Bauer BG 25 Instruction Manual
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Bauer BG 25 Instruction Manual

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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

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Summary of Contents for Bauer BG 25

  • Page 1 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...

  • Page 2: Preface

    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 +49 8252 97-2586...
  • Page 3 Sollten Sie die in dieser Betriebsanleitung verwendete Sprache nicht verste- hen, darf das Gerät / die Anlage von Ihnen nicht in Betrieb genommen wer- den. Kontaktieren Sie bitte in so einem Fall den Kundendienst der BAUER Maschinen GmbH und bestellen Sie eine Betriebsanleitung in einer für Sie verständlichen Sprache.
  • Page 4 Si vous ne comprenez pas la langue utilisée dans ce manuel d'instructions, vous ne devez pas mettre en service l'appareil/l'installation. Dans ce cas, veuillez contacter le service après -vente de BAUER Maschinen GmbH et commandez u manuel d'utilisation rédigé dans une langue compréhensibles pour vous.
  • Page 5 Als u de taal van deze gebruiksaanwijzing niet machtig bent, mag het appa- raat / 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.
  • Page 6 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 ma- nual de utilizare în limba dumneavoastră.
  • Page 7 Če jezika, uporabljenega v teh navodilih za uporabo, ne razumete, ne smete aparata / naprave poganjati. V takšnem primeru stopite v stik s servisno službo podjetja BAUER Maschinen GmbH in naročite navodila za uporabo v jeziku, ki ga razumete. Telefon...
  • Page 8 The "Safety Information" must be fol- lowed at all times. Also, pay attention to and follow all the instructions contained in the attached docu- ments (Appendix ___) of the component manufacturers. BG 25 / 2011 / 2254_BG25_en_0000498763_V01...
  • Page 9 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.

  • Page 10: Table Of Contents

    STABILITY ..........................2 - 6 2.5.1 Guidelines for Stability ......................2 - 6 2.5.2 Stability for BG 25 # 2254 - Kelly BK 25/394/4/56 ..............2 - 7 2.5.2.1 Load Capacity Chart ....................... 2 - 7 2.5.2.2 Weights / Centres of Gravity - Drilling Distance 3.39 m ............2 - 8 2.5.3...
  • Page 11 Lifting / Lowering ........................5 - 14 5.7.2 To Operate with Freewheel ....................5 - 16 DEPTH MEASURING CONTROL ..................5 - 17 5.8.1 To Reset the Depth Measuring ..................... 5 - 17 CROWD CONTROL ......................5 - 18 BG 25 / 2011 / 2254_BG25_en_0000498763_V01...
  • Page 12 Removing the Ropes ......................7 - 26 7.8.3.1 Removing the Main and Auxiliary Rope ................7 - 26 7.8.3.2 Removing the Upper Crowd Rope ..................7 - 27 7.8.4 Disassembling the Mast ....................... 7 - 28 BG 25 / 2011 / 2254_BG25_en_0000498763_V01...
  • Page 13 Changing the Oil ........................9 - 31 9.10.3.1 Main Gear ..........................9 - 31 9.10.3.2 Planetary Gears ........................9 - 33 9.10.4 Oil Sampling ......................... 9 - 35 9.10.5 Hollow Shaft Mounting Bolts ....................9 - 36 BG 25 / 2011 / 2254_BG25_en_0000498763_V01...
  • Page 14 BOLT TORQUE VALUES ....................10 - 11 10.2.1 Bolts with coarse-pitch metric thread .................. 10 - 11 10.2.2 Bolts with fine-pitch metric thread ..................10 - 12 10.3 CONVERSION TABLE ....................... 10 - 13 BG 25 / 2011 / XIII 2254_BG25_en_0000498763_V01...

  • Page 15: About The Manual

    .. / .. / ..Certification: THIS MANUAL WAS PUBLISHED IN 02.2011 THE CHAPTERS OF THIS MANUAL DESCRIPTION SAFETY 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...
  • Page 16 / or damage to the equipment if the instructions given in the manual are ignored or not correctly followed. CAUTION "Note" is used to highlight an operation, assembly or maintenance procedure. In general, observance of the information here will facilitate the work. NOTE BG 25 / 2011 / 2254_BG25_en_0000498763_V01...

  • Page 17: Nameplates

    Vorschubkraft pulling force pushing power max. Druck Betriebsdruck 2001 max. pressure working pressure Gesamtgewicht Arbeitspannung total weight working voltage Sachkundigenprüfung CE - Zeichen Motorleistung Frequenz expert test CE sign engine power frequency B0000551.wmf BK786502.wmf BG 25 / 2011 / 2254_BG25_en_0000498763_V01...

  • Page 18: After Sales Service

    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 / XVII 2254_BG25_en_0000498763_V01...

  • Page 19: Warranty Terms

    - Components and operating systems must not be dismantled or repaired at any 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.
  • Page 20 A) Liabilities and Responsibilities of BAUER – BAUER will supply spare parts required for carrying out repairs to BAUER equipment under warranty to the Client. – Spare parts will be delivered c.i.f. (cost, insurance, freight) to the Client. – If necessary, BAUER will also provide personnel for carrying our repairs under warranty.

  • Page 21: Defects Liability Claim

    Estimated additional costs: Date Name of claimant Signature Company (please print) 4. For internal use only (to be filled in by BAUER) Subject to warranty? If yes, give order number: If no, give reasons: Further reports: Further actions: Return of damaged parts by:...

  • Page 22: Personalanforderung / Staff Request

    Auszuführende Arbeiten / Works to be carried out: Besonderheiten / Special requirements: Ersatzteile / Spare parts: Kommunikation auf der Baustelle /Communication on jobsite: deutsch/German englisch/English Landessprache/Language country Datum / Date: Unterschrift / Signature: BAUER Maschinen GmbH  86529 Schrobenhausen  Tel. 0 82 52/97-0 910.097.1+2BMA 08/2008...

  • Page 23: Registrierung Betreiber Und Gerät/ Owner And Equipment Registration

    We would like to offer the equipment owner an optimum service as regards 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.

  • Page 24: Description

    Instruc- tion Manual. The equipment shall not be used after any such modifications are made unless such use after modification has been approved in writing by BAUER Maschinen GmbH as set forth below.
  • Page 25 BAUER Maschinen GmbH in writing. To obtain such an authorization a Change Request as shown below must be submitted to BAUER Maschinen GmbH.
  • Page 26 The owner requests a technical inspection of the equipment. 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/ Name: Datum/Date:...

  • Page 27: Components

    Kelly equipment 40 Drilling tool 41 Rotary drive 42 Casing drive adapter 43 Shock absorber 44 Cardan joint BK000514.wmf 45 Kelly drivers 46 Kelly bar *) does not exist with this version BG 25 / 2011 / 1 - 4 2254_BG25_en_0000498763_V01...

  • Page 28: Components Description

    Generates the crowd forces. Z) for rig fitted with cylinder crowd V) for mast lowering to the front S) for rig fitted with rope crowd H) for mast lowering to the rear BG 25 / 2011 / 1 - 5 2254_BG25_en_0000498763_V01...
  • Page 29 Consists of telescoping tubes the total length of which determines the achievable depth of the bore. Kelly bar (Kelly) It transfers torque from the rotary drive to the drill- ing tool. BG 25 / 2011 / 1 - 6 2254_BG25_en_0000498763_V01...

  • Page 30: Safety

    OFF position. - To prevent abuse and unauthorised starting of the equipment, shut it down, remove the ignition key and lock the cab whenever you leave the equipment unattended. BG 25 / 2011 / 2 - 1 2254_BG25_en_0000498763_V01...

  • Page 31: Safety Devices

    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) BK786505.wmf BG 25 / 2011 / 2 - 2 2254_BG25_en_0000498763_V01...

  • Page 32: Fire Extinguisher

    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 / 2 - 3 2254_BG25_en_0000498763_V01...

  • Page 33: Limit Switches

    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 / 2 - 4 2254_BG25_en_0000498763_V01...

  • Page 34: Fall Protection Equipment

    Never work with slack lanyards or lifeline. Be careful that lifeline and ring (2) are in proper position at all times. Lanyards must be snapped on directly to D-rings (5) on harness. *) Not used in this version BG 25 / 2011 / 2 - 5 2254_BG25_en_0000498763_V01...

  • Page 35: Stability

    – Upper 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 / 2 - 6 2254_BG25_en_0000498763_V01...

  • Page 36: Stability For Bg 25 # 2254 - Kelly Bk 25/394/4/56

    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 Mast extension --- m --- t Counterweight 6.20 + 6.20 t Kelly BK 25/394/4/56 10.10 t  1.90 t Casing drive adapter 1,500 mm ...

  • Page 37: Weights / Centres Of Gravity - Drilling Distance 3.39 M

    3.39 19.50 B0000922.wmf Undercarriage Dimensions Length of crawler tread 4.62 Track gauge, extended 3.68 Width of track shoes 0.70 B0000929.wmf *) Drilling distance = centre distance from machine to drilling tool BG 25 / 2011 / 2 - 8 2254_BG25_en_0000498763_V01...

  • Page 38: Stability For Bg 25 # 2254 - Kelly Bk 25/394/4/40

    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 Mast extension --- m --- t Counterweight 6.20 + 6.20 t Kelly BK 25/394/4/40 7.70 t  1.90 t Casing drive adapter 1,500 mm ...

  • Page 39: Weights / Centres Of Gravity - Drilling Distance 3.39 M

    3.39 19.50 B0000922.wmf Undercarriage Dimensions Length of crawler tread 4.62 Track gauge, extended 3.68 Width of track shoes 0.70 B0000929.wmf *) Drilling distance = centre distance from machine to drilling tool BG 25 / 2011 / 2 - 10 2254_BG25_en_0000498763_V01...

  • Page 40: Permissible Wind Speed

    Minor damage to buildings (roof tiles and chimney hoods are ripped off), on the sea strong gale 20.8 - 24.4 75 - 88 waves are very high and the visibility is ob- structed by spray BG 25 / 2011 / 2 - 11 2254_BG25_en_0000498763_V01...

  • Page 41: Technical Specifications

    TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS DIMENSIONS 3.1.1 Kelly Equipment BK 25/394/4/56 Dimensions in [mm] 4620 BK22545001.wmf BG 25 / 2011 / 3 - 1 2254_BG25_en_0000498763_V01...

  • Page 42: Kelly Equipment Bk 25/394/4/40

    TECHNICAL SPECIFICATIONS 3.2.1 Kelly Equipment BK 25/394/4/40 Dimensions in [mm] 4620 BK22545000.wmf BG 25 / 2011 / 3 - 2 2254_BG25_en_0000498763_V01...

  • Page 43: Equipment Specifications

    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 25/394/4/40 80.00 tonnes BG 25 / 2011 / 3 - 3 2254_BG25_en_0000498763_V01...
  • Page 44 Length of upper/lower rope without mast extension 65 / 60 m Crowd speed: "Fast crowd up" 21.4 m/min "Fast crowd down" 21.4 m/min "Slow crowd up" 5.9 m/min "Slow crowd down" 5.9 m/min BG 25 / 2011 / 3 - 4 2254_BG25_en_0000498763_V01...

  • Page 45: Rotary Drive Specifications

    = 205 kW = 2 x 250 l/min i = 26.18 high torque low torque Drehzahl n [1/min] / Speed n [rpm] Drehzahl n [1/min] / Speed n [rpm] BK832508.wmf BK832507.wmf BG 25 / 2011 / 3 - 5 2254_BG25_en_0000498763_V01...

  • Page 46: Drilling Specifications

    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 / 3 - 6 2254_BG25_en_0000498763_V01...

  • Page 47: Rope Specifications

    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 BG 25 / 2011 / 3 - 7 2254_BG25_en_0000498763_V01...

  • Page 48: Auxiliary Rope

    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 BG 25 / 2011 / 3 - 8 2254_BG25_en_0000498763_V01...

  • Page 49: Crowd Ropes

    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 BG 25 / 2011 / 3 - 9 2254_BG25_en_0000498763_V01...

  • Page 50: Noise Emission

    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. BG 25 / 2011 / 3 - 10 2254_BG25_en_0000498763_V01...

  • Page 51: Exposure To Vibration

    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.

  • Page 52: Controls And Indicators

    10.4 In Kelly/CFA mode: Rotary drive rotate left = Continuous Flight Auger 10.5 Rigging mode + Backstay cylinders selected: = Casing Oscillator Right backstay cylinder extend = Not used in this version BG 25 / 2011 / 4 - 1 2254_BG25_en_0000498763_V01...

  • Page 53: Base Machine Control Console

    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 BK19035002.wmf BG 25 / 2011 / 4 - 2 2254_BG25_en_0000498763_V01...

  • Page 54: Control Panel

    12 Crowd rope tension Freewheel/Free-fall released 13 In Drilling mode: 28 Indicator: Left backstay cylinder retract Swing brake lock 14 In Drilling mode: Right backstay cylinder retract *) Not used in this version BG 25 / 2011 / 4 - 3 2254_BG25_en_0000498763_V01...

  • Page 55: Monitor Unit

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

  • Page 56: Operation

    CAUTION 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 / 5 - 1 2254_BG25_en_0000498763_V01...

  • Page 57: Uppercarriage Swing

    To release the swing brake: ● Press button (18). BK19035004wmf Swing brake lock:  The indicator light on Control Panel comes on. BK19035010wmf Swing brake unlock:  The indicator light on Control Panel goes out. BG 25 / 2011 / 5 - 2 2254_BG25_en_0000498763_V01...

  • Page 58: Swing Control

    Letting the lever return to centre makes the swing slowly come to a stop, in hydraulic way. A quicker stop can be implemented by carefully moving the lever in the opposed direc- tion. BG 25 / 2011 / 5 - 3 2254_BG25_en_0000498763_V01...

  • Page 59: Mast Repositioning

    When this is the case: unlock the Kelly (if locked) and spool out rope CAUTION from the main winch. Immediately replace any damaged components of the overload protec- tion. BG 25 / 2011 / 5 - 4 2254_BG25_en_0000498763_V01...

  • Page 60: Mast Auto Reset To Vertical

    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. NOTE BG 25 / 2011 / 5 - 5 2254_BG25_en_0000498763_V01...

  • Page 61: Mast Repositioning By Manual Control

    Extend right backstay cylinder by  Retract left backstay cylinder by  Retract right backstay cylinder by B0000504.wmf Extending the short backstay cylinders by the control panel is possible in drilling and rigging mode. NOTE BG 25 / 2011 / 5 - 6 2254_BG25_en_0000498763_V01...
  • Page 62 BK19035019.wmf Raising the mast: B0000504.wmf  Move left / right control lever back. BK19035020.wmf Extending the long backstay cylinders by the control levers only is poss- ible in rigging mode. NOTE BG 25 / 2011 / 5 - 7 2254_BG25_en_0000498763_V01...

  • Page 63: To Adjust The Drill Distance

     Extend boom cylinders by Decreasing machine’s distance to the bore:  Retract boom cylinders by To adjust the mast parallel (see fig.), the mast inclination must be readjusted. NOTE B0000505.wmf BG 25 / 2011 / 5 - 8 2254_BG25_en_0000498763_V01...

  • Page 64: Mast Prop Control

    ● Press button and hold down. BK19035006.wmf To retract the mast prop: ● Press button and hold down. BK19035007.wmf Releasing one of these buttons too soon interrupts the action. NOTE *) Not used in this version BG 25 / 2011 / 5 - 9 2254_BG25_en_0000498763_V01...

  • Page 65: Travelling With The Rig

     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. BG 25 / 2011 / 5 - 10 2254_BG25_en_0000498763_V01...

  • Page 66: Travelling Up And Down Slopes

     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 BG 25 / 2011 / 5 - 11 2254_BG25_en_0000498763_V01...

  • Page 67: Rotary Drive Control

    Should a locking area of the outer Kelly be in the Kelly driver, the rotary CAUTION 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 / 5 - 12 2254_BG25_en_0000498763_V01...
  • Page 68 With the key-operated switch (1) set to "OFF" in the control cabinet, the 1st gear of high torque is automatically blocked. And button (17) on the control panel is out of function. NOTE return flow BK19025002.wmf BG 25 / 2011 / 5 - 13 2254_BG25_en_0000498763_V01...

  • Page 69: Winch Control

    CAUTION Risk of damaging the rig! Hoist limiters are out of function during rigging operations so that the winches must be controlled with great care. CAUTION BG 25 / 2011 / 5 - 14 2254_BG25_en_0000498763_V01...
  • Page 70 (see fig): panel is selected (see fig.): Winch selection: Set switch on control panelto Main winch (1) or to Auxiliary winch (2) (see fig.). Control of selected winch B0000702.wmf BG 25 / 2011 / 5 - 15 2254_BG25_en_0000498763_V01...

  • Page 71: To Operate With Freewheel

    NOTE Freewheel deactivation:  Release the foot switch, or  Lift / lower by the winch control lever.  Turn key-operated switch (4) back to position of Freewheel Mode "OFF". BG 25 / 2011 / 5 - 16 2254_BG25_en_0000498763_V01...

  • Page 72: Depth Measuring Control

    Depth 2 = Depth of crowd 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. NOTE BG 25 / 2011 / 5 - 17 2254_BG25_en_0000498763_V01...

  • Page 73: Crowd Control

    Do not use the fast crowd for drilling down. Or, the drilling equipment will CAUTION be damaged. WARNING! Squashing hazard! Do not reach into the moving area of the crowd sledge. BG 25 / 2011 / 5 - 18 2254_BG25_en_0000498763_V01...

  • Page 74: Manual Control Of The Crowd

    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. CAUTION BG 25 / 2011 / 5 - 19 2254_BG25_en_0000498763_V01...

  • Page 75: To Use The Main Winch In Combination With Crowd

    Where there is no such monitoring automatic, the operator himself is NOTE responsible for not endangering the capacities of the rig when forces sum up. BG 25 / 2011 / 5 - 20 2254_BG25_en_0000498763_V01...

  • Page 76: Using The Engine Diagnostic System

    (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 above). BK19035024.wmf BG 25 / 2011 / 5 - 21 2254_BG25_en_0000498763_V01...

  • Page 77: Central Lubrication Control

    (switch in the cab). NOTE A manufacturer's documentation on the Central Lubrication System is supplied in the Appendices of this manual. NOTE *) Not used in this version BG 25 / 2011 / 5 - 22 2254_BG25_en_0000498763_V01...

  • Page 78: Start-Up / Shut-Down

    ● Check all 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 / 6 - 1 2254_BG25_en_0000498763_V01...

  • Page 79: Daily Start-Up

    Risk of damaging the engine! Allow cold engine to warm up at idle speed for approx. 10 minutes! CAUTION  Move the safety stick of the pilot control to "ON" position. BG 25 / 2011 / 6 - 2 2254_BG25_en_0000498763_V01...

  • Page 80: Selecting The Engine Operating Mode

    The "Heavy duty work mode" indicator lights up. ● Press button (3). Indicator "M" lights up. BK00004000.jpg For more details, please consult the additional OPERATOR'S MANUAL supplied by the manufacturer. NOTE BG 25 / 2011 / 6 - 3 2254_BG25_en_0000498763_V01...

  • Page 81: Safety Tests Before Starting To Work

    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 "OFF" position. All hydraulic functions must be blocked. The diesel engine remains on. BG 25 / 2011 / 6 - 4 2254_BG25_en_0000498763_V01...

  • Page 82: Checking The End Limiters

     Hold left end limiter depressed and extend right backstay cylinder.  Right backstay cylinder must not extend.  Hold right end limiter depressed and extend left backstay cylinder.  Left backstay cylinder must not extend. BG 25 / 2011 / 6 - 5 2254_BG25_en_0000498763_V01...

  • Page 83: Shut-Down

     Set the battery main switch to "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 / 6 - 6 2254_BG25_en_0000498763_V01...

  • Page 84: Rigging / De-Rigging

    During rigging operations, the uppercarriage must be in line with the undercarriage and be interlocked with the same. CAUTION  Select Rigging mode:  Switch (1) on the control panel (see fig.). BK14885013.wmf BG 25 / 2011 / 7 - 1 2254_BG25_en_0000498763_V01...

  • Page 85: Wax Removal

    The treatment must be repeated until all the equipment is totally free of NOTE wax. Risk of damaging components! Detergents used must not be harmful to seals etc. Check detergents for their areas of application prior to use. CAUTION BG 25 / 2011 / 7 - 2 2254_BG25_en_0000498763_V01...

  • Page 86: Extending The Crawlers

    ● Reinstall the pins (1) at the lock posi- tion B, and secure the pins with retain- ers (2). BV737516.jpg ● Repeat the procedure with the other crawler. BG 25 / 2011 / 7 - 3 2254_BG25_en_0000498763_V01...

  • Page 87: Mounting The Counterweight

    Risk of damaging components! Counterweights consisting of several parts are to be transported in upright position. CAUTION For further information please refer to the documentation supplied with the base machine. NOTE BG 25 / 2011 / 7 - 4 2254_BG25_en_0000498763_V01...
  • Page 88 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 / 7 - 5 2254_BG25_en_0000498763_V01...
  • Page 89 BK00004003.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). BK00004004.jpg BG 25 / 2011 / 7 - 6 2254_BG25_en_0000498763_V01...

  • Page 90: Mounting The Mast

     Install the pin and secure it.  Retract backstay cylinders and raise the mast enough to enable the transport sup- ports (4) to be removed from the lower mast section. BM339512.wmf BG 25 / 2011 / 7 - 7 2254_BG25_en_0000498763_V01...

  • Page 91: Assembling The Mast Sections

    ● Install the pins and secure. ● Retract backstay cylinders to raise the lower mast section until flange faces meet. Risk of damaging components! Take care the locating pins are properly in place! CAUTION BG 25 / 2011 / 7 - 8 2254_BG25_en_0000498763_V01...
  • Page 92 (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 BM400462.jpg its rail. Precisely adjust transfer points. BG 25 / 2011 / 7 - 9 2254_BG25_en_0000498763_V01...

  • Page 93: Installing The Ropes

     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 BM091514.wmf BG 25 / 2011 / 7 - 10 2254_BG25_en_0000498763_V01...

  • Page 94: Installing The Upper Crowd Rope

     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 / 7 - 11 2254_BG25_en_0000498763_V01...

  • Page 95: Mounting Crowd Stroke Limiters

    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 / 7 - 12 2254_BG25_en_0000498763_V01...

  • Page 96: Raising The Mast

    Rig tipping hazard! Do not allow the mast to drift aside. The backstay cylinders must be re- tracted in a uniform manner and without interruptions. CAUTION BG 25 / 2011 / 7 - 13 2254_BG25_en_0000498763_V01...

  • Page 97: Mounting Retaining Clamps

     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. BK331531.wmf BG 25 / 2011 / 7 - 14 2254_BG25_en_0000498763_V01...

  • Page 98: Assembly Of Work Attachments

    Components of work attachments are extremely heavy. The operator must keep in view the person performing the assembly throughout the whole procedure. BG 25 / 2011 / 7 - 15 2254_BG25_en_0000498763_V01...

  • Page 99: Assembly Of Kelly Equipment

    7.6.1.1 Mounting the Rope Swivel 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. CAUTION The swivel must be designed for the max. lifting force of the winch used.

  • Page 100: Mounting The Rotary Drive

    9/SP-L Flush oil View A: Ansicht A View A 12/P Control oil 6/B2 9/SP-L 5/A2 4/B1 3/A1 12/P Hydraulic lines and connections wear matching identifications. NOTE B0000808.wmf  Connect electric lines. BG 25 / 2011 / 7 - 17 2254_BG25_en_0000498763_V01...

  • Page 101: Mounting Kelly Guidance

     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. B0000707.wmf *) Not used in this version BG 25 / 2011 / 7 - 18 2254_BG25_en_0000498763_V01...
  • Page 102  Remove the pins (3).  Swivel the arms (2) towards the mast (8) by 180°.  Reinstall the pins (3) and secure them. B0000709.wmf *) Not used in this version BG 25 / 2011 / 7 - 19 2254_BG25_en_0000498763_V01...

  • Page 103: Mounting The Kelly

     By the main winch, lift the Kelly as shown to right and at the same time travel with the machine towards the Kelly. B0000622.wmf Risk of damaging components! Keep the main rope vertical at all times. CAUTION BG 25 / 2011 / 7 - 20 2254_BG25_en_0000498763_V01...
  • Page 104  Mount drilling tool to Kelly with two pins. Risk of damaging components! At all times, use TWO pins to mount the drilling tool, and do not forget to secure the pins. CAUTION BG 25 / 2011 / 7 - 21 2254_BG25_en_0000498763_V01...

  • Page 105: Mounting Casing Oscillator

    BM779414.jpg Oscillation [P] Locking Oscillation [R] Unlocking Unclamping Leak oil [T] (optional) Clamping PST Pilotoil (optional) Lowering Electric connection (optional) Lifting *) Not used in this version BG 25 / 2011 / 7 - 22 2254_BG25_en_0000498763_V01...

  • Page 106: Disassembly Of Work Attachments

    Components of work attachments are extremely heavy. The operator must keep in view the person performing the disassembly throughout the whole procedure. BG 25 / 2011 / 7 - 23 2254_BG25_en_0000498763_V01...

  • Page 107: Disassembly Of Kelly Equipment

    On rotary drive fitted with an auxiliary lifting lug, the rig's auxiliary rope (4) may be used additionally to help align NOTE the rotary drive.  Lift off and put the rotary drive down on ground. B0000700.wmf BG 25 / 2011 / 7 - 24 2254_BG25_en_0000498763_V01...

  • Page 108: Disassembling The Mast

    The mast lowers. Rig tipping hazard! Take care not to let the mast drift aside during the lowering. The back- stay cylinders must be extended uniformly and without interruptions. CAUTION BG 25 / 2011 / 7 - 25 2254_BG25_en_0000498763_V01...

  • Page 109: Removing The Ropes

     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 / 7 - 26 2254_BG25_en_0000498763_V01...

  • Page 110: Removing The Upper Crowd Rope

    Knock the wedge (13) out, to relieve the rope, and pull the rope out of the socket. ● Remove the entire rope. ● Coil the rope loosely and fix it to the lower end of the mast. BG 25 / 2011 / 7 - 27 2254_BG25_en_0000498763_V01...

  • Page 111: Disassembling The Mast

    ● Travel in reverse with machine and disengage upper mast section from lower mast section. Risk of corrosion! Corrosion protect flange faces with grease if the storage or transport of the rig is expected to take long. CAUTION BG 25 / 2011 / 7 - 28 2254_BG25_en_0000498763_V01...

  • Page 112: Lowering The Trestle

     Lower the lower mast section until the transport support rests on the ground.  Pull pins (2) out of trestle. Risk of damaging components! Prevent the pins dropping down. CAUTION  Retract backstay cylinders until trestle (1) rests on bearing point (3). BK097505.wmf BG 25 / 2011 / 7 - 29 2254_BG25_en_0000498763_V01...

  • Page 113: Removing The Counterweight

    Counterweights consisting of several parts are to be transported in upright position. During their intermediate storage, the counterweights must be secured CAUTION against tipping. For further information please refer to the documentation supplied with the base machine. NOTE BG 25 / 2011 / 7 - 30 2254_BG25_en_0000498763_V01...
  • Page 114  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. BK00004004.jpg BG 25 / 2011 / 7 - 31 2254_BG25_en_0000498763_V01...
  • Page 115  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. BK00004002.jpg BG 25 / 2011 / 7 - 32 2254_BG25_en_0000498763_V01...

  • Page 116: Retracting The Crawlers

    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 / 7 - 33 2254_BG25_en_0000498763_V01...

  • Page 117: Transport

     The haulier in charge is responsible for the transport of the equipment, the machine and accessories.  The haulier should be informed of the transport dimensions and weights and the route.  A road permit must be asked for. BG 25 / 2011 / 8 - 1 2254_BG25_en_0000498763_V01...

  • Page 118: Measures To Take For Transport

    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 / 8 - 2 2254_BG25_en_0000498763_V01...

  • Page 119: Driving On / Off A Lowloader

    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°. CAUTION BG 25 / 2011 / 8 - 3 2254_BG25_en_0000498763_V01...

  • Page 120: Lifting Points

    TRANSPORT LIFTING POINTS BK1162502.wmf BG 25 / 2011 / 8 - 4 2254_BG25_en_0000498763_V01...

  • Page 121: Transport Data

    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 BG 25 / 2011 / 8 - 5 2254_BG25_en_0000498763_V01...

  • Page 122: Tying 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 / 8 - 6 2254_BG25_en_0000498763_V01...

  • Page 123: Maintenance

    "Maintenance and Repair Log". This is to be done by the per- son who carried out the job and be signed by himself and a foreman. CAUTION In case of a warranty claim, BAUER shall have the right to consult the log. BG 25 / 2011 / 9 - 1...

  • Page 124: Maintenance Plan

    - Check for missing or loose pin/screw connections - Check the locks can move easily and are working properly Inspection by competent engineer * Only during running-in period Not supplied with this version BG 25 / 2011 / 9 - 2 2254_BG25_en_0000498763_V01...

  • Page 125: Components

    - Lubricate mast pivot - Lubricate mounting bolts - Check flange bolts are firmly screwed in, tighten bolts - Replace flange bolts 10000 hrs * Only during running-in period Not supplied with this version BG 25 / 2011 / 9 - 3 2254_BG25_en_0000498763_V01...
  • Page 126 - Clean piston rods - Check tightness of cylinder - Lubricate joints Bearings and bearing pins - Lubricate all bearings and bearing pins that are equipped with lube nipples * Only during running-in period BG 25 / 2011 / 9 - 4 2254_BG25_en_0000498763_V01...
  • Page 127 Rope roller brackets - Ensure that mounting bolts of the turning blocks are firm, tighten bolts - Replace mounting bolts of the 10000 hrs turning blocks * Only during running-in period BG 25 / 2011 / 9 - 5 2254_BG25_en_0000498763_V01...

  • Page 128: Work Equipment

    - Inspect for wear and damage Drilling tool - Clean and check for wear and damage CFA/FOW/DKS equipment ** - Lubricate concreting head * Only during running-in period ** Not supplied with this version BG 25 / 2011 / 9 - 6 2254_BG25_en_0000498763_V01...

  • Page 129: Uppercarriage

    Oil cooler - Clean - Check for damage Swing mechanism - Grease external slewing ring teeth - Lubricate slewing ring and rotor bearing - Tighten up screws * Only during running-in period BG 25 / 2011 / 9 - 7 2254_BG25_en_0000498763_V01...
  • Page 130 Electrical system Batteries - Check electrolyte level - Check cable connections Fuses - Check fuses Filters - Replace air filter on wiring cabinet * Only during running-in period BG 25 / 2011 / 9 - 8 2254_BG25_en_0000498763_V01...

  • Page 131: Undercarriage

    - Change oil Crawler tracks - Check chain tension - Check that the mounting bolts for the crawler track shoes are firm Telescopic guide - Clean and grease * Only during running-in period BG 25 / 2011 / 9 - 9 2254_BG25_en_0000498763_V01...

  • Page 132: Optional Equipment

     Inspect for wear and damage  Checking the Oil Level Before each use  Replace the breather filter  Check ISO meter Before each use * Only during running-in period BG 25 / 2011 / 9 - 10 2254_BG25_en_0000498763_V01...

  • Page 133: Lubrication Plan

    13 Auxiliary winch bearing 23 Crowd rope sheave 20 Crowd winch bearing 26 Crawler guides * 28 Swing gear bearing 31 Main winch bearing Grease manually **) Not used in this version BG 25 / 2011 / 9 - 11 2254_BG25_en_0000498763_V01...

  • Page 134: Maintenance During Longer Periods Of Standstill

     From time to time during the standstill, remove dust and inspect the surface of teeth and drive pinion for beginning corrosion; clean and grease as required. Telescoping guides on undercarriage (only with extendible crawlers)  Preserve the telescoping surfaces with grease. BG 25 / 2011 / 9 - 12 2254_BG25_en_0000498763_V01...

  • Page 135: Hydraulic System

    This applies to pressure tanks in particular. 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. CAUTION BG 25 / 2011 / 9 - 13 2254_BG25_en_0000498763_V01...

  • Page 136: Hose Assemblies

    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 / 9 - 14 2254_BG25_en_0000498763_V01...

  • Page 137: Hydraulic Cylinders

     Once or twice a week, rub down piston rods with hydraulic oil, or retract and extend the rods repeatedly.  Before a longer standstill, preserve piston rods with acid free grease. BG 25 / 2011 / 9 - 15 2254_BG25_en_0000498763_V01...

  • Page 138: Filter Replacement

     Clean top and bottom of housing.  Install new filter element in top of hous- ing.  Reinstall bottom on top and screw tight. B0000623.wmf BG 25 / 2011 / 9 - 16 2254_BG25_en_0000498763_V01...

  • Page 139: Winches

    ("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 B0000846.wmf tight. BG 25 / 2011 / 9 - 17 2254_BG25_en_0000498763_V01...

  • Page 140: Changing Gear Oil

     Reinstall the screw plug (1). B0000846.wmf  Refill with new oil.  Check the oil level.  Reinstall the screw plug (2) and screw it down tight. BG 25 / 2011 / 9 - 18 2254_BG25_en_0000498763_V01...

  • Page 141: Replacing The Upper Crowd Rope

     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.  Remove the entire rope. BG 25 / 2011 / 9 - 19 2254_BG25_en_0000498763_V01...
  • Page 142 (the reeving chart in the spare parts list has more details on this). Danger of the new rope breaking! Check rope sheaves and pin retainers for damage. CAUTION B00005424.png BG 25 / 2011 / 9 - 20 2254_BG25_en_0000498763_V01...
  • Page 143  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 sledge.  Feed the rope over the right rope sheave (8) at the top of the mast. BG 25 / 2011 / 9 - 21 2254_BG25_en_0000498763_V01...
  • Page 144  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 ropes by retracting the rope tensioning cylinder. BG 25 / 2011 / 9 - 22 2254_BG25_en_0000498763_V01...
  • Page 145 Only retension the ropes when the crowd sledge is at the lower stop on the mast. CAUTION  Position the crowd sledge at the lower stop on the mast.  Retension the ropes. BG 25 / 2011 / 9 - 23 2254_BG25_en_0000498763_V01...

  • Page 146: Wire Rope Accessories

     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 / 9 - 24 2254_BG25_en_0000498763_V01...

  • Page 147: Rope Fasteners, Thimbles And Sockets

     With swaged-on rope fittings, inspect for broken wires next to the fitting, cracks in the material and firm seizure of the rope. Danger of rope breaking! If a defect is found on a rope fitting, cut off the rope end and re-fit it. CAUTION BG 25 / 2011 / 9 - 25 2254_BG25_en_0000498763_V01...

  • Page 148: Rope Sheaves

    Grease during rotating 1000 Operating hours/ rope sheave. yearly Fill in grease slowly to CAUTION prevent squeeze out bearing sealing. BM659822.jpg Rope sheaves greased by the central lubrication sys- automatical BM659823.jpg BG 25 / 2011 / 9 - 26 2254_BG25_en_0000498763_V01...

  • Page 149: Checking Rope Sheaves

    Re-machine the groove, or replace the grooves in sheaves still 1000 Operating hours/ sheave with a new one, if the groove comply with the diameter yearly does no longer comply. the rope used. BG 25 / 2011 / 9 - 27 2254_BG25_en_0000498763_V01...

  • Page 150: Rotary Drive

    - Spring-loaded ring (2) - Compression springs (3) - Shock absorbers (4) Check the rotary drive for leaks. Kj248501.wmf Risk of damaging the rotary drive! At once, replace damaged components with new ones. CAUTION BG 25 / 2011 / 9 - 28 2254_BG25_en_0000498763_V01...

  • Page 151: Checking The Oil Level

    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. CAUTION BG 25 / 2011 / 9 - 29 2254_BG25_en_0000498763_V01...

  • Page 152: Planetary Gears

    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 CAUTION oil before refilling. BG 25 / 2011 / 9 - 30 2254_BG25_en_0000498763_V01...

  • Page 153: Changing The Oil

     Inspect magnets on all drain screws and on magnetic sticks for gear abrasives, and clean the screws (see also sect. "Oil Sampling"). Check the mounting bolts of the hollow shaft (see sect. "Hollow Shaft Mounting Bolts"). NOTE BG 25 / 2011 / 9 - 31 2254_BG25_en_0000498763_V01...
  • Page 154 NOTE air that may be have been trapped.  Reinstall the filler screws and tighten them. BG 25 / 2011 / 9 - 32 2254_BG25_en_0000498763_V01...

  • Page 155: Planetary Gears

     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. KG000512.wmf Danger of scalding! Hot gear oil can cause severe injury! CAUTION BG 25 / 2011 / 9 - 33 2254_BG25_en_0000498763_V01...
  • Page 156 NOTE air that may be have been trapped.  Reinstall the filler screws and tighten them. BG 25 / 2011 / 9 - 34 2254_BG25_en_0000498763_V01...

  • Page 157: Oil Sampling

    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 / 9 - 35 2254_BG25_en_0000498763_V01...

  • Page 158: Hollow Shaft Mounting Bolts

    Loctite to threads, reinstall and tension the bolts with the specified torque. Bolt torque value [Nm] Hollow shaft mounting (2) Hex head bolts see Spare Parts List BG 25 / 2011 / 9 - 36 2254_BG25_en_0000498763_V01...

  • Page 159: Kelly Driver And Guide Flange

    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 / 9 - 37 2254_BG25_en_0000498763_V01...

  • Page 160: Checking Driver Strips For Wear

    Bolt torque value [Nm] Kelly driver strips mounting Hex socket head bolts see Spare Parts List Hex socket head bolts with nuts see Spare Parts List A - A: B - B: B0000580.wmf BG 25 / 2011 / 9 - 38 2254_BG25_en_0000498763_V01...

  • Page 161: Cardan Joint

    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 / 9 - 39 2254_BG25_en_0000498763_V01...

  • Page 162: Greasing The Shaft Seal Ring

    Brownish coloured gear oil or a heavily contaminated filter (3 or 4) can be an indicator of solid matters brought-in from the outside. CAUTION Shut down the rotary drive and contact the After Sales Service. BG 25 / 2011 / 9 - 40 2254_BG25_en_0000498763_V01...

  • Page 163: Crawler Track Assemblies

    – Tread rollers (6) – Crawler drive wheels (7) – Gear cases (8) B0000676.wmf On machine with crawlers extended, the crawler telescoping surfaces should be kept corrosion protected with grease. NOTE BG 25 / 2011 / 9 - 41 2254_BG25_en_0000498763_V01...

  • Page 164: Crawler Tracks

    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. B0000680.wmf BG 25 / 2011 / 9 - 42 2254_BG25_en_0000498763_V01...

  • Page 165: Adjusting Crawler Track Tension

    Work the grease gun until the proper track tension is obtained. ● Check the track tension again after a short travel forward and backward, and top up with more grease as necessary. ● Reinstall the cover plate. BG 25 / 2011 / 9 - 43 2254_BG25_en_0000498763_V01...
  • Page 166 Danger of injury due to pretensioned spring element (compressible sili- cone oil at 1500 to 2000 bar)! For safety reasons do not open the defective spring elements, but re- place them entirely. BG 25 / 2011 / 9 - 44 2254_BG25_en_0000498763_V01...

  • Page 167: Checking Mounting Bolts

    Track guide (3) Tread roller (4) Crossbeam (5) Drive wheel (6) Gear case (7) Telescopic cylinder mounting 560 (M20) Swing ring (8) 755 (M24) After the first 250 and then every 2000 BG 25 / 2011 / 9 - 45 2254_BG25_en_0000498763_V01...

  • Page 168: Crawler Drive Gears

     Reinstall drain plug with new seal and screw tight.  Refill with new oil to proper level. B0000514.wmf  Reinstall inspection/filler screw with new seal and screw tight. BG 25 / 2011 / 9 - 46 2254_BG25_en_0000498763_V01...

  • Page 169: Central Lubrication System Maintenance

    (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. *) Not used in this version BG 25 / 2011 / 9 - 47 2254_BG25_en_0000498763_V01...

  • Page 170: Bolted Connections

    Serious accident hazard! Replace the elements of bolted connections every time components are mounted or reassembled anew and whenever the connections have been excessively stressed from rig tipping or improper handling. BG 25 / 2011 / 9 - 48 2254_BG25_en_0000498763_V01...

  • Page 171: Lubricants / Tables

    The lubricants listed in the lubricant tables of this manual are suitable for ambient temperatures from -20°C to +40°C (-4°F to +104°F). Information on applications below -20°C and above +40°C can be or- NOTE dered from the BAUER Service Centre. BG 25 / 2011 / 10 - 1 2254_BG25_en_0000498763_V01...

  • Page 172: Lubricant Table

    2 x 5.5 planetary gear EP-XF 150 *) At 40°C: Gear oils, 38 mm petroleum At 100°C: 7.1 mm Gear oils, HVLP HC synthetic *) 40°C = 104°F ; 100°C = 212°F BG 25 / 2011 / 10 - 2 2254_BG25_en_0000498763_V01...
  • Page 173 Roller bearings/ after every ARAL Aralub HLP 2 friction bearings application Central Lubrication after every System (Base machine, ARAL Aralub HLP 2 application BG equipment) * *) Not used in this version BG 25 / 2011 / 10 - 3 2254_BG25_en_0000498763_V01...
  • Page 174 Carter SH 150 Carter SH 220 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! CAUTION BG 25 / 2011 / 10 - 4 2254_BG25_en_0000498763_V01...

  • Page 175: Gear Oils, Petroleum - Atf

    ATF D II FINA Finamatic II D GULF ATF DX II TEXACO Texamatic 4291 Dexron II D TOTAL Totalfluid ATX KLÜBER ATF DEXRON II FUCHS Titan ATF 3000 AGIP ATF IID PANOLIN BG 25 / 2011 / 10 - 5 2254_BG25_en_0000498763_V01...

  • Page 176: Hydraulic Oils, Petroleum - Hvlp(D)

    PETRONAS HVI 46 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! CAUTION BG 25 / 2011 / 10 - 6 2254_BG25_en_0000498763_V01...

  • Page 177: Hydraulic Oils, Biodegradable On Synthetic Basis - Hvlp Hc

    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 CAUTION taken on the equipment! BG 25 / 2011 / 10 - 7 2254_BG25_en_0000498763_V01...

  • Page 178: Hydraulic Oils, Biodegradable - Hees - Saturated Esters

    AVIA CASTROL CHEVRON ESSO FINA GULF TEXACO TOTAL KLÜBER FUCHS AGIP PANOLIN HLP Synth 46 Risk of damaging components! Oils from different producers must not be mixed with one another. CAUTION BG 25 / 2011 / 10 - 8 2254_BG25_en_0000498763_V01...
  • Page 179 Mobil Delvac MX 15W-40 SDM 901 Q8 T 750 SAE 15W-40 Shell Rimula Super SHELL 15W-40 TEXACO Ursa Super TD 15W-40 IGOL Trans Turbo 9x TOTAL / FINA / ELF Rubia TIR 7400 BG 25 / 2011 / 10 - 9 2254_BG25_en_0000498763_V01...

  • Page 180: Greases, Petroleum - Kp2N

    CASTROL CHEVRON ESSO Beacon EP 2 FINA Marson EPL 2A GULF TEXACO TOTAL KLÜBER Epexa 2 FUCHS Renolit MP AGIP Agip GR MUEP 2 Glissando EP 2 PANOLIN EP Grease 2 BG 25 / 2011 / 10 - 10 2254_BG25_en_0000498763_V01...

  • Page 181: Bolt Torque Values

    M 16 M 18 M 20 M 22 M 24 1120 M 27 1000 1400 1650 M 30 1350 1900 2250 M 33 1850 2600 3000 M 36 2350 3300 3900 BG 25 / 2011 / 10 - 11 2254_BG25_en_0000498763_V01...

  • Page 182: Bolts With Fine-Pitch Metric Thread

    M 16x1,5 M 18x1,5 M 20x1,5 M 22x1,5 M 24x2 1040 1220 M 27x2 1070 1500 1800 M 30x2 1490 2120 2480 M 33x2 2000 2800 3300 M 36x3 2500 3500 4100 BG 25 / 2011 / 10 - 12 2254_BG25_en_0000498763_V01...

  • Page 183: Conversion Table

    Measures for Length 0.08333 0.02778 25.4 0.0254 0.3333 304.8 0.3048 914.4 0.9144 328110 -6 109410 -6 10 -6 0.03937 0.001 39.37 3.81 1.094 1000 0.001 10 6 39370 3281 1094 1000 BG 25 / 2011 / 10 - 13 2254_BG25_en_0000498763_V01...

Table of Contents