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RIGGING / DE-RIGGING

BG 25 / 2011 /

2254_BG25_en_0000498763_V01

7 - 30

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 dis-
mounted.
Avoid getting limbs in between machine and counterweight.
Before releasing or removing safety components, secure the counter-
weights 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.

NOTE

For further information please refer to the documentation supplied
with the base machine.

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Summary of Contents for BG 25

Page 1: ...anual BG 25 BAUER Maschinen GmbH P O Box 12 60 D 86522 Schrobenhausen Germany Phone 49 8252 97 0 Fax 49 8252 97 13 59 BK000513 wmf Translation of the original instruction manual Keep this manual also for future use ...

Page 2: ...бва да пускате машината съоръжението в експлоатация В такъв случай се свържете със сервиз на BAUER Maschinen GmbH и поръчайте Ръководство за експлоатация на разбираем за Вас език Телефон 49 8252 97 2586 Факс 49 8252 97 2587 E Mail KVT bauer de CN 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电话 49 8252 97 2586 传真 49 8252 97 2587 电子邮件 KVT bauer de CZ Pokud nerozumít...

Page 3: ...r el idioma utilizado en el presente manual de usua rio no podrá poner en funcionamiento el aparato equipo En ese caso póngase por favor en contacto con el servicio de atención al cliente de BAU ER Maschinen GmbH y solicite un manual de instrucciones que esté en su idioma Teléfono 49 8252 97 2586 Fax 49 8252 97 2587 E Mail KVT bauer de EE Kui see kasutusjuhendis on keeles mida te ei oska on teile ...

Page 4: ...zik 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 upo rabu na jeziku koji razumijete Telefon 49 8252 97 2586 Telefaks 49 8252 97 2587 E pošta KVT bauer de HU Amennyiben nem érti a jelen használati útmutató nyelvét akkor nem helyez heti üzem...

Page 5: ... manwal ta tħaddim ma għan dekx 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 49 8252 97 2586 Fax 49 8252 97 2587 E Mail KVT bauer de NL Als u de taal van deze gebruiksaanwijzing niet mach...

Page 6: ...izată 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 ma nual de utilizare în limba dumneavoastră Telefon 49 8252 97 2586 Telefax 49 8252 97 2587 E Mail KVT bauer de RU Если вы не понимаете язык на котором написана данная инструкция по эксплуатации ввод устройства у...

Page 7: ...čite navodila za uporabo v jeziku ki ga razumete Telefon 49 8252 97 2586 Telefaks 49 8252 97 2587 E pošta KVT bauer de TR 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 49 8252 97 2586 Telefaks 49 8252 97 258...

Page 8: ...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 individualizati...

Page 9: ...mag netic form processing as electronically or magnetically stored media copying or disse mination 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 sup pliers consultants or agents without the prior written consent of BAUER Maschinen GmbH is hereby strictly prohibited All rights and remedie...

Page 10: ...1 2 1 GENERAL SAFETY REQUIREMENTS 2 1 2 2 EQUIPMENT SAFETY 2 1 2 3 MAJOR HAZARDS 2 1 2 4 SAFETY DEVICES 2 2 2 4 1 Emergency Stop 2 2 2 4 2 Pilot Control Safety Stick 2 2 2 4 3 Fire Extinguisher 2 3 2 4 4 Medical Box 2 3 2 4 5 Emergency Exit 2 3 2 4 6 Limit Switches 2 4 2 4 7 Fall Protection Equipment 2 5 2 5 STABILITY 2 6 2 5 1 Guidelines for Stability 2 6 2 5 2 Stability for BG 25 2254 Kelly BK 2...

Page 11: ...ONTROL PANEL 4 3 4 4 MONITOR UNIT 4 4 5 OPERATION 5 1 5 1 TRAVEL 5 1 5 1 1 To Travel and Steer 5 1 5 2 UPPERCARRIAGE SWING 5 2 5 2 1 Swing Brake 5 2 5 2 2 Swing Control 5 3 5 3 MAST REPOSITIONING 5 4 5 3 1 Mast Auto Reset to Vertical 5 5 5 3 2 Mast Repositioning by Manual Control 5 6 5 3 2 1 To Adjust the Mast Inclination 5 6 5 3 2 2 To Adjust the Drill Distance 5 8 5 4 MAST PROP CONTROL 5 9 5 5 T...

Page 12: ...UNTING THE COUNTERWEIGHT 7 4 7 5 MOUNTING THE MAST 7 7 7 5 1 Mounting the Trestle 7 7 7 5 2 Assembling the Mast Sections 7 8 7 5 3 Installing the Ropes 7 10 7 5 3 1 Installing the Main and Auxiliary Ropes 7 10 7 5 3 2 Installing the Upper Crowd Rope 7 11 7 5 4 Mounting Crowd Stroke Limiters 7 12 7 5 5 Raising the Mast 7 13 7 5 6 Mounting Retaining Clamps 7 14 7 6 ASSEMBLY OF WORK ATTACHMENTS 7 15 ...

Page 13: ...TENANCE DURING LONGER PERIODS OF STANDSTILL 9 12 9 6 HYDRAULIC SYSTEM 9 13 9 6 1 Hose Assemblies 9 14 9 6 2 Hydraulic Cylinders 9 15 9 6 3 Filter Replacement 9 16 9 6 3 1 Replacing the Line Filters 9 16 9 7 WINCHES 9 17 9 7 1 Checking the Oil Level 9 17 9 7 2 Changing Gear Oil 9 18 9 8 REPLACING THE UPPER CROWD ROPE 9 19 9 9 WIRE ROPE ACCESSORIES 9 24 9 9 1 Rope Swivel 9 24 9 9 2 Rope Hold Down Ro...

Page 14: ...the Oil Level 9 46 9 11 4 2 Changing the Oil 9 46 9 12 CENTRAL LUBRICATION SYSTEM MAINTENANCE 9 47 9 13 BOLTED CONNECTIONS 9 48 10 LUBRICANTS TABLES 10 1 10 1 LUBRICANTS 10 1 10 1 1 General 10 1 10 1 2 Lubricant Table 10 2 10 1 3 Lubricant Guide 10 4 10 1 3 1 Gear Oils Synthetic CLP HC 10 4 10 1 3 2 Gear Oils Petroleum ATF 10 5 10 1 3 3 Hydraulic Oils Petroleum HVLP D 10 6 10 1 3 4 Hydraulic Oils ...

Page 15: ...uction year 2010 Date of 1st operation Certification CE THIS MANUAL WAS PUBLISHED IN 02 2011 THE CHAPTERS OF THIS MANUAL 1 DESCRIPTION 2 SAFETY 3 TECHNICAL SPECIFICATIONS 4 CONTROLS AND INDICATORS 5 OPERATION 6 START UP SHUT DOWN 7 RIGGING DE RIGGING 8 TRANSPORT 9 MAINTENANCE 10 LUBRICANTS TABLES APPENDICES G 2254_BG25_en_0000498763_V01 ...

Page 16: ...y 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 Caution is used to identify a hazard that can result in moderate in jury and or damage to the equipment if the instructions given in the manual are ignored or not correctly followed NOTE Note is used to highlight an operation assembly or maint...

Page 17: ...üfung expert test CE Zeichen CE sign D 86522 Schrobenhausen Made in Germany Gerätetyp type Baujahr year of manufacture Bau Nr serial No Inv Nr Inv No Rückzugkraft pulling force Motorleistung engine power Gesamtgewicht total weight max Druck max pressure kN bar kg kW Trägergerät base carrier Vorschubkraft pushing power Frequenz frequency Arbeitspannung working voltage Betriebsdruck working pressure...

Page 18: ...ollowing in formation so your inquiry can be dealt with more quickly 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 ...

Page 19: ...time during the warranty period without proper authorisation Any faults must be notified to BAUER in writing on the appropri ate Warranty Claim form within 24 hours after their occur rence The Client or Operator of the BAUER equipment agrees to carry out all services throughout the warranty period within the speci fied service intervals in full compliance with the Instruction Ma nual Any work serv...

Page 20: ...If the damaged parts which are redelivered via sea freight are not redelivered in time due to the jobsite situation the after sales service department has to be informed cor respondingly at the latest 6 weeks before expiry of the deadline Concerning redeliveries via air freight an extension of the deadline is principally not possible In case requested redeliveries are not returned within the agree...

Page 21: ...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 Estimated working time hrs Estimated additional c...

Page 22: ...Baustellentelefon Jobsite phone no Zielflughafen Airport of destination Datum des gewünschten Einsatzes Date of requested assignment Gewünschtes Personal Requested staff Mechaniker Elektriker Einweiser mechanic electrician operator Voraussichtliche Dauer Estimated duration Auszuführende Arbeiten Works to be carried out Besonderheiten Special requirements Ersatzteile Spare parts Kommunikation auf d...

Page 23: ...egards customer information at all times For this reason we would ask each owner to register himself and his equipment with BAUER Maschinen GmbH by filling out this form 1 Gerätedaten Equipment Data Gerät Equipment Baunummer Serial number Betriebsstunden No of operating hours 2 Betreiberdaten Owner information Aktueller Betreiber des Gerätes mit Anschrift Current owner of the equipment including a...

Page 24: ...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 equip ment 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 optio...

Page 25: ...r All contrac tual agreements between the manufacturer and the original purchaser with respect to the requirements and restrictions of use and operation of the equipment in a country other than the one the equipment was ordered for are binding on any and all subsequent purchasers Any use of the equipment in any country other than the country for which it was ordered by the original purchaser is un...

Page 26: ...ial number 2 Änderungsdaten Change data für for Gerät Equipment Ausrüstung Attachment Anbauteil Factory installed option Änderungsbeschreibung Description of changes ggf Angebotsnr BAUER BAUER offer no if applicable Es wird hiermit ausdrücklich erklärt und bestätigt dass sich das Gerät zum aktuellen Zeitpunkt im Original zustand Auslieferungzustand befindet und ausschließlich mit BAUER Originalkom...

Page 27: ...op 15 Mast pivot 16 Masthead 17 Mast extension intermediate 18 Mast extension lower 19 Backstay cylinders 20 Uppercarriage 21 Rope swivel 22 Crowd rope tensioning cylinder 23 Supporting boom 24 Supporting trestle 25 Undercarriage 26 Crowd sledge 27 Crowd ropes upper lower 28 Thrust rod 29 Crowd winch 30 Crowd cylinder 16 13 19 24 20 5 3 4 2 13 46 21 26 29 15 1 6 42 44 41 45 43 40 25 8 27 7 9 22 14...

Page 28: ...etween the mast and the boom Masthead Houses sheaves which guide ropes over the mast Mast extension intermediate Enables use of longer drilling tools Mast extension lower Allows the crowd sledge be positioned further down Backstay cylinders Are movable supports of the mast They raise and lower the mast and allow adjustment of the inclina tion of the mast Uppercarriage Houses the engine hydraulic s...

Page 29: ...om hydraulic motors Casing drive adapter Serves as a connector between the cardan joint and the casing tube and transfers the torque Shock absorber Absorbs shocks from the Kelly bar Cardan joint Transfers torque from rotary drive to casing drive adapter and prevents torsional stress Kelly driver Transfers torque from rotary drive to Kelly bar Kelly bar Kelly Consists of telescoping tubes the total...

Page 30: ...nocked down by a component thereof is mortal The stability of the equipment must not be endangered Exceeding the rig s capacity or operating with faulty end limiters can make the equipment fall violently causing severe personal injury or even loss of life Never remove equipped safety devices or render them out of order Be observant of oil spills from the hydraulic system If there is a spill find t...

Page 31: ...p To re start pull the depressed Emergency STOP button 0 1 1 BK1478505 wmf 2 4 2 Pilot Control Safety Stick With the safety stick 1 the operator must shut off the pilot control before leaving the driver s seat With the stick in the OFF position all hydraulic functions are blocked Pilot control ON Stick moved to position 1 1 Pilot control OFF Stick moved to position 1 2 1 2 1 1 BK786505 wmf ...

Page 32: ...fig Personnel must recapitulate the text on fire extinguishers from time to time to be famili ar 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 ...

Page 33: ...lination to right ES 4 1 Initial situation ES 4 out of order Switches off engine when max permissible mast inclination to right is obtained ES 10 Initial situation boom cylinders fully extended 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 auxiliary winch ...

Page 34: ...ack 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 ...

Page 35: ...ires a new calculation of the rig s stability Machine on firm horizontal and even surface National safety codes and guidelines observed concerning the soil and working platform conditions Upper carriage held stationary with crowd and main rope load Slow swing of upper carriage with load on auxiliary rope No diagonal pull NOTE Pulling and pushing forces of the winches crowd cylinder and the present...

Page 36: ... pressure Min drilling distance m Max drilling distance 3 39 m Auxiliary rope 8 0 t 430 kPa Main rope 20 0 t 380 kPa Crowd 26 0 t 470 kPa Auxiliary rope α β γ δ α 6 β 3 γ 0 δ 110 8 0 t 750 kPa Main rope α β γ δ α 6 β 3 γ 4 δ 110 20 0 t 480 kPa Crowd α β γ δ α 6 β 3 γ 4 δ 110 26 0 t 610 kPa 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...

Page 37: ...ts with crowd sledge with counterweights without work equipment without undercarriage without KDK 424 10 0 22 4 66 B0000921 wmf Rotary drive KDK 250 K with Kelly driver 50 00 3 21 11 24 Casing drive adapter Ø 1500 mm 19 00 3 39 9 20 Kelly BK 25 394 4 56 101 00 3 39 12 30 Drilling bucket Ø 1350 mm 23 00 3 39 2 80 Swivel 1 00 3 39 19 50 B0000922 wmf Undercarriage Dimensions m S B X Z A X B0000929 wm...

Page 38: ... pressure Min drilling distance m Max drilling distance 3 39 m Auxiliary rope 8 0 t 390 kPa Main rope 20 0 t 370 kPa Crowd 26 0 t 420 kPa Auxiliary rope α β γ δ α 6 β 3 γ 0 δ 120 8 0 t 690 kPa Main rope α β γ δ α 6 β 3 γ 4 δ 120 20 0 t 490 kPa Crowd α β γ δ α 6 β 3 γ 4 δ 120 26 0 t 570 kPa Auxiliary rope α β γ α 6 β 3 γ 0 5 0 t 560 kPa Main rope α β γ α 6 β 3 γ 4 20 0 t 490 kPa Crowd α β γ α 6 β 3...

Page 39: ...nts with crowd sledge with counterweights without work equipment without undercarriage without KDK 424 10 0 22 4 66 B0000921 wmf Rotary drive KDK 250 K with Kelly driver 50 00 3 21 11 24 Casing drive adapter Ø 1500 mm 19 00 3 39 9 20 Kelly BK 25 394 4 40 77 00 3 39 14 30 Drilling bucket Ø 1350 mm 23 00 3 39 6 80 Swivel 1 00 3 39 19 50 B0000922 wmf Undercarriage Dimensions m S B X Z A X B0000929 wm...

Page 40: ... 5 1 5 Smoke drifts but vanes remain still sea is rippled 2 light breeze 1 6 3 3 6 11 Wind can be felt on your face leaves rustle sea has wavelets 3 gentle breeze 3 4 5 4 12 19 Leaves and thin twigs move pennants stretch wave crests begin to break 4 moderate breeze 5 5 7 9 20 28 Dust and paper lift twigs and branch lets sway waves are growing in length scattered white caps 5 fresh breeze 8 10 7 29...

Page 41: ...TECHNICAL SPECIFICATIONS BG 25 2011 2254_BG25_en_0000498763_V01 3 1 3 TECHNICAL SPECIFICATIONS 3 1 DIMENSIONS 3 1 1 Kelly Equipment BK 25 394 4 56 Dimensions in mm 4620 BK22545001 wmf ...

Page 42: ...TECHNICAL SPECIFICATIONS BG 25 2011 2254_BG25_en_0000498763_V01 3 2 3 2 1 Kelly Equipment BK 25 394 4 40 Dimensions in mm 4620 BK22545000 wmf ...

Page 43: ...m Undercarriage Type UW 75 BH Serial number 9161 Width over crawlers 3000 4400 mm Length of crawlers 5360 mm Width of track pads 700 mm Mast Inclination During operation without work equipment forward 6 backward 4 to left 3 to right 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 82 50 tonnes Kelly BK 2...

Page 44: ...ulling force 1st layer 80 kN Rope diameter 20 mm Rope length 50 m Rope speed 55 m min lifting with a load of 10 kN Crowd winch Type 4 261001908 Serial number 623 Max stroke of crowd sledge 8 145 mm with Kelly system Max pushing force at crowd sledge 260 kN Max pulling force at crowd sledge 260 kN Rope diameter 24 mm Length of upper lower rope without mast extension 65 60 m Crowd speed Fast crowd u...

Page 45: ... Qth 2 x 250 l min i 26 18 high torque low torque 45 37 191 9 245 7 0 20 40 60 80 100 120 140 160 180 200 220 240 260 0 5 10 15 20 25 30 35 40 Drehzahl n 1 min Speed n rpm Drehmoment Torque M kNm BK832507 wmf 37 118 14 151 11 0 25 50 75 100 125 150 175 200 0 10 20 30 40 50 Drehzahl n 1 min Speed n rpm Drehmoment Torque M kNm BK832508 wmf ...

Page 46: ...t to casing drive adapter L1 Highest possible position of Kelly lifting eye L2 Highest possible position of Kelly driver upper edge L3 Lowest possible position of Kelly driver upper edge W Length of drilling tool 2 20 m CO BAUER Casing Oscillator Drilling depth Kelly specifications Kelly type A m B m B1 m Hw m locked Kelly unlocked Kelly Weight t without CO T m with CO T m without CO T m with CO T...

Page 47: ...oist 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 88 m Diameter 28 00 mm Characteristics Lay and direction Regular lay right sZ Rotation characteristics Non rotating Rope end characteristics Pointed full thimble ...

Page 48: ...hes 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 50 m Diameter 20 00 mm Characteristics Lay and direction Regular lay right sZ Rotation characteristics Non rotating Rope end characteristics Pointed full thimble ...

Page 49: ...ust 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 upper lower 65 m 60 m Diameter 24 00 mm Characteristics Lay and direction Regular lay left zS Rotation characteristics Rotating Rope end characteristics Pointed Pointed ...

Page 50: ...Cab door closed Sound pressure level in cab LpA 75 0 dB A 2 Outside Average sound pressure level LPA 87 5 dB A Sound power level LWA 113 0 dB A 3 7 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 con sulted ...

Page 51: ...vely NOTE As long as the diesel engine complies with the effective guideline in the country of use the operator is permitted to use this equipment 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...

Page 52: ...ump spoil 9 Horn ON 10 1 Crowd down 10 2 Crowd up 10 3 In Kelly CFA mode Rotary drive rotate right 10 4 In Kelly CFA mode Rotary drive rotate left 10 5 Rigging mode Backstay cylinders selected Right backstay cylinder extend 10 6 Rigging mode Backstay cylinders selected Right backstay cylinder retract 10 7 Rigging mode Boom cylinders selected Boom cylinders retract 10 8 Rigging mode Boom cylinders ...

Page 53: ...dication Error code 6 Error codes scroll 7 Engine diagnostic Error code test 8 Not used 9 Not used 10 Freewheel Free fall mode ON OFF 11 Emergency STOP 12 Engine speed adjustment 13 Engine ignition ON OFF 14 Not used 15 Central lubrication ON Intermediate lubrication 16 Crowd sledge Lube trouble 17 Central lubrication ON OFF Not used in this version 0 1 2 4 5 3 1 11 9 10 15 16 17 13 12 6 7 8 14 BK...

Page 54: ...oom cylinders extend 10 Extendable crawlers extend retract 11 Crowd rope relieve 12 Crowd rope tension 13 In Drilling mode Left backstay cylinder retract 14 In Drilling mode Right backstay cylinder retract 15 Rotary drive low torque select 16 Rotary drive middle torque select 17 Rotary drive high torque select 18 Warning Free wheel oil filter contaminated 19 Warning Return line oil filter contamin...

Page 55: ...CONTROLS AND INDICATORS BG 25 2011 2254_BG25_en_0000498763_V01 4 4 4 4 MONITOR UNIT For Details of the Monitor Unit please refer to the supplementary documentation supplied with the equipment ...

Page 56: ...nd crawler drive 3 back When working the front idler 1 must also be oriented towards the drill ing point 1 2 3 CA00005000 wmf B0000552 wmf CAUTION Risk of damaging components of the undercarriage The undercarriage mounted to the equipment is functionally designed for stationary operation under loads and forces from drilling Travel over far distances with this equipment must be avoided NOTE For shi...

Page 57: ...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 18 19 BK19035004wmf Swing brake lock The indicator light on Control Panel comes on Swing brake unlock Th...

Page 58: ... control lever to left 15 from centre Uppercarriage swing to right Unlock swing brake Move control lever to right 15 from centre 15 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 in the opposed direc tion ...

Page 59: ...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 CAUTION Risk of components getting damaged and the rope breaking On equipment fitted with an overload protection for the main rope vari ous functions will s...

Page 60: ... in touch with the ground when the Mast Auto Reset is actuated Press Botton AT 1 and hold on The mast sets to vertical position 1 2 BK15155011 wmf NOTE Releasing the button too soon stops the action NOTE The mast will first set to vertical position in the X axis and then after a pause in the Y axis NOTE For more details please refer to the supplementary documentation supplied with equipment ...

Page 61: ...e mast is tilted to the side When using a hydraulic tube guide the mast must not be tilted side ways if the minimum drilling centre distance is selected 5 3 2 1 To Adjust the Mast Inclination In Drilling Mode Select Drilling mode BK14885017 wmf Extend left backstay cylinder by Extend right backstay cylinder by Retract left backstay cylinder by Retract right backstay cylinder by B0000504 wmf NOTE E...

Page 62: ...ing mode Bk14885013 wmf Lowering the mast Move left right control lever forward 0 1 BK19035019 wmf Raising the mast Move left right control lever back 0 1 BK19035020 wmf B0000504 wmf NOTE Extending the long backstay cylinders by the control levers only is poss ible in rigging mode ...

Page 63: ... 2 To Adjust the Drill Distance Increasing machine s distance to the bore Extend boom cylinders by Decreasing machine s distance to the bore Retract boom cylinders by B0000505 wmf NOTE To adjust the mast parallel see fig the mast inclination must be readjusted ...

Page 64: ...ng 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 BK19035006 wmf To retract the mast prop Press button and hold down BK19035007 wmf NOTE Releasing one of these buttons too soon interrupts the action Not used in this versi...

Page 65: ...e driver of the rig must be assisted by a signalman during travel Provide an obstacle free travel path Adjust the uppercarriage in line with the crawlers and apply the swing brake Lower work attachments and movable loads as close to the ground as possible Set the mast in position of minimum working range Set the mast vertical Travel on firm and level surfaces only Avoid making abrupt movements ...

Page 66: ...N Tipping hazard Observe all instructions found in sect Travelling over level ground CAUTION Tipping hazard Max permissible gradient is 15 Travel straight to the grade only Never zigzag or traverse Arrange the machine to carry the mast on the uphill side Tilt the mast slightly forward Travel up or down a slope in the man ner shown here B0000704 wmf ...

Page 67: ...ed 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 and press the button 8 CAUTION Risk of damage to the Kelly bar and or the rotar...

Page 68: ...en the Kelly bars used are not designed for the torque of the rotary drive the key operated switch 1 in the control cabinet must be turned to position of High Torque OFF to prevent damage to the Kelly 1 Limitation Torque High Limitation Torque High BK1206501 wmf CAUTION Risk of damaging the Kelly Operation with excessive torque can ruin the Kelly bar NOTE With the key operated switch 1 set to OFF ...

Page 69: ...tion WARNING Hitting hazard squashing hazard Hook up the auxiliary rope on the holding arm Do not tension hooked up rope when people are in the danger zone CAUTION Risk of damaging the winches When unspooling rope from winches the operator must ensure that three wraps of rope remain on the drums for safety reasons CAUTION Risk of damaging the rig Hoist limiters are out of function during rigging o...

Page 70: ...gging 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 2 see fig 1 2 Control of selected winch B0000702 wmf ...

Page 71: ...rn key operated switch 4 to position of Freewheel Mode ON Press foot 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 sw...

Page 72: ...g Place drilling tool in desired position Press button D 0 2 to reset the depth indicator to 0 1 2 BK15155011 wmf Depth 1 Depth of main winch Depth 2 Depth of crowd NOTE The depth measuring may be reset to zero at any time NOTE For more details please refer to the supplementary documentation sup plied with equipment ...

Page 73: ...mponents 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 ...

Page 74: ...ol 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 Press button 6 and hold on Move lever off centre 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 ...

Page 75: ...wed only in the case of a recovery and where the rig is equipped with a mast prop which is fully extended and where the attached tool string has the appropriate provisions e g a defined stop for the Kelly on the casing drive adapter in Kelly applications 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 cer tain...

Page 76: ...ashes 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 be tween scroll through the error codes Engine diagnostics Warning indicator 5 is ON Stop the engine immediately Then proceed as described under Er ror code indicator 4 is ON see abo...

Page 77: ...atic lubrication it is recommended to run the crowd sledge up and down the mast 2 3 times in order to distribute the grease from the runners to the rails Additional lubrication with a grease gun is possible through a free nipple found on the distributor block on the crowd sledge Flashing codes 1 System on 0 5 sec 0 5 sec 1 5 sec 1 6 4 5 1 sec 1 sec 1 5 sec 2 3 1 sec 1 sec off on off on off on off ...

Page 78: ...n the construction site Even before the first rigging operations are begun the operator of the equipment must be familiar with all the control elements and their capabilities 6 1 2 Visual Inspection before Starting A visual inspection and thorough check is required before putting the equipment into operation Inspect the entire equipment for loose connections and missing pins or bolts Check all com...

Page 79: ...rve instructions in the manual of the base machine Set the battery main switch to ON position Set all controls to 0 position Pull the Emergency STOP button Start the engine by turning the ignition key CAUTION Risk of damaging the engine Allow cold engine to warm up at idle speed for approx 10 minutes Move the safety stick of the pilot control to ON position ...

Page 80: ...imum Engine Speed NOTE After restarting the engine select operating mode M 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 ...

Page 81: ... by skilled personnel The equipment may be put to work only when all safety devices are in proper working order Initial situation Diesel engine is running 6 1 4 1 Checking the Emergency STOP Press the Emergency STOP button All control elements must be out of function and the diesel engine comes to a stop 6 1 4 2 Checking the Pilot Control Safety Stick Move the safety stick of the pilot control to ...

Page 82: ... 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 a...

Page 83: ...tion Move the safety stick of the pilot 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 position 6 2 2 Shut Down for...

Page 84: ... 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 hy draulic cylinders and piston rods should undergo visual inspection prior to mounting to check for fissures Before starting assembly inspect t...

Page 85: ...jet at a tem perature of 90 C 95 C approx 200 F NOTE Alternatively the equipment can be washed down with a cold water de tergent The treatment must be repeated until all the equipment is totally free of wax CAUTION Risk of damaging components Detergents used must not be harmful to seals etc Check detergents for their areas of application prior to use ...

Page 86: ...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 simultaneously On one crawler remove retainers 2 and remove pins 1 from the lock posi tion A By button Bk19030013 wmf extend the crawler while travelling for ...

Page 87: ... 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 bolts must be additionally checked after 50 operating hours with the specified torque CAUTION Risk of damaging components Counterweights consist...

Page 88: ... suitable lifting devices to the lifting equipment and to the lifting points 1 of the inside counterweight 2 Hoist counterweight 2 onto machine using lifting equipment and set it down on the frame BK00004001 jpg NOTE Lightly tension lifting devices BK00004002 jpg Mount the counterweight on the frame of the upper carriage with bolts 3 and tighten to an adequate torque see Section 10 ...

Page 89: ... equipment and to the lifting points 1 of the outside counterweight 2 Hoist counterweight 2 onto machine using lifting equipment and set it down on the frame BK00004003 jpg NOTE Lightly tension lifting devices BK00004004 jpg Mount the counterweight on the frame of the upper carriage with bolts 3 and tighten to an adequate torque see Section 10 ...

Page 90: ... 20 Mount transport supports 4 Using the control levers extend backstay cylinders and put down the mast on the ground NOTE Underpin the transport supports with timber if the ground is soft Open up the mechanical swing lock Release the swing brake Extend backstay cylinders 1 by control levers until trestle 2 can be mounted to machine with pin 3 Install the pin and secure it Retract backstay cylinde...

Page 91: ...limbs in between the mast sections Minor backstay cylinder movements can lead to major movements of the mast sections During the assembly operations the operator must keep the person working at the mast in view at all times During operation with the backstay cylinders adjust the lower mast section 3 to the next mast section 1 until holes for assembly pins 2 are in line 1 2 3 B0000567 wmf Install t...

Page 92: ...000999 wmf Remove transport supports Make hydraulic connections between the mast sections Make electric connections between the mast sections To do so remove plug 1 of electric ca ble 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 BM400462 jpg WARNING Dan...

Page 93: ...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 are at contactor weights 6 Thread ropes through contactor weights 6 of hoi...

Page 94: ...nd guide sheave 4 up and around upper left guide sheave 5 down to guide sheave on sledge 6 counter clockwise back up to sheave 7 on upper end of mast to rope tension cylinder 1 Anchor rope end with wedge to rope tension cylinder 1 WARNING 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 rop...

Page 95: ...NING Rig tipping hazard For reasons of stability the crowd sledge fitted with Kelly equipment must not be free to move to the upper mast end 8 8 3 3 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 ...

Page 96: ...r must keep in view the person working at the mast at all times Extend boom cylinders completely CAUTION Danger of being injured by falling objects All loose objects must have been removed from the mast Select backstay cylinder operation and uniformly and synchronously pull both control levers back to raise the mast CAUTION Rig tipping hazard Do not allow the mast to drift aside The backstay cylin...

Page 97: ...as the mast has been raised Select Rigging mode Completely retract both backstay cylinders by pulling the control levers back Attach retaining clamp halves 1 to one back stay cylinder Push O Ring 2 up on clamp and install in groove 3 Using a hammer knock locking ring 4 down on clamp Repeat the procedure on the other backstay cylinder 4 3 1 3 2 1 BK331531 wmf ...

Page 98: ...d 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 the assembly throughout the whole procedure ...

Page 99: ...vel Use only the genuine rope swivel of BAUER make The swivel must be designed for the max lifting force of the winch used Mount the swivel as shown in the figure below CAUTION Risk of damaging components Mount the swivel in the right way The lube nipple must be up After mounting grease the swivel and test it rotates freely 1 Main rope 2 Pin 3 Lube nipple 4 Hex head bolt 5 Lock washer 6 Washer 1 2...

Page 100: ...e onto the sledge mount with pins 1 and 2 and secure the pins 1 1 2 3 4 5 5 2 B0000700 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 Remove lifting slings Stop engine Connect hydraulic lines CAUTION Risk of damaging components Connect the leak oil line first 3 A1 5 2 Pressure 4 B1 6 B2 Return flow 1 ...

Page 101: ...e 1 are mounted with pins 3 End cover 8 is removed from the Kelly 1 3 2 B0000708 wmf 5 7 8 B0000711 wmf Mounting the Kelly guidance 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 Mount the rope swivel 6 to the swivel extension 4 see also next page 6 4 5 2 7 B0000707 wmf Not used in this version ...

Page 102: ...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 2 3 2 3 8 B0000709 wmf N...

Page 103: ...eye on Kelly must face the machine Mount rope swivel to eye on Kelly in accor dance with fig below 1 Main rope 2 Rope swivel 3 Pin 4 Kelly 5 Lock washer 6 Hex head bolt 7 Washer 8 Lube nipple 1 2 4 3 5 6 7 8 B0000621 wmf Move rotary drive to lowermost position Tilt mast forward by approx 2 3 By the main winch lift the Kelly as shown to right and at the same time travel with the machine towards the...

Page 104: ...ry drive Set mast to upright again Allow the Kelly to stop swinging and then insert it into the rotary drive NOTE Slight rotation with the rotary drive can be helpful when inserting the Kelly 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 pi...

Page 105: ...the engine of the base machine Remove dust caps from hydraulic connections Mount the hydraulic couplings in compliance with the provided numbers Make electric connection of casing oscillator and base machine View A Undercarriage seen from the rear The identified couplings are found on the front side of the two bulkheads BM779414 jpg 20 Oscillation P 21 Oscillation R 22 Unclamping 23 Clamping 24 Lo...

Page 106: ...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 the disassembly throughout the whole procedure ...

Page 107: ... Rotary Drive Set mast to upright Move crowd sledge to lowermost point Stop engine Disconnect electric lines Disconnect hydraulic lines 6 B2 4 B1 42 5 A2 3 A1 62 View A View A 1 T 9 SP L Ansicht A Ansicht A 12 P 41 117 116 B0000808 wmf 1 1 2 3 4 5 5 2 B0000700 wmf CAUTION Risk of damaging components Disconnect the leak oil line T last Attach lifting slings to lifting eyes 5 Suspend the slings to t...

Page 108: ...rcarriage with the mast located on the same side as the crawler drive wheels CAUTION Risk of colliding the mast with the crawlers The uppercarriage must be in the correct position 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 b...

Page 109: ... 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 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 ...

Page 110: ... 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 13 out to relieve the rope and pull the rope out of the socket Remove the entire rope Coil the...

Page 111: ...imes Mount transport supports to upper mast section Undo hydraulic and electric connections between mast sections Unscrew bolts from mast connecting flanges and stow the bolts for later use Lower the mast until masthead and rear mast supports rest on ground Remove pin retainers from rear side of mast and pull the pins out Travel in reverse with machine and disengage upper mast section from lower m...

Page 112: ...le Mount transport support 4 Lower the lower mast section until the transport 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 1 rests on bearing point 3 2 3 4 1 BK097505 wmf ...

Page 113: ...ving safety components secure the counter weights 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 tippin...

Page 114: ...ing the Outside Counterweight Attach suitable lifting devices to the lifting equipment and to the lifting points 1 of the counterweight 2 BK00004003 jpg NOTE Lightly tension lifting devices BK00004004 jpg Loosen the bolts 3 Remove the bolts and safety material Using lifting equipment lift the coun terweight away from the frame set it down on level stable ground and se cure it against tipping over ...

Page 115: ...pment and to the lifting points 1 of the counterweight 2 Lightly tension lifting devices BK00004001 jpg NOTE Lightly tension lifting devices BK00004002 jpg Loosen the bolts 3 Remove the bolts and safety material Using lifting equipment lift the coun terweight away from the frame set it down on level stable ground and se cure it against tipping over ...

Page 116: ...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 posi tion B By button Bk19030013 wmf retract the crawler while travelling for ward and reverse Reinstall the pins 1 at the position A...

Page 117: ...tical again Arrest and secure movable parts of the equipment Check the work platforms are safely latched to the upper carriage Put accessories to be stored safely away so they will not be an obstacle to traffic on a road or on a construction site and that they will not be interfered with by accident or abuse Additionally cover up and secure sharp edges projecting points and cutting blades The driv...

Page 118: ... is in line with the crawlers and locked to the undercarriage the crawlers are retracted the beam extensions if so equipped have been removed the counterweights have been removed as necessary After loading Underpin the lower mast section with transport supports and secure Put the safety stick of the pilot control to OFF position Stop the engine and remove the ignition key Lock the cab and remove t...

Page 119: ...OFF 5 Engine speed adjustment 6 Move pilot safety stick to ON 7 Select Rigging mode 8 Not used 9 Slightly raise lower mast section by right and left control lever 10 Travel forward by pushing both levers forward 11 Travel reverse by pulling both levers back 12 Lower mast section by right and left control lever 13 Set battery switch to OFF CAUTION Risk of damaging the equipment With the trestle sti...

Page 120: ...TRANSPORT BG 25 2011 2254_BG25_en_0000498763_V01 8 4 8 4 LIFTING POINTS BK1162502 wmf ...

Page 121: ...s Unit Weight in tonnes Machine Machine with counterweight and with lower mast section 60 70 Machine without counterweight and without lower mast section 34 50 Upper mast section with masthead 4 20 Counterweight 2 x 6 20 Equipment Rotary drive KDK 250 K 5 00 Kelly bar BK 25 394 4 56 10 10 Kelly bar BK 25 394 4 40 7 70 Casing drive adapter 1 500 mm 1 90 Drilling tool 1 350 mm 2 30 ...

Page 122: ...s the points provided for tying down are painted YELLOW On yellow undercarriages the points provided for tying down are painted BLUE In addition tying points wear a hook symbol and tell the max tension to be applied To tie down Tie the equipment down to the transporting vehicle in the professional manner and in compliance with national directives Principally the haulier in charge is responsible fo...

Page 123: ...kly Every 250 hours of operation or monthly Every 500 hours of operation or three months Every 1000 hours of operation or yearly Every 2000 hours of operation or yearly Every 3000 hours of operation or two years NOTE The specified intervals base on the hour meter of the base machine Normally the intervals are cumulative meaning that when the 1000 hours maintenance is due also the 10 50 250 and 500...

Page 124: ...tion be tween the piston eyes and the hy draulic cylinders and piston rods should undergo visual inspection prior to mounting to check for fis sures and other damage X Missing or loose bolts bolted connections X Missing or damaged safety devices such as fire extinguisher first aid kits warning signs X Leaks X Check for proper function of Controls and indicators X Safety devices such as emergency S...

Page 125: ...at the connecting bolts and screws between the mast sections if provided are firmly screwed in tighten screws X Replace connecting bolts between the mast sections if provided 5000 hrs Mast prop Ensure that bolt safety mecha nism and bolts are screwed in tightly X Lubricate pivot mount X Ladder on mast Check that the mounting bolts are firm X Check transition between the parts of the mast ladder X ...

Page 126: ...winch X Change oil Main winch X X Auxiliary winch X X Crowd winch X X Lubricate counter bearings Main winch X Auxiliary winch X Crowd winch X Ensure that mounting bolts of the winch trestles are firm tighten bolts X Replace mounting bolts of the winch trestles 10000 hrs Cylinders Clean piston rods X Check tightness of cylinder X Lubricate joints X Bearings and bearing pins Lubricate all bearings a...

Page 127: ...function X Rope hold down rollers Check parallel position to cable drum X Inspect for wear and damage X Rope sheaves Inspect for wear damage and if bearing gap is exceeded X Check sheaves are free to rotate X Check if bolts are secure X Check groove radii for deviation and edge formation X Put grease in lube nipples where fitted Rope sheaves with friction bearing Rope sheaves with roller bearings ...

Page 128: ...eck oil X Check if hollow shaft mounting bolts are securely fastened X X Check switch pressure X Nominal value 35 40 bar Change filter Line filter X X Oil pre cleaner X X Lubricate oil seal X Kelly driver guide flange shock absorber Check springs shock absorbers and buffer rings for damage X Check that the mounting bolts are firm X Check driver strips for wear X Cardan joint Check rubber buffers f...

Page 129: ...Hydraulic tank Check oil level X Change oil X X Take oil sample and check oil X Hose assemblies Have them inspected for damage by an expert X Filter element replacement Pilot control filters X X Or if contamination is indicated Return flow filters X X Leak oil filters X X Secondary filters X X Free fall filters X X Rotary drive filters X X Tank breather filter X Pressure accumulators Check preload...

Page 130: ...ly 250 h monthly 500 h 3 months 1000 h yearly 2000 h yearly 3000 h every 2 years Note Counterweight Check all fastening elements are present and firmly in place X Electrical system Batteries Check electrolyte level X Check cable connections X Fuses Check fuses X Filters Replace air filter on wiring cabinet X Only during running in period ...

Page 131: ...r damaged parts X Carry out a visual inspection of load bearing steel components e g centre bridge and crawlers to check for fissures and other damage X Perform a visual check of the crawler drive wheels tread rollers and travel gear to ensure they are firmly attached tighten if necessary X Travel gear Check oil level X Change oil X X Crawler tracks Check chain tension X Check that the mounting bo...

Page 132: ...bserve separate compressor manual Clean cooling ribs X Clean suction air filter X Replace suction air filter X Clean lubricating oil filter X Replace lubricating oil filter X Change oil X X Check maintenance unit X Drain condensate on compressor maintenance unit 70 l pressure accumulator X after every use Oxidation type catalytic converter Measure the counter pressure of the exhausts treated by th...

Page 133: ...rs joints 6 Boom pin 8 Mast pivot assembly pin 10 Mast pivot assembly joints 11 Boom cylinders joints 12 Mast supporting cylinder joint 13 Auxiliary winch bearing 20 Crowd winch bearing 26 Crawler guides 28 Swing gear bearing 31 Main winch bearing Every 250 Hours of operation 7 Supporting trestle pin 9 Mast support joint 15 Crowd cylinder joint 17 Crowd cylinder joint 22 Crowd rope tensioning cyli...

Page 134: ...ill preservation 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 turn the air conditioning on if equipped for a short while Slewing ring Preserve gear teeth From time to time during the standstill remove dust and inspect the surface of teeth and drive pinion for beginning corrosion clean and grease as required Teles...

Page 135: ...ydraulic 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 ...

Page 136: ...Leaks Damage or deformation of hose end fittings tightness impaired minor damage to the surface does not require replacement Hose slips out of end fitting Corrosion on the end fitting impairing the function and stability The hose is not assembled in compliance with instructions The storage and service life is exceeded Storage and service life Hoses and hose assemblies are to be stored in a cool an...

Page 137: ...tic lye or an abrasive CAUTION Serious accident hazard Immediately repair or replace cylinders that are not tight Every 50 operating hours or once a week grease the cylinder lugs holes for pins On cylinders that are kept extended during rest CAUTION Risk of corrosion damage in corrosion supporting environments The tasks specified below must be carried out without fail Once or twice a week rub down...

Page 138: ...ry hazard Before beginning to replace a filter element remove the pressure from the hydraulic system and allow it to cool down NOTE While the hydraulic oil is still cold it can happen that the contamination indication comes on for a little while Line filters 1 Free wheel filter 2 Leak oil filter 1 2 BK1007502 wmf Place a suitable container underneath the filter housing and unscrew the bot tom 3 Re...

Page 139: ...t 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 max min 1 2 3 B0000574 wmf Winches with sight glass Checking of the oil level can be performed with the winch in any position If the oil level has reached the lower lim...

Page 140: ...ing 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 max min 1 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 pl...

Page 141: ...s Position the 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 cylinder remove the pin from the wedge 15 Knock the wedge out 13 to release the rope and pull the rope out of the wedge Release the bolts from the clamping rail 11 on the winch 1 and remove the wedge Then put the wedge somewhere safe...

Page 142: ...sk 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 ...

Page 143: ...4 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 pre scribed 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 ...

Page 144: ...ce the wedge 15 has been mounted remove the jaw 16 from the rope tensioning cylinder again Thread the rope through the 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 Reduce the length of the overhanging rope to approx 30 cm Slightly tension the...

Page 145: ... only move the crowd sledge with another per son present to give directions Run the crowd sledge up and down several times CAUTION Danger of damaging the ropes Only retension the ropes when the crowd sledge is at the lower stop on the mast Position the crowd sledge at the lower stop on the mast Retension the ropes ...

Page 146: ...ge after an accidental drop of the Kelly bar 9 9 2 Rope Hold Down Rollers Every 50 operating hours or weekly Check rope hold down rollers for wear and proper function Check the roller is parallel to the drum of the winch Check the roller mounting bolts are properly in place and firm Adjust at tension screws until all springs are equal Do not tension worn out springs too much but replace them with ...

Page 147: ... in place in the fitting With poured rope fittings inspect for broken wires and corrosion directly where the rope exits the fitting With swaged on rope fittings inspect for broken wires next to the fitting cracks in the material and firm seizure of the rope CAUTION Danger of rope breaking If a defect is found on a rope fitting cut off the rope end and re fit it ...

Page 148: ...ope sheaves if greas ing will not do 9 9 4 1 Greasing Rope Sheaves Rope Sheave Type Prescribed interval Maintenance instructions Rope sheaves with friction bearings BM659821 jpg 10 Operating hours daily Rope sheaves with roller bearings BM659822 jpg 1000 Operating hours yearly CAUTION Risk of damaging the bearing sealing Grease during rotating rope sheave Fill in grease slowly to prevent squeeze o...

Page 149: ...ate 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 Re machine the groove or replace the sheave with a new one if the groove does no longer comply ...

Page 150: ...otary 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 ...

Page 151: ...h half way up the glass see fig CAUTION Risk of damaging the rotary drive 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 im mediately 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 th...

Page 152: ...ion While the drive is out of motion check the oil level The oil must reach half way up the glass see fig CAUTION Risk of damaging the planetary gears At all times watch for proper oil level Bj248503 wmf CAUTION Risk of damaging the planetary gears If the oil is cloudy water has intruded and the oil must be changed im mediately Drain and thoroughly flush the drive repeatedly with the new oil befor...

Page 153: ...e Place the rotary 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 1 and let the oil out 1 2 Kj248504 wmf CAUTION Danger of scalding Hot gear oil can cause severe injury Inspect magnets on all drain screws and on ...

Page 154: ...use petrol gasoline petroleum or diesel oil for rinsing here Allow the rinsing fluid to drain off completely Replace seals if 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 en gine and...

Page 155: ...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 Fit a plastic tube or hose of suitable size and length from the drain to the container Unscrew drain screws 1 and let the oil out 1 2 KG000512 wmf CAUTION Danger of scalding ...

Page 156: ...use petrol gasoline petroleum or diesel oil for rinsing here Allow the rinsing fluid to drain off completely Replace seals if 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 en gine and...

Page 157: ...se the lubricating effect so that the oil change intervals must be shortened correspon dingly Inspect the oil for water and dirt If the oil is found to be contaminated or water has intruded the seal rings must be checked and replaced as necessary Inspect the oil for solid particles abrasives The maximum permissible amount of foreign particles in the total oil fill of one gear box must not exceed 0...

Page 158: ...wmf 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 Do not put fingers into the bores NOTE Turning around the rotary drive enables checking all the bolts Unscrew mounting bolts found to be loose clean them and apply Loctite to threads reinstall and tension the ...

Page 159: ...ally only Unscrew mounting bolts found to be loose clean them and apply Loctite to threads reinstall and ten sion the bolts with the specified torque see below Bolt torque value Ma Nm Kelly driver mounting 1 Hex socket head bolts see Spare Parts List Guide flange mounting 2 Hex head bolts see Spare Parts List Set screws with nut see Spare Parts List Replacing the Kelly Driver and or Guide Flange C...

Page 160: ...rn 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 NOTE When fitting a new driver strip the play y should not exceed 0 5 mm Bolt torque value Ma Nm Kelly driver strips mounting Hex socket head bolts see Spare Parts List Hex socket head bolts with nuts see Spare Parts List x y A A B B 1 2 3 4 5 6 B B A A B000...

Page 161: ...ers 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 Where the remaining thickness X is found to be less than 15 mm replace with a new strip see below 4 A A B B 1 X 5 2 B B 3 B0000582 wmf To replace Unscrew bolts 2 and remove the tension plate 3 Pull out the strip 1 and install a new strip Re...

Page 162: ...ntil grease exits steadily along the whole circum ference arrow 3 4 1 2 3 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 dow...

Page 163: ...vided at all times 9 11 1 Routine Inspection Every 10 operating hours or daily With the uppercarriage positioned crosswise thoroughly clean crawlers free of mud and dirt Walk around inspect for wear damage and loss of oil especially on following com ponents Track pads 1 Track links 2 Carrier rollers 3 Front idlers 4 Track guides 5 Tread rollers 6 Crawler drive wheels 7 Gear cases 8 6 1 2 5 3 4 7 8...

Page 164: ...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 2 3 cm 1 1 5 m 2 3 cm 1 1 5 m 2 3 cm 1 1 5 m B0000680 wmf ...

Page 165: ...e cover plate 5 and clean the grease nipple 2 5 3 3 4 2 1 B0000725 wmf Put a high pressure grease gun to the grease nipple Work the grease gun until the proper track tension is obtained Check the track tension again after a short travel forward and backward and top up with more grease as necessary Reinstall the cover plate ...

Page 166: ...urized grease Unscrew the safety valve with great care only Retighten the safety valve when the proper track tension is obtained Check the track tension again after a short travel forward and backward Clean the nipple and surrounding free of grease Reinstall the cover plate WARNING Danger of injury due to pretensioned spring element compressible sili cone oil at 1500 to 2000 bar For safety reasons...

Page 167: ... 4 BK587502 wmf BK587440 jpg BM564683 jpg Bolted connection Bolt torque value Ma Nm Prescribed intervals in operating hours Track pad 1 570 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 ...

Page 168: ... 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 ...

Page 169: ...y take further details to the central lubrication system from the enclosed docu mentation NOTE Greases with proportions of solids like graphite or copper pastes may not be used To prevent soilings from getting in the grease and leading to obstruc tions the grease must be pressed via the lube nipples on the con tainer do not unscrew the lid The grease should be topped up until max 2 cm below the up...

Page 170: ...d con nections WARNING Serious accident hazard Replace the elements of bolted connections which have been opened up more than 25 times or which are corroded fissured deformed or have damaged threads Bolted connections of Mast pivot Winch trestles Roller brackets and Masthead Every 10000 hours of ordinary operation replace all elements used in the bolted connections WARNING Serious accident hazard ...

Page 171: ...nt check it is compatible with the previous one used The lubricants used must be fresh CAUTION 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 NOTE The lubricants listed in the lubricant tables of this manual are suitable for ambient temperatures from 20 ...

Page 172: ...Table Initial lubricant fill Application Specifica tion Viscosity grade Producer Name of product Qty litres Gear oils synthetic CLP HC Crawler drive gears ISO VG 220 SHELL Omala HD 220 2 x 6 0 Main winch ISO VG 220 SHELL Omala HD 220 15 0 Auxiliary winch ISO VG 220 SHELL Omala HD 220 3 0 Crowd winch ISO VG 220 SHELL Omala HD 220 8 0 Slewing Gear ISO VG 220 SHELL Omala HD 220 8 5 Rotary drive main ...

Page 173: ... VF 46 350 0 Hydraulic oil fixed biodegradable HEES Engine oil petroleum API CI 4 Engine SAE 15W 40 SHELL Shell Rimula Super 15W 40 18 9 Grease petroleum KP2N 20 NLGI Grade2 Multi purpose grease on lithium soap base Roller bearings friction bearings ARAL Aralub HLP 2 after every application Central Lubrication System Base machine BG equipment ARAL Aralub HLP 2 after every application Not used in t...

Page 174: ... Enersyn EP XF 150 BP Enersyn EP XF 220 CASTROL Tribol 1710 100 Tribol 1710 150 Tribol 1710 220 DEA Intor HCLP 150 Intor HCLP 220 ESSO Spartan Synthetic EP 220 FUCHS Renolin Unisyn CLP HC 100 Renolin Unisyn CLP HC 150 Renolin Unisyn CLP HC 220 KLÜBER Klübersynth EG 4 150 Klübersynth EG 4 220 MOBIL Mobilgear SHC XMP 150 Mobilgear SHC XMP 220 OPTIMOL Optigear Synth A 220 SHELL SHELL OMALA HD 100 SHE...

Page 175: ... Dexron II D Viscosity grade Producer Description At 40 C 38 mm 2 s at 100 C 7 1 mm 2 s ARAL ATF 22 SHELL Donax TA BP Autran DX II MOBIL ATF 220 AVIA AVIAFLUID ATF 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 ...

Page 176: ...rmal temperature ran ge e g Europe USA China high temperature range e g UAE Africa ARAL Vitam HF 32 Vitam VF 46 Vitam HF 46 Vitam VF 68 SHELL Tellus STX 32 TELLUS STX 46 TELLUS STX 68 BP Bartran HV 46 Bartran HV 68 MOBIL CASTROL CHEVRON ESSO FINA TEXACO STATOIL HydraWay HVXA 32 HydraWay HVXA 46 HydraWay HVXA 68 CONOCO ECOTERRA HVI 46 PANOLIN HLP UNI 46 HLP UNI 68 ADDINOL HVLPD 46 PETRONAS HVI 46 H...

Page 177: ...sis HVLP HC Viscosity grade ISO VG DIN 51519 at 40 C in mm 2 s Producer Description VG 32 VG 46 VG 68 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 conta...

Page 178: ...pplication Specification Hydraulic oil biodegradable HEES ISO 15380 VDMA 24568 Viscosity grade ISO VG DIN 51519 at 40 C in mm 2 s Producer Description VG 32 VG 46 VG 68 ARAL SHELL BP MOBIL AVIA CASTROL CHEVRON ESSO FINA GULF TEXACO TOTAL KLÜBER ELF FUCHS AGIP DEA PANOLIN HLP Synth 46 CAUTION Risk of damaging components Oils from different producers must not be mixed with one another ...

Page 179: ...al SAE 15W 40 AVIA Avia Multi HDC Plus SAE 15W 40 BP Vanellus C6 Global Plus SAE 10W 40 Vanellus C7 Global 15W 40 CASTROL RX super 15W 40 CHEVRON Chevron Delo 400 Multigrade SAE 15W 40 LUKOIL Lukoil 15W 40 TNK BP Revolux D3 ESSO XD 3 Extra 15W 40 FINA Fina Universal Plus XL SAE 15W 40 FUCHS Titan Truck Plus SAE 15W 40 GULF Gulf Super Duty Select SAE 15W 40 STATOIL MaxWay MOBIL Mobil Delvac MX 15W ...

Page 180: ...IN 51502 Greases petroleum KP2N 20 Description Producer Description Multipurpose grease on lithium soap base ARAL Aralub HLP 2 SHELL Retinax EP 2 BP Energrease LS EP 2 MOBIL Mobilux EP 2 AVIA CASTROL CHEVRON ESSO Beacon EP 2 FINA Marson EPL 2A GULF TEXACO TOTAL KLÜBER ELF Epexa 2 FUCHS Renolit MP AGIP Agip GR MUEP 2 DEA Glissando EP 2 PANOLIN EP Grease 2 ...

Page 181: ...cribe other torque values 10 2 1 Bolts with coarse pitch metric thread Strength class as per DIN ISO 898 8 8 10 9 12 9 Coarse pitch metric thread Bolt torque values MA Nm M 4 2 8 4 1 4 8 M 5 5 5 8 1 9 5 M 6 9 5 14 16 5 M 8 23 34 40 M 10 46 68 79 M 12 79 117 135 M 14 125 185 215 M 16 195 280 330 M 18 280 390 460 M 20 390 560 650 M 22 530 750 880 M 24 670 960 1120 M 27 1000 1400 1650 M 30 1350 1900 ...

Page 182: ...Fine pitch metric thread Bolt torque values MA Nm M 8x1 24 5 36 43 M 10x1 52 76 89 M 10x1 25 49 72 84 M 12x1 25 87 125 150 M 12x1 5 83 122 145 M 14x1 5 135 200 235 M 16x1 5 205 300 360 M 18x1 5 310 440 520 M 20x1 5 430 620 720 M 22x1 5 580 820 960 M 24x2 730 1040 1220 M 27x2 1070 1500 1800 M 30x2 1490 2120 2480 M 33x2 2000 2800 3300 M 36x3 2500 3500 4100 ...

Page 183: ...8 6 24 1011 6 12 1019 2 25 1025 2 61 1022 1 Measures for Output W kW kpm s PS kcal s kcal h 1 103 981 735 5 4187 1 16 10 3 1 9 81 10 3 0 7355 4 19 1 6 10 3 0 102 102 1 75 427 0 119 1 36 10 3 1 36 1 33 10 2 1 5 69 1 58 10 3 2 39 10 4 0 239 2 34 10 3 0 1757 1 2 78 10 4 0 86 860 8 43 632 3600 1 Measures for Pressure at atm bar N m Torr Psi 1 1 033 1 02 1 02 10 5 1 36 10 3 0 070 0 968 1 0 987 9 87 10 ...

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