

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

Regular lay, right (sZ) Non-rotating Pointed, full thimble

3-7


3.5.2

Auxiliary Rope WARNING! Accident risk! Ropes breaking can cause serious accidents. Ropes installed in hoist winches must have a minimum breaking load which is at least three times the winch pull force.


Technical data: Finished length Diameter

50 m 20.00 mm


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

Regular lay, right (sZ) Non-rotating Pointed, full thimble

3-8


3.5.3

Crowd Ropes WARNING! Accident risk! Ropes breaking can cause serious accidents. Ropes installed in hoist winches must have a minimum breaking load which is at least three times the winch pull force.


Technical data: Finished length (upper / lower) Diameter

65 m / 60 m 24.00 mm


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

Regular lay, left (zS) Rotating Pointed -Pointed

3-9


3.6

NOISE EMISSION

Measurements made in accordance with DIN EN 791:

1. Inside Cab (door closed) Sound-pressure level in cab

LpA =

75.0 dB(A)

2. Outside Average sound-pressure level level Sound-power level

3.7

LPA = 87.5 dB(A) LWA = 113.0 dB(A)

TEMPERATURE TEMPERATURE CONDITIONS

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

3 - 10


3.8

EXPOSURE TO VIBRATION

The operator’s exposure to vibration acceleration during operation with this equipment

is less than 0.5 m/s².

3.9

EXHAUST GAS EMISSION

The exhaust gas emission limit values comply with the 97/68/EC and 2004/26/EC stage III A and EPA/CARB TIER III directives respectively. As long as the diesel engine complies with the effective guideline in the country of use, the operator is permitted to use this equipment.

NOTE

If repair of any kind is carried out on the diesel engine using non-original components, exhaust gas emissions may not comply with the applicable guidelines in the country of use. In this case, the operator is obliged to contact "BAUER Maschinen" in order to start maintenance procedures. Once the equipment has been checked and compliance with exhaust emission limit values is ensured, it may be put back into operation.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

3 - 11

CONTROLS AND INDICATORS

4


4.1

CAB 1.1 1.3 1.5

15.5 15.1 15.3

20 19 18 17 21

1.6 1.4 1.2

2.1

3

2.3 2.2

15.4

15.2 15.6

6 7 8 9 10.3

10.7 10.5 10.1

12

10.2 10.6 10.8

16 0

1

10.4

5 4 11

BK18685002.wmf

1.1 1.2 1.3 1.4 1.5 1.6 2.1 2.2 2.3 3 4 5 6 7 8 9 10.1 10.2 10.3 10.4 10. 4 10.5

Left crawler travel forward Left crawler travel reverse In CO mode: Tube lower * In CO mode: Tube lift * In CO mode + Clamping cylinders cylinders selected: Tube unclamp * In CO mode + Clamping cylinders cylinders selected: Tube clamp * Right crawler travel forward Right crawler travel reverse In CO CO mode: Oscillate * Free-fall/Freewheel release Free-fall/Freewheel mode ON/OFF Not used Crowd fast mode ON In Kelly/CFA mode + preselection of high torque: KDK fast mode ON/OFF In Kelly mode: Dump spoil Horn ON Crowd down Crowd up In Kelly/CFA Kelly/CFA mode: Rotary drive rotate right In Kelly/CFA Kelly/CFA mode: Rotary drive rotate left Rigging mode + Backstay cylinders cylinders selected: Right backstay cylinder extend

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

10.6 Rigging mode + Backstay cylinders cylinders selected: Right backstay cylinder retract 10.7 Rigging mode + Boom cylinders cylinders selected: Boom cylinders retract 10.8 Rigging mode + Boom cylinders cylinders selected: Boom cylinders extend 11 Engine speed adjustment 12 Engine ignition ON/OFF 15.1 Winch 1 / 2 down 15.2 Winch 1 / 2 up 15.3 Uppercarriage swing to left left 15.4 Uppercarriage swing to right right 15.5 Rigging mode + Backstay cylinders selected: Left backstay cylinder extend 15.6 Rigging mode + Backstay cylinders selected: Left backstay cylinder retract 16 Emergency STOP 17 Auger cleaner retract/extend * 18 Swing brake release 19 Swing brake apply 20 Free-fall/Freewheel release 21 Pilot control ON/OFF CFA CO *

= Continuous Flight Auger = Casing Oscillator = Not used in this version

4-1


4.2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

BASE MACHINE CONTROL CONSOLE

Not used Not used Indicator: Engine preheat Engine diagnostic: Warning = Stop Engine Engine diagnostic: Indication: Error code Error codes scroll Engine diagnostic: Error code test Not used Not used Freewheel/Free-fall mode ON/OFF Emergency-STOP Engine speed adjustment Engine ignition ON/OFF Not used Central lubrication ON Intermediate lubrication* Crowd sledge Lube trouble* Central lubrication ON/OFF*

2 4

1

5 3

13 11 9

12 0

6 7 8

1

10 14 15 16

*) Not used in this version

17 BK19035002.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

4-2


4.3

CONTROL PANEL

KDK

1

KDK

KDK

2

1

8

2

9

KDK

1

returnflow

3

10

4

11

5

12

6

13

7

14

15

16

KDK

KDK

22

23

17

18

19

20

21 P

24

25

26

27

28

BK19065000.wmf

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Rigging/Drilling Rigging/Drilling mode select Main Winch 1 / Auxiliary Auxiliary Winch 2 select Not used Mast prop extend Mast prop retract In Drilling mode: Left backstay cylinder extend In Drilling mode: Right backstay cylinder extend Boom cylinders retract Boom cylinders extend Extendable crawlers extend / retract Crowd rope relieve Crowd rope tension In Drilling mode: Left backstay cylinder retract In Drilling mode: Right backstay cylinder retract

15 16 17 18 19 20 21 22 23 24 25 26 27 28

Rotary drive low torque select Rotary drive middle torque select Rotary drive high torque select Warning: Free-wheel Free-wheel oil filter contaminated Warning: Return line oil filter contaminated Not used Warning: Rotary drive leak oil pressure too high Rotary drive fast mode ON/OFF Indicator: Rotary drive fast mode mode Not used Not used Not used Indicator: Freewheel/Free-fall Freewheel/Free-fall released Indicator: Swing brake lock


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

4-3


4.4

MONITOR UNIT

For Details of the Monitor Unit, please refer to the supplementary documentation supplied with the equipment.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

4-4

OPERATION

5

OPERATION

5.1

TRAVEL

5.1.1

To Travel and Steer

CAUTION

The durability of the crawler components risks to be reduced due to improper loading! As shown, the main direction of travel should always follow the direction direction of the arrow (2); front idler (1) ahead and crawler drive (3) back. When working, the front idler (1) must also be oriented towards the drilling point. 1

2

3

CA00005000.wmf

B0000552.wmf

CAUTION

Risk of damaging components of the undercarriage! The undercarriage mounted to the equipment is functionally f unctionally designed for stationary operation under loads and forces from drilling. Travel over far distances with this equipment must be avoided! For shifting the equipment to other locations, suitable transporting means provided for the purpose are to be used!

NOTE

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5-1

OPERATION

5.2

UPPERCARRIAGE SWING

5.2.1

Swing Brake

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

CAUTION

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

WARNING! Squashing hazard, hitting hazard! Before swinging the uppercarriage, check the danger zone is free. Rearview mirror (and tail camera if equipped) must be clean at all times.

To apply the swing brake: ● Press button (19). To release the swing brake: ● Press button (18).

BK19035004wmf

Swing brake lock:  The indicator light on Control Panel comes on.

P

BK19035010wmf

Swing brake unlock:  The indicator light on Control Panel goes out.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5-2

OPERATION

5.2.2

Swing Control

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

15

Uppercarriage swing to right:  Unlock swing brake.  Move control lever to right (15) from centre. BK20545001.wmf

Letting the lever return to centre makes the swing slowly come to a stop, in hydraulic way. A quicker stop can be implemented by carefully moving the lever lever in the opposed direction.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5-3

OPERATION

5.3

MAST REPOSITIONING

CAUTION

Risk of damaging components! The mast must be parallel to the drilling axis at all times! During drilling mode – and especially during casing oscillator applications – it is important to watch the inclination of the mast on the

operator’s screen. Should the inclination change due to the forces, the mast must be repositioned to the original inclination.

CAUTION

CAUTION

Risk of components getting damaged and the rope breaking! On machines where the winches are housed in the uppercarriage, the ropes must be sufficiently slackened before the mast is repositioned. Otherwise, the ropes may be subjected to excessive stress. Risk of components getting damaged and the rope breaking! On equipment fitted with an overload protection for the main rope, various functions will shut off when the rope is overloaded and a message will appear on the operator's screen. When this is the case: unlock the Kelly (if locked) and spool out rope from the main winch. Immediately replace any damaged components of the overload protection.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5-4

OPERATION

5.3.1

Mast Auto Reset to Vertical

Risk of damaging components!

CAUTION

Neither the mast prop nor components of the drilling equipment may be in touch with the ground when the "Mast Auto Reset" is actuated.

● Press Botton Botton "AT" (1) and hold on. 

The mast sets to vertical position. 2 1

BK15155011.wmf

Releasing the button too soon stops the action.

NOTE

NOTE

NOTE

The mast will first set to vertical position in the X axis and then, after a pause, in the Y axis.

For more details please refer to the supplementary documentation supplied with equipment.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5-5

OPERATION

5.3.2

Mast Repositioning by Manual Control

CAUTION

Risk of collision! When using a hydraulic tube guide (for CFA, FOW or DKS equipment), there is a risk of collision with the cab or the hose hoop, if the minimum drilling centre distance is used and the mast is tilted to the side.  When using a hydraulic tube guide, the mast must not be tilted sideways if the minimum drilling centre distance is selected.

5.3.2.1 To Adjust Adjust the Mast Mast Inclination In Drilling Mode



Select Drilling mode:



Extend left backstay cylinder by



Extend right backstay cylinder by



Retract left backstay cylinder by



Retract right backstay cylinder by

BK14885017.wmf

B0000504.wmf

Extending the short backstay cylinders by the control panel is possible in drilling and rigging mode.

NOTE

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5-6

OPERATION

In Rigging Mode



Select Rigging mode:



Lowering the mast: Move left / right control lever l ever forward

0

Bk14885013.wmf

1

BK19035019.wmf



Raising the mast: Move left / right control lever back.

0

B0000504.wmf

1

BK19035020.wmf

NOTE

Extending the long backstay cylinders by the control levers only is possible in rigging mode.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5-7

OPERATION

5.3.2.2 To Adjust Adjust the Drill Distance Increasing machine’s distance to the bore:



Extend boom cylinders by

Decreasing machine’s distance to the bore:



Retract boom cylinders by

NOTE

To adjust the mast parallel (see fig.), the mast inclination must be readjusted. B0000505.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5-8

OPERATION

5.4

MAST PROP CONTROL * WARNING! Squashing hazard! Keep limbs out of the operating area of the mast prop.

The mast prop must be fully extended when strong forces result from the extraction of the tool.

WARNING! Tipping rig hazard! The surface under the mast prop must be safely supporting. Underpin with suitable material, as required.

To extend the mast prop: ● Press button and hold down. down. BK19035006.wmf

To retract the mast prop: ● Press button and hold down. down. BK19035007.wmf

Releasing one of these buttons too soon interrupts the action.

NOTE *) Not used in this version

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5-9

OPERATION

5.5

TRAVELLING TRAVELLING WITH THE RIG

5.5.1

Travelling over Level Ground

Risk of accident due to driver’s obstructed round -view from the cab. CAUTION

The driver of the rig must be assisted by a signalman during travel.

 Provide an obstacle free travel travel path. path.  Adjust the uppercarriage uppercarriage in line with the crawlers crawlers and apply the swing brake.

work attachments and movable loads as close to the ground as possible.  Lower work  Set the mast in position of minimum working range.  Set the mast vertical.

only.  Travel on firm and level surfaces only.  Avoid making abrupt movements.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 10

OPERATION

5.5.2

Travelling Up and Down Slopes

5.5.2.1 With Raised Mast without Drilling Equipment Tipping hazard! Observe all instructions found in sect. "Travelling over level ground"!

CAUTION

CAUTION

Tipping hazard! Max. permissible gradient is 15°. Travel straight to the grade only. Never zigzag or traverse!



Arrange the machine to carry the mast on the uphill side.



Tilt the mast slightly forward.



Travel up or down a slope in the manner shown here: B0000704.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 11

OPERATION

5.6

ROTARY DRIVE CONTROL

5.6.1

Kelly Application (Rotary Drive, constant) 7 KDK

KDK

KDK

1

8

KDK

1

2

returnflow

10 1

2

3

4

5

6

7

15

16

KDK

KDK

17 18 18

19

20

21 P

0

8

9

10

11

12

13

14

22

23

24 24

25

26

27

1

28

BK19065007.wmf

Function

BK19065009.wmf

Control

To select high torque

Press the button (17)

– To shift between high and low speed

Press the control lever (7) or button (22)

To select reduced torque + high speed

Press the button (15)

To select select reduced torque + reduced speed Press the button (16) Change speed:

Move the control lever (10) away from or back to centre

Turn the rotary drive counter-clockwise Turn the rotary drive clockwise

Move control lever (10) to the right Move control lever (10) to the left

To dump spoil (abrupt stop during clockwise rotation)

Move the control lever (10) to the left lef t and press the button (8)

CAUTION

Risk of damage to the Kelly bar and/or the rotary drive! Never dump soil, when an interlocking area of the outer Kelly is in the Kelly driver of the rotary drive. Should a locking area of the outer out er Kelly be in the Kelly driver, the rotary drive must be moved in relation to the Kelly bar before dumping the soil.

To select high speed, the indicator (23) lights up.

NOTE

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 12

OPERATION

Shifting the torques is allowed only when the rotary drive isn’t in motion m otion CAUTION

and the drilling tool not in touch with the borehole bottom!

Condition to use the "high" torque mode for Kelly bars: Only Kelly bars capable of transmitting the "High" " High" torque of the rotary drive may be used in the High torque mode. Know the max. permissible torque of your Kelly before you begin or your Kelly could get damaged. When the Kelly bars used are not designed for the torque of the rotary drive, the keyoperated switch (1) in the control cabinet must be turned to position of "High Torque OFF" to prevent damage to the Kelly. Limitation Torque High

Limitation Torque High

1

BK1206501.wmf

Risk of damaging the Kelly!

CAUTION

NOTE

Operation with excessive torque can ruin the Kelly bar.

With the key-operated switch (1) set to "OFF" in the control cabinet, the 1st gear of high torque is automatically blocked. And button butt on (17) on the control panel is out of function.

KDK

KDK

1

1

8

2

9

KDK

1

2

returnflow

3

10 10

4

11

5

12

6

13

7

14

15

16

KDK

KDK

22

23

17 18 18

24

25

19

26

20

21

P

P

27

28

BK19025002.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 13

OPERATION

5.7

WINCH CONTROL

5.7.1

Lifting / Lowering WARNING! Danger of getting squashed, entangled, drawn-in and scrubbed! Never put a hand in the winch moving area. Never reach between winch and rope. Never seize a rope in motion.

WARNING! Hitting hazard, squashing hazard! Hook up the auxiliary rope on the holding arm. Do not tension hooked-up rope when people are in i n the danger zone.

CAUTION

CAUTION

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

Risk of damaging the rig! Hoist limiters are out of function during rigging operations so that the winches must be controlled with great care.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 14

OPERATION

In Drilling mode

In Rigging mode

The Rigging mode switch on the control panel is not selected (see fig):

The Rigging mode switch on the control panel is selected (see fig.):

Winch selection: Set switch on control panelto Main winch (1) or to Auxiliary winch winch (2) (see fig.). f ig.). 1 2

Control of selected winch

B0000702.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 15

OPERATION

5.7.2

To Operate with Freewheel

The Freewheel function enables the main winch to automatically follow the drilling progress. 3

20

0

1

4

BK19035009.wmf

Precondition for release of Freewheel function: 

Load on rope is maximum: 2.0 tonnes

Freewheel activation: Turn key-operated switch (4) to position position of Freewheel Mode "ON".  Press foot switch switch (3) all way down and hold on.  Briefly press button (20). 

Freewheel is released! Indicator on control panel glows. BK19035003.wmf

NOTE

The rope will first automatically tension until the swivel is upright. This prevents drilling with the swivel overturned which would ruin the rope very soon.

Freewheel deactivation: Release the foot switch, or  Lift / lower by the winch control lever. position of Freewheel Mode "OFF".  Turn key-operated switch (4) back to position 

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 16

OPERATION

5.8

DEPTH MEASURING CONTROL

5.8.1

To Reset the Depth Measuring

● Place drilling tool in desired position. position. ● Press button " D=0 " (2), to reset the depth indicator to "0".

2 1

BK15155011.wmf

Depth 1 = Depth of main winch Depth 2 = Depth of crowd

The depth measuring may be reset to zero at any time.

NOTE

NOTE

For more details please refer to the supplementary documentation supplied with equipment.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 17

OPERATION

5.9

CROWD CONTROL

CAUTION

Risk of damaging components! Do not use the boom cylinders to boost the crowd system. Or, the crowd system will be overloaded and the drilling axis distorted. Do not use the fast crowd for drilling down. Or, the drilling equipment will be damaged.

WARNING! Squashing hazard! Do not reach into the moving area of the crowd sledge.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 18

OPERATION

5.9.1

Manual Control of the Crowd

6 10.1

10.2

0

1

BK19035011.wmf

Function

Control

Indicator

To run the crowd sledge Down

Push control lever (10.1) forward

-

To run the crowd sledge Up

Pull control lever (10.2) back

-

To change the crowd speed Speed changes with the amount of lever movement.

-

To operate in fast mode

-

CAUTION

Press button (6) and hold on Move lever off centre.

Risk of damaging components! Do not use the boom cylinders to boost the crowd system. Or, the crowd system will be overloaded and the drilling axis distorted.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 19

OPERATION

5.9.2

To Use the Main Winch in Combination with Crowd

CAUTION

Danger of damaging the slewing ring and undercarriage by overloading! Pulling by the main winch combined with pulling by the crowd system is permissible only under observance of the following instructions.

Pulling by the main winch together with the crowd system is allowed only

– – –

in the case of a recovery, and where the rig is equipped equipped with with a mast prop which is fully extended, and where the attached tool string has the appropriate provisions (e.g. a defined stop stop for the Kelly on the t he casing drive adapter, in Kelly applications)

NOTE

Equipment fitted with a mast prop may have a monitoring automatic which stops the main winch from pulling during crowd as soon as a certain value of the combined forces is exceeded. Where there is no such monitoring automatic, the operator himself is responsible for not endangering the capacities of the rig when forces sum up.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 20

OPERATION

5.10 USING THE ENGINE DIAGNOSTIC SYSTEM

Engine diagnostics: Error code indicator (4) is ON:

● ● ●

Stop the engine. Turn the ignition ON again. Press the switch (7). The error code indicator (4) flashes at a specific rhythm. Each type of error has its specific flashing sequence. For the respective allocation contact the Bauer after sales service. If more than one error is present, the button (6) can be used to switch between (scroll through) the error codes.

2 4

1

5 3

Engine diagnostics: Warning indicator (5) is ON:

● ●

Stop the engine immediately. Then proceed as described under "Error code indicator (4) is ON" (see above). 0

1

6 7

BK19035024.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 21

OPERATION

5.11

CENTRAL LUBRICATION CONTROL *

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

NOTE

NOTE

During the automatic lubrication, it is recommended to run the crowd sledge up and down the mast 2 - 3 times in order to t o distribute the grease from the runners to the rails. Additional lubrication lubrication with with a grease gun is possible through through a free nipple found on the distributor block on the crowd sledge.

Flashing codes: 1

System on

1

on off off on off off

2

Lubrication on

2


Low lubricant level

3


4


3 4

High lubricant pressure

5

5

Control failure

6

Permanent lubrication

7

Sledge lubrication failure

1.5 sec. 1.5 sec.

1 sec. 1 sec.


6


7

on off off

0.5 sec. / 0.5 sec.

1 sec. 1 sec.

To avoid failures in the central lubrication system, switch OFF central lubrication system during rigging procedure of the rig (switch in the cab).

NOTE A manufacturer's documentation on the Central Central Lubrication Lubrication System is supplied supplied in the Appendices of this manual.

NOTE *) Not used in this version

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5 - 22

START-UP / SHUT-DOWN

6


6.1

START-UP

6.1.1

Initial Start-Up

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

6.1.2

Visual Inspection before Starting

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

● ● ● ● ●

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

6-1


6.1.3

Daily Start-Up

6.1.3.1 Starting the Equipment

CAUTION    

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

CAUTION 

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

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

Move the safety safety stick of the pilot control to "ON" position.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

6-2


6.1.3.2 Selecting the Engine Operating Mode Select the Maximum Engine Speed 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

For more details, please consult the additional OPERATOR'S MANUAL supplied by the manufacturer.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

6-3


6.1.4

Safety Tests before Starting to Work WARNING! Serious accident hazard! Faulty safety devices are dangerous. All equipped safety devices must be tested prior to starting to work, and any faults found must be repaired by skilled personnel. The equipment may be put to work only when all safety saf ety devices are in proper working order.

Initial situation: - Diesel engine is running

6.1.4.1 Checking the Emergency STOP 

Press the Emergency STOP button. All control elements must be out of function and the diesel engine comes to a stop.

6.1.4.2 Checking the Pilot Control Safety Stick 

Move the safety safety stick of the pilot control to "OFF" "OFF" position. All hydraulic functions must be blocked. The diesel engine remains on.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

6-4


6.1.4.3 Checking the End Limiters Initial situation: Drilling mode selected 

Hoist limiters (HS 1 and HS 2)

Select main winch. Slowly spool in rope until suspended load (approx. (approx. 100 kg) kg) hits contactor weight. weight.  The winch must come to an immediate stop.  Repeat the procedure with the other winch.  



Boom cylinder end limiters (ES 3 / B 39)

Extend boom cylinders half way.  Selection of rigging modes must not be enabled.  Extend boom cylinders completely.  Selection of rigging modes must be enabled. 

– Mast sideward angle end limiters (ES 2 and ES 4)

WARNING! Danger of being crushed! Do not actuate end limiters with your bare hands! Only actuate them by touching with an object (piece of wood e.g.) held in your hand. Hold left end limiter depressed depressed and extend right backstay cylinder.  Right backstay cylinder must not extend.  Hold right end limiter depressed depressed and extend left backstay backstay cylinder.  Left backstay cylinder must not extend. 

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

6-5


6.2

SHUT-DOWN

6.2.1

Daily Shut-Down

      

Park the machine on firm level ground. Set the mast upright. Lower attached work work equipment, tools and suspended load as close to the ground as possible. Adjust the uppercarriage in line with the crawlers. Set all control elements to "0" position. Move the safety 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.

Before leaving, remove the ignition key and lock the cab.  Set the battery main switch to "OFF" "OFF" position. 

6.2.2

Shut-Down for a Longer Period

Fuel tank ●

Before longer periods of standstill fill up fuel tank completely with fuel because of corrosion protection.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

6-6

RIGGING / DE-RIGGING

7


7.1

GUIDELINES FOR RIGGING AND DE-RIGGING

Have assembly job carried out by skilled personnel only.  Only carry out rigging rigging and de-rigging de-rigging operations in the "Kelly mode". 

CAUTION

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

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

  

The equipment equipment must only be mounted on even and horizontal horizontal ground with the necessary load-bearing capacity. Check all components for damage. Steel components which are subjected to heavy loads (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. Before starting assembly, inspect the equipment equipment for a film of protecting wax. All such wax must be removed (see Chapter Wax W ax Removal). For lifting and loading, use only the lifting slings forming part of the basic outfit. Attach lifting slings only to provided lifting eyes. Rig tipping hazard!

CAUTION

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



Select Rigging mode:



Switch (1) on the control panel (see fig.).

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

BK14885013.wmf

7-1


7.2 

WAX REMOVAL

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

NOTE

CAUTION

Alternatively, the equipment can be washed 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 detergents for their areas of application prior to use.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7-2


7.3

EXTENDING THE CRAW CRAWLERS LERS Rig tipping hazard!

CAUTION

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

WARNING! Squashing hazard, shearing hazard and drawing-in hazard! The machine must be out of motion during work on the undercarriage. A reliable communication between person at undercarriage and operator in cab must be provided at all times. The danger zone must be cleared before crawlers are extended.

Do not extend the right and left crawler craw ler simultaneously.

● On one crawler, remove retainers (2) and remove pins (1) from the lock position A.

● By button

Bk19030013.wmf

extend the crawler while travelling forward and reverse.

● Reinstall the pins (1) at at the lock position B, and secure the pins with retainers (2).

BV737516.jpg

● Repeat the procedure with the other crawler.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7-3


7.4

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

WARNING! 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).

WARNING! Severe accident hazard! Each time the counterweight is mounted, the mounting m ounting bolts must be additionally checked after 50 operating hours with the specified torque. t orque.

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7-4


To mount counterweight(s): Mount the counterweights individually at all times!

NOTE Mounting the Inside Counterweight

● Attach suitable lifting devices to the lifting equipment and to the lifting points (1) of the inside counterweight (2). ● Hoist counterweight counterweight (2) onto machine using lifting equipment and set it down on the frame.

BK00004001.jpg

Lightly tension lifting devices.

NOTE

● Mount the counterweight on the frame

of the upper carriage with bolts (3) and tighten to an adequate torque (see Section 10).

BK00004002.jpg

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7-5


Mounting the Outside Counterweight

● Attach suitable lifting devices to the

lifting equipment and to the lifting points (1) of the outside counterweight (2). ● Hoist counterweight counterweight (2) onto machine using lifting equipment and set it down on the frame.

BK00004003.jpg


NOTE

● Mount the counterweight on the frame

of the upper carriage with bolts (3) and tighten to an adequate torque (see Section 10).

BK00004004.jpg

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7-6


7.5

MOUNTING THE MAST

7.5.1

Mounting the Trestle

 Select backstay cylinder operation.  Using the control levers, retract retract backstay cylinders and slightly raise the mast.

Risk of damaging the rig! With the trestle folded to the front, the mast may be raised by max. 20°.

CAUTION  Mount transport supports (4).

extend backstay cylinders and put down the mast on the  Using the control levers, extend ground. Underpin the transport supports with timber if the ground is soft.

NOTE  Open up the mechanical mechanical swing lock.  Release the swing brake.  Extend backstay backstay cylinders (1) by control control levers, until trestle (2) can be mounted to

machine with pin (3).  Install the pin and secure it.  Retract backstay cylinders and raise the mast enough enough to enable the transport supports (4) to be removed from the lower mast section. 1

2 3

4 BM339512.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7-7


7.5.2

Assembling the Mast Sections

● Place the mast sections on a firm and level surface surface to front of the lower lower mast section. Risk of damaging components! Clean flange faces and locating pins and check for damage.

CAUTION

● With the machine, travel travel up to the mast sections. sections. WARNING! Risk of crushing, shearing and hitting! Avoid getting limbs in between the mast sections. Minor backstay cylinder movements can lead to major movements of the mast sections. During the assembly operations, the operator must keep the person working at the mast in view at all times. ti mes.

● During operation with the backstay cylinders, cylinders, adjust the lower lower mast section (3) to the next mast section (1) until holes for assembly pins (2) are in line. 1

2

3

B0000567.wmf

● Install the pins and secure. ● Retract backstay cylinders to raise the lower lower mast section until flange faces meet. Risk of damaging components! Take care the locating pins are properly in place!

CAUTION

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7-8


● Bolt the mast section (6) to the lower mast section (5) in the manner shown here. Bolt tightening torque value Ma [Nm]: 1900 1 2 3 4 5 6

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

1 2

23 4 B0000999.wmf

● Remove transport supports. ● Make hydraulic hydraulic connections between the mast sections. ● Make electric connections between the mast sections. To do so, remove plug (1) of electric cable from transport socket (2) and plug it to the next mast section. ● Check on the ladder that fall protection rail (3) transfer points are in line. Read just at the ladder mounting points (4) as necessary.

WARNING! Danger of falling! The lanyard can slip out of its rail. Precisely adjust transfer points.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

BM400462.jpg

7-9


7.5.3

Installing the Ropes

7.5.3.1 Installing the Main and Auxiliary Auxiliary Ropes WARNING! Accident risk! Ropes breaking can cause serious accidents. which has been reeved through a rope crossbeam during  A main rope which operation and has not been marked out with a swivel is only permitted for operating mode.  Kelly operation operation is no longer permitted with this main rope. The main (4) and the auxiliary (3) rope must be installed while the mast is down. Select the "winch rigging" mode. Remove rope guard pins (1) from the masthead. Select the main winch or the auxiliary winch. With the left control lever, unwind a sufficient length of rope from the selected winch. Pass ropes over guide sheaves (5) and unwind until rope ends ends are at contactor weights (6).  Thread ropes through contactor weights (6) of of hoist limit switches switches (7).  Reinstall the rope guard pins and secure (1).  Unwind until rope ends are at resting on the machine.     

Risk of damaging components! Check contactor weights are properly attached.

CAUTION

1 5

5 1

3

4

5

1

1

5

7

6

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

BM091514.wmf

7 - 10


7.5.3.2 Installing the Upper Crowd Rope Select "winch rigging" mode.  Extend rope tensioning cylinder (1).  Remove crowd sledge sledge stoppers stoppers from transport position (2) and install them at upper end of mast (3). 

7

1

5

4

1

3

4

5 3

6 2

7 3

6

2 BFASE192.wmf

Remove crowd rope from transport deposit.  Move crowd sledge down to lowermost point.  Pass end of rope behind guide sheave sheave (4), up and around upper left guide sheave sheave (5) down to guide sheave on sledge (6), counter-clockwise back up to sheave (7) on upper end of mast to rope tension cylinder (1).  Anchor rope end with wedge to rope tension cylinder (1). 

WARNING! Serious injury hazard! 3 wraps of upper crowd rope and 3 wraps of lower crowd rope must be installed on the drum of the crowd winch, for safety reasons. Retract rope tensioning cylinder to tension the crowd ropes.  Run the crowd sledge up and down several times.  Run the crowd sledge down to the lowermost point.  Retract rope tensioning cylinder to re-tension the crowd ropes. 

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 11


7.5.4

Mounting Crowd Stroke Limiters WARNING! Rig tipping hazard! For reasons of stability, the crowd sledge fitted with Kelly equipment must not be free to move to the upper mast end.

3

8

3

8 BK587503.wmf

 Remove the two sledge travel stoppers from their position (3) on the upper mast end

and reinstall hem into bores (8) located further down the mast.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 12


7.5.5

Raising the Mast WARNING! Squashing hazard, shearing hazard and hitting hazard! Minor movements by the backstay cylinders create major movements of the mast sections. When moving the machine, the operator must keep in view the person working at the mast at all times.

●

Extend boom cylinders completely. Danger of being injured by falling objects! All loose objects must have been removed from the mast.

CAUTION

● Select backstay cylinder operation and uniformly and synchronously synchronously pull both control levers back to raise the mast.

CAUTION

Rig tipping hazard! Do not allow the mast to drift aside. The backstay cylinders must be retracted in a uniform manner and without interruptions.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 13


7.5.6

Mounting Retaining Clamps

CAUTION

Rig tipping hazard! These clamps must be mounted as soon as the mast has been raised.

 Select "Rigging" mode.  Completely retract both backstay cylinders by

pulling the control levers back.  Attach retaining clamp halves halves (1) to one back-

4

stay cylinder. 3

 Push O-Ring O-Ring (2) up on clamp and install in

groove (3).  Using a hammer, knock locking ring (4) down

on clamp.

1

3 1

2

 Repeat the procedure procedure on the other backstay

cylinder. BK331531.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 14


7.6

ASSEMBLY OF WORK ATTACHMENTS WARNING! Squashing hazard, shearing hazard, entangling hazard! Minor movements by the backstay cylinders can create sudden and uncontrolled major movements of attached components during their assembly. Components of work attachments are extremely heavy. The operator must keep in view the person performing perf orming the assembly throughout the whole procedure.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 15


7.6.1

Assembly of Kelly Equipment

7.6.1.1 Mounting the Rope Swivel

CAUTION

Serious accident hazard! At all times, the Kelly bar must be suspended by a rope swivel. Use only the genuine rope swivel of BAUER make. The swivel must be designed for the max. lifting lif ting force of the winch used.

shown in the figure below.  Mount the swivel as shown

CAUTION

Risk of damaging components! Mount the swivel in the right way. The lube nipple must be up.

 After mounting, grease the swivel swivel and test it rotates freely.

1 2 3 4 5 6

Main rope Pin Lube nipple Hex head bolt Lock washer Washer

1 6 5 2 4

3

B0000572.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 16


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

NOTE   

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

1

2

1 2

3

4 5

5

Remove lifting slings. Stop engine. Connect hydraulic lines.

B0000700.wmf

Risk of damaging components! Connect the leak oil line first.

CAUTION 3/A1, 5/2 4/B1, 6/B2 1/T 9/SP-L 12/P

NOTE

Pressure Return flow Leak oil Flush oil Control oil

Hydraulic lines and connections wear matching identifications.

Ansic Ansicht ht A: View A:

Ansic Ansicht ht A View A

6/B2 62 117 117 116 116 9/SP-L 5/A2

4/B1 42 41 3/A1 12/P 1/T

B0000808.wmf



Connect electric lines.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 17


7.6.1.3 Mounting Kelly Kelly Guidance Guidance * 2

3

Initial situation:

– – –

1

The Kelly is removed. Arms (2) for holding the guidance (1) are mounted with pins (3).

B0000708.wmf

End cover (8) is removed from the Kelly.

8 7 5 B0000711.wmf

Mounting the Kelly guidance:

6

4



Mount to the Kelly bar (5) an extension (4) for the rope swivel.



Mount the Kelly guidance (2) with bolts (7) to the Kelly bar.

7

Mount the rope swivel (6) to the swivel extension (4); see also next page.

5



2

B0000707.wmf


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 18


1

1 2 3 4 5 6 7

Main rope Mounting pin Lube nipple Swivel extension Hex socket tie bolt Lock washer Washer

3 7 6 5

2

4 B0000710.wmf



Mount main rope to swivel.



Lift the Kelly into the rotary drive.



Mount drilling tool to Kelly and drill down.

DANGER! Serious injury hazard by revolving Kelly guidance! Danger of causing damage to components! Drill with care and without people in the danger zone.

Run the rotary drive down to the lowest point.  Remove the pins (3). 



Swivel the arms (2) towards the mast (8) by 180°.



Reinstall the pins (3) and secure them.

3

2

3

2

8

B0000709.wmf


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 19


7.6.1.4 Mounting the Kelly To mount the Kelly, the mast must be in upright position and be fitted with the rotary drive.

NOTE 

Lay the Kelly bar down lengthwise lengthwise to front of the machine, in the centerline of the machine. Suspension eye on Kelly must face the machine.

NOTE 1



Mount rope swivel to eye eye on Kelly, in accordance with fig. below.

1 2 3 4 5 6 7 8

Main rope Rope swivel Pin Kelly Lock washer Hex head bolt Washer Lube nipple

2

8 7

3

6 5 4

B0000621.wmf

Move rotary drive to lowermost position.  Tilt mast forward by approx. 2 - 3°.  By the main winch, lift the Kelly as shown to right and at the same time ti me travel with the machine towards the Kelly. 

B0000622.wmf

Risk of damaging components! Keep the main rope vertical at all times.

CAUTION

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 20




Lift Kelly until its square stub stub is approx. 20 cm above the rotary drive. Risk of damaging components!

CAUTION

Avoid collision with the rotary drive! drive!



Set mast to upright again.



Allow the Kelly to stop swinging and then insert it into the rotary drive. drive. Slight rotation with the rotary drive can be helpful helpf ul when inserting the Kelly.

NOTE 

Insert the Kelly through the rotary drive.



Mount drilling tool to Kelly with two pins.

CAUTION

Risk of damaging components! At all times, use TWO pins to mount the drilling tool, and do not forget to secure the pins.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 21


7.6.2

Mounting Casing Oscillator * How to mount a casing oscillator to the machine is described in the separate manual belonging to the casing oscillator in question.

NOTE



Pass hoses from casing oscillator over left and right crawler crossbeam up to bulkheads "A".

A

BM779507.wmf

Stop the engine of the base machine.  Remove dust caps from hydraulic connections.  Mount the hydraulic hydraulic couplings in compliance with the provided numbers.  Make electric connection of casing oscillator and base machine. 

View "A": Undercarriage seen from the rear. The identified couplings are found on the front side of the two bulkheads.

BM779414.jpg

20 21 22 23 24 25

Oscillation [P] Oscillation [R] Unclamping Clamping Lowering Lifting

28 29 30 PST E1

Locking Unlocking Leak oil [T] (optional) Pilotoil (optional) Electric connection (optional)


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 22


7.7

DISASSEMBLY OF WORK ATTACHMENTS WARNING! Squashing hazard, shearing hazard, entangling hazard! Minor movements by the backstay cylinders can create sudden and uncontrolled major movements of attached components during their disassembly. Components of work attachments are extremely heavy. The operator must keep in view the person performing perf orming the disassembly throughout the whole procedure.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 23


7.7.1

Disassembly of Kelly Equipment

7.7.1.1 Removing the Kelly         

Set mast to upright position. Lower drilling tool to ground. Remove drilling tool. Unlock Kelly sections and move rotary drive to lowermost lowermost position. Lift Kelly until square square stub is approx. 20 cm above rotary drive. Tilt mast forward by 2 - 3°. Lower Kelly until Kelly Kelly rests with square stub on ground. Go on lowering the Kelly and at the same time travel in reverse reverse with with the machine. Remove Kelly from main rope.

7.7.1.2 Removing the Rotary Drive     

Set mast to upright. Move crowd sledge to lowermost point. Stop engine. Disconnect electric lines. Disconnect hydraulic lines.

Risk of damaging components! Disconnect the leak oil line (T) last.

Ansic Ansicht ht A: View A:

Ansic Ansicht ht A View A

6/B2 62 117 117 116 116 9/SP-L 5/A2

1/T

42 4/B1 41 3/A1 12/P

CAUTION Attach lifting slings to lifting eyes (5). Suspend the slings to the rig's main rope (3) (or to the hoist rope of an assist crane, if not equipped), and slightly pre-stress the rope.  Remove pin retainers and pull the pins out (1 and 2).

B0000808.wmf

 

NOTE 

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

Lift off and put the rotary drive down on ground.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

1

1 2

2

3

4 5

5

B0000700.wmf

7 - 24


7.8

DISASSEMBLING THE MAST

7.8.1

Removing the Retaining Clamps

 Using a hammer, knock the locking locking ring

(4) off the retaining clamp.  Remove the O-Ring (2) from the groove groove (3) in the clamp.  Remove the clamp halves (1) from the backstay cylinder.  Repeat the procedure procedure on the other backstay cylinder.

4 3 1

3 1

2

B0000671.wmf

7.8.2 

Lowering the Mast

Adjust the uppercarriage in line with the undercarriage, with the mast located on the same side as the crawler drive wheels. Risk of colliding the mast with the t he crawlers! The uppercarriage must be in the correct position.

CAUTION 

Unspool main and auxiliary rope, and put the ropes on the ground beside the machine.



Completely extend the boom cylinders.



Select the "De-rigging" mode.



Select backstay cylinder operation and uniformly and synchronously push both control levers forward to extend the backstay cylinders. The mast lowers.

CAUTION

Rig tipping hazard! Take care not to let the mast drift aside during the lowering. The backstay cylinders must be extended uniformly and without interruptions.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 25


7.8.3

Removing the Ropes

7.8.3.1 Removing the Main and Auxiliary Auxiliary Rope The main rope and the auxiliary rope will be retrieved with the mast lying down. 

Select the "Winch rigging" mode.



Remove rope guard pins from the masthead.



Select main winch or auxiliary winch.



Carefully spool in rope by the left control control lever.



Unthread the ropes from the contactor weights of the hoist limiters.



Spool in both rope ends to the intermediate guide block.



Reinstall the rope guard pins on the masthead.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 26


7.8.3.2 Removing the Upper Crowd Rope

To remove the rope, the mast must be lying.

NOTE 14 15 13

7

X

6

2

8/9

1

10 4

3 12

Y 8

7

"X" "X"

6 2

1

9 9

8

3

11 "Y" "Y"

6 2

10

16

4 16

3 12 BK587507.wmf

● ● ● ● ● ● ● ●

Move crowd sledge into position for transport (see fig.). Remove sledge upper end stoppers from upper mast section and reinstall into transport position (16). Completely extend the rope tensioning cylinder (7). Remove the rope clip (14). At the rope tensioning cylinder, remove the pin from the rope end socket (15). Knock the wedge wedge (13) out, to relieve relieve the rope, and pull the rope out of the socket. Remove the entire rope. Coil the rope loosely and fix it to the lower end of the mast.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 27


7.8.4

Disassembling the Mast WARNING! Squashing hazard, shearing hazard and hitting hazard! Minor movements by the backstay cylinders create major movements of the mast sections. During the disassembly operations, the operator must keep in view the person working at the mast at all times.

● Mount transport supports to upper mast section. ● Undo hydraulic and electric connections between mast sections. ● Unscrew bolts from mast connecting flanges, and stow the bolts for later use. ● Lower the mast until masthead and rear mast mast supports supports rest on ground. ● Remove pin retainers from rear side of mast, and pull the pins pins out. ● Travel in reverse with machine and disengage disengage upper mast section section from lower mast section.

CAUTION

Risk of corrosion! Corrosion protect flange faces with grease if the t he storage or transport of the rig is expected to take long.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 28


7.8.5

Lowering the Trestle

Mount transport support (4).  Lower the lower lower mast section until the transport support support rests on the ground.  Pull pins (2) out of trestle. 

CAUTION 

Risk of damaging components! Prevent the pins dropping down.

Retract backstay cylinders until trestle trestle (1) rests on bearing point (3).

3

2

4 BK097505.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 29


7.9

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

CAUTION

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

NOTE

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 30


To remove counterweight(s):

NOTE

Remove the counterweights individually at all times! Before removing, check if the screws are tight!

Removing the Outside Counterweight  Attach suitable lifting devices devices to the

lifting equipment and to the lifting points (1) of the counterweight (2).

BK00004003.jpg


NOTE  Loosen the bolts bolts (3). Remove the

bolts and safety material.  Using lifting equipment, lift the counterweight away from the frame, set it down on level, stable ground and secure it against tipping over.

BK00004004.jpg

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 31


Removing the Inside Counterweight  Attach suitable lifting devices devices to the

lifting equipment and to the lifting points (1) of the counterweight (2).  Lightly tension lifting devices.

BK00004001.jpg


NOTE  Loosen the bolts bolts (3). Remove the

bolts and safety material.  Using lifting equipment, lift the counterweight away from the frame, set it down on level, stable ground and secure it against tipping over.

BK00004002.jpg

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 32


7.10

RETRACTING THE CRAWLERS WARNING! Squashing hazard, shearing hazard and drawing-in hazard! The machine must be out of motion during work on the undercarriage. A reliable communication between person at undercarriage and operator in cab must be provided at all times. The danger zone must be cleared before crawlers are retracted.

Do not retract the right and left crawler simultaneously.

●

On both crawlers, clean and grease the sliding surfaces (3).

●

On one crawler, remove retainers (2) and remove pins (1) from the lock position B.

●

By button

Bk19030013.wmf

retract the crawler while travelling forward and reverse.

BV737445.jpg

● Reinstall the pins (1) at the position A", and secure the pins with retainers (2).

● Repeat the procedure with the other crawler.

BV737516.jpg

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

7 - 33

TRANSPORT

8

TRANSPORT

8.1

SAFETY GUIDELINES FOR TRANSPORT TRANSPORT



Only use hoisting equipment and lifting slings slings that have have sufficient capacity. capacity.

WARNING! Danger of serious accidents! Attach lifting slings only to the provided and identified lifting points. Lifting points on the machine are painted GREEN and have a hook symbol. In addition, numbers tell the weight picked up at the respective points. Lifting points on individual components are painted RED.

CAUTION   

 

  

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

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

8-1

TRANSPORT

8.2

MEASURES TO TAKE FOR TRANSPORT

MACHINE Before loading The machine must be put into the following shape before it may be driven onto a lowloader or be lifted by a crane:

– – – – – – – –

all attachments have been removed from the mast, the mast is lowered, the upper mast section is removed, the lower mast section is removed (as necessary), the uppercarriage is in line with with the crawlers and locked to the undercarriage, undercarriage, the crawlers are retracted, the beam extensions (if so equipped) have been removed. the counterweights have been removed (as necessary).

After loading

● ● ● ● ● ●

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

EQUIPMENT

●

The rotary drive must be in upright position during the transport.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

8-2

TRANSPORT

8.3

DRIVING ON / OFF A LOWLOADER 7.

10. 10.

3. 6.

12.

12.

11. 11. 11. 9.

4. 5.

13.

!!!

9. 2. 0

1

max.40°

1.

9 12

11

?

10

?

?

10A

BK15155000.wmf

1 2 3 4 5 6 7

Set battery switch to "ON" Release "Emergency STOP" button Move pilot safety stick to "OFF" Engine ignition ON / OFF Engine speed adjustment Move pilot safety stick to "ON" Select Rigging mode

CAUTION

8 Not used 9 Slightly raise lower mast section by right right and left control lever 10 Travel forward by pushing pushing both levers forward forward 11 Travel reverse by by pulling both levers back back 12 Lower mast section by by right and left control lever 13 Set battery switch to "OFF"

Risk of damaging the equipment! With the trestle still folded to the front, the lower mast section must not be raised by more than 40°.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

8-3

TRANSPORT

8.4

LIFTING POINTS

BK1162502.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

8-4

TRANSPORT

8.5

TRANSPORT DATA

Dimensions in [mm] 0 0 5 0 3 3 2

0 2 5 1

12780

0 0 8 2

0 2 4 1

12330

1400

3090

4620

700 3000 - 4380 3260

BK15725001.wmf

Weights Unit

Weight in [tonnes]

Machine Machine with counterweight and with lower mast section Machine without counterweight counterweight and without lower mast section Upper mast section with masthead Counterweight Counterweigh t

60.70 34.50 4.20 2 x 6.20

Equipment Rotary drive KDK 250 K Kelly bar BK 25/394/4/56 Kelly bar BK 25/394/4/40 Casing drive adapter  1,500 mm Drilling tool  1,350 mm

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

5.00 10.10 7.70 1.90 2.30

8-5

TRANSPORT

8.6

TYING DOWN WARNING! Serious accident hazard! Tie-downs must be attached to the provided intended points only. The chains used for tie-downs must have sufficient capacity.

Tying points

– On blue undercarriages the points provided for tying tying down are painted YELLOW. – On yellow undercarriages the points provided for tying down are painted BLUE. – In addition, tying points wear a hook symbol and tell the max. tension to be applied. To tie down

● Tie the equipment down to the transporting vehicle in the professional manner and in compliance with national directives. Principally, the haulier in charge is responsible for tying down correctly.

Example of tying points

CI439400.jpg

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

8-6

MAINTENANCE

9

MAINTENANCE

9.1

SAFETY GUIDELINES GUIDELIN ES FOR MAINTENANCE



Have maintenance carried carried out by the after sales service service only or by skilled personnel personnel authorized by the after sales service.



Replace with genuine spare parts from the BAUER BAUER Company only.



Observe the "Safety Information" book supplied with the equipment.



Carry out maintenance at the prescribed intervals.



Also observe the other manufacturers' service instructions for components components of the equipment.

9.2

MAINTENANCE INTERVALS

The maintenance for this equipment is organized into the following intervals: -

Every 10 hours of operation or daily Every 50 hours of operation or weekly Every 250 hours hours of operation or monthly Every 500 hours hours of operation or three months Every 1000 hours of operation or yearly Every 2000 hours of operation or yearly Every 3000 hours of operation or two years. The specified intervals base on the hour meter of the base machine.

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

CAUTION

Loss of the equipment warranty! Maintenance carried out on the equipment shall be entered enter ed into the supplied "Maintenance and Repair Log". This is to be done by the person who carried out the job and be signed by himself and a foreman. In case of a warranty claim, BAUER shall have the right to consult the log.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9-1

MAINTENANCE

9.3

MAINTENANCE PLAN

9.3.1

Entire Equipment

Entire equipment table Components

Maintenance interval Operation

10 h daily

50 h weekly

250 h 500 h 1000 h monthly 3 months yearly

2000 h yearly

3000 h/ every 2 years

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 for proper function of: - Controls and indicators - Safety devices such as emergency STOP, pilot control safety stick, limit switches, hoist limit switches - Free-fall function** Work platforms - Check for missing or loose pin/screw connections - Check the locks can move easily and are working properly

X X

X X

X X X

X X

Inspection by competent engineer

X X

* Only during running-in period ** Not supplied with this version

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9-2

MAINTENANCE

9.3.2

Components

Table Attachment Components


10 h daily

50 h weekly


2000 h yearly


Note

Masthead - Check that the connecting bolts and screws for the mast, if provided, are firmly screwed in; tighten screws - Replace connecting bolts for the mast, if provided

X*

10000 hrs

Mast Mast - Lubricate guide rails - Check that the connecting bolts and screws between the mast sections, if provided, are firmly screwed in; tighten screws - Replace connecting bolts between the mast sections, if provided Mast prop - Ensure that bolt safety mechanism and bolts are screwed in tightly - Lubricate pivot mount Ladder on mast** - Check that the mounting bolts are firm - Check transition between the parts of the mast ladder - Check fall protection equipment for function

X X*

5000 hrs

X X X X X

Mast pivot - Lubricate mast pivot - Lubricate mounting bolts - Check flange bolts are firmly screwed in, tighten bolts - Replace flange bolts

X X X* 10000 hrs


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9-3

MAINTENANCE



10 h daily

Winches - Check oil level Main winch Auxiliary winch Crowd winch - Change oil Main winch Auxiliary winch Crowd winch - Lubricate counter bearings Main winch Auxiliary winch Crowd winch - Ensure that mounting bolts of the winch trestles are firm, tighten bolts - Replace mounting bolts of the winch trestles

50 h weekly


2000 h yearly


Note

X X X X* X* X*

X X X

X X X X* 10000 hrs

Cylinders - Clean piston rods - Check tightness of cylinder - Lubricate joints

X X X

Bearings and bearing pins - Lubricate all bearings and bearing pins that are equipped with lube nipples

X

* Only during running-in period

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9-4

MAINTENANCE



10 h daily

50 h weekly


2000 h yearly


Note

Wire rope and accessories Ropes, rope fasteners, thimbles and sleeves - Inspect for wear and damage Rope swivel - Lubricate - Check if bolts are secure - Check slew function Rope hold-down rollers - Check parallel position to cable drum - Inspect for wear and damage Rope sheaves - 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 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


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9-5

MAINTENANCE

9.3.3

Work Equipment

Table Equipment Components


10 h daily

50 h weekly


2000 h yearly


Note

Rotary drive Rotary drive - Clean - Inspect for wear and damage - Check for leakage - Check magnetic bars for adhesion of metal parts - Check oil level Main gear Planetary gears - Change oil Main gear Planetary gears - Take oil sample and check oil - Check if hollow shaft mounting bolts are securely fastened - Check switch pressure - Change filter Line filter Oil pre-cleaner - Lubricate oil seal

X X X X

X X X* X* X X*

X X X

X

X* X*

Nominal value: 35-40 bar X X

X

Kelly driver / guide flange / shock absorber - Check springs, shock absorbers and buffer rings for damage - Check that the mounting bolts are firm - Check driver strips for wear

X X X

Cardan joint - Check rubber buffers for damage - Check if bolts are secure

X X

Crowd sledge - Check sliding strips for wear

X

Kelly bar - Inspect for wear and damage

X*

X

Drilling tool - Clean and check for wear and damage

X

CFA/FOW/DKS equipment ** - Lubricate concreting head

X


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9-6

MAINTENANCE

9.3.4

Uppercarriage

Upper carriage table Components


10 h daily

50 h weekly


2000 h yearly

Engine

Observe separate engine manual!!

Cooling system

Observe separate engine manual!!


Note

Pump distributor gear - Check oil level - Change oil

X X*

X

Hydraulic system Hydraulic tank - Check oil level - Change oil - Take oil sample and check oil Hose assemblies - Have them inspected for damage by an expert Filter element replacement - Pilot control filters - Return-flow filters - Leak-oil filters - Secondary filters - Free-fall filters - Rotary drive filters - Tank breather filter Pressure accumulators - Check preload pressure Oil cooler - Clean - Check for damage

X X*

X

X X

X* X* X* X* X* X*

X*

X X X X X X X

Or if contamination is indicated

X X

X

Swing mechanism - Grease external slewing ring teeth - Lubricate slewing ring and rotor bearing - Tighten up screws

X X*

X X*

X


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9-7

MAINTENANCE

Upper carriage table Components


10 h daily

50 h weekly


2000 h yearly


Note

Counterweight - Check all fastening elements are present and firmly in place

X

Electrical system Batteries - Check electrolyte level - Check cable connections Fuses - Check fuses Filters - Replace air filter on wiring cabinet

X X X X


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9-8

MAINTENANCE

9.3.5

Undercarriage

Undercarriage maintenance table Components


10 h daily

50 h weekly


2000 h yearly


Note

Crawler track assemblies Visual inspection - Missing or damaged parts - Carry 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 for the crawler track shoes are firm Telescopic guide - Clean and grease

X X

X

X X*

X

X X

X


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9-9

MAINTENANCE

9.3.6

Optional Equipment

Optional equipment table Components


10 h daily

50 h weekly


2000 h yearly


Note

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

X X X

Compressor -

2 - 3 weeks

Observe separate compressor manual!!

Clean cooling ribs Clean suction air filter Replace suction air filter Clean lubricating oil filter Replace lubricating oil filter Change oil Check maintenance unit Drain condensate on compressor, maintenance unit, 70 l pressure accumulator

X X X X X X

X* X X

after every use

Oxidation-type catalytic converter - Measure the counter pressure of the exhausts treated by the CRT system

X

Generator

 Inspect for wear

X

and damage  Checking the Oil Level  Replace the breather filter  Check ISO meter

Before each use X Before each use


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 10

MAINTENANCE

9.4

LUBRICATION PLAN 1 10h 18

1000h

21 1000h 22 250h

10h

2

10h 32

23 1000h

20 12 31 10 8 11 1000h 19 10h 9 50h 50h 50h 50h 50h 50h

50h

3

1000h

4

50h

13 50h 7 250h 28 50h 29 10h 26 50h

6

BK000512.wmf

Every 10 Hours of operation:

Every 250 Hours of operation:

2 14 18 29 32

7 9 15 17 22 27

Guide rails Rope sheaves ** Rope swivel * External gear ring * Rotary shaft seal

Supporting trestle pin Mast support joint Crowd cylinder joint ** Crowd cylinder joint ** Crowd rope tensioning cylinder joints Crawler cylinder joints *

Every 50 Hours of operation: 4 6 8 10 11 12 13 20 26 28 31

Backstay cylinders joints Boom pin Mast pivot assembly pin Mast pivot assembly joints Boom cylinders joints Mast supporting cylinder joint ** Auxiliary winch bearing Crowd winch bearing Crawler guides * Swing gear bearing Main winch bearing

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

Every 1000 [yearly] [yearly] Hours of operation: 1 3 19 21 23

Masthead rope sheaves * Rope sheaves Crowd rope sheave Crowd rope sheaves Crowd rope sheave

*) Grease manually **) Not used in this version

9 - 11

MAINTENANCE

9.5

MAINTENANCE DURING LONGER PERIODS OF STANDSTILL

Engine 

Every 2 to 3 weeks, start start the diesel engine and let it run in the medium r.p.m. range for about 1 hour. Risk of engine damage! If engine starting will not be possible during the standstill, preservation

CAUTION

measures must be taken. To do so, please refer to the manufacturer’s manual of the diesel engine.

Air conditioning 

Every 2 to 3 weeks, weeks, turn the air conditioning on (if equipped) for a short while.

Slewing ring  

Preserve gear teeth. From time to time during during the standstill, remove remove dust and inspect inspect the surface of teeth and drive pinion for beginning corrosion; clean and grease as required.

Telescoping guides on undercarriage (only with extendible crawlers) 

Preserve the telescoping surfaces with grease.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 12

MAINTENANCE

9.6

HYDRAULIC HYDRAU LIC SYSTEM WARNING! Injury hazard from hydraulic oil spray! Hydraulic systems shall be de-pressurized before any maintenance or repair is performed thereon. This applies to pressure tanks in particular.

CAUTION

Risk of fire from hydraulic oil spray! Hydraulic systems shall be de-pressurized before any maintenance or repair is performed thereon. This applies to pressure tanks in particular.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 13

MAINTENANCE

9.6.1

Hose Assemblies

Inspection  Hose assemblies must be inspected at least once a year by a competent person. A hose assembly on which one or several of the following f ollowing criteria are found must be replaced with a new one: hose (e.g. abrasions, cuts or fis Damage in the outer layer down to the core of the hose sures).  The outer layer of the hose is brittle (cracks in the tubing).  The hose does no longer comply with its natural shape, both with and without pres-

sure and while it is bent (e.g. layers separating, bubbles forming).  Leaks.

deformation of hose end fittings (tightness impaired); minor damage to  Damage or deformation the surface does not require replacement.  Hose slips out out of end fitting.  Corrosion on the end fitting, impairing the function and stability. stability.  The hose is not assembled assembled in compliance with with instructions.

storage and service life is exceeded.  The storage

Storage and service life  Hoses and hose assemblies are to be stored in a cool and dry place free of dust. Direct exposure to sunshine or UV-rays should be avoided. Storage and service life 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, since they do no longer meet the requirements.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 14

MAINTENANCE

9.6.2 

Hydraulic Cylinders

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

CAUTION

Risk of damaging the piston rod! Do not clean cylinder piston rods with a water jet, sharp tool, caustic lye or an abrasive.

Serious 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 (holes for pins).

On cylinders that are kept extended during rest: Risk of corrosion damage in corrosion-supporting environments! The tasks specified below must be carried out without fail.

CAUTION 

Once or twice a week, rub down piston rods with hydraulic oil, or retract and extend the rods repeatedly.



Before a longer longer standstill, preserve piston rods with acid free grease. grease.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 15

MAINTENANCE

9.6.3

Filter Replacement

9.6.3.1 Replacing the Line Filters The elements of the line filters must be replaced after the first 250 operating hours or one month. Subsequent replacements of the line filter elements are due every 1000 operating hours or whenever contamination is indicated (optional; by a warning lamp or by a text message).

WARNING! Serious injury hazard! Before beginning to replace a filter element, remove the pressure from the hydraulic system and allow it to cool down. While the hydraulic oil is still cold, it can happen that the contamination indication comes on for a little while.

NOTE Line filters: 1 2

Free-wheel filter Leak oil filter

2 1

BK1007502.wmf

 Place a suitable container underneath

   

the filter housing and unscrew the bottom (3). Remove filter element (2) from top (1) of housing and put it to hazardous waste. Clean top and bottom of housing. housing. Install new filter element in top of housing. Reinstall bottom on top and screw tight.

1 2

3 B0000623.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 16

MAINTENANCE

9.7

WINCHES

9.7.1

Checking the Oil Level

The oil level must be checked every 50 operating hours or once a week, and whenever the equipment is started up again after a longer standstill.

CAUTION

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

Winches with dipstick      

 

Position the winch such that the tube (2) is upright. Unscrew and remove the oil dipstick (1). Dry the dipstick with a clean and lint-free cloth. Reinstall the stick, completely. Pull the stick out again and read it: If the oil has sunk to the MIN mark, top up with new oil and check again. The MAX mark must not be exceeded. Clean sealing surfaces, check seal for wear and damage, replace it as required. Reinstall the dipstick and screw it down tight.

1 max. min.

2 3 B0000574.wmf

Winches with sight glass Checking of the oil level can be performed perf ormed with the winch in any position. If the oil level has reached the lower limit ("min." = 20 mm below the winch centre line), add oil through one of the t he screw plugs (2), then recheck the oil level. Be sure to avoid the oil level exceeding the upper limit ("max." = winch centre line).  Clean sealing surfaces, check seal for wear and damage, replace it as required.  Reinstall the screw plug and screw it down tight. 

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

max. 20 mm min.

1 B0000846.wmf

9 - 17

MAINTENANCE

9.7.2

Changing Gear Oil

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

CAUTION

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

Winches with dipstick         

Position the winch such that the tube (2) is upright. Unscrew and remove the oil dipstick (1). Remove the drain screw (3) and drain the gearbox. At low outdoor temperatures, flush the empty gearbox with a warmed-up part of the new oil. Clean sealing surfaces, check seal for wear and damage, replace it as required. Reinstall the drain screw. Refill with new oil. Check the oil level. Reinstall the oil dipstick (1) and screw it down tight.

1 max. min.

2 3 B0000574.wmf

Winches with sight glass Changing of the gear oil can be performed with the winch in almost any position.        

Unscrew and remove any of the screw plugs (2). Unscrew and remove any of the screw plugs (1) and allow the gear oil to drain. At low outdoor temperatures, flush the empty gearbox with a warmed-up part of the new oil. Clean sealing surfaces, check seal for wear and damage, replace it as required. Reinstall the screw plug (1). Refill with new oil. Check the oil level. Reinstall the screw plug (2) and and screw it down down tight.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

2

max. 20 mm min.

1 B0000846.wmf

9 - 18

MAINTENANCE

9.8

REPLACING REPLACING THE UPPER CROWD ROPE

CAUTION 

Risk of damaging components! When the mast is down, only move the crowd sledge with another person present to give directions!

Position the crowd crowd sledge at the lower end of the mast.

B00005424.png

Completely extend the rope tensioning cylinder (7). Remove the rope clip (14). At the rope tensioning tensioning cylinder, remove the pin from the wedge (15). Knock the wedge wedge out (13) to release the rope, and pull the rope out of the wedge. Release the bolts from the clamping rail rail (11) on the winch (1) and remove the wedge. Then put the wedge somewhere safe.  Remove the entire rope.     

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 19

MAINTENANCE

WARNING! Accident risk! When attaching the rope, always ensure you wind it round the number of times required for safety purposes (the reeving chart in the spare parts list has more details on this).

CAUTION

Danger of the new rope breaking! Check rope sheaves and pin retainers for damage.

B00005424.png

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 20

MAINTENANCE



Attach the upper crowd crowd rope, ensuring you wind wind it round the number of times required for safety purposes, to the drum (in the direction of travel - towards the right) and thread the end of the rope through the clamping rail (11) on the winch (1).

BV00004024.jpg

CAUTION     

Danger of rope breaking! The end of the rope must not protrude past the drum winch, as it can otherwise get caught on the winch trestle during winding.

Insert the wedge (21) into the clamping rail (11) and tighten the bolts (20) to the prescribed tightening torque. Feed the rope beneath the hose guide wheel (6). Feed the rope over the left rope sheave (9) at the top of the mast. Feed the rope over the rope sheave (10) on the crowd crowd sledge. Feed the rope over the right rope sheave sheave (8) at the top of the mast.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 21

MAINTENANCE

B00005424.png

There is a jaw (16) in front of the rope sheave to facilitate mounting of the wedge.

NOTE 

   

Insert the rope into the jaw (16), pre-tension it manually and screw the jaw (16) into place. Once the wedge (15) has been mounted, remove the jaw (16) from the rope r ope tensioning cylinder again. Thread the rope through the wedge wedge (15) (ensuring the other wedge (13) is securely in place) and attach it with bolts to the rope tensioning cylinder. Attach the rope clip (14) to the rope end at a distance of approx. 20 mm from the wedge (15 (15). ). Reduce the length length of the overhanging rope to approx. approx. 30 cm. Slightly tension the ropes by retracting the rope tensioning cylinder.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 22

MAINTENANCE

CAUTION 

Run the crowd sledge up and down several times.

CAUTION  

Risk of damaging components! When the mast is down, only move the crowd sledge with another person present to give directions!

Danger of damaging the ropes! Only retension the ropes when the crowd sledge is at the lower stop on the mast.

Position the crowd crowd sledge at the lower stop on the mast. Retension the ropes.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 23

MAINTENANCE

9.9

WIRE ROPE ACCESSORIES ACCESSORIES

9.9.1

Rope Swivel

Every 10 operating hours or daily: Apply grease to nipple (2) until grease exits from the housing.  Test the swivel rotates freely. Conduct the test by hand, without load sussu spended to the swivel. If the swivel will not rotate properly after it has been greased, repair or replace it with a new one.  Check tie bolts bolts (1 and 3) are firmly in place. Retension them as required, to the proper torque. Replace tie bolts with new ones when they are torn or have excessive play. 

CAUTION

9.9.2

1 2

3 B0000576.wmf

Risk of damaging components! Immediately inspect the swivel for damage after an accidental drop of the Kelly bar.

Rope Hold-Down Rollers

Every 50 operating hours or weekly:    

  

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 24

MAINTENANCE

9.9.3

Rope Fasteners, Thimbles and Sockets

Every 10 operating hours or daily: Check the wire rope is firmly in place in the fitting. With poured rope fittings, inspect for broken wires and corrosion corrosion directly directly where the rope exits the fitting.  With swaged-on rope fittings, inspect for broken wires next to the fitting, cracks in the material and firm seizure of the rope.  

CAUTION

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 25

MAINTENANCE

9.9.4

Rope Sheaves

CAUTION

Danger of rope breaking! Sluggish or seized rope sheaves subject the rope to excessive wear and abrasion and make the load distribute unevenly on the rope structure. Repair or replace as necessary sluggish or seized rope sheaves if greasing will not do.

9.9.4.1 Greasing Rope Sheaves Rope Sheave Type

Prescribed interval

Maintenance instructions

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 sealing! Grease during rotating rope sheave. Fill in grease slowly to prevent squeeze out bearing sealing.

BM659822.jpg

Rope sheaves greased by the central lubrication system

automatical

BM659823.jpg

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 26

MAINTENANCE

9.9.4.2 Checking Rope Sheaves Service

Prescribed interval

Check 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 grooves in sheaves still comply with the diameter of the rope used.

1000 Operating hours/ yearly

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

Maintenance instructions

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

9 - 27

MAINTENANCE

9.10 ROTARY DRIVE 9.10.1 Routine Inspection Every 10 operating hours or daily: 

Clean the rotary drive with a water jet.



Inspect all components for wear and damage. On rotary drives with shock absorbers check especially: -

Buffer ring (1) Spring-loaded ring (2) Compression springs (3) Shock absorbers (4)

Check the rotary drive for leaks.

1 2 3 4

Kj248501.wmf

CAUTION

Risk of damaging the rotary drive! At once, replace damaged components with new ones. ones.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 28

MAINTENANCE

9.10.2

Checking the Oil Level

9.10.2.1 Main Gear The oil level in the main gear must be checked every 10 hours of operation or daily.  Set the rotary drive to upright upright position.

drive is out of motion, check the oil level.  While the drive The oil must reach half way up the glass (see fig.). Risk of damaging the rotary drive!

CAUTION

At all times, watch for proper oil level.

Kj248502.wmf

CAUTION

Risk of damaging the rotary drive! If the oil is cloudy, water has intruded and the oil must be changed immediately. Drain and thoroughly flush the drive repeatedly with the new oil before refilling.

CAUTION

Risk of damaging the rotary drive! A too high oil level in the main gear is an indication of a defect in the planetary gears. Shut down the rotary drive and repair.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 29

MAINTENANCE

9.10.2.2 Planetary Gears The oil level in the planetary gears must be checked every 10 hours of operation or daily. upright position.  Set the rotary drive to upright  While the drive drive is out of motion, check the oil level.

The oil must reach half way up the glass (see fig.). Risk of damaging the planetary gears! At all times, watch for proper oil level.

CAUTION

Bj248503.wmf

CAUTION

Risk of damaging the planetary gears! If the oil is cloudy, water has intruded and the oil must be changed immediately. Drain and thoroughly flush the drive repeatedly with the new oil before refilling.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 30

MAINTENANCE

9.10.3

Changing the Oil

9.10.3.1 Main Gear The oil in the main gear must be changed after the first 250 operating hours and subsequently every 1000 operating hours or once a year.

NOTE

To carry out an oil change, the oil had better be as warm as possible from operating.

To change the oil:  Shut down the rotary drive.  Place the rotary drive drive such that drain screws    

(1) are in their lowermost position. Unscrew filler screws (2). Have an oil collecting container ready. Fit a plastic tube or hose of suitable size and length from the drain to the container! Unscrew drain screw(s) screw(s) (1) and let the oil out.

1

2

Kj248504.wmf

Danger of scalding! Hot gear oil can cause severe injury!

CAUTION screws and on magnetic sticks for gear abrasives, abrasives, and  Inspect magnets on all drain screws clean the screws (see also sect. "Oil Sampling").

NOTE

Check the mounting bolts of the hollow shaft (see sect. "Hollow Shaft Mounting Bolts").

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 31

MAINTENANCE

 If the outside temperature is low at the time of the oil change, change, warm up (to approx.

50°C / 122°F) a part of the new oil and rinse the gear housing with this oil before refilling. Benzol (benzene) or flushing oils too may be used here for f or rinsing.

NOTE

CAUTION

Danger of damaging the gear! Do NOT use petrol (gasoline), petroleum or diesel oil for rinsing here. Allow the rinsing fluid to drain off completely.

 Replace seals seals (if equipped), equipped), reinstall drain screws and tighten them.  Refill with new oil, and let the oil settle.  Check the oil level.

NOTE

If there is no oil to be seen in the sight glass after the gear has been refilled with the proper quantity of oil, close the filler neck, start the engine and let the drive rotate for a short while, to bleed the lines free of air that may be have been trapped.

 Reinstall the filler screws and tighten tighten them.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 32

MAINTENANCE

9.10.3.2 Planetary Gears The oil in the two planetary gears must be changed after the first 250 operating hours and subsequently every 1000 operating hours or once a year.

NOTE

To carry out an oil change, the oil had better be as warm as possible from operating.

To change the oil:  Shut down the rotary drive.  Set rotary drive to upright position  Unscrew filler screws (2).  Have an oil collecting container ready.

2

 Fit a plastic tube or hose of suitable size and

length from the drain to the container!  Unscrew drain screws screws (1) and let the oil out.

1 KG000512.wmf

Danger of scalding! Hot gear oil can cause severe injury!

CAUTION

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 33

MAINTENANCE

 If the outside temperature is low at the time of the oil change, change, warm up (to approx.

50°C / 122°F) a part of the new oil and rinse the gear housing with this oil before refilling. Benzol (benzene) or flushing oils too may be used here for f or rinsing.

NOTE

CAUTION

Danger of damaging the gear! Do NOT use petrol (gasoline), petroleum or diesel oil for rinsing here. Allow the rinsing fluid to drain off completely.

 Replace seals seals (if equipped), equipped), reinstall drain screws and tighten them.  Refill with new oil, and let the oil settle.  Check the oil level.

NOTE

If there is no oil to be seen in the sight glass after the gear has been refilled with the proper quantity of oil, close the filler neck, start the engine and let the drive rotate for a short while, to bleed the lines free of air that may be have been trapped.

 Reinstall the filler screws and tighten tighten them.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 34

MAINTENANCE

9.10.4 Oil Sampling Every 250 operating hours or monthly, take an oil sample from the main and planetary gears and inspect it:  Inspect the oil for dark or black colouring.

If the colour of the sampled oil is dark or black, the operating temperature of the oil has been above 100°C (212°F). This makes gear oil wear out prematurely pr ematurely and lose the lubricating effect so that the oil change intervals must be shortened correspondingly.  Inspect the oil for water water and and dirt.

If the oil is found to be contaminated or water has intruded, the seal rings must be checked and replaced as necessary.  Inspect the oil for solid particles (abrasives).

The maximum permissible amount of foreign particles in the total oil fill of one gearbox must not exceed 0.15 %. Particles found in the oil must not exceed 5 m in size (as measured in compliance with DIN 51592); if they do – no matter the amount – the rotary drive will have to be removed and taken apart.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 35

MAINTENANCE

9.10.5 Hollow Shaft Mounting Bolts The mounting bolts of the hollow shaft must be checked every time the oil of the rotary drive is changed.  Unscrew and remove remove access access plugs (1).  Visually, check the mounting bolts (2)

are properly in place and firm. Risk of damaging the drive!

CAUTION

Do not re-tension these bolts unless necessary or the Loctite seal of the bolts will break making the bolts loosen during operation. Check visually only. Do not put fingers into the bores.

1 1

1

NOTE

Turning around the rotary drive enables checking all the bolts.

2 B0000750.wmf

 Unscrew mounting bolts found to be

loose, clean them and apply Loctite to threads, reinstall and tension the bolts with the specified torque. Bolt torque value Ma[Nm]

Hollow shaft mounting (2) Hex head bolts

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

see Spare Parts List

9 - 36

MAINTENANCE

9.10.6

Kelly Driver and Guide Flange

9.10.6.1 Checking the Mounting Mounting Bolts Bolts Every 50 operating hours or weekly:  Visually, check mounting bolts of Kelly driver and

guide flange (1 and 2) are properly pr operly in place and firm.

CAUTION

Risk of damaging the drive! Do not re-tension these bolts unless necessary or the Loctite seal of the bolts will break making the bolts loosen during operation. Check visually only.

 Unscrew mounting bolts found to be loose, clean

1 2

them and apply Loctite to threads, reinstall and tension the bolts with the specified torque t orque (see below).

Kj248505.wmf

Bolt torque value Ma[Nm]

Kelly driver mounting (1) Hex socket head bolts

see Spare Parts List

Guide flange mounting (2) Hex head bolts Set screws with nut

see Spare Parts List see Spare Parts List

Replacing the Kelly Driver and/or Guide Flange: driver / guide flange free  Clean contacting surfaces of the hollow shaft and the Kelly driver of grease. Apply Loctite 0586 Type AVX on the cleaned surfaces.  Apply Loctite to threads of the mounting bolts, and screw the bolts down with the

specified torque in a diagonal manner.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 37

MAINTENANCE

9.10.6.2 Checking Driver Strips for Wear Every 50 operating hours or weekly: 

Check Kelly driver strips (5) for wear.

 If the wear (x) (x) is in excess excess of 8 mm, turn the strip around by 180° and reinstall it, or

replace it right away with a new one. Replace also bushings (4) and bolts (3) if they are worn down. When fitting a new driver strip, the play (y) should not exceed 0.5 mm.

NOTE Bolt torque value Ma [Nm]

Kelly driver strips mounting Hex socket head bolts Hex socket head bolts with nuts

see Spare Parts List see Spare Parts List

A - A: A:

A

A

B

B

1

B - B:

2 3 4 5

6 x

y B0000580.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 38

MAINTENANCE

9.10.7 Cardan Joint Every 10 operating hours or daily: Check suspension pins (see arrow) are properly in place and firm, with the t he holes for the pins completely assembled.  Check rubber buffers for damage. 

Kj248506.wmf

9.10.8 Sledge Sliding Strips Every 50 operating hours or weekly:  

Check the wear on the strips (1) in the runners (4) of the crowd sledge. sledge. Where the remaining thickness (X) is found to be less than 15 mm, replace with with a new strip (see below). "A" "A" B-B B-B

5 X

"A" "A"

B

B

1 2

3

4 B0000582.wmf

To replace:   

Unscrew bolts (2) and remove the tension plate (3). Pull out the strip (1) and install a new strip. Reinstall the tension plate and screw tight.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 39

MAINTENANCE

9.10.9 Greasing the Shaft Seal Ring Every 10 operating hours or daily: Clean the rotary drive.  Apply grease to nipples (1 or 2) and rotate the drive in between, from time to time.  Repeat the procedure until grease exits steadily along the whole circumference (arrow). 

3

3

1

2 4

4 K0000515.wmf

CAUTION

Risk of damaging the rotary drive! Insufficient greasing can allow solid matters to enter into the gears and cause damage.

CAUTION

Risk of damaging the rotary drive! Brownish coloured gear oil or a heavily contaminated filter (3 or 4) can be an indicator of solid matters brought-in from the outside. Shut down the rotary drive and contact the After Af ter Sales Service.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 40

MAINTENANCE

9.11

CRAWLER TRACK ASSEMBLIES WARNING! Squashing hazard, shearing hazard and drawing-in hazard! The machine must be out of motion during work on the undercarriage. A reliable communication between the person(s) working working at the undercarriage and the operator in the cab must be provided at all times.

9.11.1 Routine Inspection Every 10 operating hours or daily:

● With the uppercarriage positioned crosswise, thoroughly thoroughly clean crawlers crawlers free of mud

and dirt. ● Walk-around inspect for wear, damage and loss of oil, especially on following components:

– Track pads (1) – Track links (2) – Carrier rollers (3) – Front idlers (4) – Track guides (5) – Tread rollers (6) – Crawler drive wheels (7) – Gear cases (8) 1 2

8

7

6

3

4

5 B0000676.wmf

NOTE

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 41

MAINTENANCE

9.11.2

Crawler Tracks

9.11.2.1 To Check Check the Track Tension Check track tension every 10 operating hours or daily.



Thoroughly clean each crawler, track and rollers.



Travel forward a bit with the machine and then park it.



Using a straight rod, measure the sag of 1 - 1.5 m length of track in midway (see fig.): The distance from the rod to the track should be approx. 2 – 3 cm. Otherwise, the track tension must be readjusted.

1 - 1,5 m 2-3 cm

1 - 1,5 m 2-3 c m

1 - 1,5 m 2 - -3 c m

B0000680.wmf

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 42

MAINTENANCE

9.11.2.2 Adjusting Adjusting Crawler Track Track Tension

To tighten the track

●

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

3

2 5 1 3 4 B0000725.wmf

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

●

Reinstall the cover plate.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 43

MAINTENANCE

To loosen the track 3

2 5 1 3 4 B0000725.wmf

 Remove cover plate.

valve (1) by approx. 3 revolutions revolutions (SW 41) until excessive excessive grease grease  Unscrew the safety valve escapes at the spot identified with (4).

WARNING! Injury hazard by pressurized grease! Unscrew the safety valve with great care only.

 Retighten the safety valve valve when the proper track track tension is obtained.  Check the track tension again after a short travel forward and backward.  Clean the nipple and surrounding surrounding free of grease.  Reinstall the cover plate.

WARNING! Danger of injury due to pretensioned spring element (compressible sil icone oil at 1500 to 2000 bar)! For safety reasons do not open the defective spring elements, but replace them entirely.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 44

MAINTENANCE

9.11.3 Checking Mounting Bolts

● ●

Check visually mounting bolts are tight. Retention bolts that are loose. 5

8

4

2

3

1

6 BK587502.wmf

BK587440.jpg

BM564683.jpg

Bolt torque value Ma [Nm]

Prescribed intervals in operating hours

570 ± 30

50

Carrier roller (2)

560

250

Track guide (3)

560

250

Tread roller (4)

560

250

Crossbeam (5)

---

---

Drive wheel (6)

460

250

Gear case (7)

960

250

Telescopic cylinder mounting

560 (M20)

250

Swing ring (8)

755 (M24)

After the first 250 and then every 2000

Bolted connection Track pad (1)

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 45

MAINTENANCE

9.11.4

Crawler Drive Gears

9.11.4.1 Checking the Oil Level Check the oil level every 250 operating hours or monthly. Move machine until oil drain plug (2) on crawler drive wheel is in lowermost position.  Unscrew inspection / filler screw (1) together with seal (if equipped). The oil must reach the lower l ower edge of the filler opening; top up with oil as necessary.  Clean inspection / filler screw and sealing surfaces on housing, and replace with new seals as necessary.  Reinstall the inspection / filler screw with new seal and tighten. 

1

3 2 B0000514.wmf

9.11.4.2 Changing the 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 at least. 

      

Move machine until oil drain plug (2) on crawler drive wheel is in lowermost position. Unscrew inspection/filler screw (1) 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 and sealing surfaces on housing. Reinstall drain plug with new seal and screw tight. Refill with new oil to proper level. Reinstall inspection/filler screw with new seal and screw tight.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

1

3 2 B0000514.wmf

9 - 46

MAINTENANCE

9.12

CENTRAL LUBRICATION SYSTEM MAINTENANCE *

The grease receptacle contains 2 kg of normal commercial grease of class NGLI-Kill. 2 and must be topped up with a grease gun (if possible pneumatically) every 50 operating hours or weekly. You may take further details to the central lubrication system from the enclosed documentation.  Greases with with proportions of solids like graphite or copper pastes may

NOTE

not be used.  To prevent soilings from getting in the grease, and leading to obstructions, the grease must be pressed via the lube nipples on the container (do not unscrew the lid).  The grease should be topped up until max. 2 cm below the upper edge, otherwise the ventilation system will be smeared with grease.


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 47

MAINTENANCE

9.13 BOLTED CONNECTIONS  After the first 250 operating hours, re-tension all the bolted connections described in

the following. Generally, apply the prescribed torque on these bolts to tension them ("torque pretension method").

NOTE Bolted connections of Mast sections  Every 5000 hours of ordinary operation, operation, replace all elements used in the bolted con-

nections.

WARNING! Serious accident hazard! Replace the elements of bolted connections which have been openedup more than 25 times or which are corroded, fissured, deformed or have damaged threads.

Bolted connections of Mast pivot, Winch trestles, Roller brackets and Masthead replace all elements used in the bolted  Every 10000 hours of ordinary operation, replace connections.

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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

9 - 48

LUBRICANTS / TABLES

10

LUBRICANTS / TABLES

10.1 LUBRICANTS 10.1.1 General given in the supplied "Safety Information" book on this subject.  Observe instructions given  Use only oils and greases greases prescribed or suitable for the application in question. question.  Before changing to another kind of lubricant, check it is compatible with with the previous

one used.  The lubricants used must be fresh.

CAUTION

NOTE

Risk of damage to the equipment and loss of the equipment warranty! A damage resulting from non-observance of lubricant instructions in this manual will not be covered by the equipment warranty.

The lubricants listed in the lubricant tables of this manual are suitable for ambient temperatures from -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 Service Centre.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

10 - 1

LUBRICANTS / TABLES

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

NOTE

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

Table Initial lubricant fill Application Gear oils, synthetic Crawler drive gears Main winch Auxiliary winch winch Crowd winch Slewing Gear Rotary drive main gear Rotary drive planetary gear

Specification

Viscosity grade

Producer

Name of product

Qty. [litres]

CLP HC

Gear oils, petroleum

ATF

Gear oils, synthetic

HVLP HC

ISO VG 220 ISO VG 220 ISO VG 220 ISO VG 220 ISO VG 220

SHELL SHELL SHELL SHELL SHELL

ISO VG 220

BP

ISO VG 150

BP

Omala HD 220 Omala HD 220 Omala HD 220 Omala HD 220 Omala HD 220 BP Enersyn EP-XF 220 BP Enersyn EP-XF 150

2 x 6.0 15.0 3.0 8.0 8.5 60.0 2 x 5.5

*) At 40°C: 38 mm2/s At 100°C: 7.1 mm2/s

*) 40°C = 104°F ; 100°C = 212°F

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

10 - 2

LUBRICANTS / TABLES

Application Hydraulic oil, petroleum Hydraulic systems

Specification

Viscosity grade

Producer

Name of product

Qty. [litres]

HVLPD ISO VG 46

Hydraulic oil, fixed (biodegradable)

ARAL

Vitam VF 46

SHELL

Shell Rimula Super 15W-40

ARAL

Aralub HLP 2

ARAL

Aralub HLP 2

350.0

HEES

Engine oil, petroleum Engine

API CI-4

Grease, petroleum

KP2N-20 NLGIGrade2

SAE 15W-40

18.9

Multi-purpose grease on lithium soap base

Roller bearings/ friction bearings Central Lubrication System (Base machine, BG equipment) *

after every application after every application


BG 25 / 2011 / 2254_BG25_en_0000498763_V01

10 - 3

LUBRICANTS / TABLES

10.1.3

Lubricant Guide

10.1.3.1 Gear Oils, Synthetic Synthetic – CLP HC Table of gear oils, synthetic – CLP HC Application

Specification DIN 51517-3 ISO 12925/1

Gear oil, synthetic

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

Producer VG 100

VG 150

VG 220

Description

ARAL Degol PAS 100 AVIA Synthogear EP 100

ARAL AVIA BP CASTROL

Tribol 1710 / 100

DEA

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

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

Intor HCLP 150

Intor HCLP 220 Spartan Synthetic EP 220 Renolin Unisyn CLP HC 220 Klübersynth EG 4-220 Mobilgear SHC XMP 220 Optigear Synth A 220 SHELL Omala HD 220 Pinnacle EP 220 Carter SH 220

ESSO FUCHS

Renolin Unisyn CLP HC 100

Renolin Unisyn CLP HC 150 Klübersynth EG 4-150 Mobilgear SHC XMP 150

SHELL OMALA HD 100

SHELL OMALA HD 150 Pinnacle EP 150 Carter SH 150

KLÜBER MOBIL OPTIMOL SHELL TEXACO / CHEVRON TOTAL

CAUTION

Risk of damaging components! Oils from different producers must not be mixed with one another! Synthetic oils and mineral based oils must not be mixed!

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

10 - 4

LUBRICANTS / TABLES

10.1.3.2 Gear Oils, Petroleum – ATF Table of gear oils, petroleum – ATF Application

Specification DIN 51502

Gear oil, petroleum

Dexron II D

Viscosity grade Producer

*At 40° C: 38 mm2/s at 100° C: 7.1 mm2/s

Description ARAL

ATF 22

SHELL

Donax TA

BP

Autran DX II

MOBIL

ATF 220

AVIA

AVIAFLU AVIAFLUID ID ATF 86 86

CASTROL

TQ-D

CHEVRON/TEXACO

Texamatic 4291

ESSO

ATF D II

FINA

Finamatic II D

GULF

ATF DX II

TEXACO

Texamatic 4291 Dexron II D

TOTAL

Totalfluid ATX

KLÜBER ELF

ATF DEXRON II

FUCHS

Titan ATF 3000

AGIP

ATF IID

DEA PANOLIN

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

10 - 5

LUBRICANTS / TABLES

10.1.3.3 Hydraulic Oils, Petroleum – HVLP(D) Table of hydraulic oils, petroleum – HVLP(D) Specification DIN 51524/3 (HVLP); DIN EN ISO 6743/4 (HV) HVLP(D)

Application Hydraulic oil, petroleum

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

Producer VG 32

VG 46

VG 68

Description normal temperature range e.g. Europe, USA, China

Operation temperature

ARAL

Vitam HF 32

SHELL

Tellus STX 32

BP

high temperature range e.g. UAE, Africa

Vitam VF 46 / Vitam HF 46 TELLUS STX 46

Vitam VF 68

Bartran HV 46

Bartran HV 68

HydraWay HVXA 46

HydraWay HVXA 68

TELLUS STX 68

MOBIL CASTROL CHEVRON ESSO FINA TEXACO STATOIL

HydraWay HVXA 32

CONOCO

ECOTERRA HVI 46

PANOLIN

HLP UNI 46

ADDINOL

HVLPD 46

PETRONAS

HVI 46

CAUTION

HLP UNI 68 HVI 68

Risk of damaging components! Oils from different producers must not be mixed with one another! Zinc-free oils and oils containing zinc must not be mixed!

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

10 - 6

LUBRICANTS / TABLES

10.1.3.4 Hydraulic Oils, Biodegradable on Synthetic Basis – HVLP HC Table of hydraulic oils, biodegradable on synthetic basis - HVLP HC Application

Specification DIN 51524/3 (HVLP); DIN 51502; VDMA 24568; CEC-L-33-A-93

Hydraulic oils, biodegradable on synthetic basis

HVLP HC

Viscosity grade ISO-VG / DIN 51519 at 40° C in mm 2/s Producer VG 32

VG 46

VG 68

Description ARAL SHELL BP MOBIL AVIA

Syntofluid PE-B 30 (recommended for ambient temperatures from -40° C to +40° C)

CASTROL CHEVRON ESSO FINA GULF TEXACO STATOIL CONOCO PANOLIN ADDINOL

CAUTION

Risk of damaging components! Oils from different producers must not be mixed with one another! Zinc-free oils and oils containing zinc must not be mixed! Temperature range -40°C to -25°C requires additional measures to be taken on the equipment!

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

10 - 7

LUBRICANTS / TABLES

10.1.3.5 Hydraulic Oils, Biodegradable Biodegradable – HEES - Saturated Esters Table of hydraulic oils, biodegradable – HEES - saturated esters Application

Specification

Hydraulic oil biodegradable

HEES ISO 15380 VDMA 24568 Viscosity grade ISO-VG / DIN 51519 at 40° C in mm 2/s

Producer VG 32

VG 46

VG 68

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

CAUTION

HLP Synth 46

Risk of damaging components! Oils from different producers must not be mixed with one another.

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

10 - 8

LUBRICANTS / TABLES

10.1.3.6 Engine Oils – API CI-4 Table of engine oils – API CI-4 Application


Engine oil

API CI-4 ACEA E 7 Viscosity grade SAE / DIN 51511

Producer SAE 5W-40

SAE 10W-40

SAE 15W-40

Description AGIP ARAL

ARAL Extra Turboral SAE 10W-40

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

Vanellus C6 Global Plus SAE 10W-40

Vanellus C7 Global 15W-40

AVIA BP CASTROL CHEVRON LUKOIL TNK-BP ESSO FINA FUCHS GULF STATOIL MOBIL SPC Q8 SHELL TEXACO IGOL TOTAL / FINA / ELF

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

RX super 15W-40 Chevron Delo 400 Multigrade SAE 15W-40 Lukoil 15W-40 Revolux D3 XD - 3 Extra 15W-40 Fina Universal Plus XL SAE 15W-40 Titan Truck Plus SAE 15W-40 Gulf Super Duty Select SAE 15W-40 MaxWay Mobil Delvac MX 15W-40 SDM 901 Q8 T 750 SAE 15W-40 Shell Rimula Super 15W-40 Ursa Super TD 15W-40 Trans Turbo 9x Rubia TIR 7400

10 - 9

LUBRICANTS / TABLES

10.1.3.7 Greases, Petroleum – KP2N Table of greases, petroleum – KP2N Application


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

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

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 BOLT TORQUE VALUES

CAUTION

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

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

10.9

12.9

Bolt torque values M A [Nm] 2,8 5,5 9,5 23 46 79 125 195 280 390 530 670 1000 1350 1850 2350

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

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 - 11

LUBRICANTS / TABLES

10.2.2 Bolts with fine-pitch metric thread Strength class 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

10.9

12.9

Bolt torque values M A [Nm] 24,5 52 49 87 83 135 205 310 430 580 730 1070 1490 2000 2500

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

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 - 12

LUBRICANTS / TABLES

10.3 CONVERSION TABLE 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 for Output 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 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

ft

yd

1 12 36 0.03937 39.37 39370

0.08333 1 3 328110-6 3.81 3281

0.02778 0.3333 1 109410-6 1.094 1094

BG 25 / 2011 / 2254_BG25_en_0000498763_V01

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 - 13

Instruction manual for BG25

Recommend Documents