Instruction Manual For BG25

Instruction Manual
BG 25
BK000513.wmf
Translation of the original instruction manual
Keep this manual also for future use!

BAUER Maschinen GmbH
P.O. Box 12 60 D-86522 Schrobenhausen Germany
Phone: +49 8252 97-0 Fax: +49 8252 97-13 59
PREFACE
US
UK
BG
If you are not familiar with the language used in this operating manual you
must not operate the equipment. If you cannot read this operating manual or
understand its contents, you must contact the customer service department of
BAUER Maschinen GmbH and order a manual in a language you understand.
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BG 25 / 2011 / 2254_BG25_en_0000498763_V01
DE
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laitteistoa kyttn. Ota tss tapauksessa yhteytt BAUER Maschinen
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BG 25 / 2011 / 2254_BG25_en_0000498763_V01
II
FR
Si vous ne comprenez pas la langue utilise dans ce manuel d'instructions,

vous ne devez pas mettre en service l'appareil/l'installation. Dans ce cas,
veuillez contacter le service aprs -vente de BAUER Maschinen GmbH et
commandez u manuel d'utilisation rdig dans une langue comprhensibles
pour vous.
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BG 25 / 2011 / 2254_BG25_en_0000498763_V01
III
LU
Falls Dir d'Sprooch di an dser Betribsuleedung benotzt gtt net verstitt,

dann dierft Dir den Apparat / d'Anlag net a Betrib huelen. Kontaktiert an esou
engem Fall de Konnendngscht vun der BAUER Maschinen GmbH a bestellt
eng Betribsuleedung an enger Sprooch di Dir verstitt.
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Ja js aj lietoanas instrukcij lietoto valodu nesaprotat, js nedrkstat skt

s ierces/iekrtas ekspluatciju. aj gadjum ldzam js sazinties ar firmas BAUER Maschinen GmbH klientu apkalpoanas centru un pastt
lietoanas instrukciju, kas ir iespiesta jums saprotam valod.
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Dersom du ikke frostr det sprket som brukes i denne bruksanvisningen, m

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BAUER Maschinen GmbH og bestill en bruksanvisning p et sprk du forstr.
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BG 25 / 2011 / 2254_BG25_en_0000498763_V01
IV
PL
Jeli nie rozumiej Pastwo jzyka, w ktrym napisana zostaa instrukcja obsugi, to nie mog Pastwo uruchamia urzdzenia/instalacji. W takim przypadku naley skontaktowa si z serwisem firmy BAUER Maschinen GmbH i
zamwi instrukcj w jzyku przez Pastwa rozumianym.
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colocar a mquina/unidade em funcionamento. Neste caso, contacte o servio de assistncia da BAUER Maschinen GmbH e encomende um manual
num idioma que entenda.
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nesmiete prstroj / zariadenie uvdza do prevdzky. V takomto prpade kontaktujte, prosm, zkazncku slubu firmy BAUER Maschinen GmbH a objednajte si nvod na obsluhu v jazyku, ktormu rozumiete.
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SI
e jezika, uporabljenega v teh navodilih za uporabo, ne razumete, ne smete

aparata / naprave poganjati. V taknem primeru stopite v stik s servisno
slubo podjetja BAUER Maschinen GmbH in naroite navodila za uporabo v
jeziku, ki ga razumete.
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Bu kullanm klavuzunda kullanlan dili anlayamadnz taktirde, cihaz / sistem

sizden geri alnmayacaktr. Bu gibi bir durumda, BAUER Maschinen GmbH ile
temasa gein ve sizin anlayabileceiniz dilde bir kullanm klavuzu sipari edin.
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BG 25 / 2011 / 2254_BG25_en_0000498763_V01
VI
This Instruction Manual is written for use by operating and maintenance personnel.
Before the first use of this equipment PLEASE
First, take your time and read the "Instruction Manual" and the enclosed booklet entitled "Safety Information".
These two documents shall always be kept at the equipment to be accessible for review
at any time.
The "Instruction Manual" gives you a detailed description of the equipment, guidelines
for transport and initial start-up as well as comprehensive instructions for the operation
of the equipment, trouble shooting tips and information related to maintenance.
Technical data, weights and measurements are accurate as of the day this Instruction
Manual is printed. Due to the continuous technical advancements made, there may be
minor deviations between the technical data, weights and measurements contained in
the Instruction Manual and the equipment as actually built and delivered. These minor
deviations are, however, inconsequential and do not change in any material way nor do
they invalidate the contents of this Instruction Manual.
The equipment as delivered to you may have options that might not be pictured in the
photographs or described in the text contained in this Instruction Manual exactly as they
appear on your equipment. This is due to the individualization of the equipment based
on the wishes and orders of the individual customers and no claims of any kind shall be
based on such deviations.
The equipment shall only be used for the authorized purposes listed in the Instruction
Manual. The manufacturer shall have no liability whatsoever for the improper or
unauthorized use of the equipment, operator errors or mistakes or improper respectively insufficient maintenance.
The enclosed booklet entitled "Safety Information" contains the directions and related
information for the safe use of the equipment. The "Safety Information" must be followed at all times.
Also, pay attention to and follow all the instructions contained in the attached documents (Appendix ___) of the component manufacturers.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
VII
The "Instruction Manual" was written and published by

BAUER Maschinen GmbH Postfach 12 60 D-86522 Schrobenhausen, Germany
Copyright 2009, BAUER Maschinen GmbH
The information contained in this manual and/or any of its parts, sub-parts or chapters,
is the intellectual property of BAUER Maschinen GmbH and is protected by domestic
and international copyright and other intellectual property laws.
The information contained herein is provided for the operation, service, maintenance
and troubleshooting of the equipment described herein.
Any duplication, reproduction, translation, micro filming, storage in electronic or magnetic form, processing as electronically or magnetically stored media, copying or dissemination of these materials and/or the information contained herein, or any part thereof,
except for the internal use of BAUER Maschinen GmbH or its authorized external suppliers, consultants or agents, without the prior written consent of BAUER Maschinen
GmbH is hereby strictly prohibited.
All rights and remedies are hereby expressly reserved.
Violators will be prosecuted.
BAUER Maschinen GmbH shall have no liability whatsoever arising from or connected
in any way to the so prohibited use of the information contained herein by any person or
entity, wherever located.
BAUER Maschinen GmbH reserves the right to change, delete or otherwise alter or
modify any information contained herein, or the equipment itself, at any time and for
any reason, with or without notice.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
VIII
TABLE OF CONTENTS
PREFACE ...................................................................................................................................................... I
TABLE OF CONTENTS .............................................................................................................................. IX
ABOUT THE MANUAL ............................................................................................................................. XIV
NAMEPLATES .......................................................................................................................................... XVI
AFTER SALES SERVICE ........................................................................................................................ XVII
WARRANTY TERMS .............................................................................................................................. XVIII
DEFECTS LIABILITY CLAIM ..................................................................................................................... XII
PERSONALANFORDERUNG / STAFF REQUEST ................................................................................. XIII
REGISTRIERUNG BETREIBER UND GERT/ OWNER AND EQUIPMENT REGISTRATION ............. XIV
1
DESCRIPTION .......................................................................................................................1 - 1
1.1
EQUIPMENT APPLICATIONS ...............................................................................................1 - 1
1.2
1.2.1
1.2.1.1
1.2.1.2
COMPONENTS ......................................................................................................................1 - 4
Basic Rig / Kelly Equipment....................................................................................................1 - 4
Components Overview ...........................................................................................................1 - 4
Components Description ........................................................................................................1 - 5
SAFETY..................................................................................................................................2 - 1
2.1
GENERAL SAFETY REQUIREMENTS .................................................................................2 - 1
2.2
EQUIPMENT SAFETY ...........................................................................................................2 - 1
2.3
MAJOR HAZARDS .................................................................................................................2 - 1
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
2.5
2.5.1
2.5.2
2.5.2.1
2.5.2.2
2.5.3
2.5.3.1
2.5.3.2
2.6
SAFETY DEVICES .................................................................................................................2 - 2

Emergency Stop .....................................................................................................................2 - 2
Pilot Control Safety Stick ........................................................................................................2 - 2
Fire Extinguisher .....................................................................................................................2 - 3
Medical Box ............................................................................................................................2 - 3
Emergency Exit.......................................................................................................................2 - 3
Limit Switches .........................................................................................................................2 - 4
Fall Protection Equipment * ....................................................................................................2 - 5
STABILITY ..............................................................................................................................2 - 6
Guidelines for Stability ............................................................................................................2 - 6
Stability for BG 25 # 2254 - Kelly BK 25/394/4/56 .................................................................2 - 7
Load Capacity Chart ...............................................................................................................2 - 7
Weights / Centres of Gravity - Drilling Distance 3.39 m .........................................................2 - 8
Stability for BG 25 # 2254 - Kelly BK 25/394/4/40 .................................................................2 - 9
Load Capacity Chart ...............................................................................................................2 - 9
Weights / Centres of Gravity - Drilling Distance 3.39 m .......................................................2 - 10
PERMISSIBLE WIND SPEED ..............................................................................................2 - 11
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
IX
TECHNICAL SPECIFICATIONS ............................................................................................3 - 1
3.1
3.1.1
3.2.1
3.2
DIMENSIONS .........................................................................................................................3 - 1
Kelly Equipment BK 25/394/4/56 ............................................................................................3 - 1
Kelly Equipment BK 25/394/4/40 ............................................................................................3 - 2
EQUIPMENT SPECIFICATIONS ...........................................................................................3 - 3
3.3
3.3.1
3.4
3.4.1
3.5
3.5.1
3.5.2
3.5.3
3.6
ROTARY DRIVE SPECIFICATIONS......................................................................................3 - 5

Rotary Drive, constant ............................................................................................................3 - 5
DRILLING SPECIFICATIONS ................................................................................................3 - 6
Kelly equipment ......................................................................................................................3 - 6
ROPE SPECIFICATIONS ......................................................................................................3 - 7
Main Rope ..............................................................................................................................3 - 7
Auxiliary Rope .........................................................................................................................3 - 8
Crowd Ropes ..........................................................................................................................3 - 9
NOISE EMISSION ................................................................................................................3 - 10
3.7
TEMPERATURE CONDITIONS ...........................................................................................3 - 10
3.8
EXPOSURE TO VIBRATION ...............................................................................................3 - 11
3.9
EXHAUST GAS EMISSION .................................................................................................3 - 11
CONTROLS AND INDICATORS ...........................................................................................4 - 1
4.1
CAB ........................................................................................................................................4 - 1
4.2
BASE MACHINE CONTROL CONSOLE ...............................................................................4 - 2
4.3
CONTROL PANEL .................................................................................................................4 - 3
4.4
MONITOR UNIT .....................................................................................................................4 - 4
OPERATION ..........................................................................................................................5 - 1
5.1
5.1.1
5.2
5.2.1
5.2.2
5.3
5.3.1
5.3.2
5.3.2.1
5.3.2.2
5.4
TRAVEL ..................................................................................................................................5 - 1
To Travel and Steer ................................................................................................................5 - 1
UPPERCARRIAGE SWING ...................................................................................................5 - 2
Swing Brake............................................................................................................................5 - 2
Swing Control .........................................................................................................................5 - 3
MAST REPOSITIONING ........................................................................................................5 - 4
Mast Auto Reset to Vertical ....................................................................................................5 - 5
Mast Repositioning by Manual Control ...................................................................................5 - 6
To Adjust the Mast Inclination ................................................................................................5 - 6
To Adjust the Drill Distance ....................................................................................................5 - 8
MAST PROP CONTROL * .....................................................................................................5 - 9
5.5
5.5.1
5.5.2
5.5.2.1
5.6
5.6.1
5.7
5.7.1
5.7.2
5.8
5.8.1
5.9
TRAVELLING WITH THE RIG .............................................................................................5 - 10

Travelling over Level Ground................................................................................................5 - 10
Travelling Up and Down Slopes ...........................................................................................5 - 11
With Raised Mast without Drilling Equipment .......................................................................5 - 11
ROTARY DRIVE CONTROL ................................................................................................5 - 12
Kelly Application (Rotary Drive, constant).............................................................................5 - 12
WINCH CONTROL...............................................................................................................5 - 14
Lifting / Lowering...................................................................................................................5 - 14
To Operate with Freewheel ..................................................................................................5 - 16
DEPTH MEASURING CONTROL ........................................................................................5 - 17
To Reset the Depth Measuring.............................................................................................5 - 17
CROWD CONTROL .............................................................................................................5 - 18
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5.9.1
5.9.2
5.10
Manual Control of the Crowd ................................................................................................5 - 19

To Use the Main Winch in Combination with Crowd ............................................................5 - 20
USING THE ENGINE DIAGNOSTIC SYSTEM ....................................................................5 - 21
5.11
CENTRAL LUBRICATION CONTROL * ..............................................................................5 - 22
START-UP / SHUT-DOWN ....................................................................................................6 - 1
6.1
6.1.1
6.1.2
6.1.3
6.1.3.1
6.1.3.2
6.1.4
6.1.4.1
6.1.4.2
6.1.4.3
6.2
6.2.1
6.2.2
START-UP..............................................................................................................................6 - 1
Initial Start-Up .........................................................................................................................6 - 1
Visual Inspection before Starting ............................................................................................6 - 1
Daily Start-Up .........................................................................................................................6 - 2
Starting the Equipment ...........................................................................................................6 - 2
Selecting the Engine Operating Mode ....................................................................................6 - 3
Safety Tests before Starting to Work .....................................................................................6 - 4
Checking the Emergency STOP.............................................................................................6 - 4
Checking the Pilot Control Safety Stick ..................................................................................6 - 4
Checking the End Limiters......................................................................................................6 - 5
SHUT-DOWN .........................................................................................................................6 - 6
Daily Shut-Down .....................................................................................................................6 - 6
Shut-Down for a Longer Period ..............................................................................................6 - 6
RIGGING / DE-RIGGING .......................................................................................................7 - 1
7.1
GUIDELINES FOR RIGGING AND DE-RIGGING .................................................................7 - 1
7.2
WAX REMOVAL .....................................................................................................................7 - 2
7.3
EXTENDING THE CRAWLERS .............................................................................................7 - 3
7.4
MOUNTING THE COUNTERWEIGHT ..................................................................................7 - 4
7.5
7.5.1
7.5.2
7.5.3
7.5.3.1
7.5.3.2
7.5.4
7.5.5
7.5.6
7.6
7.6.1
7.6.1.1
7.6.1.2
7.6.1.3
7.6.1.4
7.6.2
7.7
7.7.1
7.7.1.1
7.7.1.2
7.8
7.8.1
7.8.2
7.8.3
7.8.3.1
7.8.3.2
7.8.4
MOUNTING THE MAST .........................................................................................................7 - 7

Mounting the Trestle ...............................................................................................................7 - 7
Assembling the Mast Sections ...............................................................................................7 - 8
Installing the Ropes ..............................................................................................................7 - 10
Installing the Main and Auxiliary Ropes ................................................................................7 - 10
Installing the Upper Crowd Rope ..........................................................................................7 - 11
Mounting Crowd Stroke Limiters ..........................................................................................7 - 12
Raising the Mast ...................................................................................................................7 - 13
Mounting Retaining Clamps .................................................................................................7 - 14
ASSEMBLY OF WORK ATTACHMENTS ............................................................................7 - 15
Assembly of Kelly Equipment ...............................................................................................7 - 16
Mounting the Rope Swivel ....................................................................................................7 - 16
Mounting the Rotary Drive ....................................................................................................7 - 17
Mounting Kelly Guidance * ...................................................................................................7 - 18
Mounting the Kelly ................................................................................................................7 - 20
Mounting Casing Oscillator * ................................................................................................7 - 22
DISASSEMBLY OF WORK ATTACHMENTS ......................................................................7 - 23
Disassembly of Kelly Equipment ..........................................................................................7 - 24
Removing the Kelly ...............................................................................................................7 - 24
Removing the Rotary Drive...................................................................................................7 - 24
DISASSEMBLING THE MAST .............................................................................................7 - 25
Removing the Retaining Clamps ..........................................................................................7 - 25
Lowering the Mast ................................................................................................................7 - 25
Removing the Ropes ............................................................................................................7 - 26
Removing the Main and Auxiliary Rope................................................................................7 - 26
Removing the Upper Crowd Rope........................................................................................7 - 27
Disassembling the Mast .......................................................................................................7 - 28
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
XI
7.8.5
7.9
Lowering the Trestle .............................................................................................................7 - 29

REMOVING THE COUNTERWEIGHT ................................................................................7 - 30
7.10
RETRACTING THE CRAWLERS ........................................................................................7 - 33
TRANSPORT .........................................................................................................................8 - 1
8.1
SAFETY GUIDELINES FOR TRANSPORT ...........................................................................8 - 1
8.2
MEASURES TO TAKE FOR TRANSPORT ...........................................................................8 - 2
8.3
DRIVING ON / OFF A LOWLOADER ....................................................................................8 - 3
8.4
LIFTING POINTS ...................................................................................................................8 - 4
8.5
TRANSPORT DATA ...............................................................................................................8 - 5
8.6
TYING DOWN ........................................................................................................................8 - 6
MAINTENANCE .....................................................................................................................9 - 1
9.1
SAFETY GUIDELINES FOR MAINTENANCE .......................................................................9 - 1
9.2
MAINTENANCE INTERVALS ................................................................................................9 - 1
9.3
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6
9.4
MAINTENANCE PLAN ...........................................................................................................9 - 2

Entire Equipment ....................................................................................................................9 - 2
Components ...........................................................................................................................9 - 3
Work Equipment .....................................................................................................................9 - 6
Uppercarriage .........................................................................................................................9 - 7
Undercarriage .........................................................................................................................9 - 9
Optional Equipment ..............................................................................................................9 - 10
LUBRICATION PLAN ...........................................................................................................9 - 11
9.5
MAINTENANCE DURING LONGER PERIODS OF STANDSTILL ......................................9 - 12
9.6
9.6.1
9.6.2
9.6.3
9.6.3.1
9.7
9.7.1
9.7.2
9.8
HYDRAULIC SYSTEM .........................................................................................................9 - 13

Hose Assemblies ..................................................................................................................9 - 14
Hydraulic Cylinders ...............................................................................................................9 - 15
Filter Replacement ...............................................................................................................9 - 16
Replacing the Line Filters .....................................................................................................9 - 16
WINCHES.............................................................................................................................9 - 17
Checking the Oil Level ..........................................................................................................9 - 17
Changing Gear Oil ................................................................................................................9 - 18
REPLACING THE UPPER CROWD ROPE .........................................................................9 - 19
9.9
9.9.1
9.9.2
9.9.3
9.9.4
9.9.4.1
9.9.4.2
9.10
9.10.1
9.10.2
9.10.2.1
9.10.2.2
9.10.3
9.10.3.1
9.10.3.2
9.10.4
9.10.5
WIRE ROPE ACCESSORIES ..............................................................................................9 - 24

Rope Swivel ..........................................................................................................................9 - 24
Rope Hold-Down Rollers ......................................................................................................9 - 24
Rope Fasteners, Thimbles and Sockets ..............................................................................9 - 25
Rope Sheaves ......................................................................................................................9 - 26
Greasing Rope Sheaves ......................................................................................................9 - 26
Checking Rope Sheaves ......................................................................................................9 - 27
ROTARY DRIVE ...................................................................................................................9 - 28
Routine Inspection ................................................................................................................9 - 28
Main Gear .............................................................................................................................9 - 29
Planetary Gears ....................................................................................................................9 - 30
Changing the Oil ...................................................................................................................9 - 31
Main Gear .............................................................................................................................9 - 31
Planetary Gears ....................................................................................................................9 - 33
Oil Sampling .........................................................................................................................9 - 35
Hollow Shaft Mounting Bolts .................................................................................................9 - 36
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
XII
9.10.6
9.10.6.1
9.10.6.2
9.10.7
9.10.8
9.10.9
9.11
9.11.1
9.11.2
9.11.2.1
9.11.2.2
9.11.3
9.11.4
9.11.4.1
9.11.4.2
9.12
Kelly Driver and Guide Flange ..............................................................................................9 - 37

Checking the Mounting Bolts ................................................................................................9 - 37
Checking Driver Strips for Wear ...........................................................................................9 - 38
Cardan Joint .........................................................................................................................9 - 39
Sledge Sliding Strips .............................................................................................................9 - 39
Greasing the Shaft Seal Ring ...............................................................................................9 - 40
CRAWLER TRACK ASSEMBLIES.......................................................................................9 - 41
Routine Inspection ................................................................................................................9 - 41
Crawler Tracks .....................................................................................................................9 - 42
To Check the Track Tension ................................................................................................9 - 42
Adjusting Crawler Track Tension .........................................................................................9 - 43
Checking Mounting Bolts ......................................................................................................9 - 45
Crawler Drive Gears .............................................................................................................9 - 46
Changing the Oil ...................................................................................................................9 - 46
CENTRAL LUBRICATION SYSTEM MAINTENANCE * ......................................................9 - 47
9.13
BOLTED CONNECTIONS....................................................................................................9 - 48
10
LUBRICANTS / TABLES .....................................................................................................10 - 1
10.1
10.1.1
10.1.2
10.1.3
10.1.3.1
10.1.3.2
10.1.3.3
10.1.3.4
10.1.3.5
10.1.3.6
10.1.3.7
10.2
10.2.1
10.2.2
10.3
LUBRICANTS .......................................................................................................................10 - 1
General .................................................................................................................................10 - 1
Lubricant Table .....................................................................................................................10 - 2
Lubricant Guide ....................................................................................................................10 - 4
Gear Oils, Synthetic CLP HC.............................................................................................10 - 4
Gear Oils, Petroleum ATF .................................................................................................10 - 5
Hydraulic Oils, Petroleum HVLP(D) ...................................................................................10 - 6
Hydraulic Oils, Biodegradable on Synthetic Basis HVLP HC ............................................10 - 7
Hydraulic Oils, Biodegradable HEES - Saturated Esters...................................................10 - 8
Engine Oils API CI-4 ..........................................................................................................10 - 9
Greases, Petroleum KP2N ..............................................................................................10 - 10
BOLT TORQUE VALUES...................................................................................................10 - 11
Bolts with coarse-pitch metric thread..................................................................................10 - 11
Bolts with fine-pitch metric thread .......................................................................................10 - 12
CONVERSION TABLE .......................................................................................................10 - 13
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
XIII
ABOUT THE MANUAL

THIS MANUAL IS MADE FOR
Equipment model:
Construction number:
Construction year:
Date of 1st operation:
BG 25
2254
2010
.. / .. / ....
Certification:
CE
THIS MANUAL WAS PUBLISHED IN

02.2011
THE CHAPTERS OF THIS MANUAL

1
2
3
4
5
6
7
8
9
10
DESCRIPTION
SAFETY
TECHNICAL SPECIFICATIONS
CONTROLS AND INDICATORS
OPERATION
START-UP / SHUT-DOWN
RIGGING / DE-RIGGING
TRANSPORT
MAINTENANCE
LUBRICANTS / TABLES
APPENDICES
G:\...\2254_BG25_en_0000498763_V01
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
XIV
SYMBOLS USED IN THIS MANUAL
DANGER!
"Danger!" is used to identify an immediate hazard that can result in
serious injury or loss of life if the instructions given in the manual are
ignored or not correctly followed.
WARNING!
"Warning!" is used to identify a potential hazard that can result in
serious injury or loss of life if the instructions given in the manual are
ignored or not correctly followed.
CAUTION
NOTE
"Caution" is used to identify a hazard that can result in moderate injury and / or damage to the equipment if the instructions given in the
manual are ignored or not correctly followed.
"Note" is used to highlight an operation, assembly or maintenance

procedure. In general, observance of the information here will facilitate
the work.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
XV
NAMEPLATES
Nameplates on the equipment
Assembly
Location
Nameplate
Bauer Maschinen GmbH
Total equipment
D - 86522 Schrobenhausen Made in Germany

Gertetyp
type
nchste Prfung
91011
2001
345
1
12 2
Baujahr
year of manufacture
678
Sachkundigenprfung
expert test
CE - Zeichen
CE sign
Trgergert
base carrier
Bau - Nr.
serial No
Inv. - Nr.
Inv. No
Rckzugkraft
pulling force
kN
max. Druck
max. pressure
bar
Gesamtgewicht
total weight
kg
Motorleistung
engine power
kW
Vorschubkraft
pushing power
Betriebsdruck
working pressure
Arbeitspannung
working voltage
Frequenz
frequency
kN
bar
V
Hz
B0000551.wmf
BK786502.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
XVI
AFTER SALES SERVICE
How to reach the Service Centre
Phone
+49 8252 97-25 86
Fax
+49 8252 97-25 87
E-Mail
KVT@bauer.de
Whenever you consult the Service Centre, please give the following information so your inquiry can be dealt with more quickly.
NOTE
Equipment description
- Name of model:
- Construction number:
- Number of operating hours:
Description of damage
- Date (DD.MM.YY):
- Cause of damage (if identifiable):
- Course of events leading to damage:
For possible check-backs

- Name of person to contact, phone / fax:
Description of site
- Name of site:
- Address (post code, town, street):
- Route description for a mechanic (as necessary):
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
XVII
WARRANTY TERMS
As far as a warranty agreement was concluded with the client the following terms apply to warranty procedures:
Warranty period:
The contractual agreement is principally decisive for the warranty

period; as far as no agreement on the warranty period was concluded the warranty is valid for 12 months from the time of commissioning.
Commencement:
The warranty comes officially into effect when the equipment is

put to the initial operation at the Clients, a process which must be
recorded in the "Commissioning Certificate" and verified by the
signatures of both the Client and a representative of BAUER. In
any event, the warranty shall come into effect no later than 1 week
after delivery.
Warranty conditions:
- Original BAUER spare parts must be used throughout the warranty period.
- 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 appropriate "Warranty Claim" form within 24 hours after their occurrence.
- The Client or Operator of the BAUER equipment agrees to carry
out all services throughout the warranty period within the specified service intervals in full compliance with the Instruction Manual.
- Any work (servicing, repairs etc.) carried out on the equipment
must be recorded in the Maintenance and Repair Log provided
for this purpose with each item of equipment.
Warranty exclusions:
- Improper use or operation (misuse) of the equipment.

- Failure to adequately maintain or service the equipment causing
breakdowns and damage.
- Repairs which have been carried out improperly.
- Unauthorised modifications or alterations to the equipment.
- Forceful physical damage.
- Damage resulting from incorrect or improper operation.
- All normal wear and tear.
NOTE:
Wear and tear parts include drilling tools, kelly bars, ropes etc.
If a buyer has proven, that a damage is caused by a manufacturing defect, the claim is dealt with on the basis of the warranty.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
XVIII
A) Liabilities and Responsibilities of 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.
NOTE
Any defective parts replaced under warranty shall become the property of
BAUER.
BAUER shall determine whether defective parts are to be returned to their factory at Schrobenhausen, Germany. Transport costs for redeliveries will be paid
by BAUER Maschinen GmbH (after sales service).
Redeliveries / Deadlines
Concerning requested redeliveries the following deadlines are valid from the date of arrival of the new parts on the jobsite in the assignment country until arrival of the damaged parts in Schrobenhausen.
Redeliveries via air freight:
Redeliveries via sea freight:
4 weeks
4 months
If the damaged parts, which are redelivered via sea freight, are not redelivered in time
due to the jobsite situation, the after sales service department has to be informed correspondingly, at the latest 6 weeks before expiry of the deadline.
Concerning redeliveries via air freight, an extension of the deadline is principally not
possible.
In case requested redeliveries are not returned within the agreed time period, the corresponding open amounts according to the sales invoice have to be paid by the respective customer.
B) Liabilities and Responsibilities of the Client
Any customs duties payable in the country of destination for a consignment of spare
parts supplied under warranty shall be the responsibility of the Client.
Local transport to a final destination (construction site) in connection with a warranty
claim shall also be the responsibility of the Client.
Full and meticulous compliance with all operating instructions and observance of proper
operating procedures for all equipment.
Full compliance with the specified and necessary service schedule.
Entering and maintaining full and comprehensive records in the Maintenance and Repair
Log.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
XIX
To:

After Sales Service Department
P.O. Box 12 60
86522 Schrobenhausen, Germany
Phone +49 8252 97-2586
Fax
+49 8252 97-2587
From (Customer, Agent):

Phone:
Fax:
Total number of pages of claim:
DEFECTS LIABILITY CLAIM

1. Product specifications
Equipment:
Constr. no.:
Constr. year:
Operating hours:
Current location of the equipment, postal address:

Date of commissioning:
Date of damage:
2. Description of damage
Please describe damaged parts and state their material number
Name of damaged part
Material no.
Construction no.
Note (symptoms/malfunctions, causes, position of damaged parts):
3. Delivery of new parts and repair

Replacement of damaged parts from 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 costs:
Date
Signature
Name of claimant
(please print)
Company
4. For internal use only (to be filled in by BAUER)

Subject to warranty?
If yes, give order number:
Yes
No
If no, give reasons:
Further reports:
910.396.2
01/2003
Further actions:
Return of damaged parts by:
Estimated working time (hrs):
(Signed by authorized BAUER employee)
An:

Abteilung Kundendienst
Postfach 12 60
86522 Schrobenhausen
Tel. +49 8252 97-2586
Fax +49 8252 97-2587
E-Mail KVT@bauer.de
PERSONALANFORDERUNG / STAFF REQUEST

Von Firma / Company:
Besteller / Ordered by:
Tel.:
Fax:
Bestell-Nr. / Order no.:
E-Mail:
Gert /
Equipment:
Ausrstung /
Attachment:
Betriebsstd. /
Working hours:
Bau-Nr. / Serial no.:

Standort des Gerts / Location of machine:
Ansprechpartner Baustelle /
Contact person jobsite:
Baustellentelefon /
Jobsite phone no.:
Zielflughafen / Airport of destination:

Datum des gewnschten Einsatzes / Date of requested assignment:
Gewnschtes Personal / Requested staff:
Mechaniker
mechanic
Elektriker
electrician
Einweiser
operator
Voraussichtliche Dauer / Estimated duration:

Auszufhrende Arbeiten / Works to be carried out:
Besonderheiten / Special requirements:
Ersatzteile / Spare parts:
Kommunikation auf der Baustelle /Communication on jobsite:

deutsch/German
country
Datum / Date:
englisch/English
Landessprache/Language
of
Unterschrift / Signature:
BAUER Maschinen GmbH 86529 Schrobenhausen Tel. 0 82 52/97-0
sra
910.097.1+2BMA
08/2008
An/
To:

Abteilung Kundendienst/
After Sales Service Dept.
Postfach/P. O. Box 12 60
86522 Schrobenhausen, Germany
Tel.:
+49 8252 97-2586
Fax:
+49 8252 97-2587
E-Mail: kvt@bauer.de
REGISTRIERUNG BETREIBER UND GERT/

OWNER AND EQUIPMENT REGISTRATION
Wir mchten dem Betreiber jederzeit eine optimale Dienstleistung bezglich Kundeninformationen bieten knnen.
Wir bitten deshalb jeden neuen Betreiber, sich und sein Gert ber dieses Formular bei der
BAUER Maschinen GmbH registrieren zu lassen./
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.
1. Gertedaten/Equipment Data
Gert/
Equipment:
Baunummer/
Serial number:
Betriebsstunden/
No. of operating hours:
2. Betreiberdaten/Owner information
Aktueller Betreiber des Gertes mit Anschrift/Current owner of the equipment, including address:
Firma/Company:
Abteilung/Department:
Ansprechpartner/Person to contact:
Postfach/P. O. Box:
Strae/Street:
Land/Country:
Tel./Tel.:
Fax/Fax:
E-Mail/E-mail:
Datum/
Date
Name des Ausstellers

(in Blockbuchstaben)/
Name of issuer
(in capital letters)
Unterschrift/
Signature
BAUER Maschinen GmbH 86522 Schrobenhausen, Germany Tel. +49 8252 97-0
Firma/
Company
shj
910.847.1+2BMA
11/2009
DESCRIPTION
DESCRIPTION
1.1
EQUIPMENT APPLICATIONS
The equipment shall only be used for the following operations:

Operation
Abbreviation
Authorized use?
Drilling with Kelly equipment

Drilling with Continuous Flight Auger equipment
Drilling with Front Of Wall equipment
Kelly
Yes
CFA
No
FOW
No
Drilling with dual rotary drive equipment
DKS
No
Piling with vibrator equipment

Drilling with High Pressure Injection equipment
Drilling with Full Displacement equipment
No
HPI
No
FDP
No
Drilling with soil stabilization equipment
CSV
No
Authorized use means use in strict compliance with and strict adherence to all directives, mandates, precautions and prohibitions contained in this Instruction Manual as
well as in all additional manuals and documents supplied herewith.
Everything contained in the Instruction Manual refers to and applies only to the equipment as first delivered to the original purchaser including all original attachments and
factory installed options as of the day of delivery.
Any modification of the equipment or its attachments or factory installed options made
after delivery might render the equipment unsafe and therefore invalidates this Instruction Manual. The equipment shall not be used after any such modifications are
made unless such use after modification has been approved in writing by BAUER
Maschinen GmbH as set forth below.
The manufacturer disclaims any liability of any kind arising or connected with the so
prohibited and unauthorized use of the equipment in any way unless such use after
modification has been approved in writing by BAUER Maschinen GmbH.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
1-1
DESCRIPTION
After modification of the equipment, the original attachments or factory installed options
as of the day of delivery, the equipment is not authorized for any use whatsoever and
wherever unless or until an authorization is first given by BAUER Maschinen GmbH in
writing. To obtain such an authorization a Change Request as shown below must be
submitted to BAUER Maschinen GmbH.
The authorization to use the equipment after any modification of the equipment, the
original attachments or factory installed options can only be given by BAUER Maschinen GmbH after submission and review of a properly completed Change Request.
No other person, entity or organization, including but not limited any government entity
located anywhere, shall have the right to give such an authorization. Neither any
agents, distributors, importers, dealers or subsidiaries of BAUER Maschinen GmbH
shall have the right to or are able to give such a valid authorization. Only the corporate
headquarters of BAUER Maschinen GmbH can issue a valid authorization after submission of a properly completed Change Request.
The equipment described in this Instruction Manual is only intended for and therefore shall
only be used in the country for which it was ordered by the original purchaser. All contractual agreements between the manufacturer and the original purchaser with respect to the
requirements and restrictions of use and operation of the equipment in a country other than
the one the equipment was ordered for are binding on any and all subsequent purchasers.
Any use of the equipment in any country other than the country for which it was ordered
by the original purchaser is unauthorized use and strictly prohibited unless the prior
written authorization of BAUER Maschinen GmbH has been requested and received.
Any use of the equipment in the United States of America is only allowed if the equipment was first ordered for and delivered for use within the United States of America or if
the equipment has been expressly approved and authorized in writing for use within the
United States of America by BAUER Maschinen GmbH.
Any use of the equipment other than the use authorized and described in this Instruction Manual shall constitute unauthorized and strictly prohibited use and is hereby expressly forbidden. The same applies if the equipment is used as a crane, for leveling
purposes or for the transport of people. These uses are expressly unauthorized and
hereby strictly prohibited.
The manufacturer shall not be liable for any injuries or damages of any kind which are
caused by, directly or indirectly, or are in any way, shape or form connected to, or arising from any unauthorized use described herein or any use that is not expressly authorized in this Instruction Manual.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
1-2
DESCRIPTION
An/
To:

Abteilung Kundendienst
Postfach 12 60
D-86522 Schrobenhausen
Tel.
+49 8252 97-2586
Fax
+49 8252 97-2587
E-Mail kvt@bauer.de
Von (Eigentmer, Betreiber)/From (owner, user):

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

fr/for
Gert/Equipment
Ausrstung/Attachment
Anbauteil/factory installed option
1. Grunddaten/Equipment specifications
Gert/Anlage
Equipment/
Baunummer/
Plant:
Serial number.:
Aktueller Standort des Gertes/der Anlage mit Anschrift/
Current location of the equipment/plant with complete address:
Datum der Kommissionierung/Date of commissioning (first use):
Baujahr/
Year of manufacture :
Betriebsstunden/
Operating
hours:
Anbauteile (original)/Factory installed options (OEM):

Bezeichnung/Description
Materialnummer/Material number
Baunummer/Serial number
Ausrstung (original)/Attachment (OEM):

Bezeichnung/Designation
Materialnummer/Material number
Baunummer/Serial number
2. nderungsdaten/Change data fr/for

Gert/Equipment
Ausrstung/Attachment
nderungsbeschreibung/Description of changes
Anbauteil/Factory installed option

ggf. Angebotsnr. BAUER/BAUER offer no (if applicable)
910.818.1+2BMA
05/2009 bjm
Es wird hiermit ausdrcklich erklrt und besttigt, dass sich das Gert zum aktuellen Zeitpunkt im Originalzustand (Auslieferungzustand) befindet und ausschlielich mit BAUER-Originalkomponenten bestckt ist.
Das Gert befindet sich in einem technisch einwandfreien Zustand./
It is herewith explicitly declared and confirmed that the equipment is presently in its original condition
(as delivered) and contains only genuine original BAUER OEM components.
The equipment is in a technically flawless condition.
Eigentmer bittet um technische berprfung des Gertes./
The owner requests a technical inspection of the equipment.
Name/Name
Unterschrift/Signature
Datum/Date
3. BAUER-intern (wird von BAUER ausgefllt) / For internal use of BAUER (to be filled in by BAUER)
Antrag erhalten am/Request received on:
Antrag weitergeleitet an/
VT
Name:
Datum/Date:
Request forwarded to:
EK
Name:
Datum/Date:
PM
Name:
Datum/Date:
andere/other
Name:
Datum/Date:
Name KVT-Mitarbeiter/Name of KVT employee:
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
1-3
DESCRIPTION
1.2
COMPONENTS
1.2.1
Basic Rig / Kelly Equipment
1.2.1.1 Components Overview

Basic Rig
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Boom
Boom cylinders
Swing mechanism
Crawler drives
Counterweight
Main winch
Main rope
Auxiliary winch
Auxiliary rope
Wedge *
Masthead tilting cylinder *
Kinematic triangle *
Mast (upper section / lower section)
Mast prop *
Mast pivot
Masthead
Mast extension (intermediate) *
Mast extension (lower) *
Backstay cylinders
Uppercarriage
Rope swivel
Crowd rope tensioning cylinder
Supporting boom *
Supporting trestle
Undercarriage
Crowd sledge
Crowd ropes (upper/lower)
Thrust rod *
Crowd winch
Crowd cylinder *
Kelly equipment
40
41
42
43
44
45
46
Drilling tool
Rotary drive
Casing drive adapter
Shock absorber
Cardan joint
Kelly drivers
Kelly bar
7
9
16
21
22
46
13
45
43
41
44
26
42
19
40
27
29
6
8
24
13
15
14
2
1
25
20
5
3
4
BK000514.wmf
*) does not exist with this version
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
1-4
DESCRIPTION
1.2.1.2 Components Description

Table Basic rig components description
Component
Boom
Boom cylinders
Swing mechanism
Crawler drives
Counterweights
Main winch with main rope
Auxiliary winch with auxiliary rope
Wedge
Kinematic triangle (H)
Mast (upper section / lower section)
Mast prop
Mast pivot
Masthead
Mast extension (intermediate)
Mast extension (lower)
Backstay cylinders
Uppercarriage
Rope swivel
Crowd rope tensioning cylinder (S)
Supporting boom (H)
Supporting trestle (V)
Undercarriage
Crowd sledge
Crowd ropes (upper / lower) (S)
Thrust rod (Z)
Crowd winch (S)
Crowd cylinder (Z)
Z) for rig fitted with cylinder crowd
S) for rig fitted with rope crowd
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
Description / Function
Is a movable link from the machine to the mast
pivot.
Are movable connections of the boom to the machine. They enable adjustment of the machine's
distance to the bore.
Enables rotation of the uppercarriage to both
sides.
Drive the two crawlers forward and reverse.
Render stability to the equipment.
Is used as a hoist for the Kelly.
Is used for rigging operations and load handling.
Allows changing the distance from mast to bore.
Enables parallel repositioning of the mast.
Provides guidance for the crowd sledge.
Supports the rig during withdrawal of the drilling
tool.
Is a swivel link between the mast and the boom.
Houses sheaves which guide ropes over the mast.
Enables use of longer drilling tools.
Allows the crowd sledge be positioned further down.
Are movable supports of the mast. They raise and
lower the mast and allow adjustment of the inclination of the mast.
Houses the engine, hydraulic system and controls.
Prevents rope twist.
Stresses the crowd ropes.
Enables parallel repositioning of the mast.
Is a mount for the backstay cylinders.
Carries the rig and moves it from one drilling spot
to the next.
Runs up and down the mast while carrying the rotary drive and drilling tool.
Transfer force from crowd winch to crowd sledge.
Is a distance keeper for the crowd cylinder.
Generates the crowd forces.
Generates the crowd forces.
V) for mast lowering to the front
H) for mast lowering to the rear
1-5
DESCRIPTION
Table Kelly equipment components description

Component
Description / Function
Drilling tool
Erodes and conveys soil.
Rotary drive
Generates rotary movement and torque for the

drilling tool and/or casing tube.
Its final gear is driven by planetary gears which
take power from hydraulic motors.
Casing drive adapter
Serves as a connector between the cardan joint

and the casing tube and transfers the torque.
Shock absorber
Absorbs shocks from the Kelly bar.
Cardan joint
Transfers torque from rotary drive to casing drive

adapter and prevents torsional stress.
Kelly driver
Transfers torque from rotary drive to Kelly bar.
Kelly bar (Kelly)
Consists of telescoping tubes the total length of

which determines the achievable depth of the bore.
It transfers torque from the rotary drive to the drilling tool.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
1-6
SAFETY
SAFETY
2.1
GENERAL SAFETY REQUIREMENTS
It is fundamental that the national accident prevention codes be observed where this
equipment is used.
In addition, the "Safety Information" book supplied with this equipment must be read
and understood. It contains general safety requirements and such that have been
compiled by the manufacturer especially for this type of equipment.
Also, the safety messages given in the manual of the equipment must be followed.
2.2
EQUIPMENT SAFETY
The safety built into this equipment is state-of-the-art and complies with all EC requirements.
Equipped safety devices guarantee highest possible safety standard.
2.3
MAJOR HAZARDS
- In drilling applications, the equipment operates with rotating tools. Being caught by a
rotating part is mortal.
- In vibrator applications, the equipment operates with high-frequency oscillating tools.
Getting knocked down by a component thereof is mortal.
- The stability of the equipment must not be endangered. Exceeding the rig's capacity
or operating with faulty end-limiters can make the equipment fall violently causing
severe personal injury or even loss of life.
- Never remove equipped safety devices or render them out of order.
- Be observant of oil spills from the hydraulic system. If there is a spill, find the cause
and repair it. Oil spraying with high pressure from a leak in the hydraulic system can
cause severe burns and poisoning.
- The cooling system gets very hot from operation. Coming in touch with components
containing coolant can cause burns.
- Engine, gear and hydraulic oils get very hot from operation. Touching a component
containing such oil can cause burns.
- Be sure the equipment is properly shut down before you begin a maintenance, repair or cleaning job on it: Set all controls to OFF, stop the engine and set the battery
main switch to OFF position.
- To prevent abuse and unauthorised starting of the equipment, shut it down, remove
the ignition key and lock the cab whenever you leave the equipment unattended.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2-1
SAFETY
2.4
SAFETY DEVICES
2.4.1
Emergency Stop
In an emergency!!
Press the Emergency STOP button (1)!!
All equipment functions will promptly come
to a stop.
1
0
1
To re-start, pull the depressed Emergency

STOP button.
BK1478505.wmf
2.4.2
Pilot Control Safety Stick
1.2
With the safety stick (1), the operator must
shut off the pilot control before leaving the
driver's seat. With the stick in the "OFF"
position, all hydraulic functions are blocked.
1.1
Pilot control ON: Stick moved to position (1.1)

Pilot control OFF: Stick moved to position (1.2)
BK786505.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2-2
SAFETY
2.4.3
Fire Extinguisher
Machine with an engine power of < 200 kW

is equipped with one fire extinguisher / Machine with an engine power of > 200 kW
has two fire extinguishers.
Their location in or on the machine is identified with a decal (see fig.).
Personnel must recapitulate the text on fire
extinguishers from time to time to be familiar with their use.
B0000506.wmf
2.4.4
Medical Box
A First Aid medical box is found in the operators cab. Its location is identified with a
decal (see fig.).
B0000562.wmf
2.4.5
Emergency Exit
Whenever the normal exit from the cab is

blocked, the operator can use the equipped
emergency hammer (see fig.) to smash a
window.
The hammer is found in the operator's cab
beside the operators seat.
BS756504.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2-3
SAFETY
2.4.6
Limit Switches
Table Limit switches

Name
ES 2*
ES 2.1*
Function
Limits mast inclination to left.
Initial situation:
- ES 2 out of order
Switches off engine when max. permissible
mast inclination to left is obtained.
ES 3
Enables the Rigging Mode when boom

cylinders are fully extended.
ES 4*
Limits mast inclination to right.
ES 4.1*
ES 10*
HS 1
HS 2
Initial situation:
- ES 4 out of order
Switches off engine when max. permissible
mast inclination to right is obtained.
Initial situation:
- boom cylinders fully extended
- 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

before load may hit the masthead.
ES 3
BK000515.wmf
*) optional
With switch ES 2.1 or ES 4.1 activated, the engine can be restarted by

holding the by-pass button depressed while turning the ignition on.
NOTE
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2-4
SAFETY
2.4.7
Fall Protection Equipment *

WARNING!
Danger of falling!
When climbing the mast ladder, the provided fall protection equipment
must be used.
Personnel climbing the ladder must wear a body harness secured by
lanyards to a fall protection slide and by a lifeline, at all times! The person in question must be familiar with the fall protection equipment.
1
2
3
4
5
6
7
8
Shoulder straps, orange red

Ring for attaching a lifeline
Buckles for shoulder strap positioning
Waist strap with wide support for the
back
D-rings for attaching lanyards
Rings for attaching a seat support
Seat support, blue
Leg straps, blue
1
2
3
4
5
6
7
8
B0000793.wmf
How to don
Slip on the orange-red shoulder straps like a jacket, with the lifeline ring to the back.
Pull the free end of the waist strap through the twin-buckle at the other end and return
through the inner buckle. Step into the loose hanging leg straps; pull them through the
crotch and through the corresponding rings and secure using the twin-buckle, like with
the waist strap. The seat support must be in position under the buttocks.
How to use
The body harness (DIN 7478 sec. A) may be used only in conjunction with a fallpreventing slide and lanyards (DIN 23326) or a lifeline (DIN 7471) together with a falldamping device. The harness including all accessories must be checked for good working order before put to use. Never use damaged equipment. Safe anchoring points
must be provided above the users position. Possible fall height must be kept at minimum using rope shorteners. Never work with slack lanyards or lifeline. Be careful that
lifeline and ring (2) are in proper position at all times. Lanyards must be snapped on
directly to D-rings (5) on harness.
*) Not used in this version
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2-5
SAFETY
2.5
STABILITY
2.5.1
Guidelines for Stability
Rig capacity charts are calculated in compliance with the European standard DIN EN
791 (issue 1995).
WARNING!
Rig tipping hazard!
The conditions listed in the following must be observed in order that the
stability of the rig is guaranteed.
Conditions for operation:
Rig angles and loads on main rope, auxiliary rope and crowd given in the capacity
charts are maximum values which must not be exceeded for safety reasons.
The specified loads apply only when not combined and not used on an altered setup
of equipment.
Mounting attachments which are heavier or have a higher centre of gravity (like exchanging a Kelly with CFA equipment) requires 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 centre of gravity (position of the work attachments) are factors
which have additional influence on the rigs stability.
The loads given in the capacity charts take into consideration the most
adverse position of the components.
Conditions for onsite travelling:

Firm and even travel surface. National standards and guidelines observed regarding
ground, soil and surface conditions.
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 / 2254_BG25_en_0000498763_V01
2-6
SAFETY
2.5.2
Stability for BG 25 # 2254 - Kelly BK 25/394/4/56
2.5.2.1 Load Capacity Chart

Valid only for
Mast extension --- m

Counterweight
Kelly BK 25/394/4/56
Casing drive adapter 1,500 mm
Drilling tool 1,350 mm
Conditions for operation
Crowd sledge stopper mounted (max. stroke: 8,120 mm)
--- t
6.20 + 6.20 t
10.10 t
1.90 t
2.30 t
Max permissible load / max ground pressure**

Min. drilling distance*: -- m Max. drilling distance*: 3.39 m
B0000689.wmf
B00005003.wmf
B00005002.wmf
Auxiliary
rope
8.0 t
430 kPa
Main rope
20.0 t
380 kPa
Crowd
26.0 t
470 kPa
Auxiliary
rope
=
=
=
=
= 6
= 3
= 0
= 110
8.0 t
750 kPa
Main rope
=
=
=
=
= 6
= 3
= 4
= 110
20.0 t
480 kPa
Crowd
=
=
=
=
= 6
= 3
= 4
= 110
26.0 t
610 kPa
Auxiliary
rope
=
=
=
= 6
= 3
= 0
4.0 t
590 kPa
Main rope
=
=
=
= 6
= 3
= 4
20.0 t
480 kPa
Crowd
=
=
=
= 6
= 3
= 4
26.0 t
610 kPa
Max. working platform inclination /

max. ground pressure **
5 / 340 kPa
*) Drilling distance = centre distance from machine to drilling tool

**) Max. value of ground pressure as calculated in conformance with DIN EN 791 (1995 issue)
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2-7
SAFETY
2.5.2.2 Weights / Centres of Gravity - Drilling Distance 3.39 m

Valid only for
Drilling distance*
3.39 m
Weight
[kN]
Xres
[m]
Zres
[m]
Completely equipped drilling rig
822.10
0.68
5.05
Undercarriage with connections to CO
204.00
0.00
0.55
Upper carriage with BAUER attachments,

with crowd sledge,
with counterweights,
without work equipment,
without undercarriage,
without KDK
424.10
-0.22
4.66
50.00
3.21
11.24
19.00
101.00
23.00
1.00
3.39
3.39
3.39
3.39
9.20
12.30
2.80
19.50
Component
B0000919.wmf
B0000920.wmf
B0000921.wmf
Rotary drive KDK 250 K

with Kelly driver
Casing drive adapter 1500 mm
Kelly BK 25/394/4/56
Drilling bucket 1350 mm
Swivel
B0000922.wmf
Undercarriage
4.62
3.68
0.70
A
S
B
Length of crawler tread

Track gauge, extended
Width of track shoes
Dimensions
[m]
B0000929.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2-8
SAFETY
2.5.3
Stability for BG 25 # 2254 - Kelly BK 25/394/4/40
2.5.3.1 Load Capacity Chart

Valid only for
Mast extension --- m

Counterweight
Kelly BK 25/394/4/40
Conditions for operation
Crowd sledge stopper mounted (max. stroke: 8,120 mm)
--- t
6.20 + 6.20 t
7.70 t
1.90 t
2.30 t
Max permissible load / max ground pressure**

Min. drilling distance*: -- m Max. drilling distance*: 3.39 m
B0000689.wmf
B00005003.wmf
B00005002.wmf
Auxiliary
rope
8.0 t
390 kPa
Main rope
20.0 t
370 kPa
Crowd
26.0 t
420 kPa
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
= 6
= 3
= 0
= 120
= 6
= 3
= 4
= 120
= 6
= 3
= 4
= 120
= 6
= 3
= 0
Main rope
=
=
=
= 6
= 3
= 4
20.0 t
490 kPa
Crowd
=
=
=
= 6
= 3
= 4
26.0 t
570 kPa
Auxiliary
rope
Main rope
Crowd
Auxiliary
rope
Max. working platform inclination /

max. ground pressure ***
8.0 t
690 kPa
20.0 t
490 kPa
26.0 t
570 kPa
5.0 t
560 kPa
5 / 310 kPa

**) Max. value of ground pressure as calculated in conformance with DIN EN 791 (1995 issue)
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2-9
SAFETY
2.5.3.2 Weights / Centres of Gravity - Drilling Distance 3.39 m

Valid only for
Drilling distance*
3.39 m
Weight
[kN]
Xres
[m]
Zres
[m]
Completely equipped drilling rig
798.10
0.60
5.14
Undercarriage with connections to CO
204.00
0.00
0.55
Upper carriage with BAUER attachments,

with crowd sledge,
with counterweights,
without work equipment,
without undercarriage,
without KDK
424.10
-0.22
4.66
50.00
3.21
11.24
19.00
77.00
23.00
1.00
3.39
3.39
3.39
3.39
9.20
14.30
6.80
19.50
Component
B0000919.wmf
B0000920.wmf
B0000921.wmf

with Kelly driver
Casing drive adapter 1500 mm
Kelly BK 25/394/4/40
Drilling bucket 1350 mm
Swivel
B0000922.wmf
Undercarriage
4.62
3.68
0.70
A
S
B
Length of crawler tread

Track gauge, extended
Width of track shoes
Dimensions
[m]
B0000929.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2 - 10
SAFETY
2.6
PERMISSIBLE WIND SPEED
The place to measure the wind speed is at the masthead:

Max. permissible wind speed for equipment operation
m/s
km/h
miles/h
Beaufort
20
72
45
8
Barrier effect
ktn
39
250 (N/m)
WARNING!
Rig tipping hazard!
Shut down the equipment before the value is exceeded.
Remove attached drilling tool(s) and suspended load.

Lower movable components as close to the ground as possible.
Adjust the uppercarriage in line with the undercarriage and interlock them.
Set the mast into the minimum working range.
Extend the mast prop (if equipped) to the ground.
Table of wind forces and speeds

Wind force
Beaufort
English
Wind speed
m/s
km/h
less than 1 Smoke rises straight in the air, sea is calm-glassy
calm
light air
0.3 - 1.5
1-5
Smoke drifts but vanes remain still, sea is rippled
light breeze
1.6 - 3.3
6 - 11
Wind can be felt on your face, leaves rustle,

sea has wavelets
gentle breeze
3.4 - 5.4
12 - 19
Leaves and thin twigs move, pennants

stretch, wave crests begin to break
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
fresh breeze
8 - 10.7
29 - 38
Small trees begin to sway, waves are whitecapped all over the sea
strong breeze
10.8 - 13.8
39 - 49
Sturdy branches move, wires sing, umbrellas

are hard to handle, sea is rough, crests break
near gale
13.9 - 17.1
50 - 61
Whole trees swaying, walking towards the

wind is difficult, sea is very rough, foam on
crests
gale
17.2 - 20.7
62 - 74
Branches break off, walking outdoor is extremely

difficult, waves are high, spray from crests
75 - 88
Minor damage to buildings (roof tiles and

chimney hoods are ripped off), on the sea
waves are very high and the visibility is obstructed by spray
strong gale
0 - 0.2
Wind effects
20.8 - 24.4
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
2 - 11
3.1
DIMENSIONS
3.1.1
Kelly Equipment BK 25/394/4/56
Dimensions in [mm]
4620
BK22545001.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
3-1
3.2.1
Kelly Equipment BK 25/394/4/40
Dimensions in [mm]
4620
BK22545000.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
3-2
3.2
EQUIPMENT SPECIFICATIONS
Base Machine
Uppercarriage
Type
Hyundai R 305
Engine
Type
Serial number
Output
Speed
Cummins QSC 8.3

21911488
224 kW
2000 rpm
Undercarriage
Type
Serial number
Width over crawlers
Length of crawlers
Width of track pads
UW 75 BH
9161
3000 - 4400 mm
5360 mm
700 mm
Mast Inclination
During operation without work equipment
forward
backward
to left
to right
6
4
3
3
During operation with work equipment

See load capacity chart
Operating Range
See load capacity chart
Working Weight
With:
Kelly BK 25/394/4/56
Kelly BK 25/394/4/40
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
82.50 tonnes
80.00 tonnes
3-3
Main winch
Type
Serial number
77 WH 102/13
72810
Pulling force (1st layer)

Rope diameter
Rope length
Rope speed
("lifting" with a load of 80 kN)
200 kN
28 mm
88 m
87 m/min
Auxiliary winch
Type
Serial number
4.22 1000328
1028
Pulling force (1st layer)

Rope diameter
Rope length
Rope speed
("lifting" with a load of 10 kN)
80 kN
20 mm
50 m
55 m/min
Crowd winch
Type
Serial number
4.261001908
623
Max. stroke of crowd sledge

Max. pushing force at crowd sledge
Max. pulling force at crowd sledge
Rope diameter
Length of upper/lower rope without mast extension
Crowd speed:
"Fast crowd up"
"Fast crowd down"
"Slow crowd up"
"Slow crowd down"
8,145 mm (with Kelly-system)

260 kN
260 kN
24 mm
65 / 60 m
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
21.4 m/min
21.4 m/min
5.9 m/min
5.9 m/min
3-4
3.3
ROTARY DRIVE SPECIFICATIONS
3.3.1
Rotary Drive, constant
Pth = 205 kW
Qth = 2 x 250 l/min
i = 26.18
high torque
low torque
200
260
245
240
175
220
151
150
180
Drehmoment / Torque M [kNm]
Drehmoment / Torque M [kNm]
200
191
160
140
120
100
125
118
100
75
80
50
60
45
40
25
20
0
7 9
0
37
10
15
20
25
30
35
40
Drehzahl n [1/min] / Speed n [rpm]
BK832507.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
11 14
10
37
20
30
40
50
Drehzahl n [1/min] / Speed n [rpm]
BK832508.wmf
3-5
3.4
DRILLING SPECIFICATIONS
3.4.1
Kelly equipment
L1
Dimensions [mm]
L1
L2
L3
A max.
Hd
Bore diameter [mm]
uncased
cased
L2
Casing length
without CO
with CO
L3
20767
12131
4011
16666
8452
1700
1400
Hw 0.5 m
Hw 1.5 m
Hd
Hw
Drilling depth / Kelly specifications
Kelly type
BK 25/394/4/56
BK 25/394/4/40
B
T
A [m]
16.71
12.71
B [m]
59.47
43.47
B1 [m]
59.12
43.12
Hw [m]
1.85
5.85
locked
Kelly
without
with
CO
CO
T [m]
T [m]
57.31 55.81
41.31 39.81
unlocked
Kelly
without
with
CO
CO
T [m]
T [m]
57.66 56.16
41.66 40.16
Weight
[t]
10.05
7,70
Notice:
Drilling depth specifications are based on min. operating radius of mast.

With max. operating radius the drilling depth increases by 0.456 m.
A:
A max.:
B / B1:
T:
Hw:
Hd:
L1:
L2:
L3:
W:
CO:
Length of retracted Kelly

Max lifted length of Kelly
Length of extended Kelly unlocked / locked
Max. possible drilling depth
Maximum height to drilling tool
Maximum height to casing drive adapter
Highest possible position of Kelly lifting eye
Highest possible position of Kelly driver upper edge
Lowest possible position of Kelly driver upper edge
Length of drilling tool: 2.20 m
BAUER Casing Oscillator
BS756510.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
3-6
3.5
ROPE SPECIFICATIONS
3.5.1
Main Rope
WARNING!
Accident risk!
Ropes breaking can cause serious accidents.
Ropes installed in hoist winches must have a minimum breaking load
which is at least three times the winch pull force.
The ropes' safety factors must comply with the standards required for the equipment
and must be observed.
Technical data:
Finished length
Diameter
88 m
28.00 mm
Characteristics:
Lay and direction
Rotation characteristics
Rope end characteristics
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
Regular lay, right (sZ)

Non-rotating
Pointed, full thimble
3-7
3.5.2
Auxiliary Rope
WARNING!
Accident risk!
Technical data:
Finished length
Diameter
50 m
20.00 mm
Characteristics:
Lay and direction
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
Regular lay, right (sZ)

Non-rotating
Pointed, full thimble
3-8
3.5.3
Crowd Ropes
WARNING!
Accident risk!
Technical data:
Finished length (upper / lower)
Diameter
65 m / 60 m
24.00 mm
Characteristics:
Lay and direction
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
Regular lay, left (zS)

Rotating
Pointed -Pointed
3-9
3.6
NOISE EMISSION
Measurements made in accordance with DIN EN 791:

1. Inside Cab (door closed)
Sound-pressure level in cab
LpA =
75.0 dB(A)
2. Outside
Average sound-pressure level
Sound-power level
3.7
LPA = 87.5 dB(A)

LWA = 113.0 dB(A)
TEMPERATURE CONDITIONS
The equipment can be used in outdoor temperatures ranging from -20C to +40C
(-4F to +104F).
For use at temperatures outside the specified range the manufacturer must be consulted.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
3 - 10
3.8
EXPOSURE TO VIBRATION
The operators exposure to vibration acceleration during operation with this equipment
is less than 0.5 m/s.
3.9
EXHAUST GAS EMISSION
The exhaust gas emission limit values comply with the 97/68/EC and 2004/26/EC stage
III A and EPA/CARB TIER III directives respectively.
As long as the diesel engine complies with the effective guideline in the
country of use, the operator is permitted to use this equipment.
NOTE
If repair of any kind is carried out on the diesel engine using non-original
components, exhaust gas emissions may not comply with the applicable
guidelines in the country of use.
In this case, the operator is obliged to contact "BAUER Maschinen" in
order to start maintenance procedures. Once the equipment has been
checked and compliance with exhaust emission limit values is ensured,
it may be put back into operation.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
3 - 11
4.1
CAB
1.1
1.3
1.5
15.5
15.1
15.3
20
19
18
17
21
1.6
1.4
1.2
2.1
2.3
2.2
15.4
15.2
15.6
6
7
8
9
10.3
10.7
10.5
10.1
12
10.2
10.6
10.8
16
0
10.4
5
4
11
BK18685002.wmf
1.1
1.2
1.3
1.4
1.5
1.6
2.1
2.2
2.3
3
4
5
6
7
8
9
10.1
10.2
10.3
10.4
10.5
Left crawler travel forward

Left crawler travel reverse
In CO mode: Tube lower *
In CO mode: Tube lift *
In CO mode + Clamping cylinders selected:
Tube unclamp *
In CO mode + Clamping cylinders selected:
Tube clamp *
Right crawler travel forward
Right crawler travel reverse
In CO mode: Oscillate *
Free-fall/Freewheel release
Free-fall/Freewheel mode ON/OFF
Not used
Crowd fast mode ON
In Kelly/CFA mode + preselection of high torque:
KDK fast mode ON/OFF
In Kelly mode: Dump spoil
Horn ON
Crowd down
Crowd up
In Kelly/CFA mode: Rotary drive rotate right
In Kelly/CFA mode: Rotary drive rotate left
Rigging mode + Backstay cylinders selected:
Right backstay cylinder extend
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
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 selected:
Boom cylinders extend
11 Engine speed adjustment
12 Engine ignition ON/OFF
15.1 Winch 1 / 2 down
15.2 Winch 1 / 2 up
15.3 Uppercarriage swing to left
15.4 Uppercarriage swing to right
15.5 Rigging mode + Backstay cylinders selected:
Left backstay cylinder extend
15.6 Rigging mode + Backstay cylinders selected:
Left backstay cylinder retract
16 Emergency STOP
17 Auger cleaner retract/extend *
18 Swing brake release
19 Swing brake apply
20 Free-fall/Freewheel release
21 Pilot control ON/OFF
CFA
CO
*
= Continuous Flight Auger

= Casing Oscillator
= Not used in this version
4-1
4.2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
Not used
Not used
Indicator: Engine preheat
Engine diagnostic:
Warning = Stop Engine
Engine diagnostic:
Indication: Error code
Error codes scroll
Engine diagnostic:
Error code test
Not used
Not used
Freewheel/Free-fall mode ON/OFF
Emergency-STOP
Engine speed adjustment
Engine ignition ON/OFF
Not used
Central lubrication ON
Intermediate lubrication*
Crowd sledge
Lube trouble*
Central lubrication ON/OFF*
2
4
5
3
13
11
9
12
0
1
16
BASE MACHINE CONTROL CONSOLE
6
7
8
10
14
15
16
17
BK19035002.wmf
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4-2
4.3
CONTROL PANEL
KDK
KDK
KDK
KDK
1
return flow
15
16
KDK
KDK
17
18
19
20
21
P
10
11
12
13
14
22
23
24
25
26
27
28
BK19065000.wmf
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Rigging/Drilling mode select

Main Winch 1 / Auxiliary Winch 2 select
Not used
Mast prop extend
Mast prop retract
In Drilling mode:
Left backstay cylinder extend
In Drilling mode:
Right backstay cylinder extend
Boom cylinders retract
Boom cylinders extend
Extendable crawlers extend / retract
Crowd rope relieve
Crowd rope tension
In Drilling mode:
Left backstay cylinder retract
In Drilling mode:
Right backstay cylinder retract
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Rotary drive low torque select

Rotary drive middle torque select
Rotary drive high torque select
Warning: Free-wheel oil filter contaminated
Warning: Return line oil filter contaminated
Not used
Warning:
Rotary drive leak oil pressure too high
Rotary drive fast mode ON/OFF
Indicator: Rotary drive fast mode
Not used
Not used
Not used
Indicator:
Freewheel/Free-fall released
Indicator:
Swing brake lock
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
4-3
4.4
MONITOR UNIT
For Details of the Monitor Unit, please refer to the supplementary documentation
supplied with the equipment.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
4-4
OPERATION
OPERATION
5.1
TRAVEL
5.1.1
To Travel and Steer
CAUTION
The durability of the crawler components risks to be reduced due to

improper loading!
As shown, the main direction of travel should always follow the direction
of the arrow (2); front idler (1) ahead and crawler drive (3) back.
When working, the front idler (1) must also be oriented towards the drilling point.
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!
For shifting the equipment to other locations, suitable transporting
means provided for the purpose are to be used!
NOTE
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5-1
OPERATION
5.2
UPPERCARRIAGE SWING
5.2.1
Swing Brake
The swing brake serves to arrest the uppercarriage against rotation during operation.
CAUTION
Risk of damaging components!

The swing brake may be applied only when the uppercarriage has come
to a stop.
WARNING!
Squashing hazard, hitting hazard!
Before swinging the uppercarriage, check the danger zone is free.
Rearview mirror (and tail camera if equipped) must be clean at all
times.
To apply the swing brake:

Press button (19).
18
19
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 / 2254_BG25_en_0000498763_V01
5-2
OPERATION
5.2.2
Swing Control
Uppercarriage swing to left:

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

Unlock swing brake.
Move control lever to right (15) from
centre.
BK20545001.wmf
Letting the lever return to centre makes the swing slowly come to a stop, in hydraulic
way.
A quicker stop can be implemented by carefully moving the lever in the opposed direction.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5-3
OPERATION
5.3
MAST REPOSITIONING
CAUTION
CAUTION
CAUTION

The mast must be parallel to the drilling axis at all times!
During drilling mode and especially during casing oscillator applications it is important to watch the inclination of the mast on the
operators screen. Should the inclination change due to the forces, the
mast must be repositioned to the original inclination.
Risk of components getting damaged and the rope breaking!
On machines where the winches are housed in the uppercarriage, the
ropes must be sufficiently slackened before the mast is repositioned.
Otherwise, the ropes may be subjected to excessive stress.
Risk of components getting damaged and the rope breaking!
On equipment fitted with an overload protection for the main rope, various functions will shut off when the rope is overloaded and a message
will appear on the operator's screen.
When this is the case: unlock the Kelly (if locked) and spool out rope
from the main winch.
Immediately replace any damaged components of the overload protection.
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5-4
OPERATION
5.3.1
Mast Auto Reset to Vertical

CAUTION
Neither the mast prop nor components of the drilling equipment may be
in touch with the ground when the "Mast Auto Reset" is actuated.
Press Botton "AT" (1) and hold on.

The mast sets to vertical position.
2
1
BK15155011.wmf
Releasing the button too soon stops the action.

NOTE
NOTE
NOTE
The mast will first set to vertical position in the X axis and then, after a
pause, in the Y axis.
For more details please refer to the supplementary documentation

supplied with equipment.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5-5
OPERATION
5.3.2
Mast Repositioning by Manual Control
CAUTION
Risk of collision!
When using a hydraulic tube guide (for CFA, FOW or DKS equipment),
there is a risk of collision with the cab or the hose hoop, if the minimum
drilling centre distance is used and the mast is tilted to the side.
When using a hydraulic tube guide, the mast must not be tilted sideways if the minimum drilling centre distance is selected.
5.3.2.1 To Adjust the Mast Inclination

In Drilling Mode
Select Drilling mode:
Extend left backstay cylinder by
Extend right backstay cylinder by
Retract left backstay cylinder by
Retract right backstay cylinder by
BK14885017.wmf
B0000504.wmf
Extending the short backstay cylinders by the control panel is possible

in drilling and rigging mode.
NOTE
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5-6
OPERATION
In Rigging Mode
Select Rigging mode:
Lowering the mast:

Move left / right control lever forward
Bk14885013.wmf
BK19035019.wmf
Raising the mast:

Move left / right control lever back.
B0000504.wmf
BK19035020.wmf
Extending the long backstay cylinders by the control levers only is possible in rigging mode.
NOTE
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5-7
OPERATION
5.3.2.2 To Adjust the Drill Distance

Increasing machines distance to the bore:
Extend boom cylinders by
Decreasing machines distance to the bore:
Retract boom cylinders by
NOTE
To adjust the mast parallel (see fig.), the mast

inclination must be readjusted.
B0000505.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5-8
OPERATION
5.4
MAST PROP CONTROL *

WARNING!
Squashing hazard!
Keep limbs out of the operating area of the mast prop.
The mast prop must be fully extended when strong forces result from the extraction of
the tool.
WARNING!
Tipping rig hazard!
The surface under the mast prop must be safely supporting.
Underpin with suitable material, as required.
To extend the mast prop:

Press button and hold down.
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
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5-9
OPERATION
5.5
TRAVELLING WITH THE RIG
5.5.1
Travelling over Level Ground
Risk of accident due to drivers obstructed round-view from the cab.

The driver of the rig must be assisted by a signalman during travel.
CAUTION
Provide an obstacle free travel path.
Adjust the uppercarriage in line with the crawlers and apply the swing brake.
Lower work attachments and movable loads as close to the ground as possible.
Set the mast in position of minimum working range.
Set the mast vertical.
Travel on firm and level surfaces only.
Avoid making abrupt movements.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 10
OPERATION
5.5.2
Travelling Up and Down Slopes
5.5.2.1 With Raised Mast without Drilling Equipment
Tipping hazard!
Observe all instructions found in sect. "Travelling over level ground"!
CAUTION
CAUTION
Tipping hazard!
Max. permissible gradient is 15.
Travel straight to the grade only. Never zigzag or traverse!
Arrange the machine to carry the mast

on the uphill side.
Tilt the mast slightly forward.
Travel up or down a slope in the manner shown here:

B0000704.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 11
OPERATION
5.6
ROTARY DRIVE CONTROL
5.6.1
Kelly Application (Rotary Drive, constant)
7
KDK
KDK
KDK
KDK
1
return flow
10
1
15
16
KDK
KDK
17
18
19
20
21
P
0
1
10
11
12
13
14
22
23
24
25
26
27
28
BK19065007.wmf
Function
BK19065009.wmf
Control
To select high torque
Press the button (17)
To shift between high and low speed
Press the control lever (7) or button (22)
To select reduced torque + high speed
Press the button (15)
To select reduced torque + reduced speed Press the button (16)

Change speed:
Move the control lever (10) away from or

back to centre
Turn the rotary drive counter-clockwise

Turn the rotary drive clockwise
Move control lever (10) to the right

Move control lever (10) to the left
To dump spoil
(abrupt stop during clockwise rotation)
Move the control lever (10) to the left and

press the button (8)
CAUTION
Risk of damage to the Kelly bar and/or the rotary drive!

Never dump soil, when an interlocking area of the outer Kelly is in the
Kelly driver of the rotary drive.
Should a locking area of the outer Kelly be in the Kelly driver, the rotary
drive must be moved in relation to the Kelly bar before dumping the soil.
To select high speed, the indicator (23) lights up.

NOTE
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 12
OPERATION
Shifting the torques is allowed only when the rotary drive isnt in motion
and the drilling tool not in touch with the borehole bottom!
CAUTION
Condition to use the "high" torque mode for Kelly bars:
Only Kelly bars capable of transmitting the "High" torque of the rotary drive may be
used in the High torque mode. Know the max. permissible torque of your Kelly before
you begin or your Kelly could get damaged.
When the Kelly bars used are not designed for the torque of the rotary drive, the keyoperated switch (1) in the control cabinet must be turned to position of "High Torque
OFF" to prevent damage to the Kelly.
Limitation
Torque
High
Limitation
Torque
High
BK1206501.wmf
Risk of damaging the Kelly!

CAUTION
NOTE
Operation with excessive torque can ruin the Kelly bar.
With the key-operated switch (1) set to "OFF" in the control cabinet, the
1st gear of high torque is automatically blocked. And button (17) on the
control panel is out of function.
KDK
KDK
KDK
return flow
10
11
12
13
14
15
16
KDK
KDK
22
23
17
24
18
25
19
26
20
21
27
28
BK19025002.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 13
OPERATION
5.7
WINCH CONTROL
5.7.1
Lifting / Lowering
WARNING!
Danger of getting squashed, entangled, drawn-in and scrubbed!
Never put a hand in the winch moving area.
Never reach between winch and rope.
Never seize a rope in motion.
WARNING!
Hitting hazard, squashing hazard!
Hook up the auxiliary rope on the holding arm.
Do not tension hooked-up rope when people are in the danger zone.
CAUTION
CAUTION
Risk of damaging the winches!

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

Hoist limiters are out of function during rigging operations so that the
winches must be controlled with great care.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 14
OPERATION
In Drilling mode
In Rigging mode
The Rigging mode switch on the control

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

panel is selected (see fig.):
Winch selection:
Set switch on control panelto Main winch (1) or to Auxiliary winch (2) (see fig.).
1
2
Control of selected winch
B0000702.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 15
OPERATION
5.7.2
To Operate with Freewheel
The Freewheel function enables the main winch to automatically follow the drilling progress.
3
20
0
1
BK19035009.wmf
Precondition for release of Freewheel function:

Load on rope is maximum: 2.0 tonnes
Freewheel activation:
Turn key-operated switch (4) to position 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 switch, or

Lift / lower by the winch control lever.
Turn key-operated switch (4) back to position of Freewheel Mode "OFF".
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 16
OPERATION
5.8
DEPTH MEASURING CONTROL
5.8.1
To Reset the Depth Measuring
Place drilling tool in desired position.

Press button " D=0 " (2), to reset the
depth indicator to "0".
2
1
BK15155011.wmf
Depth 1 = Depth of main winch

Depth 2 = Depth of crowd
The depth measuring may be reset to zero at any time.

NOTE
NOTE
For more details please refer to the supplementary documentation supplied with equipment.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 17
OPERATION
5.9
CROWD CONTROL
CAUTION

Do not use the boom cylinders to boost the crowd system.
Or, the crowd system will be overloaded and the drilling axis distorted.
Do not use the fast crowd for drilling down. Or, the drilling equipment will
be damaged.
WARNING!
Squashing hazard!
Do not reach into the moving area of the crowd sledge.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 18
OPERATION
5.9.1
Manual Control of the Crowd
6
10.1
10.2
BK19035011.wmf
Function
Control
Indicator
To run the crowd sledge

Down
Push control lever (10.1)

forward
To run the crowd sledge

Up
Pull control lever (10.2)

back
To change the crowd speed Speed changes with the

amount of lever movement.
To operate in fast mode
CAUTION
Press button (6) and hold on

Move lever off centre.

Do not use the boom cylinders to boost the crowd system.
Or, the crowd system will be overloaded and the drilling axis distorted.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 19
OPERATION
5.9.2
To Use the Main Winch in Combination with Crowd
CAUTION
Danger of damaging the slewing ring and undercarriage by overloading!

Pulling by the main winch combined with pulling by the crowd system is
permissible only under observance of the following instructions.
Pulling by the main winch together with the crowd system is allowed only
in the case of a recovery, and

where the rig is equipped 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 certain value of the combined forces is exceeded.
Where there is no such monitoring automatic, the operator himself is
responsible for not endangering the capacities of the rig when forces
sum up.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 20
OPERATION
5.10
USING THE ENGINE DIAGNOSTIC SYSTEM
Engine diagnostics:
Error code indicator (4) is ON:
Stop the engine.

Turn the ignition ON again.
Press the switch (7).
The error code indicator (4) flashes at
a specific rhythm. Each type of error
has its specific flashing sequence. For
the respective allocation contact the
Bauer after sales service.
If more than one error is present, the
button (6) can be used to switch between (scroll through) the error codes.
2
4
5
3
Engine diagnostics:
Warning indicator (5) is ON:
Stop the engine immediately.

Then proceed as described under "Error code indicator (4) is ON" (see
above).
0
1
6
7
BK19035024.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 21
OPERATION
5.11
CENTRAL LUBRICATION CONTROL *
The central lubrication greases automatically at preset intervals all the spots linked up to the
central lubrication system. Both the length of the lubrications and the length of the pauses are
pre-adjustable.
In addition, a red push-button enables release of lubrication at any time.
The lubrication interval will be interrupted and saved when ignition is turned off, and will be resumed when ignition is turned on again.
Not all the places to be lubricated are covered by the central lubrication system.
Please, find in the Lubrication Plan the places requiring separate lubrication.
NOTE
NOTE
During the automatic lubrication, it is recommended to run the crowd sledge up

and down the mast 2 - 3 times in order to 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
Lubrication on
Low lubricant level
High lubricant pressure
on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off
Control failure
Permanent lubrication
Sledge lubrication failure
1.5 sec.
1.5 sec.
1 sec. 1 sec.
on
off
on
off
on
off
on
off
0.5 sec. / 0.5 sec.
1 sec.
1 sec.
on
off
To avoid failures in the central lubrication system, switch OFF central lubrication
system during rigging procedure of the rig (switch in the cab).
NOTE
A manufacturer's documentation on the Central Lubrication System is supplied in
the Appendices of this manual.
NOTE
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
5 - 22
6.1
START-UP
6.1.1
Initial Start-Up
The initial start-up of the equipment concerns both the manufacturer and the future user, the customer. In general, the job required here will be carried out jointly in a training
held at the manufacturers or in a briefing on the construction site.
Even before the first rigging operations are begun, the operator of the equipment must
be familiar with all the control elements and their capabilities.
6.1.2
Visual Inspection before Starting
A visual inspection and thorough check is required before putting the equipment into
operation:
Inspect the entire equipment for loose connections and missing pins or bolts.
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 / 2254_BG25_en_0000498763_V01
6-1
6.1.3
Daily Start-Up
6.1.3.1 Starting the Equipment
Risk of damaging the equipment!

Observe instructions in the manual of the base machine!
CAUTION
Set the battery main switch to "ON" position.

Set all controls to "0" position.
Pull the Emergency STOP button.
Start the engine by turning the ignition key.
Risk of damaging the engine!
Allow cold engine to warm up at idle speed for approx. 10 minutes!
CAUTION
Move the safety stick of the pilot control to "ON" position.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
6-2
6.1.3.2 Selecting the Engine Operating Mode
Select the Maximum Engine Speed

After restarting the engine, select operating mode "M".
NOTE
Press button (1).
Indicator "H" lights up.
Press button (2).
The "Heavy duty work mode"
indicator lights up.
Press button (3).
Indicator "M" lights up.
BK00004000.jpg
For more details, please consult the additional OPERATOR'S MANUAL

supplied by the manufacturer.
NOTE
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
6-3
6.1.4
Safety Tests before Starting to Work

WARNING!
Serious accident hazard!
Faulty safety devices are dangerous.
All equipped safety devices must be tested prior to starting to work, and
any faults found must be repaired by skilled personnel.
The equipment may be put to work only when all safety 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 "OFF" position.

All hydraulic functions must be blocked. The diesel engine remains on.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
6-4
6.1.4.3 Checking the End Limiters

Initial situation: Drilling mode selected
Hoist limiters (HS 1 and HS 2)
Select main winch.

Slowly spool in rope until suspended load (approx. 100 kg) hits contactor weight.
The winch must come to an immediate stop.
Repeat the procedure with the other winch.
Boom cylinder end limiters (ES 3 / B 39)
Extend boom cylinders half way.

Selection of rigging modes must not be enabled.
Extend boom cylinders completely.
Selection of rigging modes must be enabled.
Mast sideward angle end limiters (ES 2 and ES 4)

WARNING!
Danger of being crushed!
Do not actuate end limiters with your bare hands!
Only actuate them by touching with an object (piece of wood e.g.)
held in your hand.
Hold left end limiter depressed 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 / 2254_BG25_en_0000498763_V01
6-5
6.2
SHUT-DOWN
6.2.1
Daily Shut-Down
Park the machine on firm level ground.

Set the mast upright.
Lower attached work equipment, tools and suspended load as close to the ground
as possible.
Adjust the uppercarriage in line with the crawlers.
Set all control elements to "0" position.
Move the safety stick of the pilot control to "OFF" position.
Stop the engine.
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 a Longer Period
Fuel tank
Before longer periods of standstill fill up fuel tank completely with fuel because of
corrosion protection.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
6-6
7.1
GUIDELINES FOR RIGGING AND DE-RIGGING
Have assembly job carried out by skilled personnel only.

Only carry out rigging and de-rigging operations in the "Kelly mode".
CAUTION
Severe accident hazard!

The operator must be familiar with all the control elements and their
capabilities before he starts rigging operations.
WARNING!
Danger of falling!
Personnel working on the mast or on the upper carriage must wear the
prescribed fall protection equipment.
The equipment must only be mounted on even and horizontal ground with the necessary load-bearing capacity.
Check all components for damage.
Steel components which are subjected to heavy loads (e.g. the undercarriage, upper
carriage, boom, auxiliary boom, supporting boom, kinematic triangle, mast sections,
masthead, winch trestles and the connection between the piston eyes and the hydraulic cylinders and piston rods) should undergo visual inspection prior to mounting
to check for fissures.
Before starting assembly, inspect the equipment for a film of protecting wax. All
such wax must be removed (see Chapter Wax Removal).
For lifting and loading, use only the lifting slings forming part of the basic outfit.
Attach lifting slings only to provided lifting eyes.
Rig tipping hazard!
CAUTION
During rigging operations, the uppercarriage must be in line with the

undercarriage and be interlocked with the same.
Select Rigging mode:
Switch (1) on the control panel (see fig.).
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
BK14885013.wmf
7-1
7.2
WAX REMOVAL
Prior to putting into service, remove all protecting wax with a hot water jet, at a temperature of 90C - 95C (approx. 200F).
NOTE
CAUTION
Alternatively, the equipment can be washed down with a cold water detergent.
The treatment must be repeated until all the equipment is totally free of
wax.

Detergents used must not be harmful to seals etc.
Check detergents for their areas of application prior to use.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7-2
7.3
EXTENDING THE CRAWLERS

Rig tipping hazard!
CAUTION
The crawlers must be extended as soon as the machine has been unloaded from the transporting vehicle and before rigging operations are
begun.
WARNING!
Squashing hazard, shearing hazard and drawing-in hazard!
The machine must be out of motion during work on the undercarriage. A
reliable communication between person at undercarriage and operator
in cab must be provided at all times.
The danger zone must be cleared before crawlers are extended.
Do not extend the right and left crawler simultaneously.

On one crawler, remove retainers (2)
and remove pins (1) from the lock position A.
By button
Bk19030013.wmf
extend the crawler while travelling forward and reverse.

Reinstall the pins (1) at the lock position B, and secure the pins with retainers (2).
BV737516.jpg
Repeat the procedure with the other

crawler.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7-3
7.4
MOUNTING THE COUNTERWEIGHT

WARNING!
Tipping hazard!
The machine must be fitted with the appropriate counterweight before
rigging operations are begun.
The counterweight(s) must remain unchanged and installed as long as
the machine is rigged.
WARNING!
No person must stand on or under a counterweight while it is being
mounted.
Persons working on the upper carriage must wear a fall protection belt
secured to the upper carriage (red painted loop).
WARNING!
Each time the counterweight is mounted, the mounting bolts must be
additionally checked after 50 operating hours with the specified torque.
CAUTION

Counterweights consisting of several parts are to be transported in
upright position.
For further information please refer to the documentation supplied
with the base machine.
NOTE
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7-4
To mount counterweight(s):
Mount the counterweights individually at all times!
NOTE
Mounting the Inside Counterweight
Attach suitable lifting devices to the
lifting equipment and to the lifting
points (1) of the inside counterweight
(2).
Hoist counterweight (2) onto machine
using lifting equipment and set it down
on the frame.
BK00004001.jpg
Lightly tension lifting

devices.
NOTE
Mount the counterweight on the frame
of the upper carriage with bolts (3) and
tighten to an adequate torque (see
Section 10).
BK00004002.jpg
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7-5
Mounting the Outside Counterweight

points (1) of the outside counterweight
(2).
Hoist counterweight (2) onto machine
using lifting equipment and set it down
on the frame.
BK00004003.jpg

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 / 2254_BG25_en_0000498763_V01
7-6
7.5
MOUNTING THE MAST
7.5.1
Mounting the Trestle
Select backstay cylinder operation.

Using the control levers, retract backstay cylinders and slightly raise the mast.
Risk of damaging the rig!
With the trestle folded to the front, the mast may be raised by max. 20.
CAUTION
Mount transport supports (4).
Using the control levers, extend backstay cylinders and put down the mast on the
ground.
Underpin the transport supports with timber if the ground is soft.
NOTE
Open up the mechanical swing lock.
Release the swing brake.
Extend backstay cylinders (1) by control levers, until trestle (2) can be mounted to
machine with pin (3).
Install the pin and secure it.
Retract backstay cylinders and raise the mast enough to enable the transport supports (4) to be removed from the lower mast section.
1
2 3
4
BM339512.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7-7
7.5.2
Assembling the Mast Sections
Place the mast sections on a firm and level surface to front of the lower mast section.
Clean flange faces and locating pins and check for damage.
CAUTION
With the machine, travel up to the mast sections.
WARNING!
Risk of crushing, shearing and hitting!
Avoid getting limbs in between the mast sections.
Minor backstay cylinder movements can lead to major movements of
the mast sections.
During the assembly operations, the operator must keep the person
working at the mast in view at all times.
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
B0000567.wmf
Install the pins and secure.

Retract backstay cylinders to raise the lower mast section until flange faces meet.
Take care the locating pins are properly in place!
CAUTION
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7-8
Bolt the mast section (6) to the lower mast section (5) in the manner shown here.
6
Bolt tightening torque value Ma [Nm]:

1900
1
2
3
4
5
6
Hex head bolt

Washer
Hex nut
Lock nut
Lower mast section
Upper mast section
1 2
23 4
B0000999.wmf
Remove transport supports.

Make hydraulic connections between the mast sections.
Make electric connections between the
mast sections.
To do so, remove plug (1) of electric cable from transport socket (2) and plug it
to the next mast section.
Check on the ladder that fall protection
rail (3) transfer points are in line. Readjust at the ladder mounting points (4) as
necessary.
WARNING!
Danger of falling!
The lanyard can slip out of
its rail.
Precisely adjust transfer
points.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
BM400462.jpg
7-9
7.5.3
Installing the Ropes
7.5.3.1 Installing the Main and Auxiliary Ropes

WARNING!
Accident risk!
A main rope which has been reeved through a rope crossbeam during
operation and has not been marked out with a swivel is only permitted for
operating mode.
Kelly operation is no longer permitted with this main rope.
The main (4) and the auxiliary (3) rope must be installed while the mast is down.
Select the "winch rigging" mode.

Remove rope guard pins (1) from the masthead.
Select the main winch or the auxiliary winch.
With the left control lever, unwind a sufficient length of rope from the selected winch.
Pass ropes over guide sheaves (5) and unwind until rope ends are at contactor
weights (6).
Thread ropes through contactor weights (6) of hoist limit switches (7).
Reinstall the rope guard pins and secure (1).
Unwind until rope ends are at resting on the machine.
Check contactor weights are properly attached.
CAUTION
1 5
5 1
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
BM091514.wmf
7 - 10
7.5.3.2 Installing the Upper Crowd Rope
Select "winch rigging" mode.

Extend rope tensioning cylinder (1).
Remove crowd sledge stoppers from transport position (2) and install them at upper
end of mast (3).
7
5 3
6
2
7 3
2
BFASE192.wmf
Remove crowd rope from transport deposit.

Move crowd sledge down to lowermost point.
Pass end of rope behind guide sheave (4), up and around upper left guide sheave
(5) down to guide sheave on sledge (6), counter-clockwise back up to sheave (7) on
upper end of mast to rope tension cylinder (1).
Anchor rope end with wedge to rope tension cylinder (1).
WARNING!
Serious injury hazard!
3 wraps of upper crowd rope and 3 wraps of lower crowd rope must be
installed on the drum of the crowd winch, for safety reasons.
Retract rope tensioning cylinder to tension the crowd ropes.

Run the crowd sledge up and down several times.
Run the crowd sledge down to the lowermost point.
Retract rope tensioning cylinder to re-tension the crowd ropes.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 11
7.5.4
Mounting Crowd Stroke Limiters
WARNING!
Rig tipping hazard!
For reasons of stability, the crowd sledge fitted with Kelly equipment
must not be free to move to the upper mast end.
8
BK587503.wmf
Remove the two sledge travel stoppers from their position (3) on the upper mast end
and reinstall hem into bores (8) located further down the mast.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 12
7.5.5
Raising the Mast

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

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

Do not allow the mast to drift aside. The backstay cylinders must be retracted in a uniform manner and without interruptions.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 13
7.5.6
Mounting Retaining Clamps
CAUTION
Rig tipping hazard!

These clamps must be mounted as soon as the mast has been raised.
Select "Rigging" mode.

Completely retract both backstay cylinders by
pulling the control levers back.
Attach retaining clamp halves (1) to one backstay cylinder.
Push O-Ring (2) up on clamp and install in
groove (3).
Using a hammer, knock locking ring (4) down
on clamp.
4
3
1
3
1
Repeat the procedure on the other backstay

cylinder.
BK331531.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 14
7.6
ASSEMBLY OF WORK ATTACHMENTS

WARNING!
Squashing hazard, shearing hazard, entangling hazard!
Minor movements by the backstay cylinders can create sudden and
uncontrolled major movements of attached components during their
assembly. Components of work attachments are extremely heavy.
The operator must keep in view the person performing the assembly
throughout the whole procedure.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 15
7.6.1
Assembly of Kelly Equipment
7.6.1.1 Mounting the Rope Swivel
CAUTION

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

Mount the swivel in the right way.
The lube nipple must be up.
After mounting, grease the swivel and test it rotates freely.
1
2
3
4
5
6
Main rope
Pin
Lube nipple
Hex head bolt
Lock washer
Washer
1
6
5
2
4
B0000572.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 16
7.6.1.2 Mounting the Rotary Drive
Set mast to upright.

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

lifting lug, the rig's auxiliary rope (4)
may be used additionally to help align
the rotary drive.
1 2
4
5
Remove lifting slings.

Stop engine.
Connect hydraulic lines.
B0000700.wmf

Connect the leak oil line first.
CAUTION
3/A1, 5/2
4/B1, 6/B2
1/T
9/SP-L
12/P
Pressure
Return flow
Leak oil
Flush oil
Control oil
Ansicht A:
View A:
62
6/B2
117
116
9/SP-L 5/A2
1/T
NOTE
Ansicht A
View A
42
4/B1
41
3/A1
12/P
Hydraulic lines and connections wear

matching identifications.
B0000808.wmf
Connect electric lines.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 17
7.6.1.3 Mounting Kelly Guidance *
Initial situation:
The Kelly is removed.
Arms (2) for holding the guidance (1)

are mounted with pins (3).
B0000708.wmf
End cover (8) is removed from the

Kelly.
8
7
5
B0000711.wmf
Mounting the Kelly guidance:
6
4
Mount to the Kelly bar (5) an extension

(4) for the rope swivel.
Mount the Kelly guidance (2) with bolts

(7) to the Kelly bar.
Mount the rope swivel (6) to the swivel

extension (4); see also next page.
B0000707.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 18
1
2
3
4
5
6
7
Main rope
Mounting pin
Lube nipple
Swivel extension
Hex socket tie bolt
Lock washer
Washer
3
7
6
5
4
B0000710.wmf
Mount main rope to swivel.
Lift the Kelly into the rotary drive.
Mount drilling tool to Kelly and drill down.

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

point.
Remove the pins (3).
Swivel the arms (2) towards the mast

(8) by 180.
Reinstall the pins (3) and secure them.
B0000709.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 19
7.6.1.4 Mounting the Kelly

To mount the Kelly, the mast must be in upright position and be fitted
with the rotary drive.
NOTE
Lay the Kelly bar down lengthwise to front of the machine, in the centerline of the
machine.
Suspension eye on Kelly must face the machine.
NOTE
1
Mount rope swivel to eye on Kelly, in accordance with fig. below.
1
2
3
4
5
6
7
8
Main rope
Rope swivel
Pin
Kelly
Lock washer
Hex head bolt
Washer
Lube nipple
8
7
6
5
4
B0000621.wmf
Move rotary drive to lowermost position.

Tilt mast forward by approx. 2 - 3.
By the main winch, lift the Kelly as shown to
right and at the same time travel with the
machine towards the Kelly.
B0000622.wmf

Keep the main rope vertical at all times.
CAUTION
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 20
Lift Kelly until its square stub is approx. 20 cm above the rotary drive.
CAUTION
Avoid collision with the rotary drive!
Set mast to upright again.
Allow the Kelly to stop swinging and then insert it into the rotary drive.
Slight rotation with the rotary drive can be helpful when inserting the
Kelly.
NOTE
Insert the Kelly through the rotary drive.
Mount drilling tool to Kelly with two pins.
CAUTION

At all times, use TWO pins to mount the drilling tool, and do not forget
to secure the pins.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 21
7.6.2
Mounting Casing Oscillator *

How to mount a casing oscillator to the machine is described in the
separate manual belonging to the casing oscillator in question.
NOTE
Pass hoses from casing oscillator over

left and right crawler crossbeam up to
bulkheads "A".
BM779507.wmf
Stop the engine of the base machine.

Remove dust caps from hydraulic connections.
Mount the hydraulic couplings in compliance with the provided numbers.
Make electric connection of casing oscillator and base machine.
View "A":
Undercarriage seen from the rear. The identified couplings are found on the front side
of the two bulkheads.
BM779414.jpg
20
21
22
23
24
25
Oscillation [P]
Oscillation [R]
Unclamping
Clamping
Lowering
Lifting
28
29
30
PST
E1
Locking
Unlocking
Leak oil [T] (optional)
Pilotoil (optional)
Electric connection (optional)
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 22
7.7
DISASSEMBLY OF WORK ATTACHMENTS

WARNING!
Squashing hazard, shearing hazard, entangling hazard!
Minor movements by the backstay cylinders can create sudden and
uncontrolled major movements of attached components during their
disassembly. Components of work attachments are extremely heavy.
The operator must keep in view the person performing the disassembly
throughout the whole procedure.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 23
7.7.1
Disassembly of Kelly Equipment
7.7.1.1 Removing the Kelly
Set mast to upright position.

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

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

Disconnect the leak oil line (T) last.
Ansicht A:
View A:
62
6/B2
117
116
9/SP-L 5/A2
1/T
Ansicht A
View A
42
4/B1
41
3/A1
12/P
CAUTION
B0000808.wmf
Attach lifting slings to lifting eyes (5).

Suspend the slings to the rig's main rope (3)
(or to the hoist rope of an assist crane, if not
equipped), and slightly pre-stress the rope.
Remove pin retainers and pull the pins out
(1 and 2).
NOTE
On rotary drive fitted with an auxiliary

lifting lug, the rig's auxiliary rope (4)
may be used additionally to help align
the rotary drive.
Lift off and put the rotary drive down on ground.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
1 2
4
5
B0000700.wmf
7 - 24
7.8
DISASSEMBLING THE MAST
7.8.1
Removing the Retaining Clamps
Using a hammer, knock the locking ring

(4) off the retaining clamp.
Remove the O-Ring (2) from the groove
(3) in the clamp.
Remove the clamp halves (1) from the
backstay cylinder.
Repeat the procedure on the other
backstay cylinder.
4
3
1
3
1
B0000671.wmf
7.8.2
Lowering the Mast
Adjust the uppercarriage in line with the undercarriage, with the mast located on the
same side as the crawler drive wheels.
Risk of colliding the mast with the crawlers!

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

Take care not to let the mast drift aside during the lowering. The backstay cylinders must be extended uniformly and without interruptions.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 25
7.8.3
Removing the Ropes
7.8.3.1 Removing the Main and Auxiliary Rope

The main rope and the auxiliary rope will be retrieved with the mast lying down.
Select the "Winch rigging" mode.
Remove rope guard pins from the masthead.
Select main winch or auxiliary winch.
Carefully spool in rope by the left control lever.
Unthread the ropes from the contactor weights of the hoist limiters.
Spool in both rope ends to the intermediate guide block.
Reinstall the rope guard pins on the masthead.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 26
7.8.3.2 Removing the Upper Crowd Rope
To remove the rope, the mast must be lying.

NOTE
14 15 13
8/9
10 4
3 12
Y
8
"X"
6 2
9
9
11
"Y"
6 2
10
16
4 16
3 12
BK587507.wmf
Move crowd sledge into position for transport (see fig.).

Remove sledge upper end stoppers from upper mast section and reinstall into
transport position (16).
Completely extend the rope tensioning cylinder (7).
Remove the rope clip (14).
At the rope tensioning cylinder, remove the pin from the rope end socket (15).
Knock the wedge (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 / 2254_BG25_en_0000498763_V01
7 - 27
7.8.4
Disassembling the Mast
WARNING!
Squashing hazard, shearing hazard and hitting hazard!
Minor movements by the backstay cylinders create major movements of
the mast sections.
During the disassembly operations, the operator must keep in view the
person working at the mast at all times.
Mount transport supports to upper mast section.

Undo hydraulic and electric connections between mast sections.
Unscrew bolts from mast connecting flanges, and stow the bolts for later use.
Lower the mast until masthead and rear mast supports rest on ground.
Remove pin retainers from rear side of mast, and pull the pins out.
Travel in reverse with machine and disengage upper mast section from lower mast
section.
CAUTION
Risk of corrosion!
Corrosion protect flange faces with grease if the storage or transport of
the rig is expected to take long.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 28
7.8.5
Lowering the Trestle
Mount transport support (4).

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

Prevent the pins dropping down.
CAUTION
Retract backstay cylinders until trestle (1) rests on bearing point (3).
1
3
4
BK097505.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 29
7.9
REMOVING THE COUNTERWEIGHT

WARNING!
Risk of getting crushed or hit!
No person must stand on or under a counterweight while it is being dismounted.
Avoid getting limbs in between machine and counterweight.
Before releasing or removing safety components, secure the counterweights 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

Counterweights consisting of several parts are to be transported in
upright position.
During their intermediate storage, the counterweights must be secured
against tipping.
For further information please refer to the documentation supplied
with the base machine.
NOTE
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 30
To remove counterweight(s):
Remove the counterweights individually at all times!
Before removing, check if the screws are tight!
NOTE
Removing the Outside Counterweight

points (1) of the counterweight (2).
BK00004003.jpg

devices.
NOTE
Loosen the bolts (3). Remove the
bolts
and safety material.
Using lifting equipment, lift the counterweight away from the frame, set it
down on level, stable ground and secure it against tipping over.
BK00004004.jpg
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 31
Removing the Inside Counterweight

points (1) of the counterweight (2).
Lightly tension lifting devices.
BK00004001.jpg

devices.
NOTE
Loosen the bolts (3). Remove the
bolts
and safety material.
Using lifting equipment, lift the counterweight away from the frame, set it
down on level, stable ground and secure it against tipping over.
BK00004002.jpg
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 32
7.10
RETRACTING THE CRAWLERS

WARNING!
The machine must be out of motion during work on the undercarriage.
A reliable communication between person at undercarriage and operator in cab must be provided at all times.
The danger zone must be cleared before crawlers are retracted.
Do not retract the right and left crawler simultaneously.
On both crawlers, clean and grease the

sliding surfaces (3).
On one crawler, remove retainers (2)

and remove pins (1) from the lock position B.
By button
Bk19030013.wmf
retract the crawler while travelling forward and reverse.
Reinstall the pins (1) at the position A",

and secure the pins with retainers (2).
Repeat the procedure with the other

crawler.
BV737445.jpg
BV737516.jpg
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
7 - 33
TRANSPORT
TRANSPORT
8.1
SAFETY GUIDELINES FOR TRANSPORT
Only use hoisting equipment and lifting slings that have sufficient capacity.
WARNING!
Danger of serious accidents!
Attach lifting slings only to the provided and identified lifting points.
Lifting points on the machine are painted GREEN and have a hook
symbol. In addition, numbers tell the weight picked up at the respective
points.
Lifting points on individual components are painted RED.
CAUTION
The hoist rope must be vertical at all times, to prevent swinging.

If the load begins to swing, land it immediately and readjust until the
rope is vertical again.
Arrest and secure movable parts of the equipment.

Check the work 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 driver of the transporting vehicle is responsible for checking each time before
he starts to drive that all the equipment, the machine and accessories are restrained
from movement and properly tied down to the deck of the vehicle.
The haulier in charge is responsible for the transport of the equipment, the machine
and accessories.
The haulier should be informed of the transport dimensions and weights and the
route.
A road permit must be asked for.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
8-1
TRANSPORT
8.2
MEASURES TO TAKE FOR TRANSPORT
MACHINE
Before loading
The machine must be put into the following shape before it may be driven onto a lowloader or be lifted by a crane:
all attachments have been removed from the mast,

the mast is lowered,
the upper mast section is removed,
the lower mast section is removed (as necessary),
the uppercarriage is in line with the crawlers and locked to the undercarriage,
the crawlers are retracted,
the beam extensions (if so equipped) have been removed.
the counterweights have been removed (as necessary).
After loading
Underpin the lower mast section with transport supports and secure.
Put the safety stick of the pilot control to "OFF" position.
Stop the engine and remove the ignition key.
Lock the cab and remove the key.
Put the battery main switch to "OFF" position.
Tie the machine safely down to the deck of the transporting vehicle.
EQUIPMENT
The rotary drive must be in upright position during the transport.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
8-2
TRANSPORT
8.3
DRIVING ON / OFF A LOWLOADER

7.
10. 10.
3.
6.
12.
12.
11. 11.
9.
13.
!!!
9.
2.
0
4.
5.
max.40
1.
9
12
11
10
10 A
BK15155000.wmf
1
2
3
4
5
6
7
Set battery switch to "ON"

Release "Emergency STOP" button
Move pilot safety stick to "OFF"
Engine ignition ON / OFF
Engine speed adjustment
Move pilot safety stick to "ON"
Select Rigging mode
CAUTION
8 Not used
9 Slightly raise lower mast section by right 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"
Risk of damaging the equipment!

With the trestle still folded to the front, the lower mast section must not
be raised by more than 40.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
8-3
TRANSPORT
8.4
LIFTING POINTS
BK1162502.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
8-4
TRANSPORT
8.5
TRANSPORT DATA
1520
300
2350
Dimensions in [mm]
1420
2800
12780
12330
1400
3090
4620
700
3000 - 4380
3260
BK15725001.wmf
Weights
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

Counterweight
4.20
2 x 6.20
Equipment
5.00
Kelly bar BK 25/394/4/56
10.10
Kelly bar BK 25/394/4/40
7.70
1.90
2.30
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
8-5
TRANSPORT
8.6
TYING DOWN
WARNING!
Tie-downs must be attached to the provided intended points only.
The chains used for tie-downs must have sufficient capacity.
Tying points
On blue undercarriages the points provided for tying down are painted YELLOW.
On yellow undercarriages the points provided for tying down are painted BLUE.
In addition, tying points wear a hook symbol and tell the max. tension to be applied.
To tie down
Tie the equipment down to the transporting vehicle in the professional manner and in
compliance with national directives.
Principally, the haulier in charge is responsible for tying down correctly.
Example of tying points
CI439400.jpg
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
8-6
MAINTENANCE
MAINTENANCE
9.1
SAFETY GUIDELINES FOR MAINTENANCE
Have maintenance carried out by the after sales service only or by skilled personnel
authorized by the after sales service.
Replace with genuine spare parts from the BAUER Company only.
Observe the "Safety Information" book supplied with the equipment.
Carry out maintenance at the prescribed intervals.
Also observe the other manufacturers' service instructions for components of the
equipment.
9.2
MAINTENANCE INTERVALS
The maintenance for this equipment is organized into the following intervals:
-
Every 10 hours of operation or daily

Every 50 hours of operation or weekly
Every 250 hours of operation or monthly
Every 500 hours of operation or three months
Every 1000 hours of operation or yearly
Every 2000 hours of operation or yearly
Every 3000 hours of operation or two years.
The specified intervals base on the hour meter of the base machine.
NOTE
Normally the intervals are cumulative, meaning that when the 1000 hours maintenance
is due also the 10, 50, 250 and 500 hours services will have to be carried out again.
If the equipment is used under extremely wet and dusty conditions, it may be necessary
to service more often.
CAUTION
Loss of the equipment warranty!

Maintenance carried out on the equipment shall be entered into the
supplied "Maintenance and Repair Log". This is to be done by the person who carried out the job and be signed by himself and a foreman.
In case of a warranty claim, BAUER shall have the right to consult the log.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9-1
MAINTENANCE
9.3
MAINTENANCE PLAN
9.3.1
Entire Equipment
Entire equipment table

Components
Maintenance interval
Operation
10 h
daily
50 h
weekly
250 h
500 h
1000 h
monthly 3 months yearly
2000 h
yearly
3000 h/
every
2 years
Note
Entire equipment
Visual inspection
- Missing or damaged parts
- Load-bearing steel components
(e.g. the undercarriage, upper carriage, boom, auxiliary boom, supporting boom, kinematic triangle,
mast sections, masthead, winch
trestles and the connection between the piston eyes and the hydraulic cylinders and piston rods)
should undergo visual inspection
prior to mounting to check for fissures and other damage.
- Missing or loose
bolts / bolted connections.
- Missing or damaged
safety devices, such as
fire extinguisher,
first-aid kits,
warning signs
- Leaks
Check for proper function of:
- Controls and indicators
- Safety devices such as
emergency STOP,
pilot control safety stick,
limit switches,
hoist limit switches
- Free-fall function**
X
X
X
X
X
X
X
Work platforms
- Check for missing or loose
pin/screw connections
- Check the locks can move easily

and are working properly
Inspection by competent engineer
X
X
* Only during running-in period

** Not supplied with this version
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9-2
MAINTENANCE
9.3.2
Components
Table Attachment
Components
Operation
10 h
daily
50 h
weekly
250 h
500 h
1000 h
2000 h
yearly
3000 h/
every
2 years
Note
Masthead
- Check that the connecting
bolts and screws for the
mast, if provided, are
firmly screwed in;
tighten screws
- Replace connecting bolts for
the mast, if provided
X*
10000 hrs
Mast
Mast
- Lubricate guide rails
- Check that the connecting
bolts and screws between the
mast sections, if provided, are
firmly screwed in;
tighten screws
- Replace connecting bolts between
the mast sections, if provided
X
X*
5000 hrs
Mast prop
- Ensure that bolt safety mechanism
and bolts are screwed in tightly
- Lubricate pivot mount
Ladder on mast**
- Check that the mounting bolts are
firm
- Check transition between the
parts of the mast ladder
- Check fall protection equipment
for function
X
X
X
Mast pivot
- Lubricate mast pivot
- Lubricate mounting bolts
- Check flange bolts are firmly
screwed in, tighten bolts
- Replace flange bolts
X
X
X*
10000 hrs

BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9-3
MAINTENANCE
Table Attachment
Components
Operation
10 h
daily
50 h
weekly
250 h
500 h
1000 h
2000 h
yearly
3000 h/
every
2 years
Note
Winches
- Check oil level
Main winch
Auxiliary winch
Crowd winch
- Change oil
Main winch
Auxiliary winch
Crowd winch
- Lubricate counter bearings
Main winch
Auxiliary winch
Crowd winch
- Ensure that mounting bolts of the
winch trestles are firm,
tighten bolts
- Replace mounting bolts of the
winch trestles
X
X
X
X*
X*
X*
X
X
X
X
X
X
X*
10000 hrs
Cylinders
- Clean piston rods
- Check tightness of cylinder
- Lubricate joints
X
X
X
Bearings and bearing pins

- Lubricate all bearings and bearing
pins that are equipped with lube
nipples
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9-4
MAINTENANCE
Table Attachment
Components
Operation
10 h
daily
50 h
weekly
250 h
500 h
1000 h
2000 h
yearly
3000 h/
every
2 years
Note
Wire rope and accessories

Ropes, rope fasteners,
thimbles and sleeves
- Inspect for wear and damage
Rope swivel
- Lubricate
- Check if bolts are secure
- Check slew function
X
X
X
Rope hold-down rollers

- Check parallel position to cable
drum
Rope sheaves
- Inspect for wear, damage,
and if bearing gap is exceeded
- Check sheaves are free to rotate
- Check groove radii for
deviation and edge formation
- Put grease in lube nipples,
where fitted:
- Rope sheaves with friction
bearing
- Rope sheaves with roller
bearings
X
X
X
X
X
X
Rope roller brackets

- Ensure that mounting bolts of the
turning blocks are firm,
tighten bolts
- Replace mounting bolts of the
turning blocks
X*
10000 hrs
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9-5
MAINTENANCE
9.3.3
Work Equipment
Table Equipment
Components
Operation
10 h
daily
50 h
weekly
250 h
500 h
1000 h
2000 h
yearly
3000 h/
every
2 years
Note
Rotary drive
Rotary drive
- Clean
- Check for leakage
- Check magnetic bars for adhesion
of metal parts
- Check oil level
Main gear
Planetary gears
- Change oil
Main gear
Planetary gears
- Take oil sample and check oil
- Check if hollow shaft mounting
bolts are securely fastened
- Check switch pressure
- Change filter
Line filter
Oil pre-cleaner
- Lubricate oil seal
X
X
X
X
X
X
X*
X*
X
X*
X
X
X
X*
X*
Nominal
value:
35-40 bar
X
X
Kelly driver / guide flange / shock absorber

- Check springs, shock absorbers
and buffer rings for damage
- Check that the mounting bolts are
firm
- Check driver strips for wear
X
X
X
Cardan joint
- Check rubber buffers for
damage
X
X
Crowd sledge
- Check sliding strips for wear
Kelly bar
X*
Drilling tool
- Clean and check for wear and
damage
CFA/FOW/DKS equipment **
- Lubricate concreting head

BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9-6
MAINTENANCE
9.3.4
Uppercarriage
Upper carriage table

Components
Operation
10 h
daily
50 h
weekly
250 h
500 h
1000 h
2000 h
yearly
Engine
Observe separate engine manual!!
Cooling system
Observe separate engine manual!!
3000 h/
every
2 years
Note
Pump distributor gear

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

- Pilot control filters
- Return-flow filters
- Leak-oil filters
- Secondary filters
- Free-fall filters
- Rotary drive filters
- Tank breather filter
X*
X*
X*
X*
X*
X*
Pressure accumulators
- Check preload pressure
Oil cooler
- Clean
- Check for damage
X*
X
X
X
X
X
X
X
Or if
contamination
is indicated
X
X
Swing mechanism
- Grease external slewing ring
teeth
- Lubricate slewing ring and
rotor bearing
- Tighten up screws
X
X*
X
X*
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9-7
MAINTENANCE
Upper carriage table

Components
Operation
10 h
daily
50 h
weekly
250 h
500 h
1000 h
2000 h
yearly
3000 h/
every
2 years
Note
Counterweight
- Check all fastening elements are
present and firmly in place
Electrical system
Batteries
- Check electrolyte level
- Check cable connections
X
X
Fuses
- Check fuses
Filters
- Replace air filter on wiring cabinet
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9-8
MAINTENANCE
9.3.5
Undercarriage
Undercarriage maintenance table

Components
Operation
10 h
daily
50 h
weekly
250 h
500 h
1000 h
2000 h
yearly
3000 h/
every
2 years
Note
Crawler track assemblies

Visual inspection
- Missing or damaged parts
- Carry out a visual inspection of
load-bearing steel components
(e.g. centre bridge and crawlers)
to check for fissures and other
damage
- Perform a visual check of
the crawler drive wheels, tread
rollers and travel gear to ensure
they are firmly attached;
tighten if necessary
X
X
Travel gear
- Check oil level
- Change oil
Crawler tracks
- Check chain tension
- Check that the mounting bolts
for the crawler track shoes
are firm
X
X*
Telescopic guide
- Clean and grease
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9-9
MAINTENANCE
9.3.6
Optional Equipment
Optional equipment table

Components
Operation
10 h
daily
50 h
weekly
250 h
500 h
1000 h
2000 h
yearly
3000 h/
every
2 years
Note
Air conditioning
- Operate the air conditioning system
- Clean air filters (optional)
- Clean condenser
X
X
X
Compressor
-
2 - 3 weeks
Observe separate compressor manual!!
Clean cooling ribs

Clean suction air filter
Replace suction air filter
Clean lubricating oil filter
Replace lubricating oil filter
Change oil
Check maintenance unit
Drain condensate on compressor,
maintenance unit, 70 l pressure
accumulator
X
X
X
X
X
X
X*
X
X
after every
use
Oxidation-type catalytic converter

- Measure the counter pressure of
the exhausts treated by the CRT
system
Generator
Inspect for wear
and damage
Checking the Oil Level
Replace the breather filter
Check ISO meter
Before each use

X
Before each use
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 10
MAINTENANCE
9.4
LUBRICATION PLAN
1
10h 18
1000h
21 1000h
22 250h
10h
10h 32
50h
50h
50h
50h
50h
50h
1000h
10h
20
12
31
10
8
11
19
9
50h
23 1000h
3
1000h
50h
13 50h
7 250h
28 50h
29 10h
26 50h
BK000512.wmf
Every 10 Hours of operation:
2
14
18
29
32
7
9
15
17
22
27
Guide rails
Rope sheaves **
Rope swivel *
External gear ring *
Rotary shaft seal
Supporting trestle pin

Mast support joint
Crowd cylinder joint **
Crowd cylinder joint **
Crowd rope tensioning cylinder joints
Crawler cylinder joints *

4
6
8
10
11
12
13
20
26
28
31
Backstay cylinders joints

Boom pin
Mast pivot assembly pin
Mast pivot assembly joints
Boom cylinders joints
Mast supporting cylinder joint **
Auxiliary winch bearing
Crowd winch bearing
Crawler guides *
Swing gear bearing
Main winch bearing
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
Every 1000 [yearly] Hours of operation:

1
3
19
21
23
Masthead rope sheaves *

Rope sheaves
Crowd rope sheave
Crowd rope sheaves
Crowd rope sheave
*)
**)
Grease manually
Not used in this version
9 - 11
MAINTENANCE
9.5
MAINTENANCE DURING LONGER PERIODS OF STANDSTILL
Engine
Every 2 to 3 weeks, start the diesel engine and let it run in the medium r.p.m. range
for about 1 hour.
Risk of engine damage!
CAUTION
If engine starting will not be possible during the standstill, preservation

measures must be taken. To do so, please refer to the manufacturers
manual of the diesel engine.
Air conditioning
Every 2 to 3 weeks, turn the air conditioning on (if equipped) for a short while.
Slewing ring
Preserve gear teeth.

From time to time during the standstill, remove dust and inspect the surface of teeth
and drive pinion for beginning corrosion; clean and grease as required.
Telescoping guides on undercarriage (only with extendible crawlers)
Preserve the telescoping surfaces with grease.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 12
MAINTENANCE
9.6
HYDRAULIC SYSTEM
WARNING!
Injury hazard from hydraulic oil spray!
Hydraulic systems shall be de-pressurized before any maintenance or
repair is performed thereon. This applies to pressure tanks in particular.
CAUTION
Risk of fire from hydraulic oil spray!

Hydraulic systems shall be de-pressurized before any maintenance or
repair is performed thereon. This applies to pressure tanks in particular.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 13
MAINTENANCE
9.6.1
Hose Assemblies
Inspection
Hose assemblies must be inspected at least once a year by a competent person. A
hose assembly on which one or several of the following criteria are found must be
replaced with a new one:
Damage in the outer layer down to the core of the hose (e.g. abrasions, cuts or fissures).
The outer layer of the hose is brittle (cracks in the tubing).
The hose does no longer comply with its natural shape, both with and without pressure and while it is bent (e.g. layers separating, bubbles forming).
Leaks.
Damage or deformation of hose end fittings (tightness impaired); minor damage to
the surface does not require replacement.
Hose slips out of end fitting.
Corrosion on the end fitting, impairing the function and stability.
The hose is not assembled in compliance with instructions.
The storage and service life is exceeded.
Storage and service life

Hoses and hose assemblies are to be stored in a cool and dry place free of dust.
Direct exposure to sunshine or UV-rays should be avoided.
Storage and service life
Storage time
Service life
(including storage time)
Hose
Hose assembly
2 years
2 years
6 years
Re-use
Generally, hoses that have been in service as part of a hose assembly ought not to be
re-used in a new hose assembly, since they do no longer meet the requirements.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 14
MAINTENANCE
9.6.2
Hydraulic Cylinders
Every 10 operating hours or daily, and every time before starting up again after a
longer period of rest, clean all cylinders and check them for tightness.
CAUTION
Risk of damaging the piston rod!

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

Immediately repair or replace cylinders that are not tight.
CAUTION
Every 50 operating hours or once a week grease the cylinder lugs (holes for pins).
On cylinders that are kept extended during rest:

Risk of corrosion damage in corrosion-supporting environments!
The tasks specified below must be carried out without fail.
CAUTION
Once or twice a week, rub down piston rods with hydraulic oil, or retract and extend
the rods repeatedly.
Before a longer standstill, preserve piston rods with acid free grease.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 15
MAINTENANCE
9.6.3
Filter Replacement
9.6.3.1 Replacing the Line Filters

The elements of the line filters must be replaced after the first 250 operating hours or
one month. Subsequent replacements of the line filter elements are due every 1000
operating hours or whenever contamination is indicated (optional; by a warning lamp or
by a text message).
WARNING!
Serious injury hazard!
Before beginning to replace a filter element, remove the pressure from
the hydraulic system and allow it to cool down.
While the hydraulic oil is still cold, it can happen that the contamination
indication comes on for a little while.
NOTE
Line filters:
1
2
Free-wheel filter
Leak oil filter
2
1
BK1007502.wmf
Place a suitable container underneath

the filter housing and unscrew the bottom (3).
Remove filter element (2) from top (1) of
housing and put it to hazardous waste.
Clean top and bottom of housing.
Install new filter element in top of housing.
Reinstall bottom on top and screw tight.
1
2
3
B0000623.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 16
MAINTENANCE
9.7
WINCHES
9.7.1
The oil level must be checked every 50 operating hours or once a week, and whenever
the equipment is started up again after a longer standstill.
Danger of oil spray!

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

upright.
Unscrew and remove the oil dipstick (1).
Dry the dipstick with a clean and lint-free
cloth.
Reinstall the stick, completely.
Pull the stick out again and read it:
If the oil has sunk to the MIN mark, top up with
new oil and check again.
The MAX mark must not be exceeded.
Clean sealing surfaces, check seal for wear
and damage, replace it as required.
Reinstall the dipstick and screw it down tight.
1
max.
min.
2
3
B0000574.wmf
Winches with sight glass

Checking of the oil level can be performed with
the winch in any position.
If the oil level has reached the lower limit

("min." = 20 mm below the winch centre line),
add oil through one of the screw plugs (2),
then recheck the oil level. Be sure to avoid the
oil level exceeding the upper limit ("max." =
winch centre line).
Clean sealing surfaces, check seal for wear
and damage, replace it as required.
Reinstall the screw plug and screw it down
tight.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
max.
20 mm
min.
1
B0000846.wmf
9 - 17
MAINTENANCE
9.7.2
Changing Gear Oil
The oil must be changed after the first 250 operating hours or one month. Subsequent
oil changes are due every 1000 operating hours or once a year.
CAUTION
Danger of oil spray!

Change oil only when the winch is off.
Winches with dipstick
Position the winch such that the tube (2) is

upright.
Unscrew and remove the oil dipstick (1).
Remove the drain screw (3) and drain the gearbox.
At low outdoor temperatures, flush the empty
gearbox with a warmed-up part of the new oil.
Clean sealing surfaces, check seal for wear and
damage, replace it as required.
Reinstall the drain screw.
Refill with new oil.
Check the oil level.
Reinstall the oil dipstick (1) and screw it down
tight.
1
max.
min.
2
3
B0000574.wmf
Winches with sight glass

Changing of the gear oil can be performed with the
winch in almost any position.
Unscrew and remove any of the screw plugs (2).

Unscrew and remove any of the screw plugs (1)
and allow the gear oil to drain.
At low outdoor temperatures, flush the empty
gearbox with a warmed-up part of the new oil.
Clean sealing surfaces, check seal for wear and
damage, replace it as required.
Reinstall the screw plug (1).
Refill with new oil.
Reinstall the screw plug (2) and screw it down
tight.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
max.
20 mm
min.
1
B0000846.wmf
9 - 18
MAINTENANCE
9.8
REPLACING THE UPPER CROWD ROPE
CAUTION

When the mast is down, only move the crowd sledge with another person present to give directions!
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.
Remove the entire rope.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 19
MAINTENANCE
WARNING!
Accident risk!
When attaching the rope, always ensure you wind it round the number
of times required for safety purposes (the reeving chart in the spare
parts list has more details on this).
CAUTION
Danger of the new rope breaking!

Check rope sheaves and pin retainers for damage.
B00005424.png
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 20
MAINTENANCE
Attach the upper crowd rope, ensuring you wind it round the number of times required for safety purposes, to the drum (in the direction of travel - towards the right)
and thread the end of the rope through the clamping rail (11) on the winch (1).
BV00004024.jpg
CAUTION
Danger of rope breaking!

The end of the rope must not protrude past the drum winch, as it can
otherwise get caught on the winch trestle during winding.
Insert the wedge (21) into the clamping rail (11) and tighten the bolts (20) to the prescribed tightening torque.
Feed the rope beneath the hose guide wheel (6).
Feed the rope over the left rope sheave (9) at the top of the mast.
Feed the rope over the rope sheave (10) on the crowd sledge.
Feed the rope over the right rope sheave (8) at the top of the mast.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 21
MAINTENANCE
B00005424.png
There is a jaw (16) in front of the rope sheave to facilitate mounting of

the wedge.
NOTE
Insert the rope into the jaw (16), pre-tension it manually and screw the jaw (16) into
place. Once the wedge (15) has been mounted, remove the jaw (16) from the rope
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 ropes by retracting the rope tensioning cylinder.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 22
MAINTENANCE
CAUTION
Run the crowd sledge up and down several times.
CAUTION

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

Only retension the ropes when the crowd sledge is at the lower stop on
the mast.
Position the crowd sledge at the lower stop on the mast.

Retension the ropes.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 23
MAINTENANCE
9.9
WIRE ROPE ACCESSORIES
9.9.1
Rope Swivel
Every 10 operating hours or daily:
Apply grease to nipple (2) until grease exits from

the housing.
Test the swivel rotates freely.
Conduct the test by hand, without load suspended to the swivel.
If the swivel will not rotate properly after it has
been greased, repair or replace it with a new
one.
Check tie bolts (1 and 3) are firmly in place. Retension them as required, to the proper torque.
Replace tie bolts with new ones when they are
torn or have excessive play.
1
2
3
B0000576.wmf
CAUTION
9.9.2

Immediately inspect the swivel for damage after an accidental drop of
the Kelly bar.
Rope Hold-Down Rollers
Every 50 operating hours or weekly:
Check rope hold-down rollers for wear and proper

function.
Check the roller is parallel to the drum of the
winch.
Check the roller mounting bolts are properly in
place and firm.
Adjust at tension screws until all springs are
equal. Do not tension worn out springs too much
B0000509.wmf
but replace them with new ones.
Re-align protecting bars that are bent, or replace them with new ones.
If there is excessive play, replace the roller centre pin, bushings and spacers respectively with new ones.
If grooves have been created in a roller, reface the roller (by turning it on a lathe), or
replace it with a new one. Mind that a refaced roller will have a diminished diameter
so that the respective tension springs will have to be pre-tensioned correspondingly.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 24
MAINTENANCE
9.9.3
Rope Fasteners, Thimbles and Sockets
Check the wire rope is firmly in place in the fitting.

With poured rope fittings, inspect for broken wires and corrosion directly where the
rope exits the fitting.
With swaged-on rope fittings, inspect for broken wires next to the fitting, cracks in
the material and firm seizure of the rope.
CAUTION

If a defect is found on a rope fitting, cut off the rope end and re-fit it.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 25
MAINTENANCE
9.9.4
Rope Sheaves
CAUTION

Sluggish or seized rope sheaves subject the rope to excessive wear and
abrasion and make the load distribute unevenly on the rope structure.
Repair or replace as necessary sluggish or seized rope sheaves if greasing will not do.
9.9.4.1 Greasing Rope Sheaves

Rope Sheave Type
Prescribed interval
Maintenance instructions
Rope sheaves with friction

bearings
10 Operating hours/
daily
BM659821.jpg
Rope sheaves with roller

bearings
1000 Operating hours/

yearly
CAUTION
Risk of damaging the

bearing sealing!
Grease during rotating
rope sheave.
Fill in grease slowly to
prevent squeeze out
bearing sealing.
BM659822.jpg
Rope sheaves greased by

the central lubrication system
automatical
BM659823.jpg
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 26
MAINTENANCE
9.9.4.2 Checking Rope Sheaves

Service
Prescribed interval
Check the rope sheaves

are free to rotate.

monthly
Check sheave centre pins

have the proper bearing
play and are properly in
place.

monthly
Check for burrs and edges

on the sheaves and that
grooves in sheaves still
comply with the diameter
of
the rope used.

yearly
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
Maintenance instructions
Re-machine the groove, or replace the

sheave with a new one, if the groove
does no longer comply.
9 - 27
MAINTENANCE
9.10
ROTARY DRIVE
9.10.1 Routine Inspection

Clean the rotary drive with a water jet.
Inspect all components for wear and damage.

On rotary drives with shock absorbers check especially:
-
Buffer ring (1)

Spring-loaded ring (2)
Compression springs (3)
Shock absorbers (4)
Check the rotary drive for leaks.
1
2
3
4
Kj248501.wmf
Risk of damaging the rotary drive!

At once, replace damaged components with new ones.
CAUTION
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 28
MAINTENANCE
9.10.2
9.10.2.1 Main Gear

The oil level in the main gear must be checked every 10 hours of operation or daily.
Set the rotary drive to upright position.
While the drive is out of motion, check the oil level.
The oil must reach half way up the glass (see fig.).
CAUTION
At all times, watch for proper oil level.
Kj248502.wmf
CAUTION

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

A too high oil level in the main gear is an indication of a defect in the
planetary gears. Shut down the rotary drive and repair.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 29
MAINTENANCE
9.10.2.2 Planetary Gears

The oil level in the planetary gears must be checked every 10 hours of operation or daily.
Set the rotary drive to upright position.
While the drive is out of motion, check the oil level.
The oil must reach half way up the glass (see fig.).
Risk of damaging the planetary gears!

At all times, watch for proper oil level.
CAUTION
Bj248503.wmf
CAUTION
Risk of damaging the planetary gears!

If the oil is cloudy, water has intruded and the oil must be changed immediately. Drain and thoroughly flush the drive repeatedly with the new
oil before refilling.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 30
MAINTENANCE
9.10.3
Changing the Oil
9.10.3.1 Main Gear

The oil in the main gear must be changed after the first 250 operating hours and subsequently every 1000 operating hours or once a year.
NOTE
To carry out an oil change, the oil had better be as warm as possible
from operating.
To change the oil:

Shut down the rotary drive.
Place the rotary drive 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.
Kj248504.wmf
Danger of scalding!
Hot gear oil can cause severe injury!
CAUTION
Inspect magnets on all drain screws and on magnetic sticks for gear abrasives, and
clean the screws (see also sect. "Oil Sampling").
NOTE
Check the mounting bolts of the hollow shaft (see sect. "Hollow Shaft
Mounting Bolts").
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 31
MAINTENANCE
If the outside temperature is low at the time of the oil change, warm up (to approx.
50C / 122F) a part of the new oil and rinse the gear housing with this oil before refilling.
Benzol (benzene) or flushing oils too may be used here for rinsing.
NOTE
CAUTION
Danger of damaging the gear!

Do NOT use petrol (gasoline), petroleum or diesel oil for rinsing here.
Allow the rinsing fluid to drain off completely.
Replace seals (if equipped), reinstall drain screws and tighten them.
Refill with new oil, and let the oil settle.
NOTE
If there is no oil to be seen in the sight glass after the gear has been
refilled with the proper quantity of oil, close the filler neck, start the engine and let the drive rotate for a short while, to bleed the lines free of
air that may be have been trapped.
Reinstall the filler screws and tighten them.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 32
MAINTENANCE
9.10.3.2 Planetary Gears

The oil in the two planetary gears must be changed after the first 250 operating hours
and subsequently every 1000 operating hours or once a year.
NOTE
To carry out an oil change, the oil had better be as warm as possible
from operating.
To change the oil:
Shut down the rotary drive.

Set rotary drive to upright position
Unscrew filler screws (2).
Have an oil collecting container ready.
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
KG000512.wmf
Danger of scalding!
Hot gear oil can cause severe injury!
CAUTION
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 33
MAINTENANCE
If the outside temperature is low at the time of the oil change, warm up (to approx.
50C / 122F) a part of the new oil and rinse the gear housing with this oil before refilling.
Benzol (benzene) or flushing oils too may be used here for rinsing.
NOTE
CAUTION
Danger of damaging the gear!

Do NOT use petrol (gasoline), petroleum or diesel oil for rinsing here.
Allow the rinsing fluid to drain off completely.
Replace seals (if equipped), reinstall drain screws and tighten them.
Refill with new oil, and let the oil settle.
NOTE
If there is no oil to be seen in the sight glass after the gear has been
refilled with the proper quantity of oil, close the filler neck, start the engine and let the drive rotate for a short while, to bleed the lines free of
air that may be have been trapped.
Reinstall the filler screws and tighten them.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 34
MAINTENANCE
9.10.4 Oil Sampling

Every 250 operating hours or monthly, take an oil sample from the main and planetary
gears and inspect it:
Inspect the oil for dark or black colouring.
If the colour of the sampled oil is dark or black, the operating temperature of the oil
has been above 100C (212F). This makes gear oil wear out prematurely and lose
the lubricating effect so that the oil change intervals must be shortened correspondingly.
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 gearbox must not exceed 0.15 %. Particles found in the oil must not exceed 5 m in size
(as measured in compliance with DIN 51592); if they do no matter the amount
the rotary drive will have to be removed and taken apart.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 35
MAINTENANCE
9.10.5 Hollow Shaft Mounting Bolts

The mounting bolts of the hollow shaft must be checked every time the oil of the rotary
drive is changed.
Unscrew and remove access plugs (1).
Visually, check the mounting bolts (2)
are properly in place and firm.
Risk of damaging the
drive!
CAUTION
Do not re-tension these

bolts unless necessary or
the Loctite seal of the bolts
will break making the bolts
loosen during operation.
Check visually only. Do not
put fingers into the bores.
1
1
NOTE
Turning around the rotary

drive enables checking all
the bolts.
2
B0000750.wmf
Unscrew mounting bolts found to be

loose, clean them and apply Loctite to
threads, reinstall and tension the bolts
with the specified torque.
Bolt torque value
Ma[Nm]
Hollow shaft mounting (2)
Hex head bolts
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
see Spare Parts List
9 - 36
MAINTENANCE
9.10.6
Kelly Driver and Guide Flange
9.10.6.1 Checking the Mounting Bolts

Visually, check mounting bolts of Kelly driver and
guide flange (1 and 2) are properly in place and
firm.
CAUTION
Risk of damaging the drive!

Do not re-tension these bolts unless necessary or the Loctite seal of the bolts
will break making the bolts loosen during
operation. Check visually only.
Unscrew mounting bolts found to be loose, clean

them and apply Loctite to threads, reinstall and tension the bolts with the specified torque (see below).
1
2
Kj248505.wmf
Bolt torque value

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

Hex head bolts
Set screws with nut

Replacing the Kelly Driver and/or Guide Flange:

Clean contacting surfaces of the hollow shaft and the Kelly driver / guide flange free
of grease. Apply Loctite 0586 Type AVX on the cleaned surfaces.
Apply Loctite to threads of the mounting bolts, and screw the bolts down with the
specified torque in a diagonal manner.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 37
MAINTENANCE
9.10.6.2 Checking Driver Strips for Wear

Check Kelly driver strips (5) for wear.
If the wear (x) is in excess of 8 mm, turn the strip around by 180 and reinstall it, or
replace it right away with a new one.
Replace also bushings (4) and bolts (3) if they are worn down.
When fitting a new driver strip, the play (y) should not exceed 0.5 mm.
NOTE
Bolt torque value

Ma [Nm]
Kelly driver strips mounting
Hex socket head bolts
Hex socket head bolts with nuts

A - A:
B - B:
2
3
4
5
6
x
y
B0000580.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 38
MAINTENANCE
9.10.7 Cardan Joint

Check suspension pins (see arrow) are

properly in place and firm, with the
holes for the pins completely assembled.
Check rubber buffers for damage.
Kj248506.wmf
9.10.8 Sledge Sliding Strips

Check the wear on the strips (1) in the runners (4) of the crowd sledge.
Where the remaining thickness (X) is found to be less than 15 mm, replace with a
new strip (see below).
"A"
B-B
5
X
1
"A"
B
2
3
4
B0000582.wmf
To replace:
Unscrew bolts (2) and remove the tension plate (3).

Pull out the strip (1) and install a new strip.
Reinstall the tension plate and screw tight.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 39
MAINTENANCE
9.10.9 Greasing the Shaft Seal Ring

Clean the rotary drive.

Apply grease to nipples (1 or 2) and
rotate the drive in between, from time
to time.
Repeat the procedure until grease
exits steadily along the whole circumference (arrow).
1
2
4
4
K0000515.wmf
CAUTION

Insufficient greasing can allow solid matters to enter into the gears and
cause damage.
CAUTION

Brownish coloured gear oil or a heavily contaminated filter (3 or 4) can
be an indicator of solid matters brought-in from the outside.
Shut down the rotary drive and contact the After Sales Service.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 40
MAINTENANCE
9.11
CRAWLER TRACK ASSEMBLIES

WARNING!
The machine must be out of motion during work on the undercarriage.
A reliable communication between the person(s) working at the undercarriage and the operator in the cab must be provided at all times.
9.11.1 Routine Inspection

With the uppercarriage positioned crosswise, thoroughly clean crawlers free of mud
and dirt.
Walk-around inspect for wear, damage and loss of oil, especially on following components:
Track pads (1)
Track links (2)
Carrier rollers (3)
Front idlers (4)
Track guides (5)
Tread rollers (6)
Crawler drive wheels (7)
Gear cases (8)
1 2
B0000676.wmf
NOTE
On machine with crawlers extended, the crawler telescoping surfaces

should be kept corrosion protected with grease.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 41
MAINTENANCE
9.11.2
Crawler Tracks
9.11.2.1 To Check the Track Tension

Check track tension every 10 operating hours or daily.
Thoroughly clean each crawler, track

and rollers.
Travel forward a bit with the machine

and then park it.
Using a straight rod, measure the sag

of 1 - 1.5 m length of track in midway
(see fig.): The distance from the rod to
the track should be approx. 2 3 cm.
Otherwise, the track tension must be
readjusted.
1 - 1,5 m
2-3 cm
1 - 1,5 m
2-3 cm
1 - 1,5 m
2-3 cm
B0000680.wmf
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 42
MAINTENANCE
9.11.2.2 Adjusting Crawler Track Tension
To tighten the track
Remove cover plate (5) and clean the grease nipple (2).
2
5
1 3 4
B0000725.wmf
Put a high-pressure grease gun to the grease nipple.
Work the grease gun until the proper track tension is obtained.
Check the track tension again after a short travel forward and backward, and top up
with more grease as necessary.
Reinstall the cover plate.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 43
MAINTENANCE
To loosen the track
2
5
1 3 4
B0000725.wmf
Remove cover plate.

Unscrew the safety valve (1) by approx. 3 revolutions (SW 41) until excessive grease
escapes at the spot identified with (4).
WARNING!
Injury hazard by pressurized grease!
Unscrew the safety valve with great care only.
Retighten the safety valve when the proper track tension is obtained.
Check the track tension again after a short travel forward and backward.
Clean the nipple and surrounding free of grease.
Reinstall the cover plate.
WARNING!
Danger of injury due to pretensioned spring element (compressible silicone oil at 1500 to 2000 bar)!
For safety reasons do not open the defective spring elements, but replace them entirely.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 44
MAINTENANCE
9.11.3 Checking Mounting Bolts
Check visually mounting bolts are tight.

Retention bolts that are loose.
5
6
BK587502.wmf
BK587440.jpg
BM564683.jpg
Bolt torque value

Ma [Nm]
Prescribed intervals in
operating hours
570 30
50
Carrier roller (2)
560
250
Track guide (3)
560
250
Tread roller (4)
560
250
Crossbeam (5)
---
---
Drive wheel (6)
460
250
Gear case (7)
960
250
Telescopic cylinder mounting
560 (M20)
250
Swing ring (8)
755 (M24)
After the first 250

and then every 2000
Bolted connection
Track pad (1)
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 45
MAINTENANCE
9.11.4
Crawler Drive Gears
9.11.4.1 Checking the Oil Level

Check the oil level every 250 operating hours or monthly.
Move machine until oil drain plug (2)

on crawler drive wheel is in lowermost
position.
Unscrew inspection / filler screw (1)
together with seal (if equipped).
The oil must reach the lower edge of
the filler opening; top up with oil as
necessary.
Clean inspection / filler screw and
sealing surfaces on housing, and replace with new seals as necessary.
Reinstall the inspection / filler screw
with new seal and tighten.
3
2
B0000514.wmf
9.11.4.2 Changing the Oil

The oil must be changed after the first 250 operating hours or one month. Subsequent
oil changes are due every 1000 operating hours or once a year at least.
Move machine until oil drain plug (2)

on crawler drive wheel is in lowermost
position.
Unscrew inspection/filler screw (1)
together with seal (if equipped).
Place an oil collecting container underneath the drain.
Unscrew the drain plug (2) and let the
oil out.
Clean screw and plug and sealing surfaces on housing.
Reinstall drain plug with new seal and
screw tight.
Refill with new oil to proper level.
Reinstall inspection/filler screw with
new seal and screw tight.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
3
2
B0000514.wmf
9 - 46
MAINTENANCE
9.12
CENTRAL LUBRICATION SYSTEM MAINTENANCE *
The grease receptacle contains 2 kg of normal commercial grease of class NGLI-Kill. 2

and must be topped up with a grease gun (if possible pneumatically) every 50 operating
hours or weekly.
You may take further details to the central lubrication system from the enclosed documentation.
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 obstructions, the grease must be pressed via the lube nipples on the container (do not unscrew the lid).
The grease should be topped up until max. 2 cm below the upper
edge, otherwise the ventilation system will be smeared with grease.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
9 - 47
MAINTENANCE
9.13
BOLTED CONNECTIONS
After the first 250 operating hours, re-tension all the bolted connections described in
the following.
Generally, apply the prescribed torque on these bolts to tension them
("torque pretension method").
NOTE
Bolted connections of Mast sections

Every 5000 hours of ordinary operation, replace all elements used in the bolted connections.
WARNING!
Replace the elements of bolted connections which have been openedup more than 25 times or which are corroded, fissured, deformed or
have damaged threads.
Bolted connections of Mast pivot, Winch trestles, Roller brackets and Masthead
Every 10000 hours of ordinary operation, replace all elements used in the bolted
connections.
WARNING!
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 / 2254_BG25_en_0000498763_V01
9 - 48
LUBRICANTS / TABLES
10
LUBRICANTS / TABLES
10.1
LUBRICANTS
10.1.1 General
Observe instructions given in the supplied "Safety Information" book on this subject.
Use only oils and greases prescribed or suitable for the application in question.
Before changing to another kind of lubricant, check it is compatible with the previous
one used.
The lubricants used must be fresh.
CAUTION
NOTE
Risk of damage to the equipment and loss of the equipment warranty!

A damage resulting from non-observance of lubricant instructions in this
manual will not be covered by the equipment warranty.
The lubricants listed in the lubricant tables of this manual are suitable
for ambient temperatures from -20C to +40C (-4F to +104F).
Information on applications below -20C and above +40C can be ordered from the BAUER Service Centre.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 1
LUBRICANTS / TABLES
10.1.2 Lubricant Table

The following table lists the lubricants with which the equipment is filled when leaving
the factory.
NOTE
The quantities given in the table serve as a guide only. Decisive are the
specifications found on the nameplates of the respective parts and the
actual fill level found when checking.
Alternative lubricants are listed on following pages.
Table Initial lubricant fill

Application
Gear oils,
synthetic
Specification
Viscosity grade
Producer
Name of product
Qty.
[litres]
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
60.0
2 x 5.5
Rotary drive
main gear
ISO VG 220
BP
BP Enersyn
EP-XF 220
Rotary drive
planetary gear
ISO VG 150
BP
BP Enersyn
EP-XF 150
Gear oils,
petroleum
ATF
Gear oils,
synthetic
HVLP HC
*) At 40C:
2
38 mm /s
At 100C:
2
7.1 mm /s
*) 40C = 104F ; 100C = 212F
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 2
LUBRICANTS / TABLES
Application
Hydraulic oil,
petroleum
Specification
Viscosity grade
Producer
Name of product
Qty.
[litres]
HVLPD
Hydraulic systems
ISO VG 46
ARAL
Vitam VF 46
SHELL
Shell Rimula Super

15W-40
Roller bearings/
friction bearings
ARAL
Aralub HLP 2
Central Lubrication
System (Base machine,
BG equipment) *
ARAL
Aralub HLP 2
Hydraulic oil,
fixed (biodegradable)
350.0
HEES
Engine oil,
petroleum
Engine
API CI-4
Grease,
petroleum
KP2N-20
NLGIGrade2
SAE 15W-40
18.9
Multi-purpose
grease on lithium
soap base
after every
application
after every
application
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 3
LUBRICANTS / TABLES
10.1.3
Lubricant Guide
10.1.3.1 Gear Oils, Synthetic CLP HC

Table of gear oils, synthetic CLP HC
Application
Specification
DIN 51517-3
ISO 12925/1
Gear oil,
synthetic
CLP HC (PAO)
Viscosity grade
2
ISO-VG / DIN 51562 at 40 C in mm /s
Producer
VG 100
VG 150
VG 220
Description
ARAL
AVIA
ARAL Degol
PAS 100
AVIA Synthogear
EP 100
ARAL Degol
PAS 150
AVIA Synthogear
EP 150
BP Enersyn
EP-XF 150
ARAL Degol
PAS 220
AVIA Synthogear
EP 220
BP Enersyn
EP-XF 220
Tribol 1710 / 100
Tribol 1710 / 150
Tribol 1710 / 220
Intor HCLP 150
Intor HCLP 220
BP
CASTROL
DEA
Renolin Unisyn
CLP HC 100
Renolin Unisyn
CLP HC 150
Klbersynth
EG 4-150
Mobilgear
SHC XMP 150
SHELL OMALA
HD 100
SHELL OMALA
HD 150
Pinnacle
EP 150
Spartan Synthetic
EP 220
Renolin Unisyn
CLP HC 220
Klbersynth
EG 4-220
Mobilgear
SHC XMP 220
Optigear Synth
A 220
SHELL Omala
HD 220
Pinnacle
EP 220
Carter SH 150
Carter SH 220
ESSO
FUCHS
KLBER
MOBIL
OPTIMOL
SHELL
TEXACO / CHEVRON
TOTAL
CAUTION

Oils from different producers must not be mixed with one another!
Synthetic oils and mineral based oils must not be mixed!
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 4
LUBRICANTS / TABLES
10.1.3.2 Gear Oils, Petroleum ATF

Table of gear oils, petroleum ATF
Application
Specification
DIN 51502
Gear oil,
petroleum
Dexron II D
Viscosity grade
Producer
*At 40 C:
2
38 mm /s
at 100 C:
2
7.1 mm /s
Description
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
KLBER
ELF
ATF DEXRON II
FUCHS
Titan ATF 3000
AGIP
ATF IID
DEA
PANOLIN
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 5
LUBRICANTS / TABLES
10.1.3.3 Hydraulic Oils, Petroleum HVLP(D)

Table of hydraulic oils, petroleum HVLP(D)
Specification
DIN 51524/3 (HVLP);
DIN EN ISO 6743/4 (HV)
Application
HVLP(D)
Hydraulic oil,
petroleum
zinc-free
Viscosity grade
2
Producer
VG 32
VG 46
VG 68
Description
normal temperature range e.g. Europe,
USA, China
Operation temperature
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
Bartran HV 46
Bartran HV 68
HydraWay HVXA 46
HydraWay HVXA 68
BP
MOBIL
CASTROL
CHEVRON
ESSO
FINA
TEXACO
STATOIL
HydraWay HVXA 32
CONOCO
ECOTERRA HVI 46
PANOLIN
HLP UNI 46
ADDINOL
HVLPD 46
PETRONAS
HVI 46
CAUTION
HLP UNI 68
HVI 68

Zinc-free oils and oils containing zinc must not be mixed!
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 6
LUBRICANTS / TABLES
10.1.3.4 Hydraulic Oils, Biodegradable on Synthetic Basis HVLP HC

Table of hydraulic oils, biodegradable on synthetic basis - HVLP HC
Application
Specification
DIN 51524/3 (HVLP);
DIN 51502; VDMA 24568;
CEC-L-33-A-93
Hydraulic oils, biodegradable

on
synthetic basis
HVLP HC
Viscosity grade
2
Producer
VG 32
VG 46
VG 68
Description
ARAL
SHELL
BP
MOBIL
AVIA
Syntofluid PE-B 30
(recommended for ambient
temperatures from -40 C to +40 C)
CASTROL
CHEVRON
ESSO
FINA
GULF
TEXACO
STATOIL
CONOCO
PANOLIN
ADDINOL
CAUTION

Zinc-free oils and oils containing zinc must not be mixed!
Temperature range -40C to -25C requires additional measures to be
taken on the equipment!
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 7
LUBRICANTS / TABLES
10.1.3.5 Hydraulic Oils, Biodegradable HEES - Saturated Esters

Table of hydraulic oils, biodegradable HEES - saturated esters
Application
Specification
Hydraulic oil
biodegradable
HEES
ISO 15380
VDMA 24568
Viscosity grade
2
Producer
VG 32
VG 46
VG 68
Description
ARAL
SHELL
BP
MOBIL
AVIA
CASTROL
CHEVRON
ESSO
FINA
GULF
TEXACO
TOTAL
KLBER
ELF
FUCHS
AGIP
DEA
PANOLIN
CAUTION
HLP Synth 46

Oils from different producers must not be mixed with one another.
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 8
LUBRICANTS / TABLES
10.1.3.6 Engine Oils API CI-4

Table of engine oils API CI-4
Application
Specification
DIN 51502
Engine oil
API CI-4
ACEA E 7
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40
SAE 10W-40
SAE 15W-40
Description
AGIP
ARAL
ARAL Extra Turboral

SAE 10W-40
AVIA
BP
CASTROL
Vanellus C6 Global Plus

SAE 10W-40
Sigma Truck 15W-40

Aral Plus Turboral
SAE 15W-40
Avia Multi HDC Plus
SAE 15W-40
Vanellus C7 Global 15W-40
LUKOIL
RX super 15W-40
Chevron Delo 400
Multigrade SAE 15W-40
Lukoil 15W-40
TNK-BP
Revolux D3
ESSO
STATOIL
XD - 3 Extra 15W-40
Fina Universal Plus XL
SAE 15W-40
Titan Truck Plus
SAE 15W-40
Gulf Super Duty Select
SAE 15W-40
MaxWay
MOBIL
Mobil Delvac MX 15W-40
SPC
SDM 901
Q8
TEXACO
Q8 T 750 SAE 15W-40

Shell Rimula Super
15W-40
Ursa Super TD 15W-40
IGOL
Trans Turbo 9x
TOTAL / FINA / ELF
Rubia TIR 7400
CHEVRON
FINA
FUCHS
GULF
SHELL
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 9
LUBRICANTS / TABLES
10.1.3.7 Greases, Petroleum KP2N

Table of greases, petroleum KP2N
Application
Specification
DIN 51502
Greases,
petroleum
KP2N-20
Description
Producer
Description
Multipurpose
grease
on
lithium soap base
ARAL
Aralub HLP 2
SHELL
Retinax EP 2
Energrease
LS-EP 2
Mobilux EP 2
BP
MOBIL
AVIA
CASTROL
CHEVRON
ESSO
Beacon EP 2
FINA
Marson EPL 2A
GULF
TEXACO
TOTAL
KLBER
ELF
Epexa 2
FUCHS
Renolit MP
AGIP
Agip GR MUEP 2
DEA
Glissando EP 2
PANOLIN
EP Grease 2
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 10
LUBRICANTS / TABLES
10.2
BOLT TORQUE VALUES
CAUTION
Bolt torque values given in the following tables are valid only for slightly
oiled bolted connections and where the Spare Parts List does not prescribe other torque values.
10.2.1 Bolts with coarse-pitch metric thread
Strength class as per DIN/ISO 898

8.8
Coarse-pitch metric
thread
10.9
12.9
Bolt torque values MA [Nm]
M4
2,8
4,1
4,8
M5
5,5
8,1
9,5
M6
9,5
14
16,5
M8
23
34
40
M 10
46
68
79
M 12
79
117
135
M 14
125
185
215
M 16
195
280
330
M 18
280
390
460
M 20
390
560
650
M 22
530
750
880
M 24
670
960
1120
M 27
1000
1400
1650
M 30
1350
1900
2250
M 33
1850
2600
3000
M 36
2350
3300
3900
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 11
LUBRICANTS / TABLES
10.2.2 Bolts with fine-pitch metric thread
Strength class as per DIN/ISO 898

8.8
Fine-pitch metric
thread
10.9
12.9
Bolt torque values MA [Nm]
M 8x1
24,5
36
43
M 10x1
52
76
89
M 10x1,25
49
72
84
M 12x1,25
87
125
150
M 12x1,5
83
122
145
M 14x1,5
135
200
235
M 16x1,5
205
300
360
M 18x1,5
310
440
520
M 20x1,5
430
620
720
M 22x1,5
580
820
960
M 24x2
730
1040
1220
M 27x2
1070
1500
1800
M 30x2
1490
2120
2480
M 33x2
2000
2800
3300
M 36x3
2500
3500
4100
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
10 - 12
LUBRICANTS / TABLES
10.3
CONVERSION TABLE
Measures for Power
N
dyn
105
1
10-5
9.81
9.81103
9.8110-3
1
9.81105
9.81108
981
kp
Mp
1.0210-4
1.0210-9
10-3
0.102
1.0210-4
1
103
10-3
102
1.0210-2
103
106
1
1
10-6
Measures for Energy and Operating Efficiency

J
1
10-7
9.81
3.60106
4187
1.610-19
erg
107
1
9.8110-7
3.601013
4.191010
1.610-12
kpm
0.102
1.0210-8
1
3.67105
427
1.6310-20
kWh
kcal
2.7810-7
2.7810-14
2.7210-6
2.3910-4
2.3910-11
2.3410-3
1
1.1610-3
4.4510-26
860
1
3.8310-23
ev
6.241018
6.241011
6.121019
2.251025
2.611022
1
Measures for Output

W
1
103
981
735.5
4187
1.16
kW
10-3
1
9.8110-3
0.7355
4.19
1.610-3
kpm/s
0.102
102
1
75
427
0.119
PS
kcal/s
1.3610-3
2.3910-4
1.36
1.3310-2
1
5.69
1.5810-3
0.239
2.3410-3
0.1757
1
2.7810-4
kcal/h
0.86
860
8.43
632
3600
1
Measures for Pressure

at
1
1.033
1.02
1.0210-5
1.3610-3
0.070
atm
0.968
1
0.987
9.8710-6
1.3210-3
0.0680
bar
0.981
1.0133
1
10-5
1.3310-3
0.0689
N/m
98100
101330
105
1
133
0.145
Torr
736
760
750
7510-4
1
51.72
Psi
14.22
14.69
14.5
14.510-5
19.2810-3
1
Measures for Length

in
ft
yd
1
12
36
0.03937
39.37
39370
0.08333
1
3
328110-6
3.81
3281
0.02778
0.3333
1
109410-6
1.094
1094
BG 25 / 2011 / 2254_BG25_en_0000498763_V01
mm
25.4
304.8
914.4
1
1000
106
m
0.0254
0.3048
0.9144
0.001
1
1000
km
10-6
0.001
1
10 - 13

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Instruction Manual

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EQUIPMENT APPLICATIONS ...............................................................................................1 - 1

GENERAL SAFETY REQUIREMENTS .................................................................................2 - 1

EQUIPMENT SAFETY ...........................................................................................................2 - 1

MAJOR HAZARDS .................................................................................................................2 - 1

SAFETY DEVICES .................................................................................................................2 - 2

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

ROTARY DRIVE SPECIFICATIONS......................................................................................3 - 5

TEMPERATURE CONDITIONS ...........................................................................................3 - 10

EXPOSURE TO VIBRATION ...............................................................................................3 - 11

EXHAUST GAS EMISSION .................................................................................................3 - 11

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

BASE MACHINE CONTROL CONSOLE ...............................................................................4 - 2

CONTROL PANEL .................................................................................................................4 - 3

MONITOR UNIT .....................................................................................................................4 - 4

TRAVELLING WITH THE RIG .............................................................................................5 - 10

Manual Control of the Crowd ................................................................................................5 - 19

CENTRAL LUBRICATION CONTROL * ..............................................................................5 - 22

START-UP / SHUT-DOWN ....................................................................................................6 - 1

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