Bauer Spezialtiefbau GMBH D-86522 Schrobenhausen - Postfach 12 60 - Germany Phone: Germany + 8252/97-0 Fax: Germany + 8252/97-13 59

Instruction Manual
BAUER BG22 BAUER
BAUER SPEZIALTIEFBAU GmbH

D-86522 Schrobenhausen • Postfach 12 60 • Germany
Phone: Germany + 8252/97-0
Fax: Germany + 8252/97-13 59
TABLE OF CONTENTS
Introduction
How to Use the Manual I
After Sales Service Ill
Adresses of Representatives IV
1 Description 1-1
1.1 General Plan 1-2
1.2 Main Assembly Groups 1-3
1.2.1 Rotary Drive 1-3
1.2.2 Mast 1-5
1.2.3 Crowd .1-6
1.2.4 Masthead 1-7
1.2.5 Backstay Cylinders 1-8
1.2.6 Mast Link to Base Machine with Boom Cylinders 1-9
1.2.7 Main and Auxiliary Winch 1-9
1.3 Base Machine 1-10
1.3.1 Design of the Base Machine 1-10
1.3.2 Crawler Base 1-11
1.3.3 Diesel Engine .1-12
1.3.4 Hydraulic System 1-13
1.4 Identification Numbers on the Appliance . 1-14
1.5 Limit Switches 1-15
2 Technical Data 2-1

2.1 Dimensioned Drawing 2-1
2.2 Base Machine Technical Data 2-3
2.3 Drilling Equipment Technical Data 2-5
BG 22/96
2.3.1 Winches/Cylinders 2-5
2.3.2 Wire Rope Specifications 2-6
2.3.3 Rotary Drive 2-8
2.4 Drilling Technical Data .2-9
2.5 Stability According to prEN791 for BG 22 on BS 70 2-11
2.6 Acoustic Capacity Control 2-13
2.7 Operable Temperature Range 2-13
2.8 Wind Velocity 2-14
3 Operation 3-1
3.1 Operator's Cab 3-2
3.2 Control Panel BG 22 / BS 70 3-3
3.3 Instrument Panel 3-4
3.4 Manometer Indication 3-5
3.5 Monitor Unit 3-6
3.6 Usage Instructions 3-8
3.6.1 Calibrating 3-8
3.6.1.1 Calibrating the Depth 3-8
3.7 Mast Adjustment in Drilling Mode 3-10
3.8 Preselecting the 22 mto Torque (if it Equipped) . . . . . . 3-11
3.9 Rotary Drive Slow / Rapid Acceleration 3-12
3.10 Free-Fail for Drilling Mode 3-13
3.11 Emergency-Stop Button 3-14
3.12 Travelling and Steering Controls 3-15
3.13 Swing and Brake the Uppercarriage 3-17
3.14 Controls and Adjustment Facilities in the Operator's Cab . . . . 3-18
3.14.1 Operator's Seat 3-18
3.14.2 Ventilation 3-20
3.14.3 Heating (optional) 3-21
3.14.4 Air Conditioner (optional) 3-22
3.14.5 Window Wipe and Wash 3-23
BG 22/96
3.15 Safety Devices 3-24
3.15.1 Emergency Exit 3-24
3.15.2 Left Control Console 3-25
3.15.3 Fire Extinguisher 3-25
4 Putting Into Service - Mounting - Dismounting - Transport . . .4-1

4.1 Operating the Telescopic Crawler Base (Optional) 4-2
4.2 Mounting the Counterweight 4-5
4.3 De-Preservation 4-6
4.4 Checks before Starting the Base Machine 4-7
4.5 Refuelling the Base Machine 4-10
4.6 Putting the Base Machine into operation 4-11
4.6.1 Starting the Engine 4-11
4.6.2 Starting the Engine with a Booster Battery 4-12
4.6.3 Functional Checks with the Engine Running 4-13
4.6.4 Readiness for Operation 4-14
4.6.5 Travelling 4-16
4.7 Setting Up and Mounting the Drilling Equipment 4-17
4.7.1 Mounting the Upper Mast Section 4-17
4.7.2 Reeving the Main and Auxiliary Rope 4-21
4.7.3 Raising the Mast 4-22
4.7.4 Mounting the Rotary Drive - For Rigs with Crowd Cylinder . . 4-23
4.7.5 Mounting the Rope Swivel 4-26
4.7.6 Mounting the Kelly Bar 4-27
4.8 Dismounting the Drilling Equipment 4-29
4.8.1 Dismounting the Kelly Bar 4-29
4.8.2 Dismounting the Rotary Drive 4-30
4.8.3 Dismounting the Upper Mast Section 4-31
4.9 Moving the Rig on Site 4-34
4.10 Putting the Rig out of Service 4-35
4.11 Towing 4-36
BG 22/96
TP'S
BAUER
4.12 Transportation 4-37

4.12.1 Transport Dimensions and Weights 4-38
4.12.2 Specific Safety Instructions for Transportation 4-40
5 Service and Maintenance 5-1

5.1 Safety Measures 5-1
5.2 Maintenance Intervals 5-3
5.2.1 Maintenance Works While Mounting the Drilling Rig 5-5
5.2.2 Maintenance Works During the Running-ln Period 5-5
5.2.3 Service and Maintenance Plans 5-6
^ After Every 10Operating Hours/Daily 5-7
After Every 50 Operating Hours / Weekly 5-10
After Every 250 Operating Hours / Monthly 5-13
After Every 500 Operating Hours / After Every Three Months . . 5-16
After Every 1000 Operating Hours/At least Once a Year . . . . 5-18
After Every 2000 Operating Hours / At Least Once a Year . . . . 5-20
After Every 3000 Operating Hours/At Two-Year Intervals . . . . 5-22
5.3 Lubricants 5-24
5.3.1 Disposal of Waste Oil, Filters and Additives 5-25
5.3.2 Table of Lubricants 5-27
5.4 Checking the Engine Oil Level 5-29
5.5 Engine Air Cleaner Maintenance 5-30
5.6 Servicing the Hydraulic System 5-32
5.6.1 Checking the Hydraulic Oil Level 5-32
5.6.2 Changing Hydraulic Oil 5-33
5.6.3 Replacing the Hydraulic Oil Tank Filter Element 5-35
5.6.4 Replacing the Hydraulic Oil Filter of the Pilot Line 5-36
5.6.5 Checking and Cleaning the Hydraulic Oil Cooler 5-37
5.7 Pump Distributing Gear (if it Equipped) 5-38
5.8 Maintenance of the Swing Gear 5-39
5.8.1 Lubricating the Gear Ring 5-39
• BG 22/96
- : : ;
5.8.2 Replacing the Hydraulic Oil Filter Element of the Swing Gear . . . 5-40
5.8.3 Check the Bolts 5-41
5.9 Maintenance of the Crawler Drive Wheels 5-42
5.9.1 Checking the Oil Level 5-42
5.9.2 Changing Oil 5-43
5.10 Maintenance of the Travel Mechanism 5-44
5.10.1 Checking and Adjusting the Chain Tension . 5-45
5.10.2 Crawler Shoes 5-47
5.11 Battery Maintenance 5-48
5.12 Fuses . 5-50
5.13 Troubleshooting 5-51
5.14 Hydraulic Lines Service and Maintenance 5-55
5.15 . Rope Terminals, Thimbles and Rolled Bushings 5-57
5.15.1 Rope Sheaves 5-57
5.15.2 Rope Press-Down Rollers 5-58
5.15.3 Rope Thimble Replacement 5-59
5.16 Winches 5-61
5.16.1 Checking the oil level 5-61
5.16.2 Filter of the Free-Fall Winch 5-62
5.17 Maintenance of Rope Swivels 5-63
5.18 Hydraulic Cylinders 5-64
5.19 Rotary Drive Maintenance 5-66
5.19.1 General .5-66
5.19.2 Checking Gear Oil Level 5-67
5.19.3 Changing Gear Oil 5-68
5.19.4 Bolted Connections 5-71
5.19.5 Kelly Driver Strips 5-72
5.19.6 Filter of Rotary Drive (Optional) 5-73
5.20 Checking the Slide Strips 5-74
5.21 Table of Bolts Tensile Strength and Torque Values 5-75
5.22 Conversion Tables 5-77
BG 22/96
BAUER
Appendices
A Kelly Bar Manual
B Main Winch Manual
C Auxiliary Winch Manual
D Care and Maintenance of Wire Rope
INTRODUCTION
This manual has been made to provide users with information and instructions for the
BAUER BG 22 Drilling Rig.
In the following pages you will find detailed descriptions of the unit, and instructions for
transporting, assembling, operating and servicing.
It is essential that all should be read and understood by the responsible operating and
maintenance personnel prior to starting up and before any work is carried out on the
equipment.
CAREFULLY READ THE WHOLE MANUAL THROUGH BEFORE YOU BEGIN.
Technical data, dimensions and weights relate to the date of print. They may differ slightly
to those on your version of machine, although only in some details so that the factual
information of the manual is still relevant and pertinent.
Any deviations from texts, drawings or photographs will be due to options with which your
unit is equipped, and can consequently not form grounds for complaint.
The drilling rig and the base machine may be used only for the purposes specified in this
manual. BAUER cannot be held responsible for damages caused by misuse, abuse or
neglect.
This manual is a translation from German. In case of doubt, the German text shall prevail.
Edited and published by BAUER SPEZIALTIEFBAU GmbH, 1996
© Copyright by BAUER SPEZIALTIEFBAU GmbH Schrobenhausen, Germany.

All rights reserved. No part of this manual may be reproduced, transmitted or loaned
to third parties, or be translated into an other language, without the prior permission
of the Copyright owner.
BG 22/96
BAUER
HOW TO USE THE MANUAL
To find information quickly
Read the following pages to understand the arrangement of the manual.
Numbering of Tables and Figures
Tables and figures are numbered consecutively, starting with 1 for each new chapter.
A DASH - is placed before a table no. A SLASH / is placed before a figure no.
Examples:
Table 2 - 1
T Table 1
Chapter 2
Fig. 2/1
Figure 1
Chapter 2
Numbering of Items in a Figure
Whenever a figure contains several items, these have been numbered. A reference to one
of the items uses a FULL STOP . before the item no.
Example:
Fig. /2.4
~E Item 4
Figure 2
Chapter 1
When, in the text, the relation between item and figure is obvious from the above, the
reference to the figure has been omitted and the item no. is placed in BRACKETS ( )
only.
Example: lift boom (see fig. 3/20.1) and mount it with pins (2)
BG 22/96
Cross-References
For easy use, cross-references are applied to help you find relevant information in other
parts of the manual.
Examples:
Reference to a section: ... (see sect. 3.1.1)

Reference to a figure with/without item no's:
... (see fig. 2/1)
...(see fig. 2/1.5); ...(5)
Reference to a table: ... (see table 4 - 2)
Messages
A
WARNING!
Warning is used to warn whenever incorrect observance or non-obser-

vance of instructions for working procedures and the like may lead to
injuries to personnel or lethal accidents.
A
Caution is used to warn whenever incorrect observance or non-obser-
vance of instructions for working procedures and the like may lead to
damages of the machine, plant, unit or equipment.
CAUTION
W Note is used to highlight a procedure and is in general a work facilitation.
NOTE
BG 22/96 III
AFTER SALES SERVICE
How to reach the BAUER Service Centre
• Phone: Germany +82 52/97 - 25 86
• Fax: Germany +82 52/97 - 25 87
If your ever need to call up BAUER'S after-sales service in Schrobenhau-

sen please have the following particulars at the ready so as to speed up
the procedure:
NOTE
• Name of model: BG 22
— Manufacturing No.: 23
— 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 by BAUER:
— Contact person; Phone / Fax:
• Description of site:
(Post code) town, street, name of site
— Description of how to get to the site

for mechanic (if necessary):
BG 22/96 IV
BAUER
ADRESSES OF REPRESENTATIVES
Europe Far East America
Austria East-Germany Singapur USA
A.T.B.M. Handels GmbH Josef Eiser BEC Pileco,
Achsu Magdeburg Singapore Houston, Texas
Tel. 02236-735600 Tel. 0391-225340 Tel. 7568033 Tel. 713-6913000
Fax 02236-735606 Fax 0391-225340 Fax 7537295 Fax 713-6910089
UK Suisse Thailand Mexico

Bauer Foundations Ltd. Peter Schüepp Thai Bauer Bauer Mexico S.A. de C.V.
Bacup Werksvertretungen Bangkok Mexico D. F.
Tel. 706-879219 Weingarten-Kalthäusern Tel. 2-6532076 Tel. 5-5156551
Fax 706-878224 Tel. 77727222 Fax 2-6532075 Fax 5-5161917
Fax 54532193
Portugal Spain China Peru

Geo-Hidrol Lda Sr. Arturo CanakJa Contrera Bauer Beijing Rep. Office Bauer America Latina
Lissabon Madrid Beijing Lima
Tel. 1-17977885 Tel. 1-4586326 Tel. 10-5068899 Tel. 1-4376567
Fax 1-17972273 Fax 10-5066991 Fax 1-4376567
Bulgaria China Chile

Z & M Private company Bauer Rep. Office Bauer Equipos Chile Ltda.
Sofia Tianjin Santiago de Chile
Tel. 0035-92832330 Tel. 22-3310372 Tel. 2-2114775
Fax 0035-92831217 Fax 22-3310616 Fax 2-2291985
Middle East
Germany Iraq Taiwan Argentina
Zaby Baumaschinen Holger Hansen, c/o YCL Bauer Technologies Taiwan Bauer Equipos Argentina S. A.
Fried berg Ribnitz-Damgarten Taipei Tel. + Fax 54-1-7710559
Tel. 0821-601792 Tel.03821-8773-13 Tel. 2-5057015
Fax 0821-609279 Fax 03821-877315 Fax 2-5010229
Italy Jordan Korea

Scandinava Macchine S.p.A. Holger Hansen, c/o YCL Deasung International
Genua Ribnitz-Damgarten Seoul
Tel. 10-73021 Tel. 03821-8773-13 Tel. 2-5571907
Fax 10-751267 Fax 03821-877315 Fax 2-5630922
Africa
France India Hong Kong Egypt
F.D.M.T. Sari Bauer Equipment India B & H Eng. & Equip. Ltd. ACE Arab Comp. f. Eng.
St. Lambert des Bois Calcutta Hong Kong Kairo
Tel. 1-34619868 Tel. 33-4731916 Tel. 2-5449613 Tel. 2-3525448
Fax 1-34613511 Fax 33-4731916 Fax 2-5442866 Fax 2-3525703
Greece Syrien Malaysia South-Africa

Nikolaos Tryfonas SIMA Bauer Equipment Far East Marine and Mineral Resources
Athens Damascus Petaling Jaya Kenilworth 7745
Tel. 1-2876760 Tel. 11-2231800 Tel. 0060/3/7808334 Tel. 0027-21-4183690
Fax 1-2770721 Fax 11-2212034 Fax 0060/3/7813745 Fax 0027-21-4197678
Turkey Iran Japan

Karun Engineering Falati Trading Co. Bauer Japan Corporation
Ankara Teheran Tokio ,
Tel. 312-2126606 Tel. 21-841016 Tel. 3-54742422
Fax 312-2132751 Fax 21-841016 Fax 3-54742423
Poland Lebanon
Mr. Darius Mikuluski Bauer Libanon Office
Warschau Beirut
Tel. 22-492451 Tel. 1-481390, 496751
Fax 22-495714 Fax 1-496751
Russia UAE
Dr. Levon Petrosyan Bauer International
Moskau Abu Dhabi
Tel. + Fax 095-9191614 Tel. 2-721405
095-9254474 Fax 2-725594
BG 22/96 V
BAUER
1 DESCRIPTION
The large diameter rotary drilling rig BAUER BG 22 is designed for casings up to depths
of 53 m with a max. diameter of 1800 mm.
Special drilling methods with variable equipment were developed to fulfil different tasks.
Fig. 1/1 [BFASE0021
Drilling with kelly bar Drilling with continuous Drilling with twin
flight auger (CFA) rotary drive unit (OTW)
(On The Wall)
Special feature: Special feature: Special feature:

Suitable for depths Fills the bore hole Can be operated in
of up to 53 m with concrete while pulling the direct vicinity of
the auger out buildings, canals, etc.
BG 22/96 1 -1
1.1 GENERAL PLAN
1 Masthead
Upper guide sheave 25
2
3 Rope auxiliary winch
4 Rope main winch
5 Mast upper section
6 Rope tensioner cylinder
7 Rope guide
8 Rotary drive sledge
9 Upper backstay cylinders
10 Crowd winch 24
11 Auxiliary winch with mainrope
guide sheave
12 Lower backstay cylinders
13 Supporting trestle
14 Main winch
23
15 Lifting device, counterweight
16 Counterweight 22
17 Mastfoot prop
18 Boom with boom cylinders 21
19 Mast lower section
20 Drilling tool 20
21 Casing drive adapter
22 Cardan joint 19
23 Rotary drive
24 Kelly bar
25 Rope swivel
18
Fig. 1/2 BG 15 Drilling rig IBFASEOOSI
BG 22/96
1.2 MAIN ASSEMBLY GROUPS
1.2.1 Rotary Drive
Rotary head = KDK 220
Two variable displacement axial piston motors (see fig. 1/3.1) power the rotary drive and
transfer the torque via the kelly bar to the drilling tool or via the casing drive adapter to the
casing tube.
Two planetary gears enable switching between two modes:
1 gear:
st
Maximum torque, low engine speed
-» especially for casing operations.
2 n d
gear: Light torque, high engine speed
-»especially for drilling operations.
The planetary gears are lubricated by a gear pump which is mounted to the base machine.
The optimal lubrication and cooling of the gear ring is ensured by an amount of oil contained
in the ring housing (4). The crowd cylinder or the crowd winch moves the rotary drive at
the mast up and down.
The compression springs (5) of the

shock absorber ring (6), which is flanged
to the hollow shaft, absorb the shocks at
the kelly bar. Additional shock absorbers
(2) and an elastomer cover at the spring
assembly housing contribute to keeping
noise levels low and to preserving the
equipment.
The cardanic joint (3) transfers the

torque via the casing drive adapter to the
casing tube and prevents the transmis-
sion of stress caused by bending to the
rotary drive.
Fig. 1/3 KDK 220 I BFASEIQ 3|
BG 22/96 1 -3
Rotary head = KDK 140
The rotary drive is powered by two oil engines (see fig. 1/4.1). The torque is transferred
via the kelly bar to the drilling tool or via the casing drive adapter to the casing tube.
Planetary gears enable switching between two modes:
1 st
gear: Maximum torque, low engine speed
-» especially for casing operations.
2 n d
gear: Light torque, high engine speed
-> especially for drilling operations.
Optimal lubrication and cooling of the gear ring is ensured by an amount of oil contained
in the ring housing (4). The crowd cylinder or the crowd winch move the rotary drive up
and down the mast. The upper and lower kelly drive rings, (2) and (3) respectively, transfer
the torque to the kelly bar.
Fig. 1/4 IBFASE202I
BG 22/96 1 -4
1.2.2 Mast
The rake of the mast determines the

direction of the bore. While drilling,
the rake of the mast can be altered
by the backstay cylinders: up to 6'
forward and 10* sidewards and back-
wards. For rigging or de-rigging, the
Rotary sledge
mast can be folded to the front. The
mast's sideward and backward rake
is limited mechanically. Upper mast
section
The hoisting height of the rotary sled-
ge depends on the mast length and Guide rails
the crowd type.
The distance between the bore axis

and the base machine can be adju-
sted by the boom cylinders. For all
operations where high tensile forces
are required the mastfoot prop (op-
tional) can be extended to stabilize
the drilling rig.
Crowd winch
Lower mast section
Auxiliary winch
Mast link to
base machine
Mast pivot attachment
Mastfoot prop
Fig. 1/5 Mast IBFASEECMI
BG 22/96 1 -5
1.2.3 Crowd
The drilling rig is equipped with a crowd cylinder or a crowd winch. The winch/cylinder
generates the necessary compressive and tensile forces for the drilling tool.
Winch: Cylinder:
The upper or Upper guide sheave The cylinder

lower crowd ro- stroke deter-
pe pulls the ro- mines the
tary sledge in height lifted
the required di- of the rotary
Crowd cylinder sledge.
rection.
For one wor-
king stroke the -Upper crowd rope
whole mast
length can be Guide sheave on the
used. The ope- rotary sledge
rating manual -Middle guide sheave
for the crowd
winch is in the
appendices.
Crowd winch •' i W
o
mi p
Lower crowd rope
Lower guide sheave Lfl

Fig. 1/6 IBFASEE05I
Drilling rig with winch crowd Drilling rig with cylinder crowd
BG 22/96 1 -6
1.2.4 Masthead
The masthead (see fig. 1/7) guides the main rope and the auxiliary rope over the mast via
guide sheaves (1).
It consists of a main and auxiliary cathead, (4) and (5) respectively, and is connected to
the mast by two pinning points (6) and four grub screws (7).
The auxiliary cathead for the auxiliary rope is offset 15 to the left of the main cathead.
All rope sheaves (1) are equipped with removable rope derailment guards (2).
The overhoist limit switches (9) prevent the masthead from being damaged during the
lifting operation. They are activated by weights (8).
In addition, the masthead houses a depth indicator (3) and rope force sensing devices.
2 3 4 5
Fig. 1/7 Masthead
BG 22/96 1 -7
BAUER
1.2.5 Backstay Cylinders
The two backstay cylinders serve to change the rake of the mast.
Each backstay cylinder can be extended by one third upwards and by two thirds
downwards.
The upper cyl nders serve to alter the inclination of the mast during drilling operation,
Press the
tf/ buttons on the control panel to extend and retract them.
During the whole drilling operation the rake of the mast is displayed on the monitor.
The lower backstay cylinders are used for rigging procedures. They serve to fold the
mast down to the front and are operated by the lever next to the operator's seat.
Fig. 1/8 Twin backstay cylinders IBFASE035
BG 22/96 1 -8
1.2.6 Mast Link to Base Machine with Boom Cylinders
The mast link to the base machine (see fig. 1/9) absorbs all forces and torques resulting
from drilling operations. The cylinders (1) alter the distance between the mast and the base
machine, and thereby change the drill axis.
The end position of the cylinders (mast link to base machine lowered completely) is
monitored by limit switches.
1 1
Fig. 1/9 Mast link to base machine with boom cylinders IBHALEO2SI
1.2.7 Main and Auxiliary Winch
The operating manual for the main and the auxiliary winch is in the appendices.
BG 22/96
1.3 BASE MACHINE
The base machine is a vehicle of the Sennebogen company which was specially refurbis-
hed for the BG-systems by BAUER.
1.3.1 Design of the Base Machine
The crawler crane base machine BS 70 (see fig. 1/10) is assembled as follows:
A Uppercarriage
1 Sound insulated operator's cab on elastic suspension
2 Motor compartment and storage space, hydraulic system, hydraulic and fuel tank,
electrical plant
3 Counterweight
4 Swing gear
B Undercarriage
5 Crawlers with
6 Crawler drive wheels
BG 22/96 1 -10
1.3.2 Crawler Base
Each side of the crawler base is equipped with a compact travel planetary gear powered
by a hydraulic fixed-displacement motor.
The crawler base is equipped with automatic brake valves for downhill travel as well as
service and parking brakes which are controlled hydraulically and integrated into the travel
machinery. They automatically disengage when travel is started and engage when travel
is stopped.
The crawler components are maintenance-free until they are completely worn. The
crawlers' service life is increased by the special design of the carrier rollers, tread rollers
and front idlers. Metal seals make them resistant to dirt.
The tension of the crawler chains can be adjusted hydraulically.
The travel mechanism is equipped with two crawler control pedals for forward and
backward travel and with two additional control levers which enable precise and sensitive
movements to the chains.
BG 22/96 1 -11
1.3.3 Diesel Engine
The base machine is equipped with a water-cooled Caterpillar diesel engine.
For further information see the operating manual for the engine.
Selected technical data of the engine are listed in section 3 of this manual.
BG 22/96 1 -12
1.3.4 Hydraulic System
The hydraulic system of the base machine consists of a dual-pumping unit with two axial
piston units, two-circuit functions (two simultaneous working movements), a separate
swing gear pump as well as an energy saving system (EVS).
The hydraulic system has a uniform sealing system for all cylinders, uniform SAE-type
threadings and sealed bearings.
The hydraulic oil is cooled by an oil cooler. The temperature is controlled by a hydraulic
fan, which is switched on by a thermal valve when the temperature exceeds 50 *C.
The rotational speed of the fan is dependent on the oil temperature, i.e. the higher the
temperature the higher the rotational speed and vice versa.
BG 22/96 1 -13
1.4 IDENTIFICATION NUMBERS ON THE APPLIANCE
B G 22/96 1 -14
1.5 LIMIT SWITCHES
To improve operating safety, limit switches monitor various functions:
Table 1 - 1 Limit switches
Designation Function
ES 3 Is activated when the boom cylinder is fully extended
HE 1 Overhoist limit switch, main winch (optional)
HE 2 Overhoist limit switch, auxiliary winch (optional)
B»uw-G»r*te
TyptrtBchlld
Fig. 1/12 IBFASE037I
BG 22/96 1 -15
2 TECHNICAL DATA
2.1 DIMENSIONED DRAWING
Operating weight
with 3/24 kelly bar,
KDK 140,1200 tools
and counterweight 8.2 to:
75 to
Operating weight
with 3/30 kelly bar,
KDK 220,1350 tools,
auger cleaner and
counterweight 13.2 to:
79 to
Fig. 2/1 IBFASE038I
Table 2 - 1
KDK 220
Crowd system Boom cylinder Boom cylinder
retracted (mm) extended (mm)
A Total height 22910 22660
A1 Masthead-Kellyeye 1970
B Lower edge, rotary drive in highest

position 15800 15550
C Lower edge, mast (without mastfoot

1840 1590
prop)
Lower edge, mast (with mastfoot
C1 1740 1490
prop)
D Total length, crawler base 5325
E Drill axis - swing centre 3780 4100
F Swing radius 3900
Drill axis - mast, front edge 1000
G
Drill axis - crowd rope 850
H Crowd length 13150
J Lower mast section 8800
K Upper mast section 10500
L Masthead 1770
Rake of mast, back/front/transverse 10"/6'/± 10'
BG 22/96 2-1
IBFASE039I
Fig. 2/2 Dimensioned drawing of continuous

flight auger (CFA) 0 750
2.2 BASE MACHINE TECHNICAL DATA
Base machine BAUER BS 70
3900 (Telescopic
crawler base)
3 9 2 0 (Under-
_ carriage rigid)
3 8 0 0 (rigid)
Fig. 2/3 Dimensioned drawing, base machine IBFASEE40I
Diesel engine
Caterpillar diesel engine CAT 3306 Dl-T, water-cooled
Rated output 220 kW at 2000 rpm

Number of cylinders: 6
Tank capacity: 8051
BG 22/96 2-3
Crawler base
Travelling speed: 1.5 km/h

Tensile force: 480 kN
Electrical plant
Operating voltage 24 V
2 cold-start high-capacity batteries 2 x 143 Ah
Threephase current alternator 28 V/ 35 A
Hydraulics
Double pump unit with two axial piston units,

2-K-hydraulic system with electronic load-limit control,
Generously dimensioned oil cooling system,
Toothed wheel pump for servo control
Pump delivery max. 2 x 250 l/min

Operating pressure max. 300 bar
Hydraulic tank capacity 600 I
Swing gear
Rotational speed 0 - 4 rpm (continuously adjustable)

Pump capacity 170 l/min
A multiple disk brake serves as service and parking brake.
BG 22/96 2-4
2.3 DRILLING EQUIPMENT TECHNICAL DATA
2.3.1 Winches / Cylinders
• Main winch
Type Free-fall winch

Pulling force 200 kN
Rope speed 0 - 60 m/min
Rope length 90 m
Rope diameter 28 mm
Auxiliary winch
Type Winch without free-fall

Pulling force 75 kN
Rope speed 0 - 56 m/min
Rope length 50 m
Rope diameter 20 mm
Crowd winch (optional)
Pulling force (on sledge) 260 kN

Max. rope speed 0 - 1 8 m/min
Crowd 13150 mm
Lifting rope 0 24 57 500 mm
Lowering rope 0 24 50 000 mm
Crowd cylinder (optional)
Crowd length 6.5 m

Pulling force 300 kN
Crowding force 200 kN
Max. rope speed 0 - 1 8 m/min
Crowd slow (down / up) 1.1 /2.2 m/min
Crowd fast (down / up) 6.5/13.0 m/min
BG 22/96 2-5
2.3.2 Wire Rope Specifications
Main Winch Rope
Part-No.: 245116 (DIN 50049)
Nominal diameter of rope: 28 mm

Length of rope: 90 m
Permissible deviation: 4%
Weight per metre: 3.98 kg/m
Rated strength of wires: 1960 N/mm 2
Space factor: 0.72

Stranding factor: 0.80
Calculated breaking strength: 868 kN
Minimum breaking strength: 695 kN
Total metal cross-section:
Number of load-bearing wires: 105
Total number of wires: 329
Type of inlays: steel inlay (SES)

Surface of the wires: plain (BK)
Type of lay, direction of lay: long lay (ZZ) right
Design: low tension; spinn resistant
Impregnation: greased
Rope description: external strands

(special features)
Jointless timble to DIN 3091 - 28: D | : 6 0 H 13
BG 22/96 2-6
Auxiliary Winch Rope
Part-No.: 71369
Nominal diameter of rope: 20 mm

Length of rope: 50 m
Permissible deviation: 4%
Weight per metre: 1.85 kg/m
Rated strength of wires: 1770 N/mm 2
Space factor: 0.65

Stranding factor: 0.76
Calculated breaking strength: 363 kN
Minimum breaking strength: 277.7 kN
Total metal cross-section: 205.10 m m 2
Number of load-bearing wires: 112

Total number of wires: 245
Type of inlays: steel inlay (SE)

Surface of the wires: plain (BK)
Type of lay, direction of lay: cross lay
Design: tension
Impregnation: greased
Rope description: external strands, post-sealed

(special features)
Jointless timble to DIN 3091 : Bore Di 40 mm
BG 22/96 2-7
BAUER
2.3.3 Rotary Drive
KDK140
Possible settings:
1. High rotational speed Light torque
n = 3 8 rpm 30 kNm
2. Low rotational speed or Heavy torque
nmax = 8 rpm M max = 140 kNm
KDK 220
Possible settings:
1. High rotational speed Light torque
n = 5 0 rpm 121 kNm
2. High rotational speed or Heavy torque
n = 5 0 rpm 180 kNm
3. Low rotational speed Heavy torque
n = 2 7 rpm 180 kNm
BG 22/96 2-8
BAUER
2.4 DRILLING TECHNICAL DATA
The data below is true for the mast at its highest position - boom cylinders retracted - triple
kelly bar - KDK 220.
Table 2 - 2
Dimensions (m)
Base machine BS 70
Crowd system Cylinder Winch
6.50 m
L1 20.95 20.95
L2" 10.60 16.80
L3" 4.10 3.65
Max. A * 16.75 17.21
Max. Hd * 7.15 13.35
Lifting height of 6.50 13.15
rotary sledge
Drill axis 3.78-4.10 3.78-4.10
Max. length of retracted kelly bar
The dimensions are for triple kelly bars; when four-
part kelly bars are used 0.30 m must be added
Table 2 - 3 Drilling axis
Maximum bore diameters (mm)

Cylinder Crowd winch
Without casing 1900 1700
With casing 1600 1400
With casing 1400
oscillator 1500
Table 2 - 4
Casing lengths
Without BV * Hw (m) - 0.8 m
With BV * Hw (m) -1.5 m
* BV = Casing oscillator
Fig. 2/4 IBFASE095I
BG 22/96 2-9
Table 2 - 5
Drilling depths (unlocked)

Crowd cylinder Min. rope
Max. torque 180 kNm Crowd winch
6.50 m length
Number of tele-
Weight
scopes / A(m) B(m) Hw (m) T(m) Hw (m) T(m)
(to)
Nominal depth
3/18 8.30 20.64 3.7 6.85 18.3 10.7 18.7

65 m
3/21 9.30 23.64 4.2 6.85 21.3 9.7 21.7
3/24 10.30 26.64 4.8 6.85 24.3 8.7 24.7
3/27 11.30 29.64 5.1 5.9 27.3 7.7 27.7

3/30 12.30 33.80 5.7 4.90 31.4 - -
With locked kelly bars the drilling depth is reduced

by the number of telescopes multiplied by 0.2 m
The drilling depths are based on the following starting values:
— Length of drilling tool = 1.70 m

— Length of casing drive adapter = 1.90 m
When three and four-part kelly bars are exchanged the kelly drive rings must be replaced.
Note the minimum rope length: up to the 3/27 kelly bar the minimum rope length is 65 m.
Up to the 4/32 kelly bar the minimum rope length is 70 m.

Up to the 4/48 kelly bar the minimum rope length is 85 m.
Up to the 4/58,7 kelly bar the minimum rope length is 100 m.
For further information please contact the BAUER Service Centre.
Kelly bars and drilling tools have their weights engraved. The weights must be the correct
ones for the main winch.
BG 22/96 2-10
2.5 STABILITY ACCORDING TO prEN791 FOR BG 22 ON BS 70
Drill axis 4.1 m
Drilling equipment Weight

Kelly BG 22-3/30 5.7 tonnes
Casing drive adapter 0 1500 1.9 tonnes
Auger 01350 1.3 tonnes
Counter weight 13.2 tonnes
According to prEN971 stability of the above mentioned device is guaranteed for

the following working conditions:
1. Shifting the drilling rig with the above mentioned equipment on slopes of max. 6*
Condition: Uppercarriage lengthwise, drilling equipment and dynamic loads in lowest
possible position, mast vertical. (See "Shifting the Drilling Rig" in the
Instruction Manual.)
Max. ground pressure: 320 kPa
2. Working load, auxiliary rope:
Condition: The drilling rig must be standing horizontally.
Mast inclination: vertical
Max. permissible load for swings of 360': 7.5 to
3. Main rope force:
Max. permissible main winch force in any position of the uppercarriage: 20 to
For further information on permissible working conditions see next page.
4. Crowd force:
Max. crowd force in any position of the uppercarriage: 30 to (at the casing drive
adapter: 22.5 to). Max. ground pressure: 570 kPa
For further information on permissible working conditions see next page.
The given permissible working loads for main rope, auxiliary rope and crowd are only
valid for the device and equipment as described above.
The permissible loads must not be combined (i.e. used simultaneously), even if additio-
nal equipment is used.
It is prohibited to mount any loads to the crowd system while activating the permissible
working load (see above) on the auxiliary rope.
When the permissible crowd or main winch forces are activated the uppercarriage must
be standing still.
BG 22/96 2-11
Load diagramm for max. forces with inclined rig:
Permissible swing angle of

uppercarriage with max. load: 90°
max. crowd max. main max. load on

force 300 kN rope f o r c e 2 0 0 kN auxiliary winch 75 kN
Swing angle: 3 6 0 °
Permissible total
crowd pulling force 265 kN
Permissible total
main rope force 200 kN
Permissible total load on

auxiliary winch 62 kN
111 Crowd
§§§§§§ Main winch
Auxiliary winch
2. Max. working load, auxiliary rope:

Mast inclination: max. 6' forward and 8' sideward
3. Max. main rope force:

Absolute mast inclination: max. 6' forward or max. 4' backward and max. 2' sideward.
4. Max. crowd force:

Absolute mast inclination: max. 6' forward or max. 4' backward and max. 8' sideward.
For different working conditions please contact the BAUER Service Centre.
BG 22/96 2-12
2.6 ACOUSTIC CAPACITY CONTROL
According to DIN 45635-33-KL2
Acoustic sound level LPAI = 75.7 dB(A)

in the operator's cab
Average sound pressure level LPA = 77.2 dB(A)

Sound power level LWA = 108.4 dB(A)
The vibration environment for the operator is less than 0.5 m/s .
2
2.7 OPERABLE TEMPERATURE RANGE
Temperature range -20' C -> +50* C.
BG 22/96 2-13
2.8 WIND VELOCITY
The speed of the wind must be measured if there are windy conditions. The place in which
to make the measurements is the top of the mast.
The values measured there must be compared with the maximum allowable values given
in the table below.
Maximum allowable wind:

Operation
Operation may be continued up to the following values
Barrier effect 250 N/mm 2
20.0 m/s
Wind speed
72.0 Km/h
If the wind is stronger, the equipment must be shut down as follows:
Lower drilling tool (or any other load) to the ground.
Store rotary drive in lowermast position.
The operator's cab is to be protected against objects or debris flying around (as far
as possible).
BG 22/96 2-14
3 OPERATION
General Information
In this chapter the user is provided with a pictorial overview of the operating elements,
which is later accompanied by a detailed description of their functions and operation.
Important operating notes, such as
— messages concerning operating states

— drilling widths and depths as well as
— menus featuring the next steps to be taken
are displayed on the monitors.
The following instruction manual describes the operational sequences for the drilling rig
in detail.
BG 22/96 3-1
CO
Left Right O
crawler crawler
m
Free-fall brake 30
and release 3
Free-fall on/off O
30
-Crowd fast/slow
(/)
Free-fall release -Horn O
>
-Rotary drive fast/slow CO
Disengage swing brake
-Emergency stop
Auger cleaner control Crowd DOWN
cp'
CO Rotary drive Rotary drive
CLOCKWISE J ANTICLOCKWISE
I I OB) OH)
Winch 1 or 2 DOWN
irren CD CED
Crowd UP
Upper carrige Upper carrige OD CE) OED
ÖD CD CH) Ignition
swing wing — &
a O Engine speed control
to LEFT to RIGHT
Winch 1 or 2 UP Crawlers extend or retract control
Sil
Lower
backstay
cylinders
3.2 CONTROL PANEL BG 22 / BS 70
Free-fall On/Off
Pumps 1-3 pressure
Warning lamps: gauges
not occupied Warning lamps:

Hydr. oil level Engine oil pressure
Hydr. oil feed Off indicator Engine temperature
Hydr. oil-filter
Hydr. oil temperature
Air-filter
Cooling water temperature
Battery charging
Engine fuelgauge
Swing brake
EMERGENCY S T O P
Switches
Switches
Wiper
Head light
C a b ventilator
Warning light Washer system
Swing gear lubricator

Hour meter
Engine speed control
Working lights Ignition On/Off
Not occupied Receptacle
Fig. 3/2 IBFASEE95I
BG 22/96 3-3
3.3 INSTRUMENT PANEL
2 3 4 5 6 7 8
RESET 22
TIEFE mo
í ft
AUTO 22 KIJK
TUtfM mto Oil
SOB
KELLY
17 15 13 11 10 9
18 16 14 12
Fig. 3/3 IBFASEE96I
1 Depth display reset 12-15 Upper backstay cylinders

12 right retract
Indication lamp rotary drive - high torque 13 right extend
Preselector rotary drive - high torque 14 left retract
Indication lamp rotary drive fast 15 left extend
5 Boom cylinders extend 16 Preselector SOB-mode

6 Boom cylinders retract 17 Preselector kelly-mode
7 Mast foot prop retract 18 Automatic mast adjustment

8 Mast foot prop extend
9 Indication lamp winch II

10 Preselector winch I or winch II
11 Indication lamp winch I
BG 22/96 3-4
3.4 MANOMETER INDICATION
Manometer P1 Manometer P2 Manometer P3

Pumpe 1 Pumpe 2 Pumpe 3
Fig. 3/4 IBFASE045I
Tabelle 3 - 1
Right crawler Manometer P 1

Left crawler Manometer P 2
Main winch Manometer P 1 Manometer P 2
Auxiliary winch Manometer P 1
Crowd fast Manometer P 2
Crowd slow Manometer P 3
Boom cylinder Manometer P 2
Upper backstay cylinders Manometer P 3
Lower backstay cylinders Manometer P 2
KDK Rotary drive Manometer P 1 Manometer P 2
Casing drive adapter Manometer P 3
Rope tensioner Manometer P 3
Auger cleaner Manometer P 3
Tele-under carriage Manometer P 3
Counter weight cylinders Manometer P 2 Manometer P 3
Casing oscillator Pump 4 Pump 4
BG 22/96 3-5
BAUER
3.5 MONITOR UNIT
This unit controls the drilling and gives feedback on the actual state. It consists of a graphics
monitor, a text monitor and a control panel with pushbuttons. For detailed descriptions see
next pages.
m
v
Hauptw i n d e A, SOt Hauptw 0,3 Hi I f s w
H i I f s w i nde
X-Ne i Quno
->
1,80t
0.E*
4,20 1,80
m H ENT
Y-Ne i g u n g 0,3*
T i ef e + 12,20m
19.05.93 09 ;15h
E 1 1V 1
Me I d u n g e n
<0,2
Fig. 3/5 Monitor Unit IBCHLB026I
Text monitor Graphics monitor Control panel
with an upper field for data, - Mast position —for dialog and control:
such as: - Rope force 0 + 0 Calibrating depth
Main winch E5 + B Calibrating rope load
Auxiliary winch H + ED Calibrating deviation

Sidewards deviation forwards - backwards
Forward/backward deviation S + 0 Calibrating deviation

Depth left - right
and a lower field for messages H + 0 Calibrating automatic

such as: casing drive adapter
Auxiliary winch limit switch on!!! Resets depht's indication

value
A+0 Time control
B+c English/German
indication
BG 22/96 3-6
Table 3 - 2 Messages displayed in the lower field of the text monitor
Priority listing Description of messages (examples)

1 - Limit switch 2 is defect
ALARM A The above messages require an imme-
/l\ diate check into the function of the
Defects of 2
*- -* Limit switches. Replace with new parts
surveying CAUTION as necessary.
elements
2 - Extend boom cylinders
- Y-deviation exceeding 6', extend backstay cylinders
TROUBLE
The above messages indicate that the respective
Control command cylinders are not completely extended/retracted.
is ignored NOTE Repeat the command.
- Inclinometer for forward/backward inclination is defect, or
measuring range is exceeded.
Message nas no effect on the system.
- Inclinometer for sideward inclination is defect.
3 Message has no effect on the system.
- Main winch lifting limiter is actuated:
WARNING hoisting by main winch is stopped
- Auxiliary winch lifting limiter is actuated:
Defects in sensoring hoisting by auxiliary winch is stopped
device - Rope force sensing of main rope is defect:
or High torque is blocked
incorrect switching - Rope force sensing of auxiliary rope is defect.
Message has no effect on the system
- Retract mast prop:
message appears when changing from drilling to rigging
mode
4 The routine messages provide immediate feedback on the cur-

rent state of drilling.
ROUTINE
MESSAGES These messages are displayed on the monitor without extra
audible or visual support.
BG 22/96 3-7
BAUER
3.6 USAGE INSTRUCTIONS
This section covers the calibration programming of the monitor and control unit, explains
the mast auto zero reset, the rotary drive slow/rapid acceleration and how to preselect the
30 mto torque.
3.6.1 Calibrating
The unit offers a menu for calibrating the depth.
The measuring assembly has been calibrated prior to delivery of the rig.
Should readjusting become necessary because of wear or damage of a measuring sensor,

use the following working procedure:
3.6.1.1 Calibrating the Depth
• Set winch preselector in position (main winch).
• Reel off main winch rope until the rope swivel is approx. 10 cm above ground.
Push reset button 0
• Fit a measuring tape to the rope swivel and haul in 10 m ropelength by main winch.
• Turn off base machine.
• Push buttons I I and I I simultaneously, plus start base machine, to call up the
"Depth calibration" menu.
A
CAUTION
Hold down buttons
actuated. Then release.

and until message (see fig. 3/5) appears
on the text monitor to confirm that the depth calibration menu has been
BG 22/96 3-8
• Apply button and/or to readjust the depth indication to the measured value
(10 m).
ENT
• Push button to store the entered value.
Main winch 20.001

Auxiliary winch 8.001
Sideward incl. < 15.0°
Forw./Backw. incl. 45.0° A
Depth -20.00 m
*************************
Calibrate depth!
Arrow buttons A
Go on with ENTER
Fig. 3/6 Depth calibration main menu
BG 22/96 3-9
3.7 MAST ADJUSTMENT IN DRILLING MODE
In drilling mode, especially by using cases, it is important to watch the

mast inclination on the monitor. If the mast inclination becomes displaced
relativ to the drill axis by the efficient forces, the mast must be reset in its
A
CAUTION
Auto
starting position with the functions I I or by extending/retracting the

Turn
backstay cylinders. The mast position has to be all the time parallel to
the drill axis.
MISUSE OF THE BOOM CYLINDERS

It is prohibited to put in the boom cylinders in the "Pulling mode" additional to the crowd
system for this work.
By disregard this direction the crowd system will be damaged.
Automatically reset of the mast inclination to zero
Auto
With the function

Turn
the mast moves automatically in its vertical position, but only if the
zero point is installed in the computer before.
The mast must have no contact to the ground.

NOTE
BG 22/96 3-10
3.8 PRESELECTING THE 22 MTO TORQUE (IF IT EQUIPPED)
Kelly mode
Should the more powerful torque of 30 mto become necessary for casing oscillation, use
the following instructions:
• Set mode preselector in positon (drilling mode).
• Ensure that kelly bar or drilling tool has absolute clearance in the bore hole.
22
• Push button nto

to actuate the torque.
This entry is confirmed on the monitor by the message "Drilling mode

22 mto".
NOTE
• To cancel the 22 mto torque during kelly application proceed as follows:
22
Push preselect button nto

again.
Lower kelly bar (by 20 cm at least).
Push button "Reset depth"
CAUTION!
DO NOT SHIFT TORQUES WHILE

THE ROTARY DRIVE IS RUNNING.
BG 22/96 3-11
3.9 ROTARY DRIVE SLOW/RAPID ACCELERATION
The lower button on the right four-way-lever is a SLOW/RAPID acceleration preselector

for the rotary drive: SLOW is used for drilling and RAPID for removing drilled material from
the tool. In RAPID mode, the acceleration performance is speeded up so that even tough
and sticky material will easily part from the tool.
Usage
To empty the tool:
• Select RAPID mode by pushing the button.
• Move the right four-way-lever to rotate tool.
To resume drilling:
• Return to SLOW mode by pushing the button again.
• Move the right four-way-lever to rotate tool.
Before drilling make sure the acceleration is in slow mode.
CAUTION
BG 22/96 3-12
BAUER
3.10 FREE-FALL FOR DRILLING MODE
To activate free-fall for the main winch, proceed as follows:
• Switch the free-fall on/off preselector to position "ON".
• Step on the foot brake (free-fall control) (fig. 3/3.4) and keep it pushed down while
activating the free-fall control button (3) on the left four-way lever.
• Free-fall is activated by sensitively and precisely releasing the foot brake (4).
A
CAUTION
The permissible strain on the rope in free-fall mode may not exceed 50 %
of the winch's max. tension force.
• To brake again, the foot brake must be pushed right down; or
• to turn off the free-fall mode, shift the left four-way lever to the position "Winch up" (2)
or release the switch (3).
F r e e - f a l l brake Free-fall on/off

and release
Free-fall release—
Fig. 3/7 |BFASEE84|
B G 22/96 3-13
3.11 EMERGENCY-STOP BUTTON
When the EMERGENCY-STOP button is pushed, all functions of the drilling rig are cut off
immediately.
Only the diesel engine remains running and must be switched off separately.
To restart the drilling rig the EMERGENCY-STOP button must be pulled out.
Fig. 3/8 K3AASA061I
BG 22/96 3-14
BAUER
3.12 TRAVELLING AND STEERING CONTROLS
The directions of travel "forward" and "backward" always refers to the base machine's
original direction of travel, i.e. the front idler (1) is at the front and the drive wheel at the
rear (2).
/ QD
w
\
1 2
Fig. 3/9 Direction of travel IBFASE017I
• Adjust the required engine speed using the engine hand throttle (fig. 3/10.4).
To travel straight, use the crawler control pedals as follows:

Forward: Step on both pedals
Backward: Step on both pedals
To travel in a straight line the additional crawler control levers (1 ) can also
1ÏÏ
NOTE
be used.
• To travel straight, use the crawler control levers (1 ) as follows:

Forward: both levers to position A
Backward: both levers to position B
• To turn on the spot, use the crawler control levers (1 ) as follows:

To the left: right lever to position A
left lever to position B
To the right: left lever to position A
right lever to position B
BG 22/96 3-15
• To travel and steer use the crawler control levers (1) as follows:
Forward to the left: left lever to position 0

right lever to position A
Forward to the right: right lever to position 0

left lever to position A
Backward to the left: left lever to position 0

right lever to position B
Backward to the right: right lever to position 0

left lever to position B
• To stop release crawler control pedals (fig. 2 and 3) or hand lever (1). (Lever returns
automatically to middle position.)
• Before leaving the operator's cab, lift up the left control console (armrest) and switch
the engine off by turning the ignition key to position 0. Remove the ignition key and
lock the cab behind you.
Fig. 3/10 Travelling and steering controls (overhead view) l B F A S E E 1 7

i
BG 22/96 3-16
3.13 SWING AND BRAKE THE UPPERCARRIAGE
Swing the uppercarnage by pushing the left four-way-lever to left or to right. The indication
lamp I * * I must not shining.
A
CAUTION
The swing brake is NOT to be used as a service brake to reduce the
speed of the uppercarriage slewing motion.
Hydr. Vorsteuerung ein/aus

The swing brake is in action when Hydraulic pilot line
(armrest)
Schwenkbremse lösen
Disengage swing brake
- the indication lamp is on or
'Schwenkbremse
- the left four-way lever is in position 0 or Swing brake
- the left armrest is lifted up or
Oberwagen Oberwagen
- the engine is switched off. links rechts
schwenken schwenken
Uppercarriage Uppercarriage
The swing brake is released with the swing swing to swing to
brake latch, right button on the four-way-le- left right
ver.
Fig. 3/11 IBKASJ006I
As soon as the four-way lever is shifted to position 0, the slewing motion of the uppercar-
riage is reduced hydraulically. This type of braking is not abrupt as there is a slowing-down
path of approx. 15', depending on the position of the brake pedal and the slewing speed.
Never brake the uppercarriage by steering in the opposite direction of the

slewing motion.
CAUTION
BG 22/96 3-17
3.14 CONTROLS AND ADJUSTMENT FACILITIES IN THE
OPERATOR'S CAB
3.14.1 Operator's Seat
The operator's seat (see fig. 3/12) is multiply adjustable. To adjust the seat height pull it
up to the required height and let it lock into place.
To adjust the seat springs according to the operator's weight (weight adjustment) turn the
hand wheel (fig. 3/12.3) to the left or right. The weight display scale (2) shows the weight
in.kilograms to which the seat has been adjusted.
The operator's seat can be adjusted forward and backward with or without the two control
consoles as required. Push the hand lever (4) to the left to move only the operator's seat
or pull the adjustment bracket (5) to move the seat together with the two control consoles.
The angle of the back rest can be adjusted by pushing the hand lever (9) to the right and
leaning back. To adjust the angle of the sitting cushion turn the hand wheel (6).
To make it easier for the operator to climb in and get out of the cab, the left control console
(8) can be lifted up. The liftable control console also serves as a safety device:
When it is folded up, all functions of the hydraulic working system are cut off and the
machine is secured against being started unintentionally. When the control console is
pushed down, all functions are reactivated immediately.
The operator's cab is ventilated by two air-inlets (1) located at the base of the seat.
The bowden cable for the heating is situated underneath the driver's seat on the right-hand
side.
BG 22/96 3-18
BAUER
Fig. 3/12 Operator's seat i &* i
Key to fig. 3/12:
1 Air-inlet (fan)
2 Weight display scale
3 Hand wheel, weight adjustment
4 Hand lever, forward/backward seat adjustment without control consoles
5 Adjustment bracket, forward/backward seat adjustment with control consoles
6 Hand wheel, adjustment of seat angle
7 Right control console
8 Left control console
9 Hand lever, backrest adjustment
10 E-box
11 Fuses
BG 22/96 3-19
3.14.2 Ventilation
Windshield:
The windshield can be fully opened from the inside of the cab. Make sure that the wiper
is at its leftmost position (fig. 3/13.2) before opening the windshield.
To open the windshield the pane must be unlocked from the frame by pressing the two
handles (1 ) inwards. The pane can then be pushed upwards until it hangs horizontally
underneath the skylight. When the handles are released the pane locks in its present
position. To close the windshield press the two handles inwards to unlatch the pane and
pull it down until it reaches the stoppers. Push it into the frame and release the handles to
lock it.
Make sure that the windshield is locked properly.
Skylight:
To ventilate the operator's cab slightly, open the skylight by turning the handle (4). The
pane is lifted pneumatically and kept open.
The skylight wiper is turned on and off with the switch in the upper left-hand corner of
the operator's cab (3).
The operator's door can be kept

open by locking it to the back side
of the cab. Pushing the lever (5)
forward releases the door lock.
Fig. 3/13 iBCHSDoia
BG 22/96 3-20
BAUER
3.14.3 Heating (optional)
The cab is equipped with a cooling-water heater, which is powered by the engine. The fan
can only be operated when the ignition is switched on, i.e. when the motor is running. The
operator can choose between two fan speeds and thus adjust the amount of cold or hot
air being blown into the cab using the fan switch on the instrument panel.
By pulling the infinitely variable bowden cable (at the lower right of the operator's seat) the
hot air supply is switched on. When the cable is pushed down as far as it will go and the
fan is switched on, the operator's cab is supplied with fresh air.
Make sure that the heating remains switched off during the summer
months to prevent the diesel engine from overheating.
Fig. 3/14 PMASD033
BG 22/96 3-21
3.14.4 Air Conditioner (optional)
The cab is equipped with high capacity air conditioning.

The air conditioner cabinet is installed to the rear of the operator's seat.
Functions:
• Removes moisture from the room air to provide dehumidified comfort.
• Heats/Cools the room air to provide comfortable temperature.
Controls:
• The engine must be running.
• A blower On-Off switch is located on the operator's right-hand control console. When
the switch is in 0-position, no air is blown into the cab - no function of the air conditioner.
• The air conditioner controls are on an easy-to-reach control panel located on the air
conditioner cabinet:
Toggle switch to turn air conditioner (electric power) On-Off (see fig. 1)
Round knob to regulate BLOWER SPEED, i. e. the amount of air blown into the cab (4).
Blue sliding switch (2) to regulate the FRESH AIR ventilation, i. e. the amount of fresh air
drawn from the outside. Amount increases with movement to right (max. amount is approx.
10-15%)
Red sliding switch (3) to regulate the TEMPERATURE of the air blown into the cab. Cold
increases with movement to right.
It is recommended not to cool the air in the cab to more than 6 - 8' C below the outside
temperature.
For further information on the air conditioner (start-up and service),

please refer to the manufacturer's manual found in the Appendices of this
manual.
NOTE
FDASH009I
Fig. 3/15 Air conditioner controls
BG 22/96 3-22
3.14.5 Window Wipe and Wash
Cab is equipped with washer and wiper for the front and the roof window. With the engine
on, use the toggle switch "washer system" On/Off.
The water tank is placed underneath the operator's right control console. Their water level
should be inspected, and be topped up as required, before the machine is started.
Fig. 3/16 Water tank for washer (FDASHTTEJ]
BG 22/96 3-23
3.15 SAFETY DEVICES
3.15.1 Emergency Exit
If the normal exit-way from the cab

can not be used, the operator has
the possibility to get out through
the rear window. To use this emer-
gency exit, the following has to be
done:
• Pull RED RING located in up-

per left corner of rear window. \
• Remove complete window ^
seal. \
• Push window pane outward.
• Climb out.
Fig. 3/17 Emergency exit from cab IFDASHIUI
PCVSDP28I
BG 22/96 3-24
3.15.2 Left Control Console
The left control console (operator's left armrest, see fig. 4/1) can be raised.
Raising the console cuts off the hydraulic circuit so that all hydraulically working crane
functions (except TRAVEL) will be blocked. The functions will be on again as soon as the
console has been lowered.
3.15.3 Fire Extinguisher
The equipped fire extinguisher is placed in the engine/storage compartment, in the left
side of the machine (beneath the engine air cleaner, see fig. 1/6).
To safeguard that the fire extinguisher is in proper working order in the case of an
emergency, it must be regularly inspected by skilled personnel and be replaced with a new
when required.
Handling
1. Pull safety wire.

2. Take the hose and aim it at
the source of fire.
3. Push red lever down strongly.
IBKASJ039I
BG 22/96 3-25
BAUER
4 PUTTING INTO SERVICE - MOUNTING -

DISMOUNTING - TRANSPORT
Before starting the drilling rig for the first time it must be set up. Correct mounting is
important not only to the user but also to the manufacturer. As a rule, BAUER gives a
training course in rigging procedures either at the BAUER company or on site.
Important notes before setting the rig up:
• Three people (i.e. a rig driver and two assistants) are needed to set up the BAUER
BG 15 on a site.
• Mounting is to be carried out by qualified personnel only.
• An unobstructed and level rigging area of approx. 30 x 10 m is required.
• For all hoisting and loading operations only the lifting tackle supplied by BAUER is to
be used.
• Lifting tackle may only be attached to the lifting points specially provided for this
purpose.
A
The boom cylinders must be left completely extended until the cylinder
trestle has been mounted to the base machine. If the boom cylinders must
be retracted due to lack of space when being unloaded from the low bed
CAUTION loader, the mast lower section must be vertical.
WARNING! Indication
t * —
• • • • • m•
••• •
Ef3 ••E H
Left and nghl
upper backstay WARNING! Do
cylinders relracl „ o t r e t r a c t
Right
Lower backstay
cylinders_retract
Do not raise mast more then 45' when trestle is loose.
BG 22/96 4-1
4.1 OPERATING THE TELESCOPIC CRAWLER BASE (optional)
A
The crawler base must be extended immediately after the machine has
been unloaded from the low bed loader. The drilling rig may be operated
and driven only when the crawler base is fully extended.
CAUTION The crawler base is extended without the counterweight.
Extending/Retracting the Crawlers

After any repositioning (extension or retraction) of the crawlers, their tie rod locking pins
must be reinserted and secured with retainer; otherwise, the crane is not ready for ope-
ration.
A
Rotation of the uppercarriage must prevented while the crawlers are
being extended or retracted; the swing locking bar must be installed
during the performance.
CAUTION
The swing locking bar may be removed only when both crawlers have been extended
to the maximum track gauge and when they have been secured with their respective
locking pins and retainers.
Mounting Beam Extensions

• To start with, four beam extension
blocks (4) must be mounted to the un-
dercarriage, two for each crawler:
• Using a rod inserted through the provi-
r-/
ded bore, carry the respective exten- |
sion block to crawler and place it ready I ( L i
for mounting. Take care that imprinted '
numbers match.
• Install the upper pressure plate (1) with
5 hex socket head bolts (2) (M 24 x 485)
and torque the bolts with 960 Nm using
a torque wrench.
• Install the lower pressure plate with 5
hex socket head bolts (3) (M 30 x 490)
and torque the bolts with 1900 Nm "
using a torque wrench.
• Repeat the procedure until all four ex-
tension blocks have been mounted
Fi 4 / 1 B e a m
and their bolts are properly tensio- 9- extension block with pressure
ned. plates and mounting bolts i BIAUOIS I
BG 22/96 4-2
• Remove the connecting pins and track rods on one side of the crawler base.
• Retract or extend the crawler base using the corresponding lever in the operator's cab
while driving the crawler base forward or backward.
• Fasten track rod with the connecting pins - grease as required.
• Secure connecting pin with stop spring.
• Repeat this procedure at the other side of the crawler base.
Connecting pin
Track tie red
Fig. 4/2 |BFASEE93|
BG 22/96 4-3
yj2
Retracting the Crawlers
To transport the crane on a lowloader, the crawlers must be retracted and the four be-
am extension blocks be removed:
Install the swing locking bar, to lock the uppercarriage to the undercarriage.
Remove all four locking pins from crawler track tie rods; remove each retainer spring
and pull out pin.
Start the engine while leaving the left control console RAISED.
Pull the crawler repositioning lever back to "In" and hold it until the respective crawler
has retracted completely to the minimum track gauge.
Reinstall the locking pins and secure them with retainer spring.
Repeat the above steps for the other crawler.
Stop the engine.

Remove all beam extension blocks; insert a rod through the provided bore and hold
the rod so that the extension block can not fall.
Carefully stow all removed bolts, washers and pressure plates in the storage area of
the machine.
If the machine is to stand with the

crawlers extended for a longer
period of time, the track tie rods
must be coated with grease to
A
CAUTION
protect against corrosion and to
ensure that the crawlers will pro-
perly retract.
Regularly check that there is still
a film of grease on the track tie
rods.
Fig. 4/3 Track tie rods IFDASHMBI
The telescoping guides are to be slightly greased (with a MOS2 grease)

from time to time. Check the chain tension in accordance with sect. 5.
NOTE
BG 22/96 4-4
4.2 MOUNTING THE COUNTERWEIGHT
The counterweight (8.2 to or 13.0 to) is put on planks by an auxiliary crane in prepara-
tion.
View x
Travel the crawler crane back- -Lever above
wards towards the counterweight. hydraulic tank
• Use the hand levers (view X) to

lower the wire ropes, attach the
ropes to the counterweight and se-
cure them (A).
• Lift the counterweight steadily with

the cylinders until the eyes at the
crawler crane and at the counter-
weight can be bolted with the pins
"B". Do not forget the stop spring!
• Screw the counterweight with two

screws (C) on the uppercarriage.
Fig. 4/4 IBFASEE20I
To dismount the counterweight follow the above steps in reverse order.
BG 22/96 4-5
4.3 DE-PRESERVATION
All BAUER equipment destined for shipment to overseas countries is protected against
corrosion by a water-repellent wax coating which is applied to all parts of the equipment
at the works.
For reasons of operational safety it is imperative to remove the preservation coating from
the entire equipment prior to putting it into service.
Removal is best effected with hot water jet washing or steam cleaning at a temperature of
90 *C to 95 *C and must be meticulously executed until the entire equipment is completely
free of wax.
If neither hot water nor steam are available the equipment can be washed down with a
cold water detergent. As the results amounting from such detergents vary greatly it will be
necessary to supervise this de-preservation procedure very carefully.
If required, repeat the cleaning procedure until the wax coating is removed completely.
Detergents used must not erode seals etc. Check detergents for their
areas of application prior to use.
CAUTION
BG 22/96 4-6
4.4 CHECKS BEFORE STARTING THE BASE MACHINE
Before starting the diesel engine the appliance must be inspected. Check all screwed
connections for loose or missing bolts. Check the oil and fuel pipes for leaks.
A
During operation the hydraulic system is under high pressure. Oil from
possible leaks may cause serious injuries to unprotected parts of the
body.
Before checking the appliance the hydraulic system must be depressu-
CAUTION rized. All assembly parts that are to be contacted must have cooled down.
To inspect the engine open the right maintenance door, to inspect the hydraulic system
open the left maintenance door.
Carry out the following steps:
• Check the oil level of the rotary drive. Check the kelly drive ring and the rotary sledge
wear strips for wear.
• Check the kelly bar for wear and cracks.
• Check the drilling tools (cutter, holder, kellybox etc.) for wear and cracks.
• In addition, the instructions and regulations set by the manufacturers of the winches
and the diesel engine must be observed.
BG 22/96 4-7
Hydraulic System
To check the hydraulic oil level the base machine should stand horizontally with all
cylinders completely retracted and the hydraulic oil being warm.
Check the hydraulic oil level at the gauge (fig. 4/5) and fill up tank if necessary. The glass
must be filled to the upper mark of the scale.
Check pipes for leaks and make sure that thread connections are tight.
- Schauglas
Füllstandshöhe Hydrauliktank
" Sight gauge
. H y d r a u l i k tank oil level
Hydr. Tank VerschlulJklappe

Hand valve
Fig. 4/5 Hydraulic oil gauge iRFABFnnai
Fuel System
Check pipes for leaks and make sure that thread connections are tight.
The fuel shut-off valve serves to close the fuel supply line for maintenance
purposes (e.g. when a filter must be cleaned or replaced). The valve must
be open during operation.
NOTE
BG 22/96 4-8
Engine Oil Level
Check the engine oil level with the dip stick. (See also section 5.4, Checking the Engine
Oil Level.)
Engine Compartment
Check engine compartment for oil, fuel and coolant leakage. Make sure that the engine
fastening bolts are correctly in place and tight.
Swing and Travel Gears
Check for leaks and loose or missing fastening bolts.
Protective Parts, Coverings
Check for damages and loose or missing bolts.
Operator's Cab
Check for loose objects. Check that cab is clean.
Service Indication Lamps and Display Elements
Check for damages.
Crawler Rollers
Check front idlers, drive wheels and all intermediate rollers for damage and wear. Make
sure that they are correctly in place and tight.
Crawler Treads
Check for damaged or missing bolts. Check crawler shoes and chain links for damage
and wear. Tension the chain if necessary.
BG 22/96 4-9
4.5 REFUELLING THE BASE MACHINE
A
The type of diesel fuel to be used is specified in the operating manual for
the engine.
To prevent condensation from forming in the fuel tank, it must be refilled
CAUTION at the end of every working day. •
The diesel tank has a capacity of approx. 850 I. The tank can be refuelled either via the
filling nozzle or by means of an electric refuelling pump (see fig. 4/6).
A
CAUTION
Do not allow the pump to run when no fuel is available.
Pump Feed hose

to the tank
pump
Fl ling nozzle s
T t c h
Fig. 4/6 Refuelling the base machine IBFASEE48I
BG 22/96 4-10
4.6 PUTTING THE BASE MACHINE INTO OPERATION
4.6.1 Starting the Engine
A
Before starting the engine, make sure that nobody is working at or near
the appliance and that both maintenance doors are closed. The engine
may only be run in well-ventilated rooms or in the open.
CAUTION
A buzzer is activated when the ignition is switched on. The buzzer
deactivates when the engine is started or when the ignition key is
withdrawn.
NOTE
• Insert the ignition key in the ignition/starting switch (fig. 4/7.4). The engine oil pressure
indication lamp (1 ) and the battery-charge indication lamp (2) light up.
• Check the tank contents at the fuel gauge (3).
©
Adjust the engine to medium speed with the
engine hand gas knob (5).
Sil A
• Switch engine on by turning the ignition key. The CHE
indication lamps (fig. 4/7.1 and 2) must go off.
To adjust the engine speed turn the hand gas

knob (5).
O
o s oil DB
DB3 CM (ZD
ra EM B
irra o n o o
4
(D O
5
Fig. 4/7 IBHVSF066I
BG 22/96 4-11
4.6.2 Starting the Engine with a Booster Battery
A
Before connecting jumper cables to the base machine's battery, the
ignition key must be removed. Connect booster and engine batteries
parallel: POSITIVE (+) to POSITIVE (+) and NEGATIVE ( - ) to (NEGA-
TIVE ( - ) .
CAUTION Battery jumper cables must NOT contact each other or the appliance
while the cables are being connected or removed.
• First connect the two POSITIVE (+) terminals to each other with one jumper cable and
then the two NEGATIVE ( - ) terminals with the other jumper cable.
• Start the engine.
• When the engine starts running, remove the NEGATIVE ( — ) cable first and then the
POSITIVE (+) jumper cable.
• Before operating or driving the appliance carry out functional checks as described in
section 4.6.3.
BG 22/96 4-12
4.6.3 Functional Checks with the Engine Running
The operator must always check the indicators on the control panel after the engine has
been switched on and before operation or travel is started.
If an indicator lamp lights up or the buzzer sounds, the cause of trouble

must be detected and the trouble eliminated.
NOTE
Checks
• If the engine oil pressure indication lamp (fig.

4/8.5) lights up while the engine is running, the
oil pressure is too low.
• If the engine temperature indication lamp (4)

goes on while the engine is running, the engi-
ne temperature is too high.
• If the battery-charge indication lamp (2) lights

up while the engine is running, the charging
process of the battery is interrupted, the gene-
rator is defective or a V-belt may have broken.
• If the air filter indication lamp (1) goes on, the

air filter is clogged.
i@ o a a
• If the hydraulic oil level warning lamp (3) lights
OS DES (ZD
up, the oil level in the hydraulic tank is too low. o a €M s
• If one of the hydraulic oil filter indication lamp Pel DE CD
(6) lights up, the hydraulic oil filter is clogged.
o
If the indication lamp I ^ I goes on while the
hydraulic tank is shutting. Open the flap.
is O
• If the indication lamp (7) goes on while the Fig. 4/8 IBHVSF067I
hydraulic oil temperature is too hot.
If one of the above problems occurs, SWITCH OFF ENGINE IMMEDIATELY, check the
individual units and eliminate trouble.
BG 22/96 4-13
Table 4 - 1 Troubles and warning signals
Warnini j s i g n a l
Trouble Symbol
Lamp Buzzer
Engine temperature (SI

• •
Engine oil pressure • •
r-| r
+
Battery charge • •
Engine air filter yellow • •
Hydraulic oil temperature It 11 • •
Hydraulic oil level - • •

warning lamp •TU
Hydraulic oil filters I ù|
•
4.6.4 R e a d i n e s s for Operation
The base machine is ready for operation after
— the checks as described in section 4.8.3 have been carried out,

- the oil level of the engine has been checked,
— the operating temperature has been reached,
- the left control console (armrest) has been pushed down to enable all working
functions.
The appliance is equipped with optical and/or acoustic warning elements,

which give signals when trouble occurs. The following list contains a
description of these signals and the corresponding sources of trouble.
NOTE
To warm the hydraulic oil up, turn the right control lever briefly - not longer than 10 seconds
- to the right.
The warming-up time depends on the outside temperature - the colder it is, the longer it
takes the hydraulic oil to warm up.
BG 22/96 4-14
With the appliance being warmed up by the motor running idly, the
following rules are to be observed:
NOTE
- A t temperatures of 0 "C or more it takes the appliance approx. 15 min.
to warm up.
- A t temperatures of -18 'C to 0 'C it takes the appliance approx. 30 min.
to warm up.
- A t temperatures below -18 *C or when the hydraulic system still does
not run smoothly give the appliance a longer warming-up period.
BG 22/96 4-15
BAUER
4.6.5 Travelling
The instructions and notes described in sections 4.6.1 and 4.6.4 must be
observed and complied to before starting the appliance (driving or carry-
ing out jobs).
A
As the overall view of the rig driver is limited during moving or travelling
a signal man must be in attendance.
Make sure that the necessary distance between the mast and the ground
CAUTION is kept at all times. Note that uneven ground causes the mast move
sidewards and up and down.
It is forbidden to travel along slopes with a gradient of more than 15' and
to travel across slopes!
When travelling on roads or on the site or when jobs are to be carried out
A
CAUTION
with the rig standing in slant position, it is imperative that the oil level of
the driving motor is at the maximum position of the oil stick (upper mark,
"MAX").
Travel forward Travel backward Turn right Turn left
Fig. 4/9 IBFASEË13I
• For precise movements the hand lever is used.
BG 22/96 4-16
4.7 SETTING UP AND MOUNTING THE DRILLING EQUIPMENT
The rigging and de-rigging sequences are supported by computer messages being
displayed on the monitor. Before carrying out the next operating step read the message
displayed. Then carry out the next step and confirm it by pressing the corresponding button
on the keyboard.
4.7.1 Mounting the Upper Mast Section

Position upper mast section on level and firm ground with the masthead pointing in the
direction of travel.
Place timber packing underneath mast supports when rigging on soft

ground.
CAUTION
Start engine of base machine.

• The crawler base must be fully exten-
ded and secured (applies only to tele-
scopic crawler base).
Indication lamp • The boom cylinders are kept extended
boom cylinder to full length, i.e. the indication lamp (1)
does not shine does not shine.
I
• Adjust mast forward in line with machine
(x-Deviation = 0') Fasten trestle to
••• •QSlID machine before raising mast above 45'.
@0D • 0
• The backstay cylinders are extended
steadily using levers (2) and (3) until
.p. Left backstay the eyes on the supporting trestle can
cylinder be connected to the eyes on the base
Right backstay machine with the connecting pins (4).
Supporting trestle
Connecting
pins
|BFASEE11|
Fig. 4/10
BG 22/96 4-17
• Travel base machine slowly towards upper mast section.
Clean contact areas of both flanges and locating pins thoroughly and
W check for damages. Flanges and locating pins must be free from dust and
grease.
NOTE
• Align both mast sections until pin joints (see fig. 4/11.1) at back of each mast section
line up correctly.
I
O O o o o
WÊMÊiÊÊÊmÊÊÈÊÊÊÈÊÊÊÊÊÊÊm.
Fig. 4/11 Joining upper and lower mast sections IBFASE213I
• Insert mast link pins (2).
Do not forget to secure mast link pins with split pins.
• Retract both backstay cylinders by simultaneously pulling the levers until the flanges
of the upper and lower mast section are fully squared-up. (At this point the rope
derailment guard at the front of the masthead should be approx. 10 cm above ground.)
Make sure that the locating pins on the lower mast section are accurately
aligned with the corresponding locating eyes on the upper mast section!
NOTE
BG 22/96 4-18
• Insert hexagon mounting bolts (see fig. 4/12.1), each fitted with a washer (2), into bores
from direction of upper mast section.
• Fit bushing (3), washer (2) and hexagon nuts (4) on each bolt, tighten and secure with
PAL nut (5).
TIGHTENING TORQUE: 1250 Nm
Detail "A" (see fig. 4/12)
'SS*/s ' s s S/S*

1
o^^zzzzzzi
2 3 24
Fig. 4/12 Flange connection 1BHALE023I
1 Hexagon bolt 4 Hexagon nut M 30

2 Washer B 31 5 Locking nut M 30
3 Bushing L 100
• Remove temporary mast supports and store for later use.
BG 22/96 4-19
• Plug electric combination plug (see fig 4/13.1) for overhoist limit switches, rope force
sensor and drilling depth indicator into combination socket.
BG 22/96 4-20
4.7.2 Reeving the Main and Auxiliary Rope
The main and the auxiliary rope, fig. 4/124.4 and (3) respectively, are reeved with the mast
being held in horizontal position.
Reeving procedure:
• Pull out the rope guard pins (1) from the masthead.
• Set winch preselector switch 21 to position
l
or
2
• Run required length of main or auxiliary rope off the drum by operating the left four-way
lever.
• Pass main and auxiliary rope over guide sheaves (5) and run off sufficient length of
each rope for the rope sockets and wedges to reach the base machine.
• Reinstall rope guard pins (1) and secure them.
A
CAUTION
Make sure that the front rope sheaves and the pins (2) are reinstalled.
• Thread each rope through the counterweights (6) suspended by chains from the hoist
limit switches (7).
Make sure that the chains with the counterweights are fitted correctly to
the masthead.
NOTE
1 5 1 5 4 3
6 Q
IBGVOI020I
Fig. 4/14
BG 22/96 4-21
+
BAUER
4.7.3 Raising the Mast
Before raising the mast, check that the overhoist limit switches of both winches are fully
operational, that all bolted connections are properly tightened and all pins are correctly
seated and secured.
Procedure for raising the mast:
• Extend both boom cylinders to full length - the indication lamp (fig. 4/9.1) on the control
panel goes off.
Make sure that no tools, bolts or any other items have been left on the
mast.
CAUTION
• Retract both lower backstay cylinders by operating the control levers simultaneously
to raise the mast uniformly to upright position.
• Retract boom cylinders.
Adjust the mast to the required wor-

king position by pressing the upper
backstay cylinder control buttons
Slip locking ring
over clamp
Groove
In drilling mode the lower backstay cylin-

ders are locked with fixing clamps to O-Ring in groove
prevent them from being used to adjust
the mast (see fig. 4/15), as only the upper
Fixing clamp
backstay cylinders may be used to adjust
the mast.
Fig. 4/15 IBFASEESOI
BG 22/96 4-22
BAUER
4.7.4 Mounting the Rotary Drive - For Rigs with Crowd Cylinder
The rotary drive can only be mounted when the mast is in upright position.
The KDK is mounted and dismounted together with the rotary drive sledge:
• Retract boom cylinders.
• Attach lifting slings to the provided lifting eyes on the rotary drive and to the main winch
rope.
• Lift the rotary drive slowly.
• Thread rotary drive sledge from below through the guide rails on the mast.
• Insert pins into sledge travel stopper.
• Extend crowd cylinders.
• Connect the rotary drive sledge

to the cylinder eye with pin. Lifting sling
Connect hydraulic lines (see fig.

4/16). Lifting eyes
Sledge travel
stopper
Fig. 4/16 IBFASEE22J
BG 22/96 4-23
Mounting the Rotary Drive - For Rigs with Crowd Winch
The KDK is mounted and dismounted without the rotary drive sledge:
• Move the sledge travel stoppers from C and D to A and B respectively and lock them
with pins.
• Attach lifting slings to the provided lifting eyes E on the rotary drive and to the main
winch rope.
Lift the rotary drive slowly, thread it through the guide pins on the sledge to connect it
to the rotary drive sledge.
• Connect hydraulic lines (see fig. 4/16).
Fig. 4/17 Lifting eyes IBFASE216I
BG 22/96 4-24
• Connect hydraulic lines to socket bank on rotary drive.
Crowd Winch Crowd Cylinder
View A: Clutch
Heavy-light
KDK220 torque
View A KDK70 Pilot line KDK 140
Automatic
, ' C r o w d rope
casing drive
IS/ tension
adapter \
Leak oil—0
Automatic/
casing drive
Auger to casing
^adapter
KDK220 positioning
KDK35
Clutch
heavy-light
torque
Fig. 4/18 |BFASEE23|
A
CAUTION
Connect the leak oil line first.
BG 22/96 4-25
4.7.5 Mounting the Rope Swivel
Hauptseil
main rope
Sicherungsscheibe
retaining ring
Bolzen
Sechskantschraube bolt
hexagon screw
Schmiernippel
greasing nipple
Fig. 4/19 Mounting the rope swivel IBFASEE72I
BG 22/96 4-26
BAUER
4.7.6 Mounting the Kelly Bar
Two people (i.e. the rig driver and one assistant)

are needed to mount the kelly bar.
The kelly bar can only be

mounted with the mast in fully
Hauptseil
upright position and with the Main rope
NOTE rotary drive mounted to the
mast.
Seilwirbel
Rope swivel
• Lay the kelly bar horizontally, lengthwise Schmiernippel
oben
Top
and centrally in front of the base machine. Lube nipple
unten
The lifting eye of the rope swi- Bottom
Sechskantschraube.
vel must face in the direction of Hex head bolt
21
^Bolzen
I Pin (with
the base machine. \inside thread)
Sicherungsscheibe
Lock washer
• Attach main rope swivel to the kelly bar and

secure it.
A
The rope swivel must always
be in line with the main rope
(see fig. 4/20).
CAUTION
• Shift the right four-way lever to the position

"Crowd winch down" to lower the rotary drive
completely.
• Extend both backstay cylinders and tilt mast

forward by Z - 3' by pressing the control
RICHTIG
buttons simultaneously.
PCVSDP3q
Fig. 4/20 Alignment of rope swivel
BG 22/96 4-27
• Lift kelly bar using the main winch and drive the base machine slowly towards the kelly
bar.
The main rope must always remain vertical.
NOTE
• Lift kelly bar until the kelly drill stub is approx. 20 cm above the shock absorber ring,
mounted on the rotary drive.
Avoid colliding with rotary drive.
CAUTION
Press the control buttons simultaneously to retract both backstay

. cylinders and to move the mast back to upright position.
• Wait until the kelly bar has stopped swinging before inserting it into the shock absorber
ring.
• Lower kelly bar by operating the left four-way lever ("Main winch down").
Threading through the kelly drive rings can be made easier by rotating
the rotary drive.
W
NOTE
The guide rails on the kelly bar and the recesses in the kelly drive rings
must be in alignment.
CAUTION
• Lift the rotary drive by operating the right four-way lever ("Crowd up").
• Mount drilling tool on the kelly bar with two kelly pins.
Secure the kelly pins.
CAUTION
BG 22/96 4-28
BAUER
4.8 DISMOUNTING THE DRILLING EQUIPMENT
De-rigging is carried out in reverse order of the rigging sequence.
4.8.1 Dismounting the Kelly Bar
• Raise the mast to upright position.
• Dismount drilling tool from the kelly bar.
• Use right four-way lever ("Crowd down") to lower rotary drive.
• Lift kelly bar until the kelly drill stub is approx. 20 cm above the rotary drive.
• Extend both jackstay cylinders and tilt mast forward by 2 - 3* by pressing the control
buttons 4 and simultaneously.
• Lower kelly bar by operating the left four-way lever ("Main winch down") until the kelly
drill stub rests on the ground.
• Lay kelly bar on the ground by simultaneously driving the base machine backwards
and lowering the main rope (left four-way lever "Main winch down").
Detach the kelly bar from the main rope.
• Remove the rope swivel from the main rope.
BG 22/96 4-29
BAUER
4.8.2 Dismounting the Rotary Drive
The rigs with cylinder crowd are dismounted The sledge of the rig with rope crowd
with the rotary drive sledge. remains mounted to the mast.
Lifting sling
Lifting eyes
WfW
TTT
in ii r
A n bs
Sledge travel
stopper
IBFASEE37I IBFASE216I
Fig. 4/21
Retract boom cylinders. Disconnect hydraulic lines.

The leak oil line is to be discon-
Disconnect hydraulic lines. nected last.
The leak oil line is to be disconnec- Tension main rope slightly.
ted last. Dismount rotary drive from rotary
sledge.
Tension main rope slightly. Lower rotary drive to the ground.
Move the sledge travel stopper "A"
Dismount rotary sledge from crowd to point "C" and lock it by inserting
cylinder. a pin.
Move the sledge to point "C".
Dismount sledge travel stopper. Dismount the sledge travel stopper
"B" and lock it to point "D" below the
Lower rotary drive slowly to the ground. sledge by inserting a pin.
BG 22/96 4-30
BAUER
4.8.3 D i s m o u n t i n g the Upper Mast S e c t i o n
1. Lower the mast
• Run off sufficient length of each rope for the rope sockets and w e d g e s to reach t h e
base machine.
• Remove t h e fixing clamps from the backstay cylinders.
• Extend b o o m cylinders completely. W h e n the indication lamp goes off, t h e long, lower
backstay cylinders are enabled.
• Switch t h e preselector to position "rigging mode". Operation of b o o m cylinders is

locked.
• Move c r o w d sledge to the middle of the lower mast section by operating the right
four-way lever.
• Lower the mast d o w n by pushing the t w o hand levers (3) at the right hand-side of the
driver's seat forward.
Winch 1 or 2 down Crowd down
Winch 1 or 2 up
Backstay cylinder right
Backstay cylinder left
IBFASEE10I
Fig. 4/22
B G 22/96 4-31
2. Remove ropes from upper mast section
Remove the rope guard pins from the masthead. Roll main and auxiliary rope up to the
middle rope guide (see fig. 4/23 "A") by operating winches 1 and 2. _
Reinstall front rope guides and rope guard pins (see fig. 4/23 "B").
NOTE
o o o o o o o n o o o o o o ö o
B B
IBFASE220I
Fig. 4/23
3. Dismount the upper mast section
• Mount temporary mast supports to upper mast section.
• Disconnect electric lines.
• Remove mast link bolts and store them for later use.
• The boom cylinders remain fully extended.
• Lower mast by operating the backstay cylinders until the masthead and the back
temporary mast supports lay on the ground.
• Remove bolts and split pins. Pull out both pins at the back of the mast section.
BG 22/96 4-32
BAUER
• Drive base machine backwards and disconnect the upper mast section from the lower
mast section.
When the appliance is to be transported over long distances or is not

operated for a long time the contact areas of both flanges are to be
greased to prevent corrosion.
NOTE
• Prepare the upper mast section for transportation.
• The lower mast section is lowered and secured with temporary mast supports.
• Remove connecting pins from the supporting trestle (see fig. 4/24.4). Be careful not to
let them fall on the main winch.
• Operate the backstay cylinders control lever to retract the backstay cylinders (2 and
3) uniformly until the supporting trestle lies on the boom supporting point.
Do not retract boom cylinders. Indication lamp boom cylinders does not
shine.
CAUTION
• Remove tempo-rary mast support.

• Prepare the base machine for transportation.
IBFASEË271
Fig. 4/24
BG 22/96 4-33
BAUER
4.9 MOVING THE RIG ON SITE
When the rig has to be moved on the site to be set up at a new pile position the following
instructions must be observed:
• As the overall view of the operator is limited during moving or travelling, a signal man
must be in attendance.
• Unobstructed routes and platforms are required.
• All access routes and working platforms must be constructed with firm and uniformly
compacted material. Use timber mats on soft ground as required.
• Lower rotary drive and drilling tool equipment to the lowest position possible before
moving the rig.
• Move the uppercarriage in starting position, i.e. the uppercarriage must be in line with
the undercarriage.
• Do not swing the uppercarriage when travelling.
Avoid sudden movements or abrupt braking.
Travelling up or down a slope - without

drilling equipment (see fig. 4/25)
It is forbidden to travel along
A
CAUTION
slopes with a gradient of mo-
re than 15' and to travel
across slopes!
• The mast must be in upright position and
face in the direction of the slope. Extend with
It gradients
• Travel up or down slopes as described in of up to 5°
figure 4/25.
t Extend with
• To travel up or down slopes with a gradient [gradients
of up to 5' the upper backstay cylinders are exeeding 5 °
to be extended.
• To travel up or down slopes with a gradient
of more than 5' the lower backstay cylin-
ders are to be extended (remove fixing
clamps).
Fig. 4/25 Travelling up or down
Travelling up or down a slope - with drilling equipment - see sect. 2.5 Stability.
BG 22/96 4-34
4.10 PUTTING THE RIG OUT OF SERVICE
Whenever the rig is put out of service after the drilling is completed, for maintenance and
repair or for longer idle periods the following instructions must be observed:
• Park rig on a firm and level surface.
• Lower drilling tool (or any other load) to the ground.
• Position mast upright.
• Position the uppercarriage parallel to the undercarriage.
• Make sure that all operating elements are in OFF-position.
• Shut base machine off (see manufacturer's operating manual).
• Lock operator's cab and secure it against unauthorized access.
BG 22/96 4-35
BAUER
4.11 TOWING
The drilling rig may NOT be towed away.
BG 22/96 4-36
4.12 TRANSPORTATION
For transportation the upper mast section, the rotary drive and the kelly bar are to be
dismounted from the base machine. The base machine with the lower mast section can
be transported on a normal low bed trailer.
To transport the base machine
- lock the uppercarriagetothe under-

carriage with the stay bar,
- lift up the left armrest,
- switch the engine off,
- remove the ignition key,
- lock the operator's cab behind you.
The uppercarriage is to be fixed to the

low bed trailer with the transportation
brackets (3) located at the rear of the
uppercarriage.
The hauler is responsible for the safe ^ 2 1 I I

and correct transportation of the machi- IBFASE067Ï
ne, its parts and equipment.
Fig. 4/26 Insert pin (2) in stay bar (1 )
The hauler should be informed on:
- The transport dimensions and weights.

— The haulage distance and route FROM / TO.
Be sure to apply for permission to transport the BG 15 by road in good

time.
NOTE
BG 22/96 4-37
BAUER
4.12.1 Transport Dimensions and Weights
4 Sling points
mu. 25 tonn*« illng load
for on* iHng point
4 Anschlagpunkte
mix. L u l pro o n : 25 to
- - a * Stützbock
0 b e r k a n e
^ ^ f ^ T N Upper edge,
Fig. 4/27 BFASE053
Transporting weight: Base machine with counterweight, mast lower section: 55.2 to
Table 4 - 2
(Dimensions) mm BS 70 rigid BS 70 telescopic

crawler base crawler base
A Wheel base 4400 4400
B Total length, crawler base 5325 5325
C Height, upper edge, operator's cab 3400 3400
D Ground clearance, uppercarriage 1270 1270
E Swing radius 3900 3900
F Width, crawler shoe 700 700
G Width, crawler base (retracted/extended) 3800/- 3000/4500
H Ground clearance, undercarriage 370 370'
I Base machine with lower mast section 14600 14600
J Ground clearance, mast in horizontal position 600 600
K Length, upper mast section - masthead 11750 13550
L Masthead 2650 2650
M Height, guide sheave (removable) 2000 2000
BG 22/96 4-38
Weights
Weights
Undercarriage - Tele 16.5 to
Counterweight 13.2 to
Boom 0.8 to
Boom cylinders 0.92 to
Mast lower section with auxiliary winch, rope guide assembly 5.4 to
Mast upper section with crowd cylinder, Masthead 5.2 to
Masthead 1.0 to
2 Backstay cylinders 2.4 to
Rope guide assembly with auxiliary winch without rope 0.9 to
Crowd cylinder 1.7 to
Extension rod 0.2 to
Rotary drive KDK 220 S with sledge

5.4 to
L x B x H = 1780 x 1420 x 1830 (mm)
Hydraulic installation 0.5 to
Ropes (main and auxiliary winch) 0.6 to
B G 22/96 4-39
4.12.2 Specific Safety Instructions for Transportation
• To prevent any parts and attachments to be transported from moving, falling down or
causing the transport vehicle to tip when braking abruptly, travelling on uneven ground
or at the site, they must be laid out correctly, locked and fastened securely.
• Dynamic parts of the drilling rig and the base machine must be locked and secured.
• To secure the clamping jaws during transportation, a tube with the same outer diameter
as the clamping jaws' inner diameter must be inserted into the casing oscillator.
• It is the trailer driver's responsibility to make sure that the drilling rig and the equipment
on the loading area are secured correctly before driving off.
• Locking and safety devices at the side and rear panels of the transport vehicle must
be fully operative. Tension chains are to be secured properly.
• It is forbidden to transport people on the loading area.
• Before nearing ramps to load/unload the vehicle, the boards on the loading side must
be hinged down. When opening the side boards or the tailboard make sure that no-one
is standing in the danger zone where objects may fall from the vehicle and cause
injuries.
• The side boards and the tailboard must not be used as loading platform between the
vehicle and the ramp under any circumstances. If loading platforms are to be used,
they must be secured so as not to slide away.
• Before reeling-in the rope when loading or unloading the transport vehicle by crane,
make sure that shackles, clasps and eyes or other lifting devices are secured properly.
To prevent the load from swinging, the rope must be adjusted vertically
above it. In the case of swinging, the load must be lowered to the ground
immediately and the rope readjusted in vertical position.
CAUTION
• Equipment to be stored should be placed only where it does not hinder, e.g. where
public or site traffic is not obstructed and where it can be secured properly against
unintentional or unauthorized handling.
• Sharp edges, points or cutters are to be protected by additional covers or safety devices
as required.
BG 22/96 4-40
5 SERVICE AND MAINTENANCE
5.1 SAFETY MEASURES
It is imperative to observe to the safety measures below before the

commencement of and during maintenance works. .
CAUTION
• Lower drilling tools to the ground before starting maintenance.
• Lift up left control console, switch ignition key to the position "0" and withdraw the key.
• The appliance is not to be set into operation during maintenance. Attach caution signs
to operating elements.
• The regulations for the prevention of accidents in the country concerned must be
observed. Wear safety clothing, safety glasses, safety shoes or other protective clothes
as required.
• Maintenance is to be carried out by skilled personnel only.
• Safety glasses and safety clothing are to be worn when cleaning with compressed air.
The air pressure may not exceed 2 bar.
• Avoid naked flames when checking the battery. Smoking is prohibited.
• Hot parts and lubricants must be handled with special care.
• It is forbidden to weld at the hydraulic oil tank or at oil lines due to the risk of fire.
BG 22/96 5-1
• The engine may be run only in well-ventilated rooms or in the open.
• Adjustments may not be carried out while the engine is running, during operation or
travel.
• Maintenance works at the hydraulic system may only be carried out after the unit has
been depressurized.
• Use adequately sized oil pans when changing oil and dispose of waste oil only in an
approved manner.
• The tools and devices needed for maintenance works must be safe and operable at
all times.
BG 22/96 5-2
5.2 MAINTENANCE INTERVALS
Correct servicing and maintenance keep the drilling rig operable and prevent early wearing.
Possible damages can thus be detected and repaired on time to avoid time-consuming
and costly repairs.
Due to constant wear and contact with dirt, typical for machines of this type, regular
servicing and maintenance is essential.
The various points to be serviced and maintained are grouped according to their service
and maintenance intervals:
— After every 10 operating hours/daily
— After every 50 operating hours / weekly
— After every 250 operating hours / monthly
— After every 500 operating hours / after every three months
— After every 1000 operating hours / at least once a year
— After every 2000 operating hours / at least once a year
— After every 3000 operating hours / at two-year intervals.
In the interest of the operator maintenance should be carried out thoroughly and regularly
at the specified intervals of time.
When the appliance is operated under normal conditions the intervals at which maintenan-
ce is to be carried out overlap, i.e. when maintenance is carried out at the 1000 hour
interval, the 50 hour interval maintenance is also due.
In case that the appliance is operated under extremely wet or dusty conditions it may be
necessary to carry out maintenance more often than indicated in the service and mainte-
nance plans.
BG 22/96 5-3
It is Imperative to observe the following instructions before and during
maintenance respectively:
NOTE
• Before greasing, all greasing points have to be cleaned thoroughly of dirt and old
lubricants.
• No oil and grease types other than those prescribed in section 5.3 may be used.
• Use original spare parts only.
• Keep tools and working area clean.
• Only use oils and greases kept in clean containers with caps.
• Before refilling, clean filler openings and lubricating nipples.
• To prevent dust and dirt from getting Into containers and openings, do not remove caps
and covers unless necessary.
• Before disconnecting electric or hydraulic lines, dust caps are to are to be installed on
the lines and on the sockets.
All maintenance work must be entered Into the BAUER Service and Maintenance Record
Booklet by the rig driver and countersigned.
In the case of a claim by guarantee BAUER is entitled to inspect the Service and
Maintenance Record Booklet.
For the service and maintenance of the engine please refer to the
manufacturer's additional instruction manual.
Maintenance of the kelly bar is described in Appendix A.
CAUTION
BG 22/96 5-4
5.2.1 Maintenance Works While Mounting the Drilling Rig
When the drilling rig is mounted on site the following maintenance works are to be carried
out simultaneously:
• Check wear strips on rotary drive for wear (permissible wear A s = 3 mm).
• Check main and auxiliary rope for damages (see sect. 5.15).
•• Check kelly drive ring at the rotary drive for wear.
5.2.2 Maintenance Works During the Running-ln Period
• Not all maintenance works that are to be carried out during the running-in period are
contained in the service and maintenance plans (section 5.2.3). They are to be carried
out in accordance with the following plan:
• Twice a day in the course of the first 200 operating hours (and from then on every 10
hours): Check the engine oil level (see sect. 5.4).
• After the first 10 operating hours (and from then on every 250 hours):
Clean the magnet plug of the swing gear hydraulic oil filter (see sect. 5.8).
• After the first 50 operating hours:

Change the hydraulic oil filter (see sect. 5.6.2).
• After the first 200 operating hours (and from then on every 1000 hours):
Change oil of rotary drive gear (see sect. 5.19),
Change oil of main winch,
Change oil of auxiliary winch.
• After the first 500 operating hours:

Change oil of pump distributing gear (see sect. 5.7).
• Check hydraulic unit regularly for tightness and tighten leaky connections as required.
BG 22/96 5-5
5.2.3 Service and Maintenance Plans
Key to service and maintenance plans:
Service point 1
0 Lubricate with grease
SO Change oil: drain oil and fill up with specified amount
Check / readjust
Clean
Replace bolts
Clean / replace filter
BG 22/96 5-6
After Every 10 Operating Hours / Daily
Abb. 5/1 Lubrication and maintenance points PFASE223|
BG 22/96 5-7
Table 5 - 1 After every 10 operating hours / daily
Nominal
Item Measures required Notes
values
1 Lubricate rope swivel see sect. 5.17
Rope swivel Check that mounting pins are correctly

in place and tight
Check that rope swivel rotates freely
2 Check kelly bar for wear and damage see Operating

Manual - Appen-
Kelly bar dix A
3 Clean drilling tool
Drilling tool Check teeth, chisels and flights for wear,

deformation and damage; replace or
add hard facing as necessary
4 Check cylinders for tightness see sect. 5.18
Boom cylinders Clean piston rod
5 Check both ropes for deformation and see sect. 5.15

damage and appendix
Main and auxiliary
rope
6 Check cylinders for leakage see sect. 5.18
Backstay cylinders Clean piston rod

Crowd cylinders Check the limit switches
Check the limit switches
8 Check all hydraulic pipes, hoses and see sect. 5.6

connections for leakage and damage
Hydraulic system
Check the pilot line hydraulic oil filter
9 Check engine oil level see sect. 5.4 and

Check coolant level CaterpillarOpera-
Engine ting Manual
continued
BG 22/96 5-8
Table 5 - 1 continued
Item Measures required Nominal

values Notes
10 Check for wear and damage

see sect. 5.9
Crawlers Check the chain tension
11 Test Free-fall function in accordance with

this table:
Free-fall Action Reaction
main winch
SELECT free-fall with key- Free-fall must
operated switch NOT actuate
Press free-fall PEDAL Free-fall must
NOT actuate
Press free-fall BUTTON on Free-fall must
four-way lever NOT actuate
Press free-fall PEDAL and Free-fall must
BUTTON simultaneously NOT actuate
and HOLD ON
Press free-fall PEDAL and Free-fall
BUTTON simultaneously MUST actuate
and release the pedal
Carry out sight and functional checks
Drilling rig
(whole unit)
13 Lubricate swing gear see sect. 5.8

(button in operators cab)
Swing gear
BG 22/96 5-9
After Every 50 Operating Hours / Weekly
Abb. 5/2 Lubrication and maintenance points PFASEO24|
BG 22/96 5-10
Table 5 - 2 After every 50 operating hours / weekly

values Notes
1 Check that limiters function correctly Activate limiters

by pulling up each
Overhoist limiter rope
for main and
auxiliary winch
2 Lubricate guide rails see sect. 5.3

Lubricants
Mast
3 Check springs for damage
Kelly drive ring Check rubber ring for damage, stability

including the and security
shock absorber
4 Check oil level see sect. 5.19
Rotary drive Check hydraulic system for tightness
Sledge - wear strips: see sect. 5.20

Check for wear, replace as necessary
Permissible wear: min. 22 mm
As max. 3 mm
5 Check rubber buffers for damage
Cardan joint Check that bolts are correctly in place

(optional) and tight
6 Check that pins and stop pins are see sect. 5.15
correctly in place and secure,
Rope sheaves check axial play of sheaves,
lubricate sheave axle
7 Lubricate mast pivot assembly see table 5 - 8,

Lubricants
Mast mounting Lubricate mast mounting pin
8 Check that rope hold-down rollers see sect. 5.15.6

function correctly
Main and auxiliary
winch Check that rope fastening is correctly
in place and secure
continued
BG 22/96 5-11
Table5-2 continued
Item Measures required Nominal Notes

values
9
Backstay Lubricate joints
cylinders
10 After first 50 operating hours: Replace

the hydraulic tank oil filter element
Hydraulic system see sect. 5.6
Check hydraulic oil level
11 After first 50 operating hours: 27 I

Change engine oil see Caterpillar
Engine Operating Manual,
Clean engine radiator ribs see sect. 5.5
Check and clean air filter
(Empty dust collector)
12 Activate central lubrication (nipples) see sect. 5.8
Swing gear
13 Check that fastening screws are

correctly in place, tighten if necessary
Counterweight
14 Check that crawler shoes are correctly

in place and secure
Crawler shoes
15 Check cable connections, plugs and

fuses
Electrical plant
16 Grease lubrication nipples
Lubrication points
on base machine
BG 22/96 5-12
After Every 250 Operating Hours / Monthly
Fig. 5/3 Lubrication and maintenance points PFASEOSSI
BG 22/96 5-13
Table 5 - 3 After every 250 operating hours / monthly

values Notes
1 Check axial play of sheaves

Check that sheave centre pins are correctly
Rope sheaves, in place and secure
masthead and
mast Check that masthead connection bolts are see sect. 5.21,
correctly in place and tight Tightening torques
2 Check that mounting bolts are correctly in
place and tight
Mast ladder Check ladder, rail and bracket for damages
Check that the fall protection equipment is in If applies,
safe and working order see sect. 1.3
3 Check that mast connection bolts are see sect. 5.21,
Mast
4 Check that all bolts are tight see sect. 5.19
Replace filter of KDK gear optional
Rotary drive
5 Check that flanged mounting bolts are see sect. 5.21,
Mast pivot
assembly
6 Check that pin and stop spring are correctly
in place and secure
Mastfoot prop Lubricate joint head see sect. 5.3
Lubricants
7 Check that mounting bolts are correctly in
place and tight see sect. 5.16
Main and Replace the free-fall filter
auxiliary winch Check oil level
see sect. 5.11
8 Check batteries
Electrical plant
Replace filter elements see Caterpillar

9 Operating Manual
Fuel system Clean preliminary filter of fuel feed pump
continued
BG 22/96 5-14

values Notes
10 Change oil - if it necessary scheduled oil 27 I With the API oils

sampling analysis CC/SE or CC/SF;
Engine with the API oils:
CD/SEorCD/SF
after 500 h
Check play of valves see Caterpillar

Operating Manual
Replace oil filter
Check the V-belts' tension and tension
as required
11 Tighten screws see sect. 5.8
Swing gear
12 Check gear oil levels see sect. 5.9
Crawler drive
wheels
(right and left)
13 Check that all screws and bolts are see sect. Tighte-
correctly in place and tight ning torques
Drilling rig
BG 22/96 5-15
After Every 500 Operating Hours /
After Every Three Months
Fig. 5/4 Lubrication and maintenance points PFASEOMI
BG 22/96 5-16
Table 5 - 4 After every 500 operating hours / after every three months
Nominal
Item Measures required Notes
value
1 Replace hydraulic oil tank filter element see sect. 5.6
Hydraulic system Check hydraulic oil cooler and clean it
BG 22/96 5-17
After Every 1000 Operating Hours / At least Once a Year
Fig. 5/5 Lubrication and maintenance points PFASE227|
BG 22/96 5-18
Table 5 - 5 After every 1000 operating hours / at least once a year

values Notes
1 Lubricate all sheave centre pins
Rope sheaves,
masthead
3 Change gear oil KDK 22 K: see sect. 5.19

55 I + 41
Rotary drive KDK 220 S :
70 I
KDK 140:
90 I
4 Replace mast link bolts
Mast
5 Change gear oil see sect. 5.16

Main winch 101 Operating Manu-
Main crowd and Auxiliary winch 31 al for Winches in
auxiliary winch the appendices
BG 22/96 5-19
After Every 2000 Operating Hours / At Least Once a Year
BG 22/96 5-20
Table 5 - 6 After every 2000 operating hours / at least once a year
Item Measures required Nominal Notes

value
1 Replace pilot line oil filter see sect. 5.6.4
Hydraulic system Replace the hydraulic tank filler cap
2 Change oil 8.5 I see sect. 5.9.2
Crawler drive
wheels
(right and left)
BG 22/96 5-21
After Every 3000 Operating Hours/At Two-Year Intervals
Fig. 5/7 Lubrication and maintenance points P FASE229

l
BG 22/96 5-22
Table 5 - 7 After every 3000 operating hours / at two-year intervals

value Notes
1 Change hydraulic oil,

hydraulic oil tank 600 I see sect. 5.6.2
Hydraulic system
2 Check that the fuel injector functions see Caterpillar

correctly Operating Manual
Engine
3 Replace flanged mounting bolts see sect. Tighte-

ning torques
Mast pivot
assembly
BG 22/96 5-23
5.3 LUBRICANTS
No oil and grease types other than those prescribed and suitable for the
application may be used (see table of lubricants). In case of damages
resulting from neglection of this regulation the right to claim under
A
guarantee for this appliance is invalid. If oils or greases from another
manufacturer or of another type are used, their miscibility must be
checked and approved prior to use.
CAUTION Synthetic gear oil may NOT be mixed with mineral-oil-based gear oil. The
filling amounts are written on the type plates of the individual assembly
parts. Only fresh oils and greases may be used.
The oils and lubricants described in the chapters below are suitable for
jjp? 3
ambient temperatures of -20 C to 50 C. For further information on
S=J applications at temperatures below -20 C please contact the BAUER
NOTE Service Centre.
BG 22/96 5-24
5.3.1 Disposal of Waste Oil, Filters and Additives
To dispose of waste oil, filters and additives the following instructions must be observed:
Store waste oils separately, which:
— are reusable,
— may be burnt in special destruction plants,
— have to be disposed of as hazardous waste, e.g. small amounts of unknown origin.
Do not mix waste oils under any circumstances.

• Waste oils may be given only to authorized waste oil disposal companies.
• Use adequately sized oil pans when changing oil.
• Waste oil may be disposed of in the approved manner only. It must not be mixed with
any other waste nor burnt in unauthorized plants.
• To change oil or replace filters at the engine, the swing gear, the pump distributing
gear, the driving gear, the hydraulic system, etc. please refer and fully comply to the
additional instructions supplied by the manufacturer of the base machine and the
engine.
Preventive environment protection is cost-saving and safeguards the

future and the quality of life. The authorities must be notified of incorrect
disposal of waste oil.
NOTE
BG 22/96 5-25
Biodegradable oils and greases
The use of biodegradable oils and greases is prescribed where leakages of mineral-oil-
based lubricants may endangerthe environment, e.g. at jobs in protected and conservation
areas.
When changing to environmentally friendly lubricants it is imperative to comply to the

following instructions:
• Fully synthetic liquids and liquids that are free of mineral oil or lubricants based on
vegetable oil may not be mixed with mineral-oil-based lubricants under any circumst-
ances. It is necessary to rinse tanks and containers thoroughly before filling them with
another type of lubricant.
• Before changing to biodegradable lubricants the manufacturers' instructions on the

compatibility of each lubricant with sealings, hoses, filter systems and the interior
painting of tanks must be obtained where not provided and complied to.
• It may be necessary to convert the above-mentioned parts for use with biodegradable
lubricants. This may be done only on consultation with the BAUER Service Centre and
after their written approval has been obtained.
BG 22/96 5-26
5.3.2 Table of Lubricants
In order to ensure the smooth running of the BG 22 drilling rig, BAUER recommends the
following lubricants:
Table5-8 Lubricants
Drilling Manufac-
equipment Product Quantity turing
application company
Rotary drive Degol BG 150 55 I Aral SOH 100
Oegol BG 220
(for gear operating
temperatures of up Avilub RSX150 Avia
to 60 'C we recom-
mend ISO VG 150 EnergolGR-XP150 BP
oils. Energol GR-XP 220
For gear operating
temperatures ex- Alpha SP 220 Castrol
ceeding 60 'C ISO
VG 220 oils are to NL Gear Compound 150 Chevron
be used.) NL Gear Compound 220
Spartan EP 150 Esso
Spartan EP 220
Giran 150 Fina
Giran 220
Pontonic N 85W/90
Pontonic MP 85W/90
EP Lubricant HD 150 Gulf

Mobilgear 629 Mobil
Mobilgear 630
Mobilube GX 90
Mobilube HD 90
Ornala Oel 150 Shell

Ornala Oel 220
Multigear Lubricant EP 90 Texaco

Meropa 150
Carter EP 150 Total
Carter EP 220
Ornala Oel 150 2x4.51 Shell
continued
BG 22/96 5-27
Drilling Manufac-
equipment Product Quantity turing Specifi-
application company cation
Main winch SAE 90 22 I Gear oil

Auxiliary winch SAE 90 31 DIN 51 502
see Operating Manual for winches> in the Appendk;es
Bolted Multipurpose grease Aral DIN 51 825

connections Multipurpose grease Avia (KP2K)
Long-life grease BP
Dura-Lith Grease EP 2 Chevron
Hydraulic tank HDW46 6001 HYDO

MIL-L2104C
CD/TO-2
Drive wheel gear SAE 85 W - 90 91 Deagear

case EP-B
API - GL 590
Swing gear, ex- Lumo Sulventa EP Adhesive oil

ternal gear ring
Engine oil ARAL SAE15W40 271
Fuel tank 8501 Diesel
Fluid grease NL Gl grade 00
Spray grease Molybdenum disulphide
The oil quantities given in the table above are only approximate values.
The exact and actual filling amount must be checked at the oil level
indicator of the respective part. The oil service points must be checked
NOTE and filled according to. the prescribed maintenance intervals.
The swing gear planetaries, the swing gear brake and the service brake
are lubricated by the hydraulic system and are maintenance-free.
BG 22/96 5-28
5.4 CHECKING THE ENGINE OIL LEVEL
For further information on the engine's maintenance, please refer to the Caterpillar
Operating Manual.
Checking the Engine Oil Level
During the running-in period of the engine (approx. 200 operating hours), the oil level must
be checked twice a day.
From then on it must be checked after every 10 operating hours or daily. The base machine
must be standing horizontally and the engine must have been shut down a while
beforehand.
• Pull out the dip stick (see fig. 5/8.1) and wipe it with a clean cloth.
• Push the oil dip stick down as far as it will go, pull it out again and read the oil level. It
must be between the upper notch (MAX) and the lower notch (MIN).
• If the oil level is at the lower notch (MIN), unscrew the cap (see fig. 5/8.2) from the filler
neck.
• Clean the cap and the filler neck. Refill oil.
• Check the oil level with the dip stick. The oil level must not exceed the upper notch
(MAX).
• Reinstall the cap tightly on the filler neck.
Fig. 5/8 Checking the engine oil level BFASE0541
BG 22/96 5-29
5.5 ENGINE AIR CLEANER MAINTENANCE
Insufficient functioning of the engine air cleaner (fig. 5/9) is indicated by a lamp on the right
control console and supported by an acoustic alarm, which both come on as soon as the
max. permissible flow resistance is reached.
The primary element of the filter should be cleaned, or replaced as necessary, when lamp
and buzzer give indication.
Replacing the primary element:

• Unscrew retaining strap, remove filter cover and pull out primary element. Replace with
new element if cleaning will not do. Install new primary element, reinstall filter cover
and screw on retaining strap.
Replacing the safety element:
The safety element which is fastened to the inner rear wall of the filter housing, should be
replaced with a new whenever the primary element is replaced.
• Remove filter cover, pull out primary element, unfasten and remove safety element.
Clean filter housing, install new safety element, reinstall primary element, reinstall filter
cover and screw on retaining strap.
To clean the filter primary element, DO NOT use petrol an alkaline

solution or hot liquid.
NOTE
Staubsammler
Dust cup
Filter-Hauptpatrone
Filter primary element
Sicherheitselement
Safety element
Sicherungsbligel
Retaining strap
Fig. 5/9 Engine air cleaner PAASF205I
BG 22/96 5-30
Cleaning the dust cup:
The air cleaner is also equipped with a dust cup (see fig. 5/10), the dust cup should be
emptied and cleaned every 50 hours of operation or weekly.
• Unscrew wing-nut and remove lid.
• Remove cup and empty it.
• Clean cup with a clean, dry cloth and reinstall.
• Reinstall lid and fasten with wing-nut.
Staubsammler entleeren
Emptying the dust cup
Filter housing
Fig. 5/10 Air filter and dust cup PAASF193I
BG 22/96 5-31
5.6 SERVICING THE HYDRAULIC SYSTEM
To service the hydraulic system, open the left maintenance door. To close the door, push
it down until it latches.
WARNING!
A
During operation the hydraulic system is under high pressure. Oil from
possible leaks may cause serious injuries to unprotected parts of the
body.
Before checking the appliance the hydraulic system must be depressu-
rized.
5.6.1 Checking the Hydraulic Oil Level
The hydraulic oil level is to be checked after every 50 operating hours or weekly.
The base machine must be standing horizontally. All cylinders must be fully retracted and
the hydraulic oil must be warm.
Check the hydraulic oil level at the sight gauge (see fig. 5/11). The gauge must be filled to
the upper mark of the scale. Refill through the filler neck as necessary.
-J Schauglas
Fiillstandshohe Hydrauliktank
Sight gauge
Hydraulik tank oil level
I
1 —
Hydr. Tank Verschluftklappe

Hand valve
PFASE009I
Fig. 5/11 Checking the hydraulic oil level
BG 22/96 5-32
5.6.2 Changing Hydraulic Oil
The first hydraulic oil change is to be carried out after 2000 operating hours or annually.
From then on hydraulic oil must be changed after every 3000 operating hours or at two-year
intervals.
The base machine must be standing horizontally and all cylinders must be fully retracted.
WARNING!
Let the hydraulic oil cool down before changing it. The hydraulic tank is
under pressure. Before changing the oil, carefully unscrew the cap (fig.
5/12) from the filler neck to release pressure in the hydraulic tank.
Be careful not to spill oil on the ground or in water. Make sure that waste
oil is disposed of correctly.
Ansicht A
View A
Hydraulikol- Ansicht A:
filter
View A:
[Hydraulic
oil fitter
Fig. 5/12 Hydraulic oil filter PFASE0551
Because of the large amount of hydraulic oil to be changed (approx. 8501)

we recommend to pump out as much oil as possible and then let the rest
drain off into an appropriate container.
A
Make sure that no dirt can get into the hydraulic oil tank while pumping it
out. The hydraulic oil filter is to be reinstalled immediately after the oil has
been pumped out. Refill hydraulic oil through the filler neck only.
CAUTION
BG 22/96 5-33
Unscrew the filter cap (fig. 5/12) and remove the hydraulic oil filter. Pump out hydraulic
oil through this opening.
Reinstall the hydraulic oil filter. Reinstall the filter cap and tighten.
Unscrew the cap from the filler neck.
Place an appropriate container beneath the outlet of the hydraulic oil tank. Unscrew
the outlet plug (fig. 5/13) together with the seal.
Clean the outlet plug and the sealing surface. Replace the seal.
When the oil has drained off completely, reinstall the outlet plug together with the seal
and tighten.
Refill the tank through the filler neck until the correct oil level is reached on the sight
gauge (fig. 5/11).
Screw on the filler neck cap tightly.
Fig. 5/13 Outlet plug PFASE149I
/l\ To prevent damage to the hydraulic oil pumps, bleed them free of air after
t * l each hydraulic oil change.
CAUTION
Bleeding the pumps:

• On pump top, carefully loosen bleed screw without removing it; hold it slightly pressed
with your thumb.
• Hold on until all air has escaped and oil exits.
• Clean housing, and screw bleed screw tight.
BG 22/96 5-34
5.6.3 Replacing the Hydraulic Oil Tank Filter Element
The hydraulic oil filter element is to be replaced for the first time after 50 operating hours
or one week. From then on it Is to be replaced after every 500 operating hours or every
3 months.
WARNINGS
Allow the hydraulic oil tank to cool down before starting maintenance.
The hydraulic tank is under pressure. Before removing the hydraulic oil
filter element the filler neck cap must be unscrewed slowly to release
pressure in the tank.
• Unscrew the cap (fig. 5/12), remove it and pull out the hydraulic oil filter.
• Dismount the filter element from the cap. Dispose of the filter element as hazardous
waste.
• Clean all components. Check seal for damage and wear and replace it as necessary.
Mount a new filter element to the cap.
• Reinstall the cap with the filter element and tighten. Screw on the filler neck cap tightly.
BG 22/96 5-35
5.6.4 Replacing the Hydraulic Oil Filter of the Pilot Line
The hydraulic oil filter of the pilot line is to be replaced after every 2000 operating hours or
annually.
WARNING!
A Switch the engine off and allow the oil and the components to cool down
before replacing the filter cartridge.
Filter Vorsteuerung
0j/Filter, pilot line
Fig. 5/14 PFASE0561
To replace the filter cartridge proceed as follows

(see fig. 5/15):
Unscrew the lower part.
• Remove the filter cartridge from the lower part

and dispose of the filter cartridge as hazard- Filterpatrone
ous waste. FiJ ter elememt
• Clean upper and lower parts. Install a new

filter cartridge into the lower part.
• Screw the lower part to the upper part and

tighten.
PFASE0661
Fig. 5/15 Replacing the filter cartridge
BG 22/96 5-36
5.6.5 Checking and Cleaning the Hydraulic Oil Cooler
The hydraulic oil cooler is to be checked for tightness and damage after every 500 opera-
ting hours or every 3 months.
Proceed as follows:
• Check the hydraulic oil cooler, located in the storage space, for leaks and bent or
damaged cooling ribs.
• Blow-clean the cooling ribs and radiator fins with dry and filtered compressed air of
approx. 2 bar.
BG 22/96 5-37
5.7 PUMP DISTRIBUTING GEAR (IF IT EQUIPPED)
Check the oil level every 250 operating hours or every 6 weeks.
A
CAUTION
The oil level may be checked only when the gear is out of operation.
The oil level is checked with a dip stick. To be able to use the dip stick
the filler screw must be removed.
NOTE
Changing oil with oil temperatures of up to 70 C:

The oil of the pump distributing gear is to be changed for the first time after 500 operating
hours or after 3 months at the latest. From then on it is to be changed after every 6000
operating hours or after one year at the latest. The machine must be standing horizontally.
Notes for changing oil:
• Place an appropriate container for waste oil (101) beneath the outlet.
Oil amount: approx. 8 I.
• Clean the sealing surfaces of screws and bolts and of the housing. Check them all for
wear.
Ölwechsel am Pumpenyerteilergetriebe
Ansicht um 9 0 ° gedreht
Oil change at the pump
AÄdistributing gear Einfüllschraube
Filler screw
Kontrollschraube
Control screw
Ölstand--jf/r - - QU-level
Fig. 5/16 PFASE1411
BG 22/96 5-38
5.8 MAINTENANCE OF THE SWING GEAR
5.8.1 Lubricating the Gear Ring
Lubricate the gear ring by briefly pressing the "Lubrication swing gear" button while turning
the uppercarriage to the right every day.
Lubricate nipples to kingpin and turntable every 50 hours or every week. Work the gun
until fresh grease escapes at bearing points.
c
Filter Drehwerk
Filter, swing gear
Drehwerk
Swing gear
Rotorlagerung
Kugeldrehverbindung
hub nipples
to kingpin and Taster zum EinsprUhen
turn ta ble am Bedienpult
Button to lubricate the swing
gear on the controi panel
(TTcl OED GH)
OS) CD OED
OED
OED
Fett-Behälter
für Drehkranzverzahnung
(außen)
Grease container
for external gear ring Drehkranz
Gear ring
Fig. 5/17 BFASE162I
BG 22/96 5-39
5.8.2 Replacing the Hydraulic Oil Filter Element of the Swing Gear
The hydraulic oil filter element (see fig. 5/18.4) is to be replaced after the first 50 operating
hours or one week and from then on every 2000 operating hours or every year.
The magnet plug (2) is to be cleaned after the first 50 operating hours and from then on
every 2000 operating hours or every year.
Switch the engine off and allow the oil and the components to cool down
before replacing the hydraulic oil filter element.
CAUTION
• Unscrew cap (fig. 5/18.1) and remove it together

with the spring (3) from housing.
• Withdraw hydraulic oil filter element (4) from hou-

sing and dispose of filter element as hazardous
waste.
• Place an appropriate container beneath housing,

unscrew and remove outlet screw (5) together with
seal and let sediments drain off.
• Clean magnet plug (2), cap, spring, inner side of the

filter, outlet screw and all sealing surfaces. Check
seal on cover for damage and wear and replace
seal as necessary. Replace seal of outlet screw.
• Reinstall outlet screw together with new seal and

tighten. Insert new hydraulic oil filter element and
Fig. 5/18 Replacing the
install spring. Screw on cap together with seal and
hydraulic oil PFASEO2I
tighten.
Fig. 5/19 Hydraulic oil filter for swing gear P FASE15

°1
BG 22/96 5-40
5.8.3 Check the Bolts
The swing gear hexagon bolts are to be checked and tightened with a torque wrench after
the first 50 operating hours and from then on every 250 operating hours.
Hex. bolts M 16-10.9 Tightening torque 279 Nm

BG 22/96 5-41
5.9 MAINTENANCE OF THE CRAWLER DRIVE WHEELS
The oil level is to be checked every 250 operating hours or every 6 weeks. The oil is to be
changed for the first time after 500 operating hours or 3 months and from then on after,
every 1000 operating hours or every 6 months. The machine must be standing horizontally.
5.9.1 Checking the Oil Level
• Rotate the crawler until the gear case outlet plug (fig. 5/20.2) on the wheel drive is
located in the lowest possible position.
• Remove inspection/filler screw (1 ) together with seal (if equipped).
• Check the oil level. The oil must be level with the lower edge of the filler neck. Refill oil
as necessary.
• Clean inspection/filler screw and sealing surface on housing. Replace seal (if
equipped).
Screw on inspection/filler screw together with new seal (if equipped) and tighten.
The lower edge of the

filler neck is the maxi-
mum filling height. The
NOTE filling hole is halfway up.
Check the bolts

1
The crawlers bolts (3) are to be checked
and tightened after the first 50 operating
hours and from then on every 250 opera-
ting hours or monthly.
3
2
Fig. 5/20 Crawler drive wheel H-CASCOSTI
BG 22/96 5-42
5.9.2 Changing Oil
A
CAUTION
Do NOT spill oil on the ground or in water. Make sure that waste oil is
disposed of correctly.
• Rotate the crawler until the gear case outlet plug (2) on the wheel drive is located in
the lowest possible position.
• Unscrew and remove inspection/filler screw (1).
• Place an appropriate container beneath outlet. Unscrew and remove outlet screw
together with seal (if equipped).
• After the oil has drained off, clean sealing surfaces on housing and both screws.
Replace seals (if equipped). Screw in outlet screw together with seal and tighten.
• Fill each crawler drive wheel gear case with 9 I oil. Screw in inspection/filler screw
together with new seal (if equipped) and tighten.
ITCASC0S7I
BG 22/96 5-43
5.10 MAINTENANCE OF THE TRAVEL MECHANISM
After a job is completed the travel mechanism is to be cleaned thoroughly of mud and sand
with a water jet or hot steam.
The travel mechanism is to be checked for wear and damage after every 10 operating
hours or daily.
Check the following components for wear and damage:
- Carrier rollers (fig. 5/21.1)

- Chain links (2)
- Front idlers (3)
— Chain guides (4)
— Tread rollers (5)
— Crawler shoes (6)
6 5 4 3
Abb. 5/21 Travel mechanism iBeHSD02g
BG 22/96 5-44
5.10.1 Checking and Adjusting the Chain Tension
The tension of the crawler chains is to be checked every 10 operating hours or daily and
readjusted as necessary.
• Thoroughly clean crawlers, chains and slide faces.
• Drive the drilling rig slowly forwards on firm and level ground and allow it to coast.
• Place a straight rod between upper tread rollers.
• The slack between the rod in the middle of two rollers and the chain should not exceed
2 - 3 cm.
2-3 c m
Fig. 5/22 Measuring the chain tension IGBASHO4OI
If the slack is more or less than 2 - 3 cm the chain is to be readjusted (tensioned or

slackened).
Tension the chain as follows:
• Lift up one crawler from the ground.
• Remove cover plate (fig. 5/23.1).
• Fit the head of a high-pressure grease gun to the lubrication nipple (fig. 5/23.2).
BG 22/96 5-45
• Apply grease with the gun until the chain has the correct tension (see fig. 5/22).
• Check the tension again after rolling the chain briefly forwards and backwards with the
crawler still being lifted.
• Reinstall cover plate.
• Let the crawler down again. Tension crawler on the other side in the same way.
If the front roller is extremely dirty, the roller may be under high pressure
which makes tightening difficult. In this case set the crawler down to the
ground again and remove the grease nipple together with the threaded
NOTE fitting. A large amount of grease will run off from the compensator spring
and the pressure will be removed without having to slacken the chain.
Then, reinstall the fitting and proceed as described above to tighten the
chain.
Slacken the chain as follows:
• Lift up one crawler from the ground.
• Remove cover plate (fig. 5/23.1 ).
• Rotate the grease nipple (2) approx. 3 times anticlockwise until the excess grease runs
off.
• Retighten the grease nipple when the chain tension is correct (see fig. 5/22).
• After rolling the chain briefly forwards and backwards with the crawler still being lifted,
check the tension again.
• Clean the grease nipple and housing of excess grease.
BG 22/96 5-46
• Reinstall cover plate.
• Let the crawler down again. Slacken the crawler on the opposite side in the same way.
5.10.2 Crawler Shoes
Check every 50 operating hours or weekly that the fastening screws of the crawler shoes
(fig. 5/23.3) are correctly in place and tight.
The required tightening torque for tightening the crawler shoes is 235 to 265 Nm (24 to
27 kpm).
Fig. 5/23 Tensioning and slackening the chain PCHSDO26I
BG 22/96 5-47
5.11 BATTERY MAINTENANCE
Checking the electrolyte level
The electrolyte level of the batteries is to be checked every 250 operating hours or every
6 weeks.
A
CAUTION
Avoid naked flames and do not smoke while working near batteries. Be
careful that acid does not contact your skin. Wear safety glasses!
The batteries are to be filled with distilled water only. Do not add acid.
Adding acid may cause a rise above the required concentration.
When the battery is fully charged the acid concentration is 1.28 kg/dm . 3
Should this concentration sink below 1.22 kg/dm in semi-discharged
A
3
condition, recharge the battery.
Undercharged batteries are sensitive to frost. The liquid freezes easily

and thus causes damage to the battery case. In the case of frost it is
CAUTION necessary to take special care that the batteries are well-charged. Keep
batteries clean and dry.
When the battery is to be connected to a 12 V consumer, an appropriate
24/12 V voltage transformer must be used.
• Turn off electricity with battery main

switch.
• To maintain the batteries, swing the
switch box open.
• Remove the six caps from each bat-
tery.
• Check the electrolyte level: All plates
must be completely covered by the
electrolyte fluid, but the fluid may not
exceed a level of 15 mm above the
upper edges of the plates. Refill distil
led water if necessary.
• Reinstall the caps and tighten.
BG 22/96 5-48
4-
SAUER
Checking the cable connections
• The cable connections are to be checked every 50 hours or weekly.
Check that the cables at the battery terminals are correctly and firmly in place. Check
them for damage and dirt. Clean the battery connections as necessary and coat them
with the appropriate grease.
Replacing batteries
• First unclamp the negative cable (-) and then the positive cable (+).
• Coat terminals with the appropriate grease.
• Clamp the positive cable (+) to the positive terminal and then the negative cable (-) to
the negative terminal of the new battery.
• Tighten the battery fastening.
BG 22/96 5-49
5.12 FUSES
Fuses are to be checked every 50 operating hours or weekly.
The fuse box is situated underneath the driver's seat on the left-hand side.
• Open the fuse box (fig. 5/25) and check fuses for damage. Replace them as necessary.
Clean oxidized contacts.
Use only the prescribed fuse types with the appropriate strengths of
current. Fuses may not be repaired under any circumstances.
CAUTION
The inner side of the fuse-box lid contains a description of the fuses and their functions.
Fig. 5/25 Fuse box in the cab

IGAASB032I
BG 22/96 5-50
5.13 TROUBLESHOOTING
General Information
The following tables contain detailed information on troubles which may occur while starting
or operating the machine, the sources of trouble and the measures to be taken to eliminate
the trouble.
In the case that a defect or incorrect condition cannot be eliminated, contact the BAUER
Service Centre.
Table 5 - 9 Troubleshooting
Trouble Cause Elimination
External leakages
Oil and fuel leakage in the Loose hose connections Tighten hose connections
engine compartment
Damaged seals and/or hoses Replace seals and/or hoses
Check the engine oil level

(sect. 5.4), refill oil as ne-
cessary
Oil leakage in the hydraulic Loose hose connections Tighten hose connections
system
Check the hydraulic oil level
(sect. 5.6.1 ft.), refill oil as
necessary
Damaged seals and/or hoses Replace seals and/or hoses,

contact the BAUER Service
Centre as necessary
continued
BG 22/96 5-51

External leakage (continued)
' Oil leakage at the drive wheel Loose plugs Tighten plugs
gear cases
Damaged seals Replace seals, check the oil

level (sect. 5.9), refill oil as
necessary
Oil leakage from the swing Loose connections Tighten connections

gear
Grease leakage from the Damaged seals Replace seals, contact the
turntable BAUER Service Centre as
necessary
Diesel engine
Engine does not start or No fuel Refill the fuel tank

starts sluggishly
Battery weak Start the engine with an
auxiliary (booster) battery,
charge or replace batteries,
check the electrolyte level
(sect. 5.11)
See the CAT Operating

Manual
Indication lamps
The engine oil pressure indi- Oil pressure too low Switch engine off immedia-
cation lamp lights up while tely, check the oil level
the engine is running (sect. 5.4), refill oil as neces-
sary
The engine temperature in- Oil level too low or too high See the CAT Operating
dication lamp lights up while Air filter clogged Manual
the engine is running
continued
BG 22/96 5-52

Control switches
Switches do not work Switches defective Consult the BAUER Service

Centre
Malfunction in the switching

circuit concerned
Operation
Crawlers do not move Brakes still engaged Release parking and/or

service brakes
Gear shifting defective Contact the BAUER Service
Centre
Equipment does not function Hydraulic oil level too low Check the hydraulic oil level
correctly or does not func- Oil leakage and/or malfunc- (sect. 5.6.1 ff.), refill oil as
tion at all tions in the hydraulic system necessary
Check the hydraulic system,

the working cylinders, hoses
and hose connections for
tightness
Malfunction in one of the Contact the BAUER Service

working circuits Centre
Pilot line is depressurized Check the safety control,

contact the BAUER Service
Centre as necessary
Hydraulic pump does not Malfunction in the pump Contact the BAUER Service
work circulation Centre
Hydraulic pump delivers too Pump worn or defective Replace hydraulic pump
little oil or does not deliver
oil at all
continued
BG 22/96 5-53
Operation (continued)
Noises at the hydraulic Hydraulic pump sucks air Check connections for tight-
system ness, tighten as necessary,
replace damaged hoses and
seals
Hydraulic pump delivers too Check the hydraulic oil level

little oil (sect. 5.6.1 ft), refill oil as
necessary
Pressure control valve flutters Readjust pressure control

valve, contact the BAUER
Service Centre as necessary
Hydraulic oil temperature Hydraulic cooler dirty Clean hydraulic cooler

too high
Too little hydraulic oil Check the hydraulic oil level
(sect. 5.6.1 ff.), refill oil as
necessary
Noise from a working cylinder No lubrication film on the Contact the BAUER Service
in motion piston rod Centre
BG 22/96 5-54
SAUER
5.14 HYDRAULIC LINES SERVICE AND MAINTENANCE
Storage and Service Life
Hydraulic hoses are subject to a natural ageing process, so that even with appropriate
storage and permissible working conditions their service life is limited.
Inappropriate storage, mechanical damage and excessive load are the most common
factors for hose failure.
Service life, differing from the values indicated in table 5-10, may be exceeded in certain
cases as a matter of experience.
Hoses being subjected to the limit of permitted load stresses (e.g. high temperatures,
frequent bending and movement, extreme pulse frequencies) may have to be taken out of
service at reduced intervals. For details consult your BAUER Service Section.
Table 5 - 1 0 Guide lines for storage and service life

(calculated from date of manufacture)
Hoses Hose Lines
Storage period 4 years Storage period 2 years
Service life 6 years
Re-using Old Hoses
Hoses which have been operated as part of a hydraulic line should not be reprocessed,
because they do not meet requirements according to DIN 20 066.
The manufacturer reprocessing old hoses carries the full responsibility, with regard to
suitability and safety regulations.
The functional compatibility of hoses and fittings used must be certified.
BG 22/96 5-55
iAUER
According to DIN 20 066 reprocessed hoses must be marked with an additional RP on the
fitting.
Criteria for Disposal of Hoses
Hoses must be replaced when any of the following faults are discovered during inspection:
• Damage to outer layer down to sheathing (e. g. abrasion, cuts or cracks).
• Brittle outer layer (cracks in hose material).
• Deformations - while pressurized and without load, or on bending e. g. formation of

blisters, separation of layers - which do not correspond to the natural shape of the hose
(for details refer to DIN 20066 Section 4).
• Leaks.
• Damage or deformation of sheathing (sealing capacity impaired). Minor surface

damage does not require the hose to be replaced.
• Fitting protruding from hose.
• Installation procedure not complied with (DIN 20 066 Section 4).
• Storage period or service life exceeded (table 5-10).
Reference to section 2 of table 5 -10 is recommended, if details of storage period and

service life are not available.
BG 22/96 5-56
5.15 ROPE TERMINALS, THIMBLES AND ROLLED BUSHINGS
• Terminals, thimbles and bushings must be checked at regular intervals for proper
positioning of the rope.
• Check cast rope terminals for wire breakage and corrosion, especially where the rope
structure enters the casting.
• Check rolled terminals for wire breakage next to the bushing, cracks in the terminal
housing and sliding movement of the rope. Wire breakage is often difficult to detect on
these sections. Be sure to inspect thoroughly.
• Shorten rope and renew connection, if breakage or defects of this kind are detected.
5.15.1 Rope Sheaves
Rope sheaves must be checked when required, but at least at intervals of 250 operating
hours or once every month.
Special care must be taken to ensure that all components rotate freely.
• Be sure to check bearing clearance and connection of axial bolts. Seizure of rope
sheaves causes increased abrasion, wear and irregular stresses on the rope structure.
• Sticky and/or seized sheaves must be repaired, exchanged and replaced if the defect
cannot be rectified by greasing the bearings of the component.
• Sheaves must be geased at intervals of 1000 operating hours but at least once a year.
• Check also if the sheave groove matches the nominal diameter of the rope. If the groove
has been enlarged during lenghty operation, it must be refurbished (if still possible) or
•the sheave must be exchanged. This must also be done if the groove in the sheave
has become too narrow.
• Refurbishment is also required if abrasion has created edges in the groove. Edges in
the groove of the sheave cause local stress and increased abrasion of the rope.
• Rope guards must be inspected at intervals together with rope sheaves. Be sure to
check, that sheaves or the rope do not rub on the rope guard.
• Rope guards must be renewed, if they are worn or if the rope is guided only by grooves
of the sheaves.
BG 22/96 5-57
5.15.2 Rope Press-Down Rollers
Rope guiding rollers serve to guide ropes on and off the winch cable drum, when unreeling
or reeling-in ropes.
Rope guiding rollers must be checked for proper function at intervals of 50 operating hours
but at least once every week.
• Be sure to check especially on parallel positioning of the guiding rollers on the winch
drums.
Check screws for firm seat. All tensioning

springs must be set at equal pulling
strength. Do not readjust tensioning
springs which are worn, but replace them.
Realign and straighten safety hoops, or

replace. Worn bolts, bushings and spacers
Seilandruckrolle
Rope hold-down roller must be renewed.
Rope guiding rollers with grooves must be

refurbished (turn cylindrical^ along on the
outside), or replaced. Refurbishes guiding
Fig. 5/26 [TCASC053I
rollers are reduced in diameter.
Adjust tensioning springs accordingly.
BG 22/96 5-58
BAUER
5.15.3 Rope Thimble Replacement
The thimbles used on the wire ropes of BAUER Drilling Rigs are jointless one-piece die
cast thimbles conforming to DIN 3091.
Thimble material: GTW-40 (malleable cast iron)

GGG-40 (spheroidal graphite cast iron)
Thimble selection guide for liftcrane rope (sizes are in mm)
s = nominal size = 20 22 24 26 28 30 34 36 38 42
max. rope dia.
di = finished eye 40 50 40 50 60 60 80 80 80 80
dia., with a tolerance
space of D10
BG 22/96 5-59
Dimensions, tolerances and weights (sizes are in mm)
d d1
Nominal K DQIU
Finished
size = a a nflW
dimension,
dimen-
max. sion with D10 Weight
rope dia. tolerance c h hi h2 rl r2 S1 s2
Margi- Margi- kgl)
nal nal
devia- devia- from to
tions tions
± ±
20 22 0.6 31 0.6 35 40 50 100 13.5 161 32 200 6 20 7 1.61

22 24 0.6 33.5 0.6 38 43 55 110 15 177 35 220 7 22 7.5 2.11
24 26 0.8 36 0.8 41 46 60 120 16.5 193 38 240 7 24 8 2.71
26 29 0.8 39.5 0.8 44 49 65 130 18 209 42 260 8 26 9 3.55

28 31 0.8 42 0.8 47 52 70 140 20 224 45 280 8 28 10 4.2
32 35 0.8 47 0.8 53 58 80 160 23 256 51 320 10 32 11 6.3
36 40 1 53 1 59 65 90 180 26 288 58 360 11 36 13 8.84

40 44 1 58 1 65 71 100 200 29 320 64 400 12 40 14 11
44 48 1 63 1 70 76 110 220 32 352 70 440 13 44 15 15
1) Weight is based on a density of 7.8 and a bore of d i = raw dimension
Material strength requirement
No visible crack, deformation or other damage in the material of the jointless thumble must
result when the thumble is loaded to the breaking point of a rope having a rated wire
breaking strength of 1960 N/sq.mm.
BG 22/96 5-60
5.16 WINCHES
Check the oil level of the winch gears weekly or after long periods of standstill before
reoperation.
The oil is to be changed for the first time after 250 operating hours or 6 weeks and from
then on after every 1000 operating hours or every year. When oil is to be changed the
machine must stand horizontally.
5.16.1 Checking the oil level
• Unscrew and remove the in-

spection / filler screw (fig.
5/27).
• Check the oil level with the

dip stick. The oil level must
be between the upper notch
(MAX) and the lower notch
(MIN).
• If the oil level is lower than

or at the lower notch (MIN),
refill oil and check the oil
level again. The oil level
may not exceed the upper
notch (MAX).
• Clean the sealing surfaces,

check sealing for damage
and wear and replace it as
necessary.
• Screw on inspection/filler Fig. 5/27 Inspection/filler screw IBFASEISH

screw and tighten.
The oil level may be checked only when the gear is out of operation.
CAUTION
The operating manual for the winches is in the appendices.
BG 22/96 5-61
5.16.2 Filter of the Free-Fall Winch
The filter element of the free-fall filter is to be replaced for the first time after the first 50
operating hours of the rotary drive and from then on after every 250 operating hours.
WARNING!
Fig. 5/28 IBFASE144I
To replace the filter cartridge proceed as follow:
• Remove the filter cartridge from the lower part and dispose of the filter cartridge as
hazardous waste.
• Clean upper and lower parts. Install a new filter cartridge into the lower part.
• Screw the lower part to the upper part and tighten.
BG 22/96 5-62
5.17 MAINTENANCE OF ROPE SWIVELS
Rope swivels serve to prevent wire ropes from twisting

and untwisting during kelly drilling operations and under
load.
Rope swivels are to be greased every 10 operating hours

or at least once a day. Make sure to apply enough grease.
- it must run off at the side of the swivel housing.
When greasing the rope swivel, check also that the

swivels rotate freely.
Special attention is to be drawn on the rope swivel at the

main winch, which connects the rope with the kelly bar.
t
v )
Fig. 5/29 IBCHLB037I
• The swivel is to be checked for free rotation without load, i.e. without kelly bar or tool,
by turning the swivel by hand. The kelly bar is to be lowered to the ground or into a
bore. To check the swivel, it must be removed from the kelly bar.
• If the swivel still does not rotate freely after greasing, it must be repaired or replaced.
• To guarantee smooth operation and operating safety only original BAUER spare parts
are to be used.
• In addition, the fastening pins between the swivel and the rope end socket, the kelly
eye on the main rope and the lifting tackle (shackle, hook etc.) on the auxiliary rope
are to be checked every time the rope swivel is greased. Loose fastening bolts are to
be retightened according to their tightening torques (see sect. 5.20). Worn pins or pins
with too much slack are to be replaced.
BG 22/96 5-63
5.18 HYDRAULIC CYLINDERS
• All hydraulic cylinders are to be checked for tightness and cleaned daily or at least
every 10 operating hours as well as after long periods of standstill and before
reoperation.
• To clean piston rods, no sharp-edged tools, acid liquids or scouring powders may be
used.
• When the cylinders are cleaned regularly, a water hose with nozzle or rather a
high-pressure steam jet should be sufficient.
Hydraulic cylinders which are used exclusively to rig and adjust the device
and whose extended piston rods are exposed to weather and site
conditions can be protected with form oil (by coating or spraying).
NOTE
• Leaking hydraulic cylinders must be repaired or replaced immediately. Depressurize

the system before carrying out repairs.
• Hydraulic cylinders cannot be repaired on site. They are to be repaired and replaced
only in authorized workshops by skilled personnel.
WARNING!
When a hydraulic cylinder on the drilling rig is damaged, an auxiliary crane

must be used to secure the equipment to be dismounted.
Non-observance to this rule may cause damage to the equipment or even
lead to serious and/or fatal accidents.
• Loose hydraulic fittings are to be immediately sealed with plugs (hose side and cylinder
side).
BG 22/96 5-64
BAUER
Notes to Storing Hydraulic Cylinders
Before storing hydraulic cylinders please observe the following instructions:
— All connections are to be sealed with plastic or metal plugs.
- Cylinders should be filled with an operating medium or preservation protection oil.
— For long-term storage the piston rod ends and the bearings are to be greased with
corrosion preventive.
- Keep the cylinders in a dry room at approx. 14 - 20 *C.
WARNING!
A
Due to solar radiation when the hydraulic cylinders are stored in the open,
the oil pressure inside may become so high that removing any sealing
parts is extremely dangerous. This is especially true for crowd cylinders
of drilling rigs. To prevent the danger of accidents appropriate safety
measures are to be taken on consultation with BAUER.
BG 22/96 5-65
+
5.19 ROTARY DRIVE MAINTENANCE
5.19.1 General
The rotary drive is to be thoroughly cleaned at the end of every workday.
If you remove accumulations before they may cake, premature wear of the rotary drive will
be avoided.
Water with a sufficient pressure can be used for the cleaning.
Inspect also for external damage to the drive and for loose or missing bolts.
Damaged dampers or compression springs must be replaced promptly.
A
CAUTION
Operating with damaged dampers or broken springs can cause damage
to the rotary drive.
Federn
Compression spring
Anschlagdämpfer
Daraper
[ ]
Fig. 5/30 Shock absorbers BGAAA001
BG 22/96 5-66
BAUER
5.19.2 Checking Gear Oil Level
BG rotary drives are equipped with sight gauges for inspection of the oil level inside. For
inspection, the mast must be in upright position.
The oil level here is to be checked every 50 hours of operation or on a weekly basis,
whichever comes first.
The oil level must be half

way up the gauge at all
times!
normaler
Ölstand
Ôlstandsauge
Oil level sight gauge
Fig. 5/31 Checking the oil level IBGAAA002I
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
BG 22/96 5-67
BAUER
5.19.3 Changing Gear Oil
The first oil change on the rotary drive is to be carried out after the drive's initial 200 hours
of operation, at the latest. All subsequent oil changes are due every 1000 hours of
operation or annually, whichever comes first.
If the oil in the primary gearboxes is heavily contaminated so that their oil has to be changed
too, it is absolutely necessary that each of the gearboxes be separately and COMPLETELY
refilled with the new oil. Otherwise, there will be a temporary absence of lubricant in the
gearbox.
^^^^ Running a primary gearbox without lubrication will inevitably damage it.
CAUTION
Whenever it is intended to change to an other brand of oil, the compatibility of the two oils
must be tested beforehand.
It is preferable that the rotary drive be still warm from operating when the oil change is
carried out.
If the drained oil is dark or black coloured, its operating temperature has been above
100 °C. This makes oil wear out sooner, and lose its lubricating effect, so that the oil change
intervals must be shortened correspondingly.
The drained oil should be inspected for impurities and metal particles (abrasives), the
maximum permissible amount being 0.15 % of the total oil from one oil change.
Particles found in the oil must not exceed max. 5 jam in size; it they do - no matter the
amount - the rotary drive will have to be removed and taken apart.
When the outside temperature is low at the time of the oil change, it is recommended to
warm up a part of the new oil (to approx. 50 °C) and flush the drive with this oil before
refilling, in order that particles and impurities may flow off.
Benzol (benzene) or flushing oils may be used as well to flush the rotary drive, however
NOT petrol (gasoline), petroleum or diesel oil.
The flushing agent must be allowed to drain off completely before the drive is refilled with
new oil.
BG 22/96 5-68
To change oil, proceed as follows:
WARNING!
Hot gear oil can cause severe injuries!
NEVER mix a synthetic oil with a petroleum-based oil!
CAUTION
Use only fresh oil, from a product recommended in the Lubricant Table.
See the filling quantity on the nameplate of the rotary drive or in the manual.
Before unscrewing a drain plug (see fig. 5/32), remove all filler screws (see fig. 5/33).
Observe the position of the rotary drive.
Have an oil collecting container ready; it must be large enough to hold all the oil!
When necessary, place a plastic tube or hose of suitable size and length between the
drain plug and the container!
Ansicht "A"
View "A"
Ablaßschrauben (4 Stk.) Schraube für

4 drain plugs Ölprobe
Oil sampling
screw
Ansicht "A"
View "A"
Fig. 5/32 Oil drain plugs IBGAAA0031
BG 22/96 5-69
BAUER
Check magnets on drain plugs for gear abrasives, and clean the magnets.
• Replace seal at drain plugs (if equipped with seal) and reinstall plugs with new seals
and tighten.
• Refill the drive with new oil and then reinstall filler screws and tighten (see fig. 5/33).
Ansicht ';A"
View "A"
Einfüllschrauben
Filier screws Ansicht "A"
View "A
Fig. 5/33 Oil filler screws IBGAAA004]
Check the oil level and top up as necessary.
BG 22/96 5-70
5.19.4 Bolted Connections
The mounting bolts on the rotary drive are secured with Loctite and need checking only
every 100 hours of operating that they are properly in place and not loose.
DO NOT retension the bolts unless it is necessary, or the Loctite seal will
break.
CAUTION
Take care to loosen or tension bolts in a diagonal manner only.
In case that the kelly driver and guide flange are to be replaced, clean first the contacting
surfaces of the new kelly driver / hollow shaft and hollow shaft / guide flange free of grease,
and then seal them with Loctite 0586 Type AVX when installing.
Apply Loctite also to the thread of the mounting bolts, insert the bolts and tighten them to
the proper torque (see M below). a
Befestigungsschrauben
Kellymitnehmer M20 (30 Stk.)
Kelly driver
mounting bolts M20 (qty.30)
M : 5 2 0 - 5 4 0 Nm
a
Befestigungsschrauben
FUhrungsflansch M24 (36 Stk.)
Cuide flange [MB 1
C
mounting bolts M24 (qty.36)
]
Mg: 9 0 0 - 9 2 0 Nm
Fig. 5/34 Bolt torque values IBGAAA0061
BG 22/96 5-71
5.19.5 Kelly Driver Strips
If the kelly driver strips are excessively worn down (> 8 mm, see fig. 5/35), they must be
replaced with new strips.
If bushings and bolts (see fig. 5/35) are torn, they must be replaced with new ones as well.
When fitting a new strip, the play (see fig. 5/35) should not exceed 0.5 mm.
The torque to apply on the M12 mounting bolts is 80 Nm.
Verschraubungen
Bolted connections
oben unten
Upper Lower
Verschleiß Buchse Spiel

Bushing Play
Wear
Mitnehmerleiste
Driver strip
Fig. 5/35 Driver strips IBGAAAOOSI
BG 22/96 5-72
5.19.6 Filter of Rotary Drive (Optional)
The filter element of the KDK gear is to be replaced for the first time after the first
50 operating hours of the rotary drive and from then on after every 250 operating hours of
the KDK.
WARNING!
Switch the engine off and allow the oil and the components to cool down
before replacing the filter cartridge.
To replace the filter cartridge proceed as follows:
• Remove the filter cartridge from the lower part and dispose of the filter cartridge as
hazardous waste.
• Clean upper and lower parts. Install a new filter cartridge into the lower part.
• Screw the lower part to the upper part and tighten.
BG 22/96 5-73
5.20 CHECKING THE SLIDE STRIPS
Check the slide strips on the sledge of the rotary drive every 100 hours for wear.
If the wear exceeds 3 mm (i. e. if the strips are thinner than 22 mm), the strips must be
replaced by new ones.
Ansicht "A"
View A
Schnitt B-B
iUl
ir
Mast • •As max.3mm
1I i
• M i n d e s t m a ß (22mm)
rain, thickness
I
|—Gleitleiste
| Slide strip
otf—Spannplatte
i Tension plate
1
Schraube
Hexagon screxu
Getriebeschlitten
Sledge
Fig. 5/37 IBHAAA011I
BG 22/96 5-74
SAUER
5.21 TABLE OF BOLTS TENSILE STRENGTH AND TORQUE

VALUES
1 ) Minimum screwing-in depth with blind hole threads
Table 5-11 applies to tolerance class medium (6 H)

(other tolerance classes will require correspondingly allocated screwlng-in depths)
Bolt strength class 8.8 8.8 10.9 10.9 12.9 12.9

Thread fineness d/P <9 >9 <9 >9 <9 >9
St 37 1.0 d 1.25 d
St 50, C 45 N, 0.9 d 1,0 • d 1.2-d 1.4-d

46 Cr 2 N, 46 Cr 4 N
C 45 V, 46 Cr 4 V, 0.8 d 0.9 • d 1.0 d 1.1 d

42CrMo4V
d = outside thread diameter [mm]

Screws with metric ISO thread [standard thread]
P = lead of thread [mm]
up to M 30 have one d/p < 9
> M 36 have one d/p > 9
2) Bolt torque value and the torquing to be used when installing
MA' = 0.9 . MA
The torque will depend on numerous factors, but in particular on the friction coefficient in
the thread as well as at the head or nut face.
For a mean friction value of mG - mK = 0.14 the tightening torque MA for pretensioning to
FSP and also the fitting tightening torque MA' for fitting with a torque wrench is given in
Table 10-5 taking into account a scattering of 10%.
BG 22/96 5-75
BAUER
Table 5-11 Tensile strength and torques for bolts with standard metric
thread DIN 13, for - 0.14
Strength class as 8.8 10.9 12.9

per DIN/ISO 898
Permanent elongation limit 640 for <M 16

940 1100
Rpo.2 N/mm 660 for >M 16
Metric Stress. Core Tensile Theor. MA' = Tensile Theor. MA' = Tensile Theor. MA' =
ISO cross section strength tight. 0.9 MA strength tight. 0.9 MA strength tight. 0.9 MA
thread, section torque for Md- torque for Md- torque for Md-
DIN 13 wrench wrench wrench
As g ^3 g Fn MA Fn MA Fn M A
mm mm N Nm Nm N Nm Nm N Nm Nm
M5 14.2 12.7 6400 6.1 5.5 9300 8.9 8.0 10900 10.4 9.3
M6 20.1 17.9 9000 10.4 9.3 13200 15.5 13.9 15400 18 16.2
M8 36.6 32.8 16500 25 22.5 24200 37 33 28500 43 38
M 10 58 52.3 26000 51 45 38500 75 67 45000 87 78
M 12 84.3 76.2 38500 87 78 56000 130 117 66000 150 135
M14 115 105 53000 140 126 77000 205 184 90000 240 216
M16 157 144 72000 215 193 106000 310 279 124000 370 333
M18 193 175 91000 300 270 129000 430 387 151000 510 459
M 20 245 225 117000 430 387 166000 620 558 194000 720 648
M 22 303 282 146000 580 522 208000 830 747 243000 970 873
M 24 353 324 168000 740 666 239000 1060 954 280000 1240 1116
M 27 459 427 221000 1100 990 315000 1550 1395 370000 1850 1665
M 30 561 519 270000 1500 1350 385000 2100 1890 450000 2500 2250
M 33 694 647 335000 determine by 480000 determine by 560000 determine by

measuring the measuring the measuring the
M36 817 759 395000 elongation of 560000 elongation of 660000 elongation of
the screw the screw the screw
M 39 976 913 475000 670000 790000
M42 1120 1045 542000 772000 904000
M45 1300 1224 635000 905000 1059000
M48 1470 1377 714000 1018000 1191000
M52 1760 1652 857000 1221000 1429000
M 56 2030 1905 989000 1408000 1648000
M 60 2360 2227 1156000 1647000 1927000
MA changes as ^iG or |aK varies
BG 22/96 5-76
5.22 CONVERSION TABLES
Table 5 - 1 2 Conversion tables
Units of Force
N dyn kp Mp p
1 5
10 5
0,102 1,02-10'f 102
4
10' 5
1 5
1.02-10" 1,02-10" 9
1,02-10" 2
9,81 , 9,81-10? 10" 10T

6
9,81-10 3
9,81-10° 10 . 3
10
9,81-10" 3
981 10" 3
10' 6
1
Units of Energy- and Work
J erg kpm kWh kcal ev
7
10 0,102 2,78-10" 7
2,39-10" 4
6,24-10]?
8
1 7
1.02-10" 2,78-10'l 4
2,39-1 Q'l 1
6.24- 10 !
9,81 9,81-10" 7
2,72-10' 6
2,34-10' 3
6,12101!
3,60-10 6
3,60-10 3
3,67-10 5
1 3 860 2.25- 1 Of.
4 1 8 7 4,19-1Q . 1 0
427 1.16-10-3 2,61 -10 22
19
1.6-10" 19
1.6-10" 12
1,63-10-*° 4,45-10 3,83-10" 23
1
Units of Power
w kW kpm/s PS kcal/s kcal/h
3 4
1 3 10' 0,102 1.36-10" 3

2,39-10" 0,86
10 3
1 3 102 1,36 0,239 . 860
3
981 9,81-10" 3
1 1.33-10" 2
2,34-10" 8,43
735,5 0,7355 75 1 0,1757 632
4187 4,19 427 5,69 1 , 3600
1,16 1.6-10" 3
0,119 1.58-10" 3
2,78-10" 4
1
Units of Pressure
at atm bar N/m 2

Torr cmWS
1 0,968 0,981 98100 736 1000

1,033 1 1,0133 101330 760 1033
1,02 0,987 . 1 5
10 5
750 . 1020
4 2
1,02-10"! 9,87-10"° 10"5
. 1 75-10" 1.02-10"
1.36-10' 3
1.32-10" 3
1.33-10" 3
133 1 1,36
10" 3
9,68-10" 4
9,81-10" 4
98,1 0,736 1
BG 22/96 5-77
;
APPENDICES
A KELLY BAR MANUAL
B MAIN WINCH MANUAL
C AUXILIARY WINCH MANUAL
D CARE AND MAINTENANCE OF WIRE ROPE
BG 22/96
BAUER
K E L L Y BAR MANUAL
Care and Maintenance of Kelly Bars
Contents:
1 Instructions Regarding the Use of Kelly Bars 2
2 Maintenance 5
2.1 Maintenance Intervals 5
2.2 Prescribed Services 6
3 Repair Welding 9
3.1 Steps for Repairing 9
3.2 Butt Welding 10
3.3 To Weld Gibs onto the Kelly 11
3.4 To Replace the Kelly Square-Shaped Tool Joint 13
3.5 Welding Rod Specifications 15
Users are also advised to read the operating instructions for kelly bars as given in the
separate BAUER "Operating Manual for Drill Rigs, Tools and Accessories".
KBM/96 1
BAUER
1 INSTRUCTIONS REGARDING THE USE OF KELLY BARS
Kelly bars are designed for the purpose of transferring torques and pressures onto a drilling
tool. The kelly used must therefore be treated with as much care as the drilling rig and the
tool and bits themselves in order that consistent drilling performance be ensured.
To avoid that the kelly gets damaged during operation, or from incorrect hand-
ling, the following instructions must be observed:
• Not all types of kellys are designed for the full torque of the rotary drive of the drilling
rig: Know the max. permissible torque for the kelly and do not exceed it with the rotary
drive.
• Kellys and drilling tools are allowed to be used only for drilling applications; earthmo-
ving, conveying or levelling jobs are not permissible.
• Kellys may not be used for bringing borehole casings or drilling tools into alignment.
• Never immerse a kelly into fluid concrete, or the kelly may be ruined.
• Kellys may be operated with free-fall facility only as long as the total load on the kelly
rope does not exceed half of the max. pulling capacity of the corresponding winch.
Example:
Pulling capacity of main Weight of kelly: 7.6 tonnes (see chapter 2

winch is 20 tonnes (type 4/44) of drilling rig
manual)
+ +
Weight of auger bit: 1.6 tonnes (see imprint
(0 1500 mm) on tool)
Calculation: 20 tonnes : 2 = 10 tonnes > Total: 9.2 tonnes
Summation: Kelly may still be used with free-fall.
2 KBM/96
• With a kelly inserted in a borehole, it is no longer allowed to make any readjustments
with the base machine or at the mast of the drilling rig.
Exception: If the mast is displaced from its initial working angle, due to the working
forces, it must be readjusted.
• Drilling operation with a kelly may be started only when the kelly has been inserted
completely so that the drilling tool stands on the bottom of the borehole.
• For drilling with a kelly in hard formations, the' kelly must be of interlockable type;
operating with sections not properly locked together would result in excessive wear
or damage of the kelly.
• In extremely tough conditions (such as one-sided drilling in hard material), it is

important that no additional forces are put on the kelly, or it could kink and start
tumbling: If one-sided stress on the drilling tool, adapt the crowd force correspondingly.
• In conditions where the borehole is extremely deep or the drilling diameter extremely
large, special attention must be paid that teeth and chisels are in good working order:
Replace with new drilling bits in good time, do by no means attempt to make up for
worn out bits by increasing the crowd force on the kelly.
• When extending a kelly, readjust torque and pressure (decrease as necessary) to

adapt to the conditions.
• When withdrawing a kelly from a borehole, keep an eye on the outermost section:
If the outermost section lifts from its rest on the rotary drive, one of the inner sections
is not properly unlocked to retract.
- STOP lifting by main winch -
to avoid that the locking mechanism will open now, or the section would slip through
and get damaged.
- REINSERT kelly to bottom of borehole -
and then rotate anticlockwise with the rotary drive and pull by the main winch to
completely unlock and properly retract all sections.
Kelly and mast must be parallel at all times of operation.
CAUTION
KBM/96 3
If the drilling rig is equipped with a winch load sensoring device, keep
•fer 3
also an eye on the drilling monitor unit and compare there the indicated
values of
NOTE »T ol depth" and "Winch load"

0
to see if sections are unlocking properly:

After having retracted one section, the indicated value of "Winch load"
should increase only by the weight of the respective section.
In this way it is also possible to determine where among the sections an
unlocking does not function properly.
The method of comparing "Tool depth" with "Winch load" is useful also
while extending a kelly (whereby the weight decreases correspondingly
with each extended section).
4 KBM/96
2 MAINTENANCE
Correct maintenance prevents the kelly from wearing down prematurely.
It also helps in detecting a damage in a beginning stage which, in turn, may save the user
excessive repair.
2.1 Maintenance Intervals
For kellys used under normal soil conditions

(non-cohesive and cohesive soils up to grade 6)
Prescribed intervals for: double and triple kellys quadruple kellys
1 st inspection after: 100- 150 hrs 50- 100 hrs
subsequent inspections every: 400 - 500 hrs 250 - 300 hrs
For kellys used under tougher conditions (with soil grades exceeding 6 or rock), the
intervals should be shortened by half the time given.
In case of a failure such as - sections are slipping through

- kelly top cover is deformed
— sections will not retract or extend smoothly
the kelly must be removed at once and be inspected.
Disassembly and repair will require a free space as long as double the length of the kelly
when it is retracted.
KBM/96 5
2.2 Prescribed Services
Flush the kelly free of dirt after every work shift, and thoroughly clean it before any
maintenance is carried out.
When inspecting, pay special attention to wear on the following components:
Kelly with 2 x 3 gibs Kelly with 2 or 3 gibs
Kelly eye 7
— K e l l y eye 1
Rubber bumpers "J7
Locking r e c e s s e s 3
Drive gibs in
transition zone 6
Close-up view
Impact ring 9
Wear ring "JO
Drive shell 4
Drive gib Q
IABKAAE16I
See further description on next page.
6 KBM/96
The following lists the components which are itemized with numbers in the figures on the
previous page, and gives the typical damages which may occur. For welding work, please
refer to the instructions in section 3 - Repair Welding.
Component Damage Repair
1 Kelly eye Cracks in bore Replace with new eye;

see welding instructions
2 Shock absorbers Worn out or smashed In case the damage is caused

(on rotary drive) by accidental dropping of kelly
sections, the kelly will in gene-
ral be damaged as well so that
it must be disassembled and
repaired
3 Locking recesses Cracks or edges worn down Rebuild by welding;

4 Drive shells Upper edge worn down Rebuild by welding;

5 Pilot bit Cracks or deformation in Cut off and replace with new
lower part tubing; see welding instructions
6 Drive gibs Cracks in transition zone, or Grind, repair by welding;

burrs and slits on edges, or see welding instructions
worn down edges
7 Compression spring Jolted or broken Replace with new
8 Square-shaped Cracks in upper part Replace with new tool joint;

tool joint see welding instructions
9 Impact ring Worn down surface Rebuild by welding;

10 Wear ring Cracks or worn down Renew with new;

11 Rubber bumpers Worn down Replace with new
12 Tubing material Deformed, out of shape Cut off deformed tubing and
replace with new; see wel-
ding instructions
KBM/96 7
BAUER
Also to be inspected are — all welds for cracks

- a l l bolts that they are properly in place and firm.
A
CAUTION
A kinked, bent or excessively worn kelly must be removed from service.
NEVER lubricate a kelly.
8 KBM/96
3 REPAIR WELDING
The following gives general information; if the repair is of a more complicated kind, please
consult the BAUER Service Centre for advice.
Repairs may be carried out by trained and qualified personnel only. Work safety and
prevention of accident regulations must be observed.
After finished welding job, extend all sections one by one to full extent to check that the
movability has not been affected.
3.1 Steps for Repairing:
1st Grind faces to be joined, remove burrs and clean weld zone free of grease.
Break
- ¡1
If the break is ragged, it may be necessary to

replace the broken section with new tubing,
whereby the "A" dimension must be kept.
1
/ !
Joint
IABKAAE01I
2nd Determine what material the parts are made from.
The gibs, the square-shaped tool joint and the eye for the rope swivel are
of alloy steel and require preheating.
NOTE
• Use a sheltered location free of draught (workshop).
• Preheat the weld zone (the joint and 200 mm outwards on both sides) to 150 "C -
180 'C.
• Postheat finished weld to 180 °C.
KBM/96 9
BAUER
3rd Observe the following when several parts are to be welded together:
• Keep the "A" dimension of the keily inner bar.
• Keep linear alignment.
• Avoid pitting surfaces with the arc or the flame.

T <
• After welding, grind all seams smooth and flush.
3.2 Butt Welding •

ÏÏ
IABKAA002I
Use a fit-up fixture to hold parts.
25^ »Joint
JABKAAE03I
Tack-weld spotwise (25 mm) 3 blank

steel rods onto the tubing for fixture
• Welding
Detail of B-B and "A":

.2
Parts must be linear.

A gap of 2 mm must be
.Gibs provided for fusion at the
root.
Weld in tubing and welds in gibs The welded root pass
must be staggered by approx. 50 mm. should not protrude be-
yond the tubing.
IABKAAE04J
10 KBM/96
BAUER
3.3 To Weld Gibs onto the Kelly
Maximum permissible wear
When Uniform When One-sided Material
— St 52
JT13X 10 ^T777T77T77T77T77Tr7777
*jvVj V — 25CrMo4v
StE690
St 52
I ; r
25CrMo4v
ftBKAA017
Uniform wear on the gibs, One-side wear requires

the drive shells and repair, to prevent
the locking recesses must functional failure.
not exceed 10 mm.
KBM/96 11
BAUER
With kellys having 2 or 3 gibs:
NOTE
When welding-on a gib, start in the middle of the kelly bar and work towards the ends.
Avoid irregular distribution of heat over the bar - differences in temperature must be kept
at a minimum to prevent distortion.
To balance the temperature of the bar, we recommend the following "alternating" work
procedure: Stop welding after 300 mm of produced weld, rotate the bar 120° to other gib
and resume welding here, and so on.
Do not weld at recesses in zones between
12 KBM/96
3.4 To Replace the Kelly Square-Shaped Tool Joint
Two different types of kelly tool joints are described in the following:
a) A tool joint which is larger than the diameter of the inner bar.
b) A tool joint which is smaller than the diameter of the inner bar.
All parts must be preheated (see section 3.1) before welding.
NOTE
a) Tool joint larger than kelly inner bar
2 4 3
1 Kelly tool joint

2 Kelly inner bar
3 Guiding ring
4 Gibs
IABKAA008I
16 . 16
• Fit gibs linear with the shape of the tool joint.
• Weld together the inner bar tubing (2) and the tool joint (1),
see detail "Z".
A
CAUTION
Be careful to keep linear alignment and the "A"
dimension. 6
• Weld gibs (4) onto tool joint (1) and tubing (2).
Produce the weld (see arrow) all the way

through in one go.
NOTE
N Weld
50.
• Weld on guiding ring (3). R8KAAE10
KBM/96 13
BAUER
b) Tool joint smaller than keily inner bar
Section B-B:
B- C—^
- -+ f - --
' ' ' ' ' ' ' ' ' r I r
B—i
JABKAAE14]
IABKAA015I
1 Kelly tool joint 3 Guiding ring Section C-C:

2 Kelly inner bar 4 Gibs
empty
• Weld together tool joint (1) and Inner bar tubing (2), see
section D-D and detail "Z".
A
CAUTION
Be careful, to keep linear alignment and the
"A" dimension.
IABKAAE13I
Section D-D:
• Weld gibs (4) onto tubing (2) and tool joint (1) as far as
to "*" in section D-D. See also section C-C (empty space
at arrow).
• Join guiding ring (3) with gibs (4): Weld together along
provided chamfers as far as to "X" in figure above.
20"
ABKÄA011I
The lengths of the individual

welds can be understood by
IABKAA012I
comparing sections B-B and
C-C (arrows) in figures above.
Detail "Z"
14 KBM/96
3.5 WELDING ROD SPECIFICATIONS
The types of electrodes to use for kelly repair welding are as follows:
• For welding the Root Pass of butt welds:
Rod Electrode SH Yellow R Dia. 2.5 mm
DIN 1913: E 4343 (B) 7 *) Chemical properties:

ISO 2560: E 43.4 RR 22 C Si Mn
AWS A5.1: E6013 0.08 % 0.20 % 0.55 %
B.S. 639: E 4343 RR 22
SFA-5.1: E6013
• For welding Intermediate Pass and Coat Pass:
Rod Electrode Phoenix Blue
DIN 1913: E5122R(C)3 Chemical properties:

ISO 2560: E51.2R12 C Si Mn
AWS A5.1: E6012 0.09 % 0.25 % 0.50 %
B.S. 639: E5122 R 12
SFA-5.1: E6012
BAUER Order Specifications: Dia. Length Part No.

2.5 X 350 48630
3.25 X 350 700912
4.0 X 350 700913
Rod Electrode Phoenix Kb Special
DIN 1913: E5132B(R) 10 Chemical properties:

ISO 2560: E51.3B23 C Si Mn
AWS A5.1: E7016 0.08 % 0.35 % 0.80 %
B.S. 639: E 5132 B 23 (H)
SFA-5.1: E7016
*) also for intermediate pass and coat pass
KBM/96 15
BAUER Order Specifications: Dia. Length Part No.
2.5 x 350 52000
3.25 x 350 49293
4.0 x 450 52001
Wire Electrode Union K 56
Material: 1.51 Chemical properties:

DIN 8559: SG3 C Si Mn
AWS A5.18: ER 70S-6 0.09% 1.05% 1.70%
SFA-5.18: ER 70S-6
BAUER Order Specifications: Dia. Part No.

1.2 700265
0.8 700997
16 KBM/96
BAUER
B MAIN WINCH MANUAL
BG 22/96
ZOLLERN SERVICE BLATT
SERVICE FORM
FEUILLE DE SERVICE
Getriebe T yp ZHP 2 9
Gear Type
Réducteur Type
G erate INTar O 6 . 2 9 1 O 2 O 6
Aggregat No.
Appareil No.
Serien Mar 112

Serial No.
Serie No.
Au. f t r a INT I T
Order No.
Commande No.
Firma Bauer S p e z i a l t i e f b a u GmbH

Company
Société
Anschrift P o s t f a c h 1260
Adress D-86522 Schrobenhausen
Adresse
Abteilung zu Hdn. Frau Ostermeier

Department
Service
Bestell- Nr. : Firmen Nr,

Order- No. : Company No,
Commande- No. : Société No.
Geräte Type: - Sach Nr,

Aggregat Type: I d e n t . No,
Appareil Type: P r o d u i t No.
Bau/Komm. Nr, Pos. Nr.

Constr. No, Pos. No.
Constr.Spec. No. Rep. No.
Projekt Nr. :
Proj e c t No. :
Projet No. :
ZOLLERN VERTRIEBS-GmbH + Co.

Heustraße 1
D-88518 H e r b e r t i n g e n
T e l e f o n 07586-959-0, T e l e f a x - S e r v i c e - D e p . 07586-959-710, Telex 732 218
L i e f e r u m f a n g : 5-fach d e u t s c h / e n g l i s c h
Doc.-No. : 190011173.1/SB 22.08.96 We/KD
MONTAGELAENGE 784 TECHNISCHE DATEN TECHNICAL DATA
ASSEMBLING LENGTH NENNSEIL2UG AN OER TROMMEL IN LAGE
<N|
ROPE LOAO AT THE DRUM
1
IN LAYER
543.9
NENNSEILZUG BEI FREIFALLBETRIEB IN LAGE
ROPE LOAO IMPACT IN LAYER
ABTRIEBSDREHMOMEHT OUTPUT TORQUE

ABTRIEBSDREHUOMENT OUTPUT TORQUE STAT. MAX T AB (HI)
ANTRIEBSOREHMOMENT INPUT TORQUE T AH INU)
SEILGESCHWINDIGKEIT IN LAGE ROPE SPEED IN LAYER 3 0 / 6 0 1 7
ABTR IEBSOREHZAHL OUTPUT SPEED N AB I M I H - I ) 14.7/ 29,4

ANTRIEBSOREHZAHL INPUT SPEED N All (MIN-I) 1086 / 2I7J
ANTRIEBSOREHZAHL INPUT SPEED N All (MIN-I) 2173
UEBERSETZUNO -74
SEILRILLENSTEIGUNG RECHTS / LINKS

IHM)
ROPE OROOVE PITCH RIOHT HAND / L E F T HANO
RILLUNG NORMAL/ SONOER/ OHNE

GROOVE SYSTEM HORUAL/ SPECIAL/ WITHOUT
SEIL0 ROPE0 / ANZ. 0. SEILLAGEN mno.OF ROPE LAYERS
NUTZBARE SE ILLAENGE USEABLE ROPE LENOIH
SICHERHEITSWINDUNGEN LAENCE ANZAHL

OEAO ENO TURNS LENGTH NUMBER
BREMSE PARKINO BRAKE TYPE
FEOERN PRO BREMSE S P R I N G S PER ONE BRAKE GR 1 I GR T 22 I 22

REIBFLAECHEN AUSSENLAMELLEN INNENLAMELLEN
F R I C T I O N SURFACE EXTERNAL OISCS INTERNAL OISCS
20 II 10
LUEFTENDORUCK PRESS. AT END OF BRAKE RELEASE |MIN|MA7 25 I 300~

BACK PRESSURE
DYNAMISCHES BREMSUOMENT B E I NASSLAUF
T OYN INU)
DYNAMIC BRAKINO TORQUE RET RUNNING
STATISCHES BREMSMOMENT B E I NASSLAUF TROCKENLAUF
T STAT (NU) 1 376
STATIC BRAKINO TORQUE »ET RUHHINO 0RY RUNNINO
MOTOR - HYDRAULISCH HYORAULIC H Y D R O M A T IK A6VU250/8I/2
MOTOR - ELEKTRISCH
ANTRIEBSWELLE NASS »ET / TROCKEN DRY N
INPUT SHAFT WELLEN 0 SHAFT 0 | ZAEHNEZAHL TEETH" 50 01H5480|24
LAENGENABSTANO LINEAR MEASURE MIN|MIH|X/Y (MÙ7
DREHSINNi MOTOR ZUR TROMMEL G L E I C H / ENTGEGENGESETZT
SENSE OF ROTATION I MOTOR TO DRUM SAUE / OPPOSITE SENSE
TROUUEL-WERKSTOFF ROPE DRUM MATERIAL GGG 40
MASSE OHNE ANTRIEBSMOTOR MASS »ITHOUT MOTOR fc) 1510
GETRIEBEOEL TRANSMISSION O I L
ERFORDERLICHE FUELLMENGE QUANTITY REQUESTEO TÖfTj)

FETT OUT SI82S
AUSLEGUNG FEM
LAYOUT A C C . FEU M5 / L 2 / 1 5 ' BE I N AB • 2 5 M I N " 1
P - CONST.
WINDE ENTSPRICHT! EUROPANORM-ENTWURF CEN TC 151 /STAND 14.12.90)

- S I C H E R H E I T OER BREMSE GEGEN L O S R E I S S E N i S i 1 . 3
-SEILSCHLOSSAUSLEGUNGi F , S E I L S C H L O S S - 0 . 7 . F . S E I L Z U G
-INCH CORRESPONOINO 10
INITIAL BRAKE AVAY S I
BREMSE IM A B T R I E B OUTPUT BRAKE 75P22 |l- JTJT?
GR.I/CB.2/GR.3 38/22/-
DYNAMISCHES BREMSMOMENT B E I NASSLAUF
22 740
OYHAMIC BRAKINO TOROUE »ET RUNNING
LUEFTENDORUCK PRESS. AT END OF BRAKE R E L E A S E |M|H|MAX 85 / 100
ANS ICH' CABLE FIXIHO FOR REVERS I NO OPERATI OH OIL BRAKE PRESSURE
VIEW Y SEILSCHLOSS FUER FREIFALLBETRIEB CASLE FIXING FOR FREE FALL APPLICATION STAUDRUCK-DRUCKOEL BACK PRESSURE
(PASSEND ZU EINGEZEICHNETEM (SUIIA9C.SE FOR »INOINO DIRECTION AS
SEI LABGANG ) SHOWN ) STAUDRUCK-SPUELOELEING. • ACK f A I S I . COO. I NO O I L I N *
ANZUGSMOUENT FUER M 1 6 - 19SNM TIGHTENING TORQUE FOR U 16- I95NU
FESTIGKEITSKLASSE 6.8 6TRENGTHRATINC 1.1 STAUORUCK-SPUELOELAUSC • IAOC W J M . C O O I . I I I O O H ouip 1.5 POS. 8
SPUELOELAUSTRIT TSTEMP. 130
UEBERDRUCKVENTIL 0.04 BAR PRESSURE VALVE IE*.or COOLIIN ou oütrui
SPUELOELRUECKLAUF •!• COOLING OIL ORA IH LINE
i . usa . a
OELFUELLUNG BZW. S P U E L O E L O Ï L Í I U I N O « E S > . oit CIRCULAI im
FREI FALLSTEUERUNG UND AN- AUSGANG 2 . UJ3 • 2
HYDR. ROHR 0 28 DIN 239IC PIPE 0 28 TO O l » 239IC
SCHLUESSE SIEHE BEIBLATT SPUELOELANSCHLUSS " S " COOLING O I L DRAIN L I N E
m c i F H l c o t i m u m t l u AW» C O H H I C I I O N ] At A I I A O X O weit M22 • 1,5 R O H R 0 12 Uli • 1.5 P I P E 0 12
C E 1 I C H I B E R I C H T IGT 07.04.9SITRAUHER
LUEFTDRUCK "P* 2 . M 16 • 1 . 5 R E L E A S E PRESSURE PORT
ANTRIEB-ARBEITSSTELLUNG ANTRIEB-TRANSPORTSTELLUNG 2 • M 22 i I . 5 IQ47J b OL B E R I C H l T Ö T " 3.01.95 BERCER
NUR* G E F I L T E R T E S OEL VERWETTENDEN 11254 a MASS 1348 WAR 1338 UNO MASS 164 »AR 174 3 0 . 0 5 . 9 4 UALEK
IN OPERATION DURING TRANSPORT
I N B E T R I E B N A H M E NUR ANTRIEB IN FILTERFEINHEIT 2 0 - 2 5 m »
TRANSPORTSTELLG. ANZUGSMOMENT FUER M 1 6 - I 9 5 N M TIOHTENINO TORQUE FOR OAIUU HAUE
B E F E F E S T I C T UIT a.e ZHP G.29 - EG
Ô f ARBEITSSTELLUNG
2 SCHRAUBEN
FESTIGKEITSKLASSE 8.«
FUER MOTOR 4.M20/33 TIEF/2ENTIER0 200
SIRENGIHRATINO
FOR UOIOR 4.U20/33 DEEP/CEHTR .0 200 )LLERN GE2 20.03. UALEK
BEFESTIGUNG SIEHE CR. S I E H E POS. 1.5
ORUCKOELANSCHLUSS FUER LAMELLENBREMSE HYOflAULIC CONNECTION FOR UJLTI-OISC FREIFALLWINDE (SB)
-l A - 4- POS.13
TRANSPORT ONLY IN u 1 2 . I . 5 / 1 2 T I E F - NUR G E F I L T E R T E S OEL BRAKE M 12.I.5/12 DEEP - USE ONLY
HYDRAULIC OIL FILTERED -
U A S 5 I A 9 SCALE
SIARIINC ONLY IN THIS POSITION VERWENDEN - F I L T E R F E I H H E I T 2 0 - 2 5 u UESH-SI2E 20-25. EZ/A3

uns POSITIOH FI1TINC « I T H TCIEFCH O T Ü f l l / S t l HUÍ 7 3 M I 1 Hilf At Q7SB6/S9575
- ^ 0 2 BOLTS. SIZE OF OELABLASS R 1 / 2 ' OIL OUTLET R 1/2'
Finnic BOLTS ACCORDING BUH
ACCORDING
POSITION I I I OELEINFUELLUNG/ !flto
- SEILWINDE
E - »54
OELMESSTAB/EHTLUEFTUNO 0 . 2 BAR
ANLACE-UNO ANSCHRAUBFIAECHEN O E L - . F E I I UND L A C K F R E I SURFACE TO B E F R E E FROM O I L AND C R E A S E ROPE WINCH 0 6 . 2 9 10206 VOM
COPYING OF THIS DOCUMENT, AND GIVING I T TO OTHERS AND THE USE OR COMMUNICATION OF THE CONTENTS THEREFOR. ARE FORBIDDEN"
WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENT OF DAMAGES. ALL RIGHTS ARE RESERVED IN THE EVENT OF
TIE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN FUERSTLICH HOHENZOLLERNSCHE WERKE LAUCHERTHAL
i-i-HWTwfi OF TUTS DOCUMENT. ANO GIVING I T TO OTHERS AND THE USE OR COMMUNICATION OF THE CONTENTS THEREFOR. ARE FORBrDflEM
COPYING OF THIS DOCUMENT. AND GIVING IT TO OTHERS AND THE USE OR COMMUNICATION OF THE CONTENTS THEREFOR ARE FORBIDDEN
WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENT OF DAMAGES. ALL RIGHTS ARE'.RESERVED IN THE EVENT OF
05 00
03 - J o OJ ro oo
m o o
ro
ro
—1—1—1
•<•<-<
mm
NO
) O (D
im m
I -4 Ç
!g S
• Q
•mi T|
i- r I —
m Z
• C/)
-n O
> TJ -H
» > m
H
00 00 C/4 - J C/J 0 J - - N J « J O l - v l O J 0 0 0 0
£2 r- 1 1
Ol
i i o - o oi - ro s j o^rogooioocBOioo o^^
z z
o o
COPYING OF THIS DOCUMENT. AND GIVING I T TO OTHERS AND THE USE OR COMMUNICATION OF THE CONTENTS THEREFOR. ARE FORBIDDEN
WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENT OF DAMAGES. ALL RIGHTS ARE RESERVED I N THE EVENT OF
ro
4».
s;
RS
ci ¡0
oa
Z 2
zo, I
25 in 03
3î m
HlO H
P m
m A
5
S*
*-
N>
VO
V/1
O
I
m
3D
COPYING OF THIS DOCUMENT. AND GIVING I T TO OTHERS AND THE USE OR COMMUNICATION OF THE CONTENTS THEREFOR. ARE FORBIDDEN
W T T U m i T F V P P E S S AtITHORTTY. O F F E N D E R S ARE LIABLE TO THE PAYMENT OF DAMAGES. ALL RIGHTS ARE -RESERVED IN THE EVENT OF
MOTORSEITIG
MOTOR SIDE
COTE MOTEUR
DRUCKFEDER
PRESSURE SPRING
RESSORT DE PRESSION
DRUCKOELANSCHLUSS
CONNECT PRESSURE OIL
98 97 96
GETRIEBESEITIG
GEAR SIDE
COTE REDUCTEUR
ACHTUNG /.ATTENTION ROLLERN
•GITR^BÈ^ZU^Î^HMEN: DER ERSATZTEILLISTE pos 2k 47 V HYDRAULIK-LAMELLENBREMSE
D E R D R U C K F E D E R N I S T
TYP BEZEICHNUNG
SOARFPAR^LIST ^GEAP ARV Q U A N
A S S U R E SPRINGS FROM
T I T V 0 , 7
POS
.T20R
TYPE DESCRIPTION HYDRAULIC-MULTIPLE-DISC-BRAKE
POUR L A QUANTITE NECESSAIRE DES RESSORTS DE PRESSION VOYEZ REP TYPE DESIGNATION F R E I N A LAMELLES HYDRAULIQUE
L E S L I S T E S DES P I E C E S DE RECHANGE "REDUCTEUR" " ™ A L U
BLATT/PAGE/PAGE . MASSTAB/SCALE/ECHELLE | NAME/NAME/NOM RASHMANN |OATUM/DATE/DATE 16.12 92 S06700718

7} -v -o
m o p
•oui B
00
m m
5
S-
RS w
3" P 1
m
'1
c i
1 / \ J1
P
m
I t
BE
! (Cr—^— -^k \!
O
COPYING OF THIS DOCUMENT, AND GIVING IT TO OTHERS AND THE USE OR COMMUNICATION OF THE CONTENTS THEREFOR. ARE FORBIDDEN
WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENT OF DAMAGES. ALL RIGHTS ARE RESERVED IN THE EVENT OF
z
gpLLERN
pos 51 TYP BEZEICHNUNG ABSCK.USSDECKEL ZUR FFB TEILE -NR 1 4.31 50009
POS TYPE DESCRIPTION COVER PLATE PART -«0
REP TYPE DESIGNATION PLAQUE C E RECOUVRQ€NT ARTICLE-HO
a ATT/PACC/PAŒ XX / XX HASSTAB/SCALE/ECHELLE |NAHE/NAME/NOH KOCH DATUH/DATE/DATE 10 12.11*2|2N /A3/A3

DATUM E R S A T Z T E I L - L I S T E ZOLLERN VERTRIE3S-GM3H & CO
- — HEUSTRASSE 1
22.08.96 S P A R E - P A R T - L I S T D-88518 KERBERTINGEN/WÜRTT.
SEILWINDE ZHP 6.29 062910206 ROPE WINCH GEWICHT ÖLEINFÜLLMENGE

WEIGHT OIL QTY
SERIEN - NR. 112 SERIAL - NO. 112 1510,0 KG 22,0 LTR.
SEITE - 1
XXXXXXXXXXXXXXXXXXXXXXXÄX^XXXXXÄX^
ACHTUNG : BEI ERSATZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN

ATTENTION : IF YOU ORDER SPARE PARTS PLEASE INDICATE TYPE AND SERIAL NUMBER
XXXXXXXXXXXXXXXXXXXXXXXXXX
POS-NR. STÜCK TEILE-NR. BEZEICHNUNG - DEUTSCH BEZEICHNUNG - ENGLISCH TECHNISCHE - DATEN

POS-NO. QTY PART -NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH TECHNICAL - DATA
1/ o 1,0 142950138 GETRIEBE KPL. GEAR CPL.
1/121 18,0 411230118 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 24X180 ZN 8.8 DIN 912
1/122 24,0 411230095 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 16X120 ZN 8.8 DIN 912
1/131 1,0 441100640 WELLENDICHTRING SHAFT SEALING RING 440X470X20 B2 DIN3760
1/132 1,0 441100683 WELLENDICHTRING SHAFT SEALING RING 140X170X15 BA DIN3760
1/141 1,0 442000001 PROFILSCHNUR SEALING RING WZ.NR 6/2823
1/142 1,0 542000010 BEFESTIGUNGSBAND OTHER ACCESSORIES PF 6180
1/143 1,0 542100010 HÜLSE NUT 8X0,4
1/153 1,0 453000153 RILLENKUGELLAGER BALL BEARING 220X340X37 DIN 625
1/190 1,0 524100010 ÖLVENTIL PRESSURE VALVE HUB 11,5-1008050200
1/193 1,0 441000213 FLACH-DICHTRING SEALING RING A 18X 22X1,5 DIN7603
21/ 0 1,0 142950139 SEILTROMMEL ROPE DRUM
21/ 1 1,0 242901365 SEILTROMMEL ROPE DRUM

21/ 5 1,0 242901367 SEILBLECH CABLE FIXING AND WEDGES
21/ 20 24,0 411130573 SECHSKANTSCHRAUBE HEXAGON BOLT M 24X 55 ZN 8.8 DIN 933
21/ 21 24,0 411130573 SECHSKANTSCHRAUBE HEXAGON BOLT M 24X 55 ZN 8.8 DIN 933
21/ 23 10,0 242600346 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 16X 45 3MM-LOCH DIN 912
22/ 0 1,0 142950096 FLANSCH FLANGE
22/ 2 1,0 242901307 FLANSCHPLATTE FLANGE PLATE

22/ 3 1,0 242901312 BREMSGEHÄUSE HOUSING
22/ 4 1,0 242400744 GEHÄUSEDECKEL HOUSING COVER
22/' 5 1,0 242400164 DECKEL COVER
22/ 6 1,0 242700976 LAMELLENTRÄGER CLUTCH PLATE CARRIER
22/ 7 1,0 242400163 DRUCKPLATTE PRESSURE PLATE
22/ 8 1,0 242400162 RING RING
22/ 10 1,0 242600406 RING WASHER
22/ 12 1,0 242400698 KOLBEN PISTON
22/ 15 1,0 242600348 SCHEIBE WASHER
22/ 33 12,0 506700851 AUßENLAMELLE MULTIPLE DISC "EXTERN" DIN 867-=WEICH=L7,00
22/ 34 11,0 506700886 AUßENLAMELLE MULTIPLE DISC "INTERN" =ENGL.=60G-NUT-L5,50
22/ 35 1,0 506700604 QUADRING QUADRING 189,86X7,00 366 Y-70
22/ 36 1,0 506700605 QUADRING QUADRING 113,66X5,33 366 Y-70
22/ 37 2,0 541200007 STÜTZRING GASKET-RING 10188,00X200,90X2,50
22/ 38 1,0 541200008 STÜTZRING GASKET-RING ID112,50X122,30X1,70
22/ 40 1,0 541000473 O-RING SEALING RING 425 X3 VITON
22/ 41 1,0 541000468 O-RING SEALING RING 200 X3 VITON
22/ 44 1,0 441200414 WELLENDICHTRING SHAFT SEALING RING 130X160X12+2BC FPM
22/ 45 1,0 441100416 WELLENDICHTRING SHAFT SEALING RING 180X210X15 BA NBR DIN3760
22/ 46 1,0 441100697 WELLEN-DICHTRING SHAFT SEALING RING 220X250X15 32 NBR DIN3760
DATUM E R S A T Z T E I L - L I S T E ZOLLERN VERTRIEBS-GMBH & CO
-- HEUSTRASSE i
22.08.96 SPARE-PART-LIST D-88518 HERBERTINGEN/WÜRTT.
SEILWINDE ZHP 6.29 062910206 SOPE WINCH GEWICHT ÖLEINFÜLLMENGE

WEICHT OIL QTY
SEITE - 2
XXXXXXXXXX
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
ACHTUNG BEI ERSATZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN
ATTENTION IF YOU ORDER SPARE PARTS PLEASE INDICATE TYPE AND SERIAL NUMBER
xxxxxxxxxxxxxxxxxxxxxxxx^

POS-NO. QTY • PART -NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH TECHNICAL - DATA
22/ 50 1,0 453000028 RILLENKUGELLAGER BALL BEARING 120X180X28 DIN 625

22/ 51 - 1,0 453400117 PENDEL-ROLLENLAGER PENDULUM ROLLER BEARING 180X250X 52 S.MB DIN 635
22/ 58 12,0 404100032 SCHEIBE WASHER DI 10,5/DA 18,0/H1,6 DIN 433
22/ 59 1,0 503200092 SPRENG-RING CIR CLIP SB135*2,5 BOHRUNG
22/ 60 1,0 403100060 SICHERUNGSRING CIR CLIP 120,OOX—,-X 4,00 DIN 471
22/ 61 1,0 403200074 SICHERUNGSRING CIR CLIP — ,-X180,00X 4,00 DIN 472
22/ 62 1,0 403200083 SICHERUNGSRING CIR CLIP 250X5,0 BOHRUNG DIN 472
22/ 63 2,0 503200116 SPRENGRING CIR CLIP S3250*3,0 BOHRUNG
22/ 70 4,0 411230046 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 8X 20 ZN 8.8 DIN 912
22/ 75 12,0 421200378 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 10X110 10.9 DIN 912
22/ 78 1,0 413300003 RING-SCHRAUBE SEALING SCREW M 12 DIN 580
22/ 80 1,0 414030004 VERSCHLUSS-SCHRAUBE SCREW SPINDLE M 16*1,5 ZN DIN 908
22/ 81 1,0 441000211 FLACH-DICHTRING SEALING RING A 16X 20X1,5 DIN7603
22/ 98 2,0 524100006 RÜ.SCHL.VENTIL M 16X1,5 PRESSURE VALVE GEHÄUSE 2BAR ÖFFN.DR
22/200 1,0 540500023 HYDRAULIKSCHLAUCH HYDRAULIC HOSE MIT VERSCHR.BR75L225
24/ 0 1,0 142950141 ANTRIEB DRIVE CPL.
24/ 1 1,0 242400491 BREMSFLANSCH BRAKE FLANGE

24/ 4 1,0 242400677 ANTRIEBSHÜLSE DRIVING SLEEVE
24/ 6 1,0 242400709 HÜLSE SLEEVE
24/ 7 1,0 242400059 MOTORFLANSCH MOTOR FLANGE
24/ 8 1,0 242400068 MOTORFLANSCH MOTOR FLANGE
24/ 19 1,0 242400043 RING RING
24/ 22 12,0 411230354 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 12X140 ZN 8.8 DIN 912
24/ 30 1,0 453000039 RILLENKUGELLAGER BALL BEARING 90X140X24 • DIN 625
24/ 40 1,0 403200066 SICHERUNGSRING CIR CLIP — ,-X140,00X 4,00 DIN 472
24/ 41 1,0 403100054 SICHERUNGSRING CIR CLIP 90,OOX-'-,-X 3,00 DIN 471
24/ 43 2,0 403200029 SICHERUNGSRING CIR CLIP — ,-X 42,OOX 1,75 DIN 472
24/ 50 1,0 441100573 WELLENDICHTRING SHAFT SEALING RING 100X130X12 BA DIN3760
24/ 53 1,0 441100665 WELLEN-DICHTRING SHAFT SEALING RING 110X130X 8 B l DIN3760
24/ 54 1,0 441100687 WELLEN-DICHTRING SHAFT SEALING RING 45X 75X 8 BA DIN3760
24/ 58 1,0 541000314 O-RING SEALING RING 285 X3
24/ 70 10,0 404300224 PASS-SCHEIBE WASHER 28X 40X1,0 DIN 988
24/ 91 1,0 242400492 SCHEIBE WASHER
24/ 95 1,0 506701019 ÖLDRUCKEINHEIT HYDR.-PART FOR DISC BRAKE
HEUSTRASSE 1
22.08.96 S P A R E - P A R T - L I S T • D-88518 HERBERTINGEN/WÜRTT.
>
WEIGHT OIL QTY
SEITE - 3
XXXXXXXXXXXÄXXXXXXÄXXX^XXXXXÄXXX^
ACHTUNG : 3EI ESSATZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN

ATTENTION : "IF YOU ORDER SPARE PARTS PLEASE INDICATE TYPE AND SERIAL NUMBER '
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX^
POS-NR. STOCK TEILE-NR. BEZEICHNUNG - DEUTSCH BEZEICHNUNG - ENGLISCH TECHNISCHE - DATEN

24/ 96 1,0 506700225 LAMELLENTRÄGER CLUTCH PLATE CARRIER

24/ 97 11,0 506700162 AUSSENLAMELLE MULTIPLE DISC "EXTERN"
24/ 98 10,0 506700163 INNENLAMELLE MULTIPLE DISC "INTERN"
Ä
24/120 2,0 524100009 ÖLVENTIL PRESSURE VALVE HUB 3,5-1008050100
2,0 441000213 FLACH-DICHTRING SEALING RING A 18X 22X1,5 DIN7603
W 24/121
38/ 0 1,0 142950140 BREMSWELLE BRAKE SHAFT
38/ 1 1,0 242901366 ZAHNWELLE SHAFT

51/ 0 1,0 143150009 ABSCHLUSSDECKEL COVER
51/ 3 1,0 242700873 DECKEL COVER

51/ 32 1,0 541800021 VERSCHLUSS-STOPFEN SEALING. PLUG
60/ 0 1,0 142950080 ÖLLEITUNG OIL PIPE

60/ 2 1,0 240700141 GEWINDESTUTZEN PIPING PIECES
60/ 3 1,0 540100903 HOHLSCHRAUBE THREADED JOINT CONNECTION DIN 7623-R0HR-D 22
_ 60/ 4 1,0 540200043 RINGSTUTZEN THREADED JOINT CONNECTION DIN 7642
^ 60/ 5 2,0 441000220 FLACH-DICHTRING SEALING RING A 26X 31X2,0 DIN7603
60/ 6 1,0 540500012 HYDRAULIKSCHLAUCH HYDRAULIC HOSE A=26,0 1=19,0 1525-12
60/ 11 1,0 519000035 KREUZ THREADED JOINT CONNECTION 3/4
60/ 12 1,0 540100262 VERSCHRAUBUNG THREADED JOINT CONNECTION R3/4"
60/ 13 1,0 540200012 SCHLAÜCHARMATUR PIPE FIXATION GA 15701-12
60/ 14 1,0 540100982 REDUZIERSTUTZEN .THREADED JOINT CONNECTION RI3/4"Xl/2"
60/ 16 1,0 414030043 VERSCHLUSS-SCHRAUBE SCREW SPINDLE G 1/2 ZN DIN 910
60/ 31 1,0 234200058 ROHR PIPE
60/ 32 2,0 540900020 ROHRSCHELLE CLAMP
60/ 43 1,0 540100904 HOHLSCHRAUBE THREADED JOINT CONNECTION DIN 7643-R0HR-D 15
60/ 44 1,0 540200041 RINGSTUTZEN THREADED JOINT CONNECTION DIN 7642-NW 12-L 71
60/ 46 1,0 540500011 HYDR.-SCHLAUCH THREADED JOINT CONNECTION A=19,0 1=12,7 1525-08
0
60/ 47 1,0 540200008 SCHL.-ARMATUR PIPE FIXATION
60/ 48 1,0 540100910 VERSCHRAUBUNG THREADED JOINT CONNECTION Gl/2"
60/ 49 1,0 519000221 T-STÜCK THREADED JOINT CONNECTION I 3/4"-I l/2"-A 3/4"
60/ 63 1,0 543400071 MEßSTAB OIL DIPSTICK ANSCHL.R3/4" -L=350
HEUSTRASSE 1
22.08.96 S P A R E - P A R T - L I S T D-88518 K E R B E R T I N G S N / W Ü R T T .

WEIGHT OIL QTY
XXÄXXXXXXXXXXXXXXXXXXXXXXXXXXXXX^

ATTENTION : I F YOU ORDER SPARE PARTS PLEASE INDICATE TYPE AND SERIAL NUMBER
XXXXXXXXXXXXXXXXXXXXXXXXÄXXXXXXXXXXXXXX

70/ 0 1,0 100002006 BREMSLEITUNG CONNECTIONS FOR BRAKE
70/ 1 1,0 543400074 ENTLÜFTUNGSVENTIL PRESSURE VALVE 0,02-0,07BAR-EL 4,7 M10*l,0
75/ 0 22,0 100003010 FEDERN SPRINGS
75/ 1 22,0 402100310 DRUCKFEDER SPRINGS
76/ 0 22,0 100003011 FEDERN SPRINGS
77/ 0 38,0 100003018 FEDERN SPRINGS
78/ 0 22,0 100003019 FEDERN SPRINGS

ZOLLERN ZOLLERN
VERTRIEBS- SEILWINDE GETRIEBE
GmbH + Co. Ab t . KD
1. B e s c h r e i b u n g "
D i e Z o l l e r n - S e i l w i n d e b e s t e h t aus e i n e r S e i l w i n d e d e r T y p e n b a u r e i h e ZHP
6... u n d e i n e r F e d e r d r u c k - L a m e l l e n b r e m s e ( F r e i f a l l b e t r i e b s b r e m s e ) für das
k o n t r o l l i e r t e , s c h n e l l e Ablassen d e r L a s t . D i e F r e i f a l l b r e m s e kann m i t
e i n e r k o m p l e t t e n h y d r a u l i s c h e n Steuerung g e l i e f e r t werden.
Die S e i l w i n d e kann a l s k o m p l e t t e E i n h e i t m i t F r e i f a l l b e t r i e b s b r e m s e , i n
e i n e m Windenbock b e f e s t i g t , g e l i e f e r t w e r d e n .
1.1 Seilwinde ZHP 6...
D i e S e i l w i n d e i s t i n k o m p a k t e r B a u k a s t e n - B a u w e i s e a u f g e b a u t . Das
Z o l l e r n - P l a n e t e n g e t r i e b e m i t e i n e r oder mehreren V o r s c h a l t p l a n e t e n s t u f e n
und F e d e r d r u c k - L a m e l l e n b r e m s e ( H a l t e b r e m s e ) i s t i n d e r S e i l t o m m e l
i n t e g r i e r t . D e r Abtriebsplanetenträger i s t m i t dem S t a h l b a u v e r b u n d e n .
Das R e a k t i o n s m o m e n t d e r 2. u n d 3. P l a n e t e n s t u f e w i r d über d i e g e s c h l o s s e n e
F r e i f a l l b r e m s e i n den S t a h l b a u e i n g e l e i t e t . D i e Wälzlager u n d
dieVerzahnungsteile im P l a n e t e n g e t r i e b e sowie d i e Verzahnung der A n t r i e b s -
hülsen - M o t o r w e l l e n v e r b i n d u n g w e r d e n d u r c h T a u c h s c h m i e r u n g s i c h e r m i t öl
v e r s o r g t . Das a b t r i e b s s e i t i g e G e g e n l a g e r i s t m i t e i n e r L a n g z e i t s c h m i e r u n g
v e r s e h e n . D i e öleinfüll- u n d ölablaßstopfen s i n d an d e r vom P l a n e t e n -
g e t r i e b e nach außengeführten Ölleitung. Der ölstand w i r d m i t t e l s
ölmeßstab k o n t r o l l i e r t .
D i e S e i l t r o m m e l kann m i t bzw. ohne S e i l r i l l e n ausgeführt w e r d e n .
1.2 Freifallbremse
M i t d e r F r e i f a l l b r e m s e w e r d e n d i e Innenräder des P l a n e t e n g e t r i e b e s
( R e a k t i o n s m o m e n t ) w a h l w e i s e f e s t g e h a l t e n o d e r gelöst. Im F r e i f a l l b e t r i e b
d r e h t s i c h das P l a n e t e n g e t r i e b e i m B l o c k um das E i n g a n g s s o n n e n r a d . D i e
Außenlamellen a u s S t a h l s i n d i m Bremsgehäuse d u r c h e i n e E v o l v e n t e n -
v e r z a h n u n g g e h a l t e n . Der Stahlträger d e r I n n e n l a m e l l e n i s t m i t e i n e m
S p e z i a l b e l a g bestückt, d e r t r o t z h o h e r t h e r m i s c h e r B e l a s t b a r k e i t e i n
w e i c h e s S c h a l t e n ermöglicht. D i e F r e i f a l l b r e m s e w i r d d u r c h F e d e r k r a f t
g e s c h l o s s e n u n d d u r c h Öldruck geöffnet. Bremsgehäuse u n d I n n e n l a m e l l e n -
träger s i n d k o n s t r u k t i v so g e s t a l t e t , daß das gesamte Kühlöl zwangsweise
das L a m e l l e n p a k e t durchspült. D i e s e r ölkreislauf muß a u c h i m H u b b e t r i e b
und i m S t i l l s t a n d d i e g e s c h l o s s e n e F r e i f a l l b r e m s e kühlen. Ab c a . 30 - 100
b a r ( j e nach A n z a h l d e r D r u c k f e d e r n ) w e r d e n d i e F e d e r n über den K o l b e n
und D r u c k p l a t t e zurückgezogen, d.h. d i e Bremse i s t vollständig gelüftet.
ZOLLERN VERTRIEBS - GmbH + Co.

Heustraße 1
T e l e f o n 07586-59-0, T e l e f a x - K u n d e n d i e n s t 07586-59-710, T e l e x 732 218
Dok.-Nr.: W6701001.S/TXTKD Seite 1

ZOLLERN ZOLLERN
VERTRIEBS- ROPE WINCH GETRIEBE
GmbH + Co. A b t . KD
1. Description
The Z o l l e r n .rope w i n c h c o n s i s t s o f a r o p e w i n c h o f t h e c o n s t r u c t i o n
s e r i e s t y p e ZHP 6... a n d a s p r i n g p r e s s u r e d i s c b r a k e ( f r e e f a l l b r a k e )
f o r a c o n t r o l l e d q u i c k l o w e r i n g o f t h e l o a d . The f r e e f a l l b r a k e c a n b e
d e l i v e r e d w i t h a complete h y d r a u l i c c o n t r o l .
The r o p e w i n c h c a n be d e l i v e r e d as a c o m p l e t e u n i t w i t h f r e e f a l l b r a k e
mounted i n a w i n c h s u p p o r t .
1.1 Rope w i n c h ZHP 6...
The r o p e w i n c h i s c o n s t r u c t e d i n a compact u n i t a s s e m b l y s y s t e m . The

Z o l l e r n p l a n e t a r y g e a r i s i n t e g r a t e d i n t h e r o p e drum w i t h one o r s e v e r a l
superposed p l a n e t a r y stages and s p r i n g p r e s s u r e d i s c brake ( h o l d i n g
b r a k e ) . The o u t p u t p l a n e t a r y c a r r i e r i s c o n n e c t e d w i t h t h e s t e e l
c o n s t r u c t i o n . The r e a c t i o n i m p u l s e o f t h e 2. a n d 3. p l a n e t a r y s t a g e i s
i n t r o d u c e d i n t o t h e s t e e l c o n s t r u c t i o n v i a a c l o s e d f r e e f a l l b r a k e . The
a n t i f r i c t i o n b e a r i n g s a n d t o o t h e d p a r t s i n t h e p l a n e t a r y g e a r as w e l l as
the t o o t h i n g o f t h e d r i v e sleeve and motor s h a f t connection a r e p r o v i d e d
w i t h o i l b y d i p g r e a s i n g . The c o u n t e r b e a r i n g a t t h e o u t p u t s i d e i s
p r o v i d e d w i t h a l o n g - t i m e g r e a s i n g . The o i l f i l i n g a n d o i l d r a i n i n g p l u g s
a r e a t t h e o i l s u p p l y l i n e a t t h e o u t s i d e o f t h e p l a n e t a r y g e a r . The o i l
l e v e l i s c o n t r o l l e d b y means o f a o i l d i p s t i c k .
The r o p e drum c a n be d e l i v e r e d w i t h r e s p . w i t h o u t r o p e g r o o v e s .
1.2 F r e e f a l l brake
The i n n e r w h e e l s o f t h e p l a n e t a r y g e a r r e a c t i o n i m p u l s e a r e b l o c k e d o r
l o o s e n e d on c h o i c e b y means o f a f r e e f a l l b r a k e . I n case o f f r e e f a l l
o p e r a t i o n t h e p l a n e t a r y gear t u r n s i n c l u s t e r around t h e i n p u t sun wheel.
The o u t e r d i s c s o f s t e e l a r e h o l d i n t h e b r a k e h o u s i n g b y an i n v o l u t e
t o o t h i n g . The s t e e l c a r r i e r o f t h e i n n e r d i s c s i s e q u i p p e d w i t h a s p e c i a l
c o a t i n g e n a b l i n g a s o f t s w i t c h i n g i n s p i t e o f h i g h t h e r m i c a l l o a d i n g . The
f r e e f a l l b r a k e i s c l o s e d b y s p r i n g p r e s s u r e a n d opened b y o i l p r e s s u r e .
The b r a k e h o u s i n g a n d t h e i n n e r d i s c c a r r i e r a r e c o n s t r u c t e d i n s u c h a
manner t h a t t h e c o m p l e t e c o o l i n g o i l i s r i n s i n g t h e d i s c s . T h i s o i l
c i r c u l a t i o n has t o c o o l t h e c l o s e d f r e e f a l l b r a k e d u r i n g t h e l i f t i n g and
a t s t o p . A t ab. 30-100 b a r ( d e p e n d i n g o n t h e number o f t h e p r e s s u r e
s p r i n g s ) t h e s p r i n g s a r e r e t r a c t e d v i a t h e p i s t o n and t h e p r e s s u r e p l a t e
i . e . t h e brake i s completely v e n t i l a t e d .
ZOLLERN VERTRIEBS - GmbH + Co.

Heustraße 1
Doc.-No.: W670 2001.S/TXTKD Page 1

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
2. Einbau - und Montageanweisung

Die S e i l w i n d e w i r d a l s k o m p l e t t e E i n h e i t a n g e l i e f e r t .
Zum Einbau d e r Winde müssen A n t r i e b s p a r t i e , Ölleitungen und d i e
F r e i f a l l b r e m s e d e m o n t i e r t werden.
- Z u e r s t Aufnahme-Konstruktion prüfen ( s i e h e E i n b a u z e i c h n u n g ) .
Die Anschraubflächen müssen i n g l e i c h e r Ebene sauber b e a r b e i t e t s e i n .
Demontage
- öleinfüll-, ölablaßleitung demontieren.
(Bohrungen m i t Verschlußschrauben verschließen)
- Komplette A n t r i e b s e i n h e i t abnehmen ( s i e h e Pos. 13 i n d e r

Einbauzeichnung).
- Komplette F r e i f a l l b r e m s e m i t der Bremswelle aus der S e i l t r o m m e l

abziehen.
Montage
A l l e Verbindungsflächen m e t a l l i s c h b l a n k r e i n i g e n . D i e Z y l i n d e r s c h r a u b e n
m i t dem e r f o r d e r l i c h e n Anzugsmoment anziehen und m i t L o c t i t e Typ 242
sichern.
- S e i l w i n d e i n d i e A u f n a h m e k o n s t r u k t i o n e i n f a h r e n und b e f e s t i g e n .
- K o m p l e t t e A n t r i e b s e i n h e i t m o n t i e r e n und m i t Z y l i n d e r s c h r a u b e n
befestigen.
Achtung: Einbaulage i n d e r Einbauzeichnung beachten.

- F r e i f a l l b r e m s e m i t Bremswelle i n d i e S e i l t r o m m e l bzw. Aufnahme-
k o n s t r u k t i o n m o n t i e r e n und b e f e s t i g e n .
Montagehinweis: Zur Montage der B e f e s t i g u n g s s c h r a u b e n für d i e F r e i f a l l -
bremse i s t es u n t e r Umständen e r f o r d e r l i c h das Gehäuse
etwas nach l i n k s , bzw.nach r e c h t s zu drehen.
H i e r z u d i e F r e i f a l l b r e m s e am Druckölanschluß anschließen,
m i t ca.70-100 b a r b e a u f s c h l a g e n und das Gehäuse i n d i e
entsprechende R i c h t u n g drehen.
- Öleinfüll-, ölablaßleitung m o n t i e r e n und am K r a n s c h i l d befestigen.

("Max."- Kerbe am ölmeßstab M i t t e G e t r i e b e ) .
- Getriebeölstand m i t t e l s Ölmeßstab überprüfen. Gegebenenfalls Getriebeöl
nachfüllen ( S o r t e s i e h e W a r t u n g s a n l e i t u n g ) .
- Lamellenbremse (Haltebremse) anschließen und h y d r a u l i s c h lüften.
Antriebshülse muß s i c h l e i c h t durchdrehen l a s s e n .

Heustraße 1

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
- Vor Montage des A n t r i e b s m o t o r s , Verschlußstopfen an der Antriebshülse

e n t f e r n e n und A n t r i e b s m o t o r m o n t i e r e n .
Achtung: Verschlußstopfen wurde n u r a l s T r a n s p o r t s i c h e r u n g verwendet.

Um Passungsrost zu vermeiden und somit dem Verschleiß der
Verzahnung Antriebshülse - M o t o r w e l l e vorzubeugen wurde der
A n t r i e b der S e i l w i n d e so k o n s t r u i e r t , daß d i e Verzahnung d u r c h
Tauchschmierung ständig m i t Getriebeöl geschmiert w i r d .
- Vor Inbetriebnahme, F r e i f a l l b r e m s e am Druckölanschluß "P" anschließen
und Druckölkammer durch mehrmaliges S c h a l t e n und durch öffnen der
oberen Verschlußschraube entlüften.
- Freifallbremsgehäuse entlüften, d i e Spühlölrücklaufleitung i s t oben,

Anschluß "T", anzuschließen. Der Staudruck d a r f 1,5 b a r n i c h t
übersteigen.
- Um e i n e ausreichende Kühlung der F r e i f a l l b r e m s e zu e r r e i c h e n , muß d i e
Kühlleistung des Kühlers und d i e Öl-Durchflußmenge b e i härterem E i n s a t z
so d i m e n s i o n i e r t werden, daß e i n e öltemperatur am ölrücklauf (gemessen
am A u s t r i t t d e r F r e i f a l l b r e m s e ) von max. 130 Grad C n i c h t überschritten
w i r d . A l s e r s t e r A n h a l t s w e r t für d i e öldurchflußmenge kann 25 b i s 30
l t r / m i n angenommen werden.
- F r e i f a l l b r e m s e h y d r a u l i s c h lüften.
Achtung: Max. Lüftdruck von 100 b a r n i c h t überschreiten.
- S e i l t r o m m e l muß s i c h l e i c h t i n b e i d e D r e h r i c h t u n g e n bewegen l a s s e n .
- S e i l w i n d e m i t laufendem Motor auf F u n k t i o n überprüfen, insbesondere
F u n k t i o n d e r Haltebremse, F r e i f a l l b r e m s e und d i e Steuerung des
Antriebsmotors.
Bei H u b b e t r i e b , N o r m a l b e t r i e b
- Haltebremse geöffnet, Motor i n B e t r i e b , F r e i f a l l b r e m s e geschlossen.
Freifallbetrieb
- F r e i f a l l b r e m s e geöffnet, L a s t w i r d abgesenkt, Haltebremse geschlossen.

- D i e Senkgeschwindigkeit und das Bremsmoment d e r F r e i f a l l b r e m s e w i r d
d u r c h den Lüftdruck am H y d r a u l i k z y l i n d e r d e r F r e i f a l l b r e m s e g e s t e u e r t .
- N i e d e r e r Lüftdruck - max. Bremsmoment, m i t steigendem Lüftdruck
v e r m i n d e r t e s Bremsmoment, größere S e n k g e s c h w i n d i g k e i t .
Wichtiger Hinweis:
F i n d e t e i n A r b e i t e n m i t d e r Winde im F r e i f a l l b e t r i e b s t a t t , so d a r f d i e
beim Senken d e r Last a u f t r e t e n d e Z u g k r a f t 50% des maximal zulässigen

Heustraße 1
T e l e f o n 07586-59-0, Telefax-Kundendienst 07586-59-710, Telex "732 218

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
Nennseilzuges nicht überschreiten.
- S e i l einfädeln und m i t D r u c k s c h r a u b e n festklemmen.

Druckschrauben entsprechend s i c h e r n .
- Im übrigen v e r w e i s e n w i r a u f d i e t e c h n i s c h e n Angaben u n s e r e r
Einbauzeichnung.

Heustraße 1
Dok.-Nr.: W6501002.S/TXTKD Seite

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
2. I n s t r u c t i o n " f o r d e s i g n and assembly

The rope winch i s d e l i v e r e d as complete u n i t .
For f i t t i n g t h e winch, d i s m a n t l e d r i v i n g p a r t , o i l p i p e s and
free-fall-brake.
- F i r s t check screw-on c o n s t r u c t i o n (see i n s t a l l a t i o n d r a w i n g ) .
The screw-on-surfaces have t o be worked p r o p e r l y t o t h e same l e v e l .
Disassembly
- Remove o i l f i l l i n g and o i l d r a i n l i n e ,
( l o c k b o r i n g s w i t h s e a l i n g screws)
- Disassemble complete d r i v i n g u n i t (see pos. 13 on o u r i n s e r t d r a w i n g ) .

- Draw o f f complete f r e e - f a l l - b r a k e w i t h b r a k e - s h a f t o u t o f t h e c a b l e
drum.
Assembly
Clean m e t a l l i c a l l y p o l i s h e d a l l c o n n e c t i n g s u r f a c e s . Screw up t h e
c y l i n d e r screws w i t h t h e necessary t i g h t e n i n g t o r q u e and secure them w i t h
L o c t i t e t y p e 242.
- Descend and f i x rope w i n c h t o screw-on construction
- Mount complete d r i v i n g u n i t and f i t i t w i t h c y l i n d e r screws.
A t t e n t i o n : Please n o t e f i x i n g p o s i t i o n a c c o r d i n g t o i n s e r t d r a w i n g .
- Mount and f i x f r e e - f a l l - b r a k e w i t h brake s h a f t i n t o t h e c a b l e drum

r e s p . screw-on c o n s t r u c t i o n .
Mountage I n s r u c t i o n s : For t h e f r e e - f a l l - b r a k e , i t may perhaps be

necessary t o t u r n t h e h o u s i n g t o t h e l e f t r e s p .
to t h e r i g h t side.
For t h i s purpose connect t h e f r e e - f a l l - b r a k e t o
t h e o i l p r e s s u r e c o n n e c t i o n p r o v i d e i t w i t h ab
70-100 b a r and t u r n t h e h o u s i n g t o t h e
corresponding d i r e c t i o n .
- Mount o i l f i l l i n g and o i l d r a i n l i n e and f i x i t a t t h e crane p l a t e
("max" - groove a t o i l d i p s t i c k i n t h e mid o f g e a r ) .
- Check gear o i l l e v e l w i t h o i l d i p s t i c k . F i l l i n gear o i l i f necessary

( t y p e i n d i c a t e d on o u r maintenance i n s t r u c t i o n ) .
- Connect m u l t i p l e d i s c b r a k e ( h o l d i n g b r a k e ) and r e l e a s e h y d r a u l i c a l l y .
D r i v e s l e e v e s h o u l d be e a s i l y t u r n a b l e .
- B e f o r e mountage o f t h e d r i v e motor, remove l o c k i n g p l u g f r o m the drive
s l e e v e and mount d r i v e motor.

Heustraße 1
Doc.-No.: W6502002.S/TXTKD Page 1

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
A t t e n t i o n : The p l u g was o n l y used f o r t r a n s p o r t s e c u r i t y . To

a v o i d r u s t and t o p r e v e n t the waste o f t h e gear t e e t h
d r i v e sleeve - motor f l a n g e , t h e d r i v e o f the winch
was c o n s t r u c t e d i n such a manner t h a t t h e gear t e e t h
are always l u b r i c a t e d w i t h gear o i l by splashed l u b r i c a t i o n .
- B e f o r e t a k i n g i n t o o p e r a t i o n , f r e e f a l l brake has t o be connected on

t h e s i d e t o t h e o i l - p r e s s u r e p i p e and t h e o i l p r e s s u r e chamber r e l e a s e d
by commanding s e v e r a l times and by opening t h e above s e a l i n g screws.
- Free f a l l brake housing has t o be r e l e a s e d , back-flowing-wash-oil-pipe

has t o be connected above. Back p r e s s u r e may n o t exceed 1,5 bar.
- I n order t o get a s u f f i c i e n t c o o l i n g o f the f r e e f a l l brake, t h e

c o o l i n g e f f i c i e n c y o f the c o o l e r and t h e o i l f l o w q u a n t i t y must by hard
employment be c a l c u l a t e d so t h a t t h e o i l - t e m p e r a t u r e a t t h e o i l r e t u r n
f l o w (measured on t h e o u t p u t o f t h e f r e e - f a l l - b r a k e ) does n o t exceed
t h e maximum o f 130 degrees C. As f i r s t r e f e r e n c e v a l u e o f t h e o i l f l o w
q u a n t i t y t a k e 25 t o 30 l i t r . / m i n .
- Release f r e e - f a l l - b r a k e h y d r a u l i c a l l y .
A t t e n t i o n : The maximum r e l e a s i n g p r e s s u r e o f 100 b a r s may n o t be
exceeded.
- Cable drum s h o u l d be e a s i l y t u r n a b l e i n b o t h d i r e c t i o n s .
- Rope winch has t o be checked w i t h r u n n i n g motor r e g a r d i n g t o f u n c t i o n ,
e s p e c i a l l y f u n c t i o n o f h o l d i n g brake, f r e e - f a l l and command o f t h e
d r i v e motor.
D u r i n g h o i s t i n g and normal o p e r a t i o n
- H o l d i n g brake opened, motor r u n n i n g , f r e e - f a l l - b r a k e s h u t .
During free-fall-operation
- F r e e - f a l l - b r a k e opened, l o a d i s lowered down, h o l d i n g brake i s s h u t .

- The l o w e r i n g speed and t h e b r a k i n g t o r q u e o f t h e f r e e - f a l l - b r a k e i s
commanded by t h e r e l e a s i n g p r e s s u r e o f t h e h y d r a u l i c c y l i n d e r a t t h e
free-fall-brake.
- Lower r e l e a s i n g p r e s s u r e - maximal b r a k i n g t o r q u e , w i t h i n c r e a s i n g
r e l e a s i n g p r e s s u r e - reduced b r a k i n g t o r q u e , g r e a t e r l o w e r i n g speed.
Urgent Note
I n case a f r e e - f a l l o p e r a t i o n i s r e a l i z e d w i t h t h e winch t h e t r a c t i v e
power o c c u r i n g when l o w e r i n g t h e l o a d may n o t exceed 50% o f t h e max.
admissable i n d i c a t e d rope t r a c t i o n .

Heustraße 1
T e l e f o n 07586-59-0, T e l e f a x - K u n d e n d i e n s t 07586-59-710, Telex 732 218

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
- I n t r o d u c e rope and f i x w i t h p r e s s u r e screws.

The screws a r e t o be secured.
- Furthermore we p o i n t o u t t o t h e t e c h n i c a l d a t a i n o u r i n s t a l l a t i o n
drawing.

Heustraße 1

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
Wartungsanleitung
Schmierung
Das Z o l l e r n - S e i l w i n d e n p l a n e t e n g e t r i e b e h a t Tauchschmierung.
Ölfüllung ab Werk : AVIA Getriebeöl Hypoid 90 EP.

Auswahl nach DIN : DIN 51502.
Bezeichnung : Schmieröl, DIN 51517-CLP 220.
Die Öleinfüllmenge i s t a u f dem T y p e n s c h i l d v e r m e r k t . Wird das G e t r i e b e
ohne öl a u s g e l i e f e r t , i s t m i t einem A u f k l e b e r d a r a u f hingewiesen.
Das a b t r i e b s e i t i g e F l a n s c h l a g e r i s t m i t S c h m i e r f e t t gefüllt.
Fettfüllung ab Werk : AVIA A v i a l i t h 2 EP
Bezeichnung nach DIN: S c h m i e r f e t t , DIN 51825 - KP2K.
Da Langzeitfüllung, b r a u c h t d i e s e Fettfüllung n i c h t ergänzt oder
ausgetauscht zu werden.
Das Bremsgehäuse d e r F r e i f a l l b r e m s e muß immer vollständig m i t öl gefüllt
bzw. durchgespült werden, d e r Druck d a r f jedoch 1,5 b a r n i c h t übersteigen.
Geeignet s i n d grundsätzlich handelsübliche Hydrauliköle, bezüglich

R e i b w e r t v e r h a l t e n , Ölkohlebildung, Schaumbildung usw.
Besonders g e e i g n e t :
Automatic-Transmissions-Fluid (ATF).
Empfehlung für Wartungstermine

Öl-Kontrolle: Wöchentlich.
Nach längerer S t i l l s t a n d z e i t - v o r Wiederinbetriebnahme.
Ölstand : Das Getriebeöl muß b i s z u r MIN./ MAX.-Markierung am
Ölmeßstab eingefüllt s e i n .
Der ölstand d a r f n u r b e i s t i l l s t e h e n d e m G e t r i e b e
geprüft werden.
Ölwechsel : Nach 200, dann a l l e 2000 B e t r i e b s s t u n d e n , mindestens jedoch
1 x jährlich.
Ölwechsel möglichst i n betriebswarmen Zustand vornehmen.
Es i s t sehr zu empfehlen, b e i n i e d r i g e n
Umgebungstemperaturen m i t e i n e r erwärmten Teilmenge Neuöl
zu spülen, d a m i t möglicher A b r i e b bzw. V e r u n r e i n i g u n g e n
abfließen können.

Heustraße 1
T e l e f o n 07586-59-0, Telefax-Kundendienst 07586-59-710, Telex 732 218
Dok.-Nr.: W6001006. S'/TXTKD Seite

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
Maintenance I n s t r u c t i o n s
Lubrication
The Z o l l e r n - r o p e winch p l a n e t a r y gear has splashed l u b r i c a t i o n .
O i l f i l l i n g ex f a c t o r y : AVIA gear o i l Hypoid 90 EP.
Choice a c c o r d i n g t o DIN : DIN 51502.
D e s c r i p t i o n a c c o r d i n g t o DIN: O i l , DIN 51517-CLP 220.
The o i l q u a n t i t y t o f i l l i n i s mentionned on t h e name p l a t e .
I f t h e gear i s d e l i v e r e d w i t h o u t o i l we p o i n t o u t t o t h a t w i t h a s t i c k e r .
The f l a n g e b e a r i n g on t h e d r i v i n g s l i d e i s f i l l e d w i t h grease.
Grease f i l l i n g ex f a c t o r y : AVIA A v i a l i t h 2 EP
Choice a c c o r d i n g t o DIN : DIN 51502.
D e s c r i p t i o n a c c o r d i n g t o DIN: Grease, DIN 51825-KP2K.
As i t i s l i f e - t i m e - g r e a s i n g , t h e r e i s no need t o renew o r change i t .
The brake h o u s i n g o f t h e f r e e f a l l brake has always t o be c o m p l e t e l y
f i l l e d o r r i n s e d w i t h o i l , b u t t h e p r e s s u r e may n o t exceed 1,5 b a r .
G e n e r a l l y , a l l commercial h y d r a u l i c o i l s a r e q u a l i f i e d f o r
f r i c t i o n - c o e f f i c i e n t , o i l c o k i n g , foam f o r m a t i o n e t c .
Especially q u a l i f i e d i s :
A u t o m a t i c - T r a n s m i s s i o n s - F l u i d (ATF)
Recommendation f o r maintenance i n t e r v a l s
O i l c o n t r o l : weekly.
A f t e r longer periods o f disuse - before using i t again.
Oil level : The gear o i l has t o be f i l l e d i n up t o t h e min./max. mark a t
t h e o i l s i g h t g l a s s e s . The o i l l e v e l may o n l y be checked
w i t h n o n - r u n i n g gear.
O i l change : a f t e r 200 and t h e n a f t e r 2000 s e r v i c e hours each,

b u t a t l e a s t once a y e a r .
O i l change o n l y w i t h s e r v i c e t e m p e r a t u r e c o n d i t i o n .
I t i s recommended t o r i n s e w i t h a warm p a r t o f new o i l
when ambient t e m p e r a t u r e i s low, so t h a t p a r t i c l e s and
d i r t may f l o w o u t .

Heustraße 1
ZOLLERN Schmierstoffempfehlung ZOLLERN
VERTRIEBS- für ZOLLERN - G e t r i e b e Getriebe
GmbH + Co. Abt. KD
! Schmieröl-Auswahl ! Schmierölauswahl ! S c h m i e r f e t t Auswahl

! nach API GL5 ! nach DIN 51502 ! nach DIN 51502
! Schmieröl ! Schmieröl ! Schmierfett

! SAE 90 J DIN 51517-CLP 220 ! DIN 51825-KP2K
ARAL ! A r a l Getriebeöl I BG 220 ! A r a l F e t t HLP 2

! HYP 90 !
AVIÄ ! A v i a Getriebeöl ! RSX 220 ! A v i a A v i a l i t h 2 EP

! Hypoid 90 EP !
BP ! BP Hypogear EP 90 ! GR-XP 220 ! BP Energr. LS EP 2
CASTROL ! C a s t r o l EPX 90 ! Alpha SP 220 ! C a s t r o l Spheerol EPL 2

! Grease
ELF ! T r a n s e l f Typ B ! R e d u c t e l f SP 220 ! ELF Epexa 2

! SAE 90 !
ESSO ! Esso Getriebeöl ! Spartan EP 220 ! Esso Beacon 2 EP

! GX-D90 !
FUCHS ! Fuchs Getriebeöl ! Compound 106 ! Fuchs R e n o l i t FEP 2

! Renogear Hypoid 901 VG 220
GULF ! G u l f M u l t i - P u r p o s e ! EP L u b r i c a n t . G u l f Crown Grease No.2

! Gear L u b r i c a n t ! HD 220
! SAE 90 !
MOBIL ! Mobilube HD-A 90 ! M o b i l g e a r 630 ! Mobilux 2 EP
SHELL ! S h e l l S p i r a x MB 90! Omala 220 ! S h e l l A l v a n i a EP 2
Ölwechsel- und F e t t s c h m i e r i n t e r v a l l e s i e h e W a r t u n g s a n l e i t u n g .

Heustraße 1
Dok.-Nr.: SCHMIERD.1/TXTKD Seite 1

ZOLLERN RECOMMENDATION FOR LUBRICANTS ZOLLERN
VERTRIEBS- FOR ZOLLERN - GEARS Getriebe
GmbH + Co. Abt. KD
! Choosen a c c o r d i n g ! Choosen a c c o r d i n g Choosen a c c o r d i n g

! t o API GL5 ! t o DIN 51502 ! t o DIN 51502
! Oil ! Oil ! Grease

! SAE 90 ! DIN 51517-CLP 220 ! DIN 51825-KP2K
ARAL ! A r a l Gear o i l ! BG 220 ! A r a l Grease HLP 2

! HYP 90 !
AVIA ! A v i a Gear o i l ! RSX 220 . A v i a A v i a l i t h 2 EP

! Hypoid 90 EP !
BP ! BP Hypogear EP 90 ! GR-XP 220 . BP Energr. LS EP 2
CASTROL ! C a s t r o l EPX 90 ! Alpha SP 220 . C a s t r o l Spheerol EPL 2

. Grease
ELF ! T r a n s e l f Typ B ! R e d u c t e l f SP 220 . ELF Epexa 2

! SAE 90 !
ESSO ! Esso Gear o i l ! Spartan EP 220 . Esso Beacon 2 EP

! GX-D90 !
FUCHS ! Fuchs Gear o i l ! Compound 106 . Fuchs R e n o l i t FEP 2

! Renogear Hypoid 90! VG 220
GULF ! G u l f M u l t i - P u r p o s e ! EP L u b r i c a n t . Gulf Crown Grease No.2

I SAE 90 !
MOBIL ! Mobilube HD-A 90 ! M o b i l g e a r 630 . Mobilux 2 EP
SHELL ! S h e l l S p i r a x MB 90! Omala 220 . S h e l l A l v a n i a EP 2
O i l change and g r e a s i n g i n t e r v a l s see maintenance instruction.

Heustraße 1
Doc.-No.: SCHMIERE.1/TXTKD Page 1

ZOLLERN ZOLLERN
VERTRIEBS- Anweisung für G e t r i e b e i n s p e k t i o n GETRIEBE
GmbH + Co. Abt. KD
1. I n s p e k t i o n s i n t e r v a l l e
A l l e 1000 B e t r i e b s s t u n d e n , mindestens 1 mal jährlich s o l l t e das
abgelassene Getriebeöl geprüft werden. Für e i n repräsentatives ölmuster
i s t es zweckmäßig, das öl i n betriebswarmem Zustand abzulassen.
2. Prüfung
Zur Überprüfung, ob im G e t r i e b e e i n e ausreichende ölmenge vorhanden war,
s o l l die. Menge des abgelassenen Öles m i t d e r vorgeschriebenen ölmenge
v e r g l i c h e n werden. D i e v o r g e s c h r i e b e n e Ölmenge i s t aus dem T y p e n s c h i l d
des G e t r i e b e s oder d e r W a r t u n g s a n l e i t u n g zu entnehmen.
3, Prüfung a u f Ölfärbung
Wenn das Gebrauchtöl e i n e dunkle,- schwarze Färbung a u f w e i s t , s i n d im

B e t r i e b Temperaturen von über 100 Grad C, a u f g e t r e t e n , A l s Folge t r i t t
verstärkte A l t e r u n g des Öles auf, d i e s b e d e u t e t v e r m i n d e r t e
Schmierfähigkeit. Der Ölwechsel muß dann i n kürzeren I n t e r v a l l e n
durchgeführt werden.
Hat d i e ölprobe e i n e trübe Färbung, kann d i e s a u f eingedrungenes Wasser

h i n w e i s e n . E i n s o f o r t i g e r Ölwechsel m i t mehrmaliger gründlicher Spülung
durch Frischöl muß vorgenommen werden. Es i s t zu empfehlen, das G e t r i e b e
zu demontieren und d i e T e i l e a u f Korrosionsschäden zu überprüfen.
4. Prüfung a u f f e s t e F r e m d s t o f f e
Wir empfehlen e i n e Prüfung d e r F r e m d s t o f f e nach DIN 51592.
Die Probe w i r d , g e g e b e n e n f a l l s u n t e r geringem Erwärmen, i n Reinbenzol
gelöst und über e i n benzolbeständiges f e i n p o r i g e s M e m b r a n f i l t e r
f i l t r i e r t . Der Rückstand w i r d gewaschen, g e t r o c k n e t , gewogen und a l s
Gehalt an f e s t e n F r e m d s t o f f e n angegeben.
Gesamtbeurteilung:
Max. zulässiger F r e m d s t o f f - M a s s e n a n t e i l i s t ca. 0,15 % von d e r
Gesamtölmasse d e r Getriebefüllung. D i e F r e m d s t o f f t e i l e dürfen j e d o c h n u r
aus feinem A b r i e b bestehen ( b i s max. 25 ym). Wird d e r zulässige Wert
n i c h t überschritten kann nach Ölwechsel d e r B e t r i e b des G e t r i e b e s
fortgeführt werden.
Wenn grobkörniger A b r i e b (über 25 ym) oder Abblätterungen von M a t e r i a l

der Zahnflanken f e s t g e s t e l l t werden, i s t unabhängig vom M a s s e n a n t e i l , das
G e t r i e b e zu demontieren. D i e Zahnflanken d e r Zahnräder, insbesondere das
große Sonnenrad d e r A b t r i e b s p l a n e t e n s t u f e i s t durch S i c h t p r o b e zu
überprüfen.

Heustraße 1
Dok.-Nr.: ANWEISD1/TXTKD Seite 1

ZOLLERN ZOLLERN
VERTRIEBS- Anweisung für Getriebeinspektion GETRIEBE
GmbH + Co. Abt. KD
B e i normalem V e r s c h l e i s s und n a c h d e r E i n l a u f p e r i o d e s i n d d i e
R a u h i g k e i t s s p i t z e n vom Z a h n f l a n k e n s c h l e i f e n geglättet und d i e
Z a h n f l a n k e n haben e i n e g l a t t e , h e l l e , glänzende Oberfläche.
B e i a l l e n a n d e r e n Merkmalen, w i e Schleifverschleiß, R i e f e n , F r e s s e n ,
Grübchen, Abblätterungen, R i s s e und p l a s t i s c h e Verformung müssen d i e
Zahnräder g e t a u s c h t werden, bzw. i s t e s dann zweckmäßig, e i n e
Generalüberholung des G e t r i e b e s durchzuführen.

Heustraße 1

ZOLLERN ZOLLERN
VERTRIEBS- I n s t r u c t i o n f o r Gearbox I n s p e c t i o n GETRIEBE
GmbH + Co. Abt. KD
1. Inspection Intervals
The d r a i n e d gearbox o i l s h o u l d be checked e v e r y 1.000 o p e r a t i n g hours,
b u t a t l e a s t once per y e a r . I n o r d e r t o o b t a i n a r e p r e s e n t a t i v e o i l
sample, t h e o i l should be d r a i n e d w i t h t h e gear box a t o p e r a t i n g
temperature.
2. Checking t h e Drained O i l
I n o r d e r t o check whether t h e r e was a s u f f i c i e n t q u a n t i t y o f o i l i n t h e
gearbox, t h e q u a n t i t y o f o i l d r a i n e d has t o be compared w i t h t h e q u a n t i t y
p r e s c r i b e d . The p r e s c r i b e d o i l q u a n t i t y i s i n d i c a t e d on t h e gearbox
r a t i n g p l a t e o r s p e c i f i e d i n t h e maintenance i n s t r u c t i o n s .
3. Checking f o r O i l D i s c o l o u r a t i o n
I f t h e used o i l d i s p l a y s a dark, b l a c k c o l o u r i n g , t h i s i n d i c a t e s t h a t
temperatures o f over 100 degrees C. have o c c u r r e d d u r i n g o p e r a t i o n . As a
consequence, more r a p i d ageing o f t h e o i l o c c u r s , causing reduced
l u b r i c a t i n g p r o p e r t i e s . The o i l change must t h e n be c a r r i e d o u t a t more
frequent i n t e r v a l s .
I f t h e o i l sample has a c l o u d y c o l o u r i n g , t h i s can i n d i c a t e t h e

p e n e t r a t i o n o f water.
An immediate o i l change must be performed and t h e gearbox f l u s h e d o u t

t h o r o u g h l y s e v e r a l times w i t h f r e s h o i l . I t i s t o be recommended t h a t
the gearbox i s disassembled and t h e p a r t s examined f o r c o r r o s i o n .
4. Checking f o r S o l i d F o r e i g n M a t t e r
We recommend t o check f o r f o r e i g n substances r e g a r d i n g DIN 51592.
The sample w i l l be d i s s o l v e d i n pure b e n z o l , i f necessary warm up a
l i t t l e , and t h e n f i l t e r i t t h r o u g h a benzol r e s i s t a n t , f i n e - p o r e d
membrane f i l t e r . The r e s t w i l l be washed, d r i e d , weighed and i n i c a t e d as
amount o f s o l i d f o r e i g n substances.
O v e r a l l Assessment:
The max. p e r m i s s i b l e w e i g h t o f f o r e i g n m a t t e r i s approx. 0.15 % o f t h e
t o t a l weight o f o i l i n t h e gearbox. However, t h e f o r e i g n m a t t e r must
c o n s i s t o n l y o f f i n e a b r a s i o n (up t o max. 25 ym). I f t h e p e r m i t t e d v a l u e
i s n o t exceeded, t h e gearbox can c o n t i n u e t o be operated a f t e r t h e o i l
change.
I f coarse a b r a s i o n (above 25 ym) o r f l a k e s o f m a t e r i a l from t h e p r o f i l e s

of t h e gear t e e t h a r e d i s c o v e r e d , t h e gearbox must be disassembled,
i r r e s p e c t i v e o f t h e amount o f f o r e i g n m a t t e r . The p r o f i l e s o f t h e gear

Heustraße 1
Doc.-No.: ANWEISE1/TXTKD Page 1

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
w h e e l s , i n p a r t i c u l a r t h e l a r g e sun wheel o f t h e o u t p u t p l a n e t a r y g e a r
s e t , s h o u l d be i n s p e c t e d v i s u a l l y . With normal wear and a f t e r t h e
r u n n i n g - i n p e r i o d , t h e rough peaks s h o u l d have been smoothed by t h e
f r i c t i o n between t h e t o o t h p r o f i l e s and t h e p r o f i l e s s h o u l d have a
smooth, b r i g h t , s h i n y s u r f a c e .
I f any o t h e r c h a r a c t e r i s t i c s a r e d e t e c t e d , s u c h a s wear due t o g r i n d i n g ,

s c o r e s , s c u f f s , p i t s , f l a k i n g , c r a c k s or p l a s t i c d i s t o r t i o n , t h e gear
w h e e l s s h o u l d be r e p l a c e d and/or a g e n e r a l o v e r h a u l of t h e gearbox
c a r r i e d out.

Heustraße 1

ZOLLERN Anzugsmoment für Befestigungsschrauben. ZOLLERN
VERTRIEBS- T i g h t e n i n g t o r q u e s f o r screws. GETRIEBE
GmbH + Co. Moment de serrage pour v i s de f i x a t i o n (mN). Abt. KD
Pares de a p r i e t e p a r a t o r n i l l o s de fijación.
Festigkeitsklassen (Reibungszahl 0,125)

strength-class (frictioncoefficient)
Classe de r e s i s t a n c e ( c o e f f i c i e n t de f r i c t . )
Clases de r e s i s t e n c i a ( c o e f i c c i e n t e de f r i c . )
8.8 10.9 12.9

M 4 2,7 Nm 3,8 Nm 4,6 Nm
M 5 5,5 Nm 8,0 Nm 9,5 Nm
M 6 9,5 Nm 13,0 Nm 16,0 Nm
M 8 23,0 Nm 32,0 Nm 39,0 Nm
M 10 46,0 Nm 64,0 Nm 77,0 Nm
M 12 80,0 Nm 110,0 Nm 135,0 Nm
M 14 125,0 Nm 180,0 Nm 215,0 Nm
M 16 195,0 Nm 275,0 Nm 330,0 Nm
M 18 270,0 Nm 390,0 Nm 455,0 Nm
M 20 385,0 Nm 540,0 Nm 650,0 Nm
M 22 510,0 Nm 720,0 Nm 870,0 Nm
M 24 660,0 Nm 930,0 Nm 1100,0 Nm
M 27 980,0 Nm 1400,0 Nm 1650,0 Nm
M 30 1350,0 Nm 1850,0 Nm 2250,0 Nm
Schrauben g e s i c h e r t m i t L o c t i t e Typ 242.

Secured by L o c t i t e Type 242.
F r e i n de v i s p a r L o c t i t e Type 242.
T o r n i l l o s asegurados con L o c t i t e Tipo 242.
Verbindungsflächen an den G e t r i e b e t e i l e n m i t L o c t i t e Typ 640 a b g e d i c h t e t

F i t t i n g s u r f a c e s s e a l e d by L o c t i t e Type 640.
Les s u r f a c e s des elements de f i x a t i o n s o n t assurées p a r L o c t i t e Type 640.
S u p e r f i c i e s de u n i o n hermetizadas con L o c t i t e T i p o 640.
Planflächen an d e r Haltebremse m i t L o c t i t e Type 573 a b g e d i c h t e t .
S u r f a c i n g on brake s e a l e d by L o c t i t e Type 573.
Les s u r f a c e s du f r e i n de r e t e n u e s o n t etanches p a r L o c t i t e Type 573.
S u p e r f i c i e s p l a n a s en e l f r e n o de retención hermetizadas con L o c t i t e
Tipo 573.
Verschraubungsgewinde d e r R o h r l e i t u n g e n und d i e Verbindungsfläche des

A n t r i e b s m o t o r s zum G e t r i e b e m i t L o c t i t e Typ 572 a b g e d i c h t e t .
Screwing o f t h e t u b i n g and t h e c o n n e c t i o n s u r f a c e s o f t h e d r i v i n g motor
t o t h e gear a r e s e a l e d w i t h L o c t i t e t y p e 572.
Raccord a v i s des c o n d u i t e s e t l a s u r f a c e du moteur d'entrainement au
réducteur o n t e t e etanches p a r L o c t i t e t y p e 572.
Rosca d e l r a c o r de l o s tubos y l a s u p e r f i c i e de u n i o n d e l motor de
accionamiento con e l engranaje están estanqueizadas con L o c t i t e
Tipo 572.
A n w e n d e r v o r s c h r i f t e n d e r Firma L o c t i t e beachten.
Note a p p l i c a t i o n i n s t r u c t i o n s o f L o c t i t e .
F a i t e s a t t e n t i o n aux i n s t r u c t i o n s d ' u t i l i s a t i o n de L o c t i t e .
Tenganse en cuenta l a s i n s t r u c c i o n e s de utilización dadas p o r L o c t i t e .

Heustraße 1
Doc-No.: ANZUGSM5/TXTKD Page 1

M E R K B L A T T
über d i e A u f r e c h t e r h a l t u n g d e r B e t r i e b s b e r e i t s c h a f t
von S e i l w i n d e n und Drehwerksgetrieben
1. ) E i n l e i t u n g
Bei d e r k o n s t r u k t i v e n A u s l e g u n g und Berechnung von Kränen w i r d e i n e Gesamt-

Gebrauchsdauer (Lebensdauer) zu Grunde g e l e g t . D i e verwendeten A g g r e g a t e ,
wie' u.a. Seilwinden und D r e h w e r k s g e t r i e b e , werden e b e n f a l l s u n t e r Berücksich-
t i g u n g der E i n s c h a l t d a u e r und der B e l a s t u n g s a r t ( L a s t - K o l l e k t i v ) a u f e i n e
z e i t l i c h begrenzte, t h e o r e t i s c h e Lebensdauer d i m e n s i o n i e r t . Wenn e i n Kran oder
e i n e S e i l w i n d e z.B. m i t einem härteren B e l a s t u n g s k o l l e k t i v b e t r i e b e n w i r d a l s
für d i e Auslegung angenommen, kann d i e Gesamt-Gebrauchsdauer s t a r k verkürzt
werden. Auch d i e B e t r i e b s t e m p e r a t u r (» öltemperatur) h a t z.B. e b e n f a l l s e i n e n
s e h r s t a r k e n Einfluß a u f d i e Schmierfähigkeit und Lebensdauer des Öles und
d a m i t auf d i e Lebensdauer e i n e s P l a n e t e n g e t r i e b e s .
Zur A u f r e c h t e r h a l t u n g d e r B e t r i e b s s i c h e r h e i t müssen deshalb vom K r a n b e t r e i b e r ,

neben der gründlichen Wartung, b e r e i t s v o r E r r e i c h e n d e r t h e o r e t i s c h e n Gesamt-
Gebrauchsdauer r e c h t z e i t i g vorbeugende "Instandhaltungs-Maßnahmen" e i n g e l e i t e t
werden.
2.) Vorbeugende Instandhaltung
2.1) VersenIeiBkontroHe PIanetengetrrebe
In unserer "Anweisung für G e t r i e b e l n s p e k t i o n e n " haben w i r w i c h t i g e H i n w e i s e

bezüglich öifärbung und f e s t e Fremdstoffe gegeben bzw. Konsequenzen aus dessen
Ergebnissen empfohlen.
Z w i s c h e n z e i t l i c h g i b t es g u t p r a k t i k a b l e Möglichkeiten, k u r z f r i s t i g genaue
ölanalyseo beim " S p e z i a l i s t e n " durchführen zu lassen.
Fa. WEARCHECK GmbH, 83098 Brannenburg, i s t e i n e unabhängige Faml I i e n g e s e i I s c h a f t ,

d i e m i t modernsten Analysen-Automaten und z u g e s c h a l t e t e r Datenbank I n n e r h a l b
von 2-3 Tagen ölanalysen durchführt.
D i e ölanalyse g i b t Aufschluß über Menge und A r t von Verschleißmetallen,

A d d i t i v e , V e r u n r e i n i g u n g e n und ölzustand, dessen Gesamtergebnis nochmals
a l l g e m e i n verständlich i n t e r p r e t i e r t w i r d .
WEARCHECK GmbH a r b e i t e t im Verband und i n ständigem E r f a h r u n g s a u s t a u s c h m i t dem

WEARCHECK-Labor i n USA, Kanada, England, Südafrika, A u s t r a l i e n , B e l g i e n und
Spanien.
(Nähere Hinwelse e r h a l t e n S i e von Wearcheck

T e l . 08034-1690 - Fax. 08034-1699)
- 2 -
- 2 -
2.2) V e r s c h l e i B k o n t r o l l e Z a h n p r o f i l W e l l e
HydrauIi kmotor/AntrIeb PIanetenqetrIebe
Im Z a h n p r o f i l b e i d e r T e i l e e n t s t e h e n durch Schwingungen k l e i n s t e R e l a t i v -
bewegungen, d i e zum Verschleiß ( R e i b k o r r o s i o n , Passungsrost) führen können.
Insbesondere b e i extremen B e t r i e b s b e d i n g u n g e n , z.B. G r e i f e r b e t r i e b , C o n t a i n e r -
b e t r i e b m i t hoher V o l l a s t e i n s c h a l t d a u e r usw., kann nach längerer B e t r i e b s d a u e r
s t a r k e r Verschleiß a u f t r e t e n . D i e r e s t l i c h e n v e r b l e i b e n d e n schmalen Z a h n p r o f i l e
können u.U. das v o l l e Motormoment n i c h t mehr übertragen bzw. d i e Zähne werden
abgeschert.
Deshalb w i r d d r i n g e n d empfohlen, spätestens nach ca. 3000 B e t r i e b s s t u n d e n den

Verschleiß d e r Z a h n p r o f i l e durch Demontage d e r Ölmotoren zu prüfen. Wenn k e i n
oder nur g e r i n g e r Verschleiß f e s t g e s t e l l t wurde, s o l l t e d i e s e Prüfung i n an-
gemessenen Zeiträumen (z.B. jährlich) w i e d e r h o l t werden, um e i n e n genaueren
Aufschluß über den VersohIeißfortschritt zu e r f a h r e n .
S o l l t e durch Verschleiß, gegenüber dem Neuzustand, mehr a l s ca. 30% d e r Zahn-

b r e i t e abgetragen s e i n , muß e i n Austausch d e r T e i l e e r f o l g e n .
In diesem F a l l e empfehlen w i r den Einbau e i n e r öl geschmierten Z a h n p r o f i I - V e r -

bindung. Den hierfür e r f o r d e r l i c h e n Umbausatz e r h a l t e n S i e b e i Angabe des
G e t r i e b e t y p e s und d e r Serien-Nummer bei u n s e r e r S e r v i c e - A b t e i l u n g .
2.3) Verschleißkontrolle SeIItrommeIIager
Bei der m o t o r s e i t i g e n S e i I t r o m m e l l a g e r u n g werden r e i c h l i c h d i m e n s i o n i e r t e

Nadellager, f l a n s c h s e i t i g P e n d e l r o l l e n l a g e r verwendet. Für d i e Lebensdauer
d i e s e r Wälzlager I s t d i e regelmäßige Nachschmierung entsprechend den v o r g e -
schriebenen S c h m i e r i n t e r v a I I e n von e n t s c h e i d e n d e r Bedeutung.
Bei der m o t o r s e i t i g e n Lagerung w i r d d e r Raum zwischen I n n e r e r D i c h t u n g und

äußerer L i p p e n d i c h t u n g m i t A l t f e t t gefüllt. Bei d e r gegenüberliegenden
F l a n s c h l a g e r u n g b i l d e t das ausgepreßte A l t f e t t e i n e n F e t t k r a g e n . E i n e U n t e r -
suchung d i e s e s A l t f e t t e s h i n s i c h t l i c h Färbung, A b r i e b und F r e m d s t o f f e liefert
frühzeitig w i c h t i g e Hinweise über den Zustand und Verschleiß des Lagers. Eine
zusätzliche Überprüfung des L a g e r s p i e l e s g i b t e b e n f a l l s Aufschluß über einen
möglichen Verschleiß des Lagers.
Das normale S e i I t r o m m e l l a g e r s p i e l beträgt zwischen 0,2 - 0,4 mm j e nach S e i l -
windengröße.
Achtung:
Bei w e i t f o r t g e s c h r i t t e n e m Verschleiß des m o t o r s e i t I g e n S e i I t r o m m e l l a g e r s e n t -
stehen zusätzliche, erhöhte Kräfte an d e r Schraubverbindung zwischen Seiltrommel
und P l a n e t e n g e t r i e b e .
- 3 -
- 3 -
3.) V o r t e i l e f ü r den G e r ä t e - B e t r l e b e r :
Wertvolle, frühzeitige Informationen über den Zustand der Planetengetriebe

und Sei Itrommel lagerung lassen l a n g f r i s t i g e Planungen und Dispositionen
für preiswerte Instandsetzungen vor dem Maschinenausfall zu. Teure S t i l l -
standzeiten zu ungeeigneten Zeitpunkten werden vermieden.
Sparen S i e Kosten und Ä r g e r , e r g r e i f e n S i e Maßnahmen
zur vorbeugenden Instandhaltung 1

S P E C I F I C A T I O N
f o r m a i n t a i n i n g the operatIng c o n d i t i o n of
rope winches and gear boxes
1.) I n t r o d u c t i o n
The c o n s t r u c t i v e i n t e r p r e t a t i o n and c a l c u l a t i o n o f cranes i s based on a t o t a l

o p e r a t i o n p e r i o d ( l i f e t i m e ) . The used a g g r e g a t e s such as rope winches and gear
boxes are a l s o dimensioned t o a temporary l i m i t e d , t h e o r e t i c a l l i f e t i m e con-
s i d e r i n g t h e i r o p e r a t i n g p e r i o d and k i n d o f l o a d i n g ( l o a d c o n t r o l ) . In case a
c r a n e o r a rope winch i s o p e r a t e d by g r e a t e r loads t h a n dimensioned, t h i s may
considerably shorten the t o t a l operation p e r i o d . Also the operation temperature
(» o i l temperature) has g r e a t I n f l u e n c e t o l u b r i c i t y and o i l l i f e t i m e and so t o
t h e l i f e t i m e of t h e p l a n e t a r y gear.
For m a i n t a i n i n g t h e o p e r a t i n g s e c u r i t y , t h e c r a n e o p e r a t o r has - b e s i d e s t h e
c a r e f u l maintenance - t o t a k e p r e v e n t i v e "maintenance measures" i n t i m e ,
b e f o r e t h e t h e o r e t i c a l t o t a l o p e r a t i o n p e r i o d w i l l be reached.
2.) Prevent i ve ma intenanc e
2.1) Wear c o n t r o l o f p l a n e t a r y gear
Our " I n s t r u c t i o n f o r gear i n s p e c t i o n " g i v e s I m p o r t a n t r e f e r e n c e s as t o o i l

c o l o r and s o l i d i m p u r i t i e s r e s p . recommends consequences o f t h e i r r e s u l t s .
Meanwhile t h e r e are p r a c t i c a b l e p o s s i b i l i t i e s t o I n s t r u c t immediate e x a c t o i l

analysises at " s p e c i a l i s t s " .
Messrs. WEARCHECK GmbH, 83098 Brannenburg, i s an independent f a m i l y company

who makes o i l a n a l y s i s e s w i t h i n 2-3 days w i t h l a t e s t apparatuses and connected
d a t a bank.
The o i l a n a l y s i s g i v e s e x p l a n a t i o n on q u a n t i t y and t y p e of a b r a s i o n m e t a l s ,
a d d i t i v e s , i m p u r i t i e s and o i l s t a t u s . I t s t o t a l r e s u l t w i l l be e x p l a i n e d
g e n e r a l l y i n t e l l i g i b l e once more a f t e r w a r d s .
WEARCHECK GmbH i s w o r k i n g In a s s o c i a t i o n and s t e a d y exchange o f e x p e r i e n c e w i t h

WEARCHECK Labours in USA, Canada, Great B r i t a i n , South A f r i c a , A u s t r a l i a ,
Belgium and Spain.
(For f u r t h e r d e t a i l s c o n t a c t Wearcheck - Phone 08034-1690 - Fax 08034-1699)
- 2 -
- 2 -
2.2) Wear control tooth profile shaft

hydraulic motor/drive planetary gear
Oscillations cause smallest relative movements in the tooth profile which may
imply their wear (fretting corrosion). Especially under extreme working conditions,
e.g. service with grabs, containers with high full load operation etc., strong
wear may occur after a longer service period. The remaining weakened cross-
sections of the tooth profiles may probably no more transfer the full motor
torque resp. the teeth are sheared off.
Therefore we recommend to dismantle the oil motors and check the wear of the
tooth profile after about 3000 working hours. In case there is no or less wear,
this inspections should be repeated in adequat periods (e.g. annually) in order
to get an exact information concerning the progress of wear.
In case such wear should have caused a reduction of the tooth thickness of more
than appr. 30% against to new ones, the parts must be exchanged.
In this case we recommend to mount an oil lubricated tooth profile connection.

You can get this conversion-set from our service department by Indicating them
the gear type and its serial number.
2.3) Wear control cable drum bearing

For the cable drum bearing on the motor side ample dimensioned needle bearings
and self-aligning roller bearings on flange side are used. It is very important to
grease them regularly according to the indicated greasing intervals.
Regarding the bearing on motor side the space between Inner seal and outer lip
seal Is filled with old grease. At the opposite flange bearing, the extruded
old grease builds up a grease collar. An inspection of this old grease concerning
color, abrasion and foreign materials gives important references about the
status and wear of the bearing early in time. An additional inspection of
bearing clearance gives references concerning a probable wear of i t . The usual
cable drum bearing clearance is 0,2 - 0,4 mm, depending on the rope winch size.
AttentI on:
In case the cable drum bearing on motor side is much worn, there occur additional
elevated forces at the screw connection between cable drum and planetary gear.
- 3 -
- 3-
3.) Advantages for the operator:

Useful information in time concerning the condition of planetary gear and
cable drum bearing means long-termed plannings and disposals for reasonable
repairs before their total breakdown. Expensive periods of disuse to un-
suitable times can so be avoided.
Avoid expenses and worry - take measures
to prevent i ve ma Intenance !
BAUER
C AUXILIARY WINCH MANUAL

Z O L L E R N S E R V I C E BLATT
SERVICE FORM
FEUILLE DE SERVICE
G e t r i ebi T y p ZHE» 4-
Gear Type
Réducteur Type
Geräte 4 . 2 2 1 0 0 9V
Aggregat No.
Appareil No.
S e r i &xi 1ST: I S O 1 6 3
Serial No.
Serie No.
Auf -trag-! Nxr - 6 / 5 1 2 2 5 v o m 3 1 O 1 -9 6

Order No. 6/50942,6/44692,6/44584
Commande No.
Firma Bauer S p e z i a l t i e f b a u GmbH

Company
Société
Anschrift Postfach 1260

Adress D-86522 Schrobenhausen
Adresse
Abteilung zu Hdn. Frau Ostermeier

Department
Service
Bestell- Nr.: 1122589 vom 06.10.95 Firmen Nr.

Order- No.: 1122474 vom 31.08.95 Company No.
Commande- No.: 1121756 und 1121685 S o c i e t e No.
Geräte Type : Sach Nr. 215064

Aggregat Type: Ident. No.
Appareil Type: Produit No.
Bau/Komm. Nr. Pos. Nr.

Constr. No. Pos. No.
Constr.Spec. No.: Rep. No.
Projekt Nr. :
Project No. :
Proj e t No. :

Heustraße 1
D-88518 Herbertingen
Telefon 07586-59-0, Telefax-Service-Dep. 07586-59-710, Telex 732 218
Lieferumfang: 5-fach d e u t s c h / e n g l i s c h
Doc.-No. : 190011133/SB 04.04.96 We/KD
WINDEHLAENGE OHME F L A N ^ ^ 6 4 1 134 EINZELHEIT Z
1 t U l N rjLiic L»AÍL.\ I i , K U .
- l _
N E N N S E I L Z U G All D E R ! R O M M E L III LAC f
W INCH LENGTH WITHOUT F* DETAIL Z
ROPE LOAD AT THE DRUM III L A * Ii
Ii ) 75 :.oj •
i
1
1
1
ABTRIEBSDREHMOMENT OUIPUT IORCUE T «8 (NU» 15 ODD
ABTRIEBSDREHMOMENT OUTPUT IORCJ.F. 5IAI. T AB (NU) 30 s e a - -
'
ANTR1EBSOREHMOMENT INPUT IGPQUE I AN im t ••CO
J4. SE 1 L C E S C H W 1 N D 1 G K E 1 T III : •G E ROPE V tO I N L ' I E P i (u UIN; 50 ICC! !
ABTRIEBSOREH:MIL CJIPUI STEEG II A3 ( u m - : ) 40 a."
ANIRIEBSDREHZAHL INCUT sprro II AN (UKI-I t 1 J70-íí5tf
ANTRIEDSDREHZAIIL "INPUT SFEFU" LIA' II AN
UEBEI'.SETZUIIC P A : IO 1 2'.*
SEILRILLENSltIGUNC RF'-HT-; U
ROPE GROOVE PITCH RIGI.I HAND JQI
RILLUNG NÚNBALJ;. SOiiBtP I
GROOVE SYSTEM SPlClil *i m a '
ia»M»L I"I
SEIL 0 ANZAHL O I R -5EILLACEN
ROPE 0 [ HuuflEP OF PLI'E LAYERS
NUTZBARE SEILLAENCE USEABLE "PlV* ~ï7i?~ûl
SICHERHEI TS*INDUNGEN LAEIIGE ANZJIIL
DEAO END TURNS LENGTH MJUÖER
PARKING BRAKE
FEDERN PRO BREMSE SPRINGS PER ONE BRAKE GRIICPÎTGHY
REIBFLAECHEN AUSSENLAMELLEN INIII'NL A M E L L E N
F R I C T I O N SURFACE EXTERNAL D I S C S INTERNAL D I S C S HS
LUEFTEHDDRUCK P R E S S . A T EIIO O F B R A K E R E L E A S E |MIN|MAX
STAUDRUCK BACK PRESSURE
MO .2 I AB h D Y N A M I S C H E S BREMSMOMENT BEI H A S S l AUF

T DYN (NM)
DYNAMIC BRAKING TORQUE .ET R U N N I N G
S T A T I S C H E S BREMSMOMENT BEI NASSLAUF TROCKENLAUF
T STAT (NU)
STATIC B R A K I N G T O R Q U E .ET RUHNINC OPT RUNNING
MOTOR - HYDRAULISCH
MOTOR - ELEKTRISCH
ANTRIEBSWELLE TRECKEN OR'
NASS 'EI |ïïr
INPUT SHAFT WELLEN 0 SHAFT 0 | ZAEIINE7AHL TEETH
LAENGENABSTAHD LINEAR MEASURE MINJMIN X/Y (IN)
D R E H S I N N : A N T R I E B ZU A B T R I E B ENTGEGENGESETZT
SENSE OF ROTATION i INPUT TO OUTPUT OPPOSITE SENSE
TROMMEL-WERKST OFF POPE DRUM LU IFR I AL
MASSE OHNE AHTRIEBSUOIOR UASS • i rilOUT MOTOR 1K0I I
TRANSMISSION i
ANSICHT
GETRIEBEC€L= SFEZ. UIL-llO!c EHSPIECHEiC SA£ >
'
ERFORDERLICHE FUELLMENGE OUANTIIY HEQJESIED
VIEW X CREASE ACC. DIN
AUSLEGUNG FEM
L2 / M6 / T6
LAYOUT ACC. FEM
50
ACHTUNG: MOTORFLANSCH NACH AIIBAU DES

HYDR. MOTORS MIT ATE O E L FUELLEII
CA 0 . 2 LTR.
GETR I EBE-MOTORWELLF. MASSLAUF
GETRENNTER OELHAUSMALT
C P L . I N P U T DRIVE CAN 9 E REMOVED FOR THE

INSTALLATION OF THE WINCH B Y RELEASING
THE B CHEESE HEAD SCREWS OF THE OUTER
PARI OF THE MOTOR FLANGEANO ALSO THE
6 UNCOVEREOCHEESE HEAD SCREWS IN THE
LOWER PART OF THE MOTOR FLANGE
TO PROVIOE t HOLE PLACEO ON TOP RESP
BELOW IH MOUNTING STRUCTURE FOR O I L
OUTLET ANO PRESSURE R E L E A S E OF GEAR
F U E R MOTOR 4 . M l 6 / 3 3 T I E F / Z E N T R I E R 0 160 FOR MOTOR 4.M 16/.10 O E E P / C E H I R . 0 180

FLANSCH FUER EINBAU O E R WINDE
ABNEHMBAR
UEBERDRUCKVENTIL 0 . 0 4 DAR PRESSURE VALVE
I SaiUIERNIPPEL DIN 71412 I CREASE N I P P L E TO P I N 7 1 4 1 2
ROHRSCHELLE RAPR 1/2"
AMTRI EB-ARBE I TS'JTELl L'IIG ANTRIEB-TRAHSPORTSTELLUNG OELMESSTAB (WINDENLAGE BEI AUFGER.TURM) O I L MEASURING S T I C K (WINCH POSITION
TOWER I S IN V E I I C A L P O S I T I O N ) ' 0 4 7 3 o_ OEL UND G E W I Ç H I B E R l C H I IGT
IN O P E R A T I O N OURINO T R A N S P O R T ^ ANTR I E B IN
IHBETRIFHHAIIME N U R OELABLASS R 3/8' OIL OUTLET R i / f
un A N i i i i e n III Tr\ X" TRAIISPORTSTELLG. DRUCKOELANSCHLUSS FUER LAMELLENBREMSE HTDRAULIC CONNECTION FOR M U L T I - O l S C 1993
AHBEIT'JSIF.LLUIIG © \ V B E F E F E S T I G T MIT M 1 2 . 1 . 5 / I 2 T I E F - NUR G E F I L T E R T E S O E L BRAKE M 1 2 . 1 . 5 / I 2 OEEP - USE ONLY ZHP 4.2? '.VC
)LLERN -!CE
HTDRAULIC O I L F I L T E R E D - 2 K L f III
SCHRAUBEN VERWENDEN - F I L T E R F E I N H E I T 2 0 - 2 5 u
MESH-SIZE 3 D - » .
BEFESTIGUNG SIEHE GR. S I E H E P O S . ces £INSAIZ
POS. ANSCHLUSS FUER NOCKEN-ENDSCHALTER 3 8 T I E F CONNECTION FOR CAM L I M I T S I I T C H - J I DEEP HEUSIR.I U A S S Ï A B scA-.t
y s E
REVERS 1ER* INDE
TRANSPORT ONLV I N 3.M6 / 15 T I E F TK 0 1 4 5 . Z E N T R I E R . 0 1 2 0 3tM6 / 15 OEEP.PCD 0145.CENTR 0 1 2 0
7944 HERBERT INGE» EZ/A3
S T A R T I N G ONLY I N THIS POSITION
O E L E I N F U E L L U N G - OELMESSTAB
T H I S P C S 11 I ON F I T T I N G WITH TELEFON 07386/591 Ï E I E X 1122*9 lELEfAK 0 7 5 5 8 / 5 9 ! . ^
B O L T S . S I Z E OF U E B E R O R U C K V E N T I L 0 . 2 BAR
FITTING ACCORDING
P O S I T ICTI
8 0 L T S ACCORDING
POSITION
I ANZUGSMOMENT F U E R MI 6
FESTIGKEITSKLASSE 8.8
Iii,». SE ILWINDE 0 4.2 2 1009'
AHLACE-UHD ANSCHRAUBFLAECHEH P E L - . F E T T UUP LACKFREI SURFACE TO BE F R E E FROM O I L ANO GREASE ROPE WINCH
665
75,76
gOLLERN
POS TYP 4 . 2 2 BEZEICHNUNG SEILWINDE TEILE-NR 0 4 . 2 2 10097
POS TYPE DESCRIPT ION ROPE WINCH PART -NO
REP TYPE DESIGNAT ION TREU IL A CABLE ARTICLE-NO
BLATT/PAGE/PAGE MASSTAB/SCALE/ECHELLE |NAME/NAME/NOM WE/KD DATUM/DATE/IVTE 04 .04 .1996|xX>:/1 >/A4
131 141 151 1 0 3 1 2 4 1 0 6 1 5 3 121 2 9 1 6 2 161 3 0 97 95 96
- ^ tt
) : Q •=
!:' '•
•r Ui
i - V)
tu I;
, • uj •
û r
'•i
Li
r.
i o '
0 O .
.0 >- 1
V OD •
• 111
u. *•
7. a
101 13 1 0 2 1.4 12 16 15 1 1 27 28 22 26 21 25 24 23 3J0LLERN

POS 1 TYP BEZEICHNUNG GETRIEBE TEILE-NR 1 /J . 22 50024
POS TYPE DESCRIPT ION GEAR PART -NO - o •.
REP TYPE DESIGNAT ION REDUCTEUR ART I CLE-NO >- I
BLATT/PAGE/PAGE MASSTAB/SCALE/ECHELLE |NAME/NAME/NOM We/KD DATUM/DATE/DATE 20.03.1996|kd /A1/A4

u
jjOLLERN 1
21 u. :
POS TYP BEZEiCHNUNG SEILTROMMEL K P L TEILE-NP. -1422 50067-

POS TYPE DESCRIPTION ROPE DRUM PART -NO
PEP TYPE OESIGNATION TAMBOUR A CABLE COMPLET ARTICLE-NO
BLA TT/PAGE/PAGE MASSTAB/SCALE/ECHELLE | NAME/NAME/NCM TEUFEL OA TUM/OATE/OA TE U.0S93 |
00 0>
mQ o
U M «1
ro
ro
-<-<-<
T U H
mm
o o
mm
5 3
•n -n -n
r r
> > r
mz >
o n
r- x
O
-
r
rn
> 13 -I
33 > m
H Si M
gg
ai
o
o
o
C O P Y I N G OF T H I S DOCUMENT. A N D G I V I N G I T TO OTHERS AND T H E U S E OR C O M M U N I C A T I O N OF T H E CONTENTS THEREFOR. ARE F O R B T D D E N

W I T H O U T E X P R E S S A U T H O R I T Y . O F F E N D E R S ARE L I A B L E T O T H E P A Y M E N T OF DAMAGES. A L L R I G H T S ARE R E S E R V E D I N T H E E V E N T O F
59 19 53 07 04 12 96 43 50 30 40 120 54
08 60
, 61
23 123 122
,cqx) 22
GOLLERN
pos 24 TYP BEZEICHNUNG ANTR I EB TEiLC-NR 1 4 . 2 2 500G6
POS TYPE DESCRIPTION DRIVE IN PART - M O
REP TYPE DESIGNAT ION ENTREE DE REDUCTEUR ARTICLC-NO
BLATT/PAGE/PAGE MASSTAB/SCALE/ECHELLE |NAWE/NAME/NOM We/KD DATUM/DATE/D/-TE 20.03. 1996[KD , A2/A<
,
I—o c/)-g
no
we >m mm
33>
n
rw rmern
w> ~o
-t >-i mm
mo 3 J > CD O
«c — m m
U Z T N33
m-i i-i—« c r
WM W I w
•H
Hm m n
•urn z i
t-i « z n m
R 2 cim z
n m m n m>
m n >m i z
wn Z N
— -~ m>
DW • > Z I
33 •
mM > r
-<
o
mm O m 33
n c
*S >
>m z o
zen -i 33
<D M C
m;o H n
m
• CO
-< *
m
OF
SO
RE
g
033
m
CH ~
33 D 33
oto
H z
m
mo en w
cm
33 en (n
stJ c33 H
33
m D
m
CO m
en 33
en T)
33
h-1 1-4 m
33
O
z Z (0
< o >
-i
en NI
o
-c m H
33
m
M m
M
2
o
LLISTE
r m o o
> "0 55 to
ru
-I H
-< -<
mm
n o n
o m rn o
-H > - I o o o
m 33 S) H - I
xi co m m
m
o o m S
ni m m c m co s
n m
HO n -1 M co m
m M M
> T] T c:
1 O - I
- -> ë TO
o m M
o
3 I
mg
z > ^
M J>
r n r-
PF M
(n "D 1
x m r~
3o >
com
C r w
Sx m
m 2
co
m
s
CO
m
c
M
m
m
33
COPYING OF THIS DOCUMENT, AND GIVING I T TO OTHERS AND THE USE OR COMMUNICATION OF THE CONTENTS THEREFOR ARE FORBIDDEN
WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENT OF DAMAGES. ALL RIGHTS ARE RESERVED I N THE EVENT OF
THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN FUERSTLICH HOHENZOLLERNSCHE WERKE LAUCHERTHAL
DATUM E R S A T Z T E I L - L I S T E ZOLLERN' VERTRIEBS-GMBH & CO
HEUSTRASSE 1
04.04.96 S P Ä R E - P Ä R T - L I S T D-88518 HERBERTINGEN'/WÜRTT.

WEIGHT OIL QTY
SERIEN - NR. 150 '- 163 SERIAL - NO. 150 - 163 298,0 KG 3,0 LTR.
SEITE - 1
************************************************
ACHTUNG : BEI ERSÄTZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN
******************************************************************************************************************

1/ 0 1 o 142250024 GETRIEBE GEAR + OUTPUT
1/11 . 1 0 232200001 INNENRAD INTERNAL-WHEEL

1/ 12 3 0 232200170 PLANETENRAD • PLANETARY WHEEL
1/ 13 1 0 242200156 SONNENRAD SUN WHEEL
1/ 14 6 0 453300175 ZYLINDER-ROLLENLAGER CYLINDER ROLLER BEARING AD 5 3 , 7 1 7 - L 24,0
1/ 15 6 0 403200226 SICHERUNGS-RING CIR CLIP 54X2,0 BOHRUNG DIN 472
1/ 16 6 0 503400019 ANLAUFSCHEIBE WASHER AD 5 3 , 7 1 7 -— - L 3,3
1/ 21 1 0 232000167 INNENRAD INTERNAL-WHEEL
1/ 22 3 0 232000214 PLANETENRAD PLANETARY WHEEL
1/ 23 1 0 242000156 SONNENRAD SUN WHEEL
1/ 24 6 0 453300174 ZYLINDER-ROLLENLAGER CYLINDER ROLLER BEARING AD 4 6 , 5 2 0 -— - L 18,0
1/ 25 6 0 403200031 SICHERUNGSRING CIR CLIP — , - X 47,00X 1,75 DIN 472
1/ 26 6 0 503400018 ANLAUFSCHEIBE WASHER AD 4 6 , 5 2 0 -— - L 1,9
1/ 27 1 0 232000170 PLANETENTRÄGER PLANETARY CARRIER
1/ 28 3 0 234502512 PLANETENACHSE PLANETARY AXLE
1/ 29 1 0 403100044 SICHERUNGSRING CIR CLIP 6 5 , 0 0 X — ,-- X 2,50 DIN 471
1/ 30 1 0 503100043 SPRENGRING CIR CLIP SW 65*1,5 WELLE
1/ 95 1 0 242700936 DECKEL COVER
1/ 96 1 0 453000252 RILLEN-KUGELLAGER BALL BEARING 20X 52X15 DIN 625
1/ 97 18 0 411230081 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 12X 80 ZN 8.8 DIN 912
1/101 1 0 242200404 PLANETENTRÄGER PLANETARY CARRIER
1/102 3 0 232400135 PLANETENACHSE PLANETARY AXLE
1/103 1 0 242200237 LAGERRING BEARING RING
1/106 1 0 242200240 ZWISCHENGEHÄUSE INTERMEDIATE HOUSING
1/121 18 0 411230094 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 16X100 ZN 8.8 DIN 912
1/124 3 0 411230059 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 10X 20 ZN 8.8 DIN 912
1/131 1 0 441100596 WELLENDICHTRING SHAFT SEALING RING 260X290X16 B2 NBR DIN3760
1/141 1 0 442000008 PROFILSCHNUR SEALING RING 4X11WZ.NR
1/151 1 0 453300164 ZYLINDERROLLENLAGER CYLINDER ROLLER BEARING AD259,470V-4.22-L 29
1/153 1, 0 453000028 RILLENKUGELLAGER BALL BEARING 120X180X28 DIN 625
1/161 1 0 403100060 SICHERUNGSRING CIR CLIP 1 2 0 , 0 0 X — - X 4,00 DIN 471
1/162 1 0 403200074 SICHERUNGSRING CIR CLIP — , - X 1 8 0 00X 4,00 DIN 472
142250067 SEILTROMMEL ROPE DRUM
1 242200304 SEILTROMMEL ROPE DRUM

1 263500314 SEILBLECH CABLE FIXING AND WEDGES
6 412300591 GEWINDESTIFT SCREW M 12* 30 DIN 915
18 411230087 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 16X 40 ZN 8.8 DIN 912
2 541800035 VERSCHLUSS-STOPFEN SEALING PLUG D 4 0 , 0 / 42-- H 1 5 , 0 / 1 8
1 263000172 SEILKLEMME CABLE FIXING AND WEDGES
2 411130525 SECHSKANTSCHRAUBE HEXAGON BOLT M 16X 55 ZN 8.8 DIN 933
22/ 0 1,0 142250001 FLANSCH FLANGE + PLATE CPL.

•
HEUSTRASSE 1
04.04.96 S P A R E - P A R T - L I S T D-88518 HERBERTINGEN/WÜRTT.

WEIGHT OIL QTY
SERIEN - NR. 150 - 163 SERIAL - NO. 150 - 163 298,0 KG 3,0 LTR.
SEITE - 2
**********************************************
******************************************************************************************************************
POS-NR. STÜCK ' TEILE-NR. BEZEICHNUNG - DEUTSCH BEZEICHNUNG - ENGLISCH TECHNISCHE - DATEN
POS-NO. QTY . PART -NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH TECHNICAL - DATA
22/ 1 1 0 242200153 FLANSCH FLANGE

22/ 3 1 ,0 234600295 SCHEIBE WASHER
22/ 4 1 r0 403200068 SICHERUNGSRING CIR CLIP — ,-X150,00X 4,00 DIN 472
Ä 22/ 5 1 ,0 688100003 FILZ-DICHTSTREIFEN FELT STRIP 5,OX 4,0 DIN5419
• 22/ 6 1 r0 453400071 PENDEL-ROLLENLAGER PENDULUM ROLLER BEARING 85X150X 36 DIN 635
22/ 8 1 0 242200154 DECKEL COVER
22/ 9 1 0 234500242 MITNEHMER DRIVER
22/ 10 1 f0 411230417 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 8X 85 ZN 8.8 DIN 912
22/ 12 2 0 417000094 SPANNSTIFT PIN 4,OX 16 DIN1481
24/ 0 1 ,0 142250066 ANTRIEB DRIVE CPL.
24/ 1 1 0 242400325 BREMSFLANSCH BRAKE FLANGE

24/ 4 1 0 242400055 ANTRIEBSHÜLSE DRIVING SLEEVE
24/ 6 1 0 242400011 HÜLSE SLEEVE
24/ 7 1 0 242400099 MOTORFLANSCH MOTOR FLANGE
24/ 8 1 0 242400529 MOTORFLANSCH MOTOR FLANGE
24/ 12 1 0 242400038 SCHEIBE WASHER
24/ 19 1 0 242400042 RING RING
24/ 21 6 0 411230343 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 10X130 ZN 8.8 DIN 912
24/ 22 6 0 411230378 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M 10X110 ZN 8.8 DIN 912
24/ 23 8 0 411230063 ZYLINDERSCHRAUBE CYLINDRICAL SCREW M'lOX 40 ZN 8.8 DIN 912
Ä 24/ 30 1 0 453000018 RILLENKUGELLAGER BALL BEARING 55X 90X18 DIN 625
• 24/ 40 1 0 403200051 SICHERUNGSRING CIR CLIP — , - X 90,00X 3,00 DIN 472
24/ 41 1 0 403100038 SICHERUNGSRING CIR CLIP 5 5 , 0 0 X — , - X 2,00 DIN 471
24/ 43 2 0 403200022 SICHERUNGSRING CIR CLIP — , - X 31,00X 1,20 DIN 472
24/ 50 1 0 441100571 WELLENDICHTRING SHAFT SEALING RING 62X 85X10 BA FPM DIN3760
24/ 53 1 0 441100664 WELLEN-DICHTRING SHAFT SEALING RING 90X110X 8 Bl FPM DIN3760
24/ 54 1 0 441100173 WELLENDICHTRING SHAFT SEALING RING 35X 62X 7 BA NBR DIN3760
24/ 56 1 0 541000249 O-RING SEALING RING 47 X2 NBR-72
24/ 60 1 0 414030001 VERSCHLUSS-SCHRAUBE SCREW SPINDLE M 10*1,0 ZN DIN 908
24/ 61 1, 0 441000207 FLACH-DICHTRING SEALING RING A 10X 1 3 X 1 , 0 . DIN7603
24/ 67 6 0 541800007 VERSCHLUSS-STOPFEN SEALING PLUG D 10,7/ 16--H 5,5/ 8 5
24/ 70 15, 0 404300219 PASS-SCHEIBE WASHER 22X 30X1,0 DIN 988
24/ 78 1 0 242400407 SCHEIBE WASHER
24/ 95 1 0 506701020 ÖLDRUCKEINHEIT HYDR.-PART FOR DISC BRAKE
24/ 96 1 0 506700221 LAMELLENTRÄGER CLUTCH PLATE CARRIER
24/ 97 8, 0 506700154 AUSSENLAMELLE MULTIPLE DISC "EXTERN"
24/ 98 7 0 506700155 INNENLAMELLE MULTIPLE DISC "INTERN"
24/120 2, 0 524100009 ÖLVENTIL PRESSURE VALVE HUB 3,5-1008050100
A 24/121 2, 0 441000213 FLACH-DICHTRING SEALING RING A 18X 22X1,5 DIN7603
W
24/122 1, 0 524100011 VENTIL PRESSURE VALVE 0,3 BAR MIT ENTL.
24/123 1 0 441000207 FLACH-DICHTRING SEALING RING A 10X 13X1,0 DIN7603
60/ 0 1, 0 142250094 ÖLLEITUNG OIL PIPE

- - HEUSTRASSE 1
04.04,96 S P A R E - P A R T - L I S T ' D-88518 HERBERTINGEN/WÜRTT.

WEIGHT OIL QTY
SERIEN - NR. 150 - 163 SERIAL - NO. 150 - 163 298,0 KG 3,0 LTR.
SEITE - 3
*****************************************
ACHTUNG : BEI ERSÄTZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN
ATTENTION : I F YOU ORDER SPARE PARTS PLEASE INDICATE TYPE AND SERIAL NUMBER
******************************************************************************************************************

60/ 1 2,0 540100301 T-VERSCHRAUBUNG THREADED JOINT CONNECTION 250B

60/ 2 1,0 620140063 PRÄZ-STAHLROHR STEEL PIPE
60/ 3 1,0 540100918 VERSCHRAUBUNG THREADED JOINT CONNECTION Gl/2"
60/ 4 1,0 519000034 KREUZ THREADED JOINT CONNECTION 1/2
60/ 5 1,0 540100986 REDUZIERSTUTZEN THREADED JOINT CONNECTION RIl/2"X3/8"--<400B
60/ 8 2,0 540900021 ROHRSCHELLE CLAMP
60/ 10 1,0 519000155 DOPPELNIPPEL PIPING PIECES
60/ 11 1,0 519000222 T-STÜCK THREADED JOINT CONNECTION I l/2"-I 1/2"--A 1/2"
60/ 12 1,0 540100910 VERSCHRAUBUNG THREADED JOINT CONNECTION G 1/2"
60/ 13 1,0 540100919 VERSCHRAUBUNG THREADED JOINT CONNECTION -315B
60/ 14 1,0 620140063 PRÄZ-STAHLROHR STEEL PIPE
60/ 18 1,0 543400072 MEßSTAB OIL DIPSTICK ANSCHL.R1/2" -L=280
60/ 19 1,0 543400066 ÖLMEßSTAB OIL DIPSTICK ANSCHL.G1/2 L450
60/ 22 1,0 519000154 DOPPELNIPPEL PIPING PIECES
60/ 23 1,0 242200328 HALTEBLECH SPECIAL SINGLE PART
60/ 25 2,0 540100221 GERADE-VERSCHRAUBUNG THREADED JOINT CONNECTION
60/ 30 2,0 540100683 VERSCHLUSS-BUTZEN SEALING PLUG M22X1,5
64/ 0 1,0 100001951 KEGELSCHMIERNIPPEL • GREASE NIPPLE
64/ 1 1,0 449900003 KEGELSCHMIERNIPPEL GREASE NIPPLE AM 10X 1 DIN71412
70/ 0 1,0 100002107 BREMSLEITUNG CONNECTIONS FOR BRAKE
70/ 1 1,0 543400014 ENTLÜFTUNGSVENTIL PRESSURE VALVE 0,04 BAR MESSING M10*l,0
75/ 0 22,0 100003008 FEDERN SPRINGS
75/ 1. 22,0 402100308 DRUCKFEDER SPRINGS 10,4N/MM-S= 28,2-RE
76/ 0 22,0 100003009 FEDERN SPRINGS
76/ 1 22,0 402100309 DRUCKFEDER SPRINGS 14,7N/MM-S= 18,1-LI

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
Einbau- Demontage- und Montageanweisung

Die S e i l w i n d e w i r d k o m p l e t t m o n t i e r t a n g e l i e f e r t . Zum Einbau müssen an
der S e i l w i n d e der k l e i n e Flansch, d i e k o m p l e t t e A n t r i e b s e i n h e i t und d i e
Ölleitungen d e m o n t i e r t werden.
- Z u e r s t Aufnahme-Konstruktion prüfen ( s i e h e Einbauzeichnung).

Die Anschraubflächen müssen i n g l e i c h e r Ebene sauber b e a r b e i t e t s e i n .
Demontage
- öleinfüll-,Ölablaßleitung demontieren.
(Bohrungen m i t Verschlußschrauben verschließen)
- Am Gegenlager k l e i n e n Flansch abziehen.
- Befestigungsschrauben entfernen (siehe Einbauzeichnung)
und k o m p l e t t e A n t r i e b s e i n h e i t vom S e i l w i n d e n g e t r i e b e abnehmen.
Montage
- Seilwinde i n d i e Kranschilder einfahren.
- Planetenträger m i t Markierung "OBEN" b e f e s t i g e n , Schrauben m i t dem
e r f o r d e r l i c h e m Drehmoment anziehen. Es w i r d empfohlen, zur
Schraubensicherung z. B. L o c t i t e Typ 242 zu verwenden. Der Reibschluß
bzw. d i e S c h e r f e s t i g k e i t kann d u r c h Verwendung von z. B. L o c t i t e Typ
640 an den Befestigungsflächen erhöht werden.
- K l e i n e n F l a n s c h gleichmäßig und gerade a u f z i e h e n .
"Ächtung: Keine Gewalt anwenden"
- Komplette A n t r i e b s e i n h e i t an das S e i l w i n d e n g e t r i e b e m o n t i e r e n .
- Vor der Montage s i n d d i e Flanschflächen und d i e Gewindebohrungen von
e v e n t u e l l e n L o c t i t e - bzw. F e t t - und ölrückständen m e t a l l i s c h b l a n k zu
reinigen.
- B e i der Montage muß a u f d i e i n u n s e r e r Einbauzeichnung angegebene
Einbaulage g e a c h t e t werden.
- Öl- bzw. Entlüftungsleitung an das S e i l w i n d e n g e t r i e b e m o n t i e r e n .
- ölablaß - öleinfülleitung am K r a n s c h i l d b e f e s t i g e n .
("Max."- Kerbe am ölmeßstab M i t t e G e t r i e b e ) .
- Getriebeölstand m i t t e l s Ölmeßstab überprüfen. Gegebenenfalls Getriebeöl
nachfüllen ( S o r t e s i e h e W a r t u n g s a n l e i t u n g ) .
- B r e m s l e i t u n g anschließen und Lamellenbremse h y d r a u l i s c h lüften,
Antriebshülse muß s i c h l e i c h t durchdrehen l a s s e n .

Heustraße 1

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
- H y d r a u l i k m o t o r anbauen, M o t o r f l a n s c h m i t ATF-Öl füllen ( s i e h e

Wartungsanleitung).
- S e i l einfädeln und m i t Druckschrauben festklemmen.

Druckschrauben entsprechend s i c h e r n .
- S e i l w i n d e m i t laufendem Motor a u f F u n k t i o n überprüfen, insbesondere

F u n k t i o n d e r Haltebremse (Lamellenbremse) und d i e Steuerung des
Antriebsmotors.
- Im übrigen verweisen w i r a u f d i e t e c h n i s c h e n Angaben unserer

Einbauzeichnung.

Heustraße 1
ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
Disassembly and Assembly I n s t r u c t i o n :
The rope winch i s d e l i v e r e d as a complete u n i t .

For f i t t i n g t h e winch, dismount d r i v e u n i t , o i l p i p e s and s m a l l f l a n g e .
- F i r s t check screw-on c o n s t r u c t i o n (see i n s t a l l a t i o n d r a w i n g ) .
The screw-on-surfaces have t o be worked p r o p e r l y t o t h e same l e v e l .
Disassembly
- Remove o i l f i l l i n g and o i l d r a i n l i n e ,
( l o c k b o r i n g s w i t h s e a l i n g screws)
- Remove s m a l l f l a n g e a t t h e second j o u r n a l b e a r i n g .
- Remove clamping screws (see assembly d r a w i n g ) and remove complete
d r i v e u n i t o f f rope w i n c h gear.
Assembly
- Put rope w i n c h i n t o t h e crane frame.

- F i x p l a n e t a r y c a r r i e r w i t h mark "OBEN". T i g h t e n screws w i t h necessary
t o r q u e . We recommend t o use L o c t i t e t y p e 242 f o r screw s e c u r i t y . The
t e n s i l e shear can be i n c r e a s e d by u s i n g f o r example L o c t i t e t y p e 640 a t
the clamping s u r f a c e s .
- Put i n s m a l l f l a n g e e q u a l l y and s t r a i g h t .
" A t t e n t i o n : Use no f o r c e "
- Mount complete d r i v e u n i t on t h e rope winch gear.
- B e f o r e assembly c l e a n a l l f l a n g e s u r f a c e s and t a p h o l e s . They have t o

be f r e e from L o c t i t e - , o i l and grease r e s t s .
- D u r i n g assembly pay a t t e n t i o n t o t h e f i t t i n g p o s i t i o n a c c o r d i n g t o
our assembly drawing.
- Mount o i l and v e n t i l a t i o n p i p e s a t t h e rope w i n c h gear.
- F i x o i l d r a i n p i p e and o i l f i l l - i n p i p e a t t h e crane frame.
(Max n o t c h a t o i l d i p s t i c k - m i d t h o f g e a r )
- Check gear o i l l e v e l w i t h o i l d i p s t i c k . F i l l i n gear o i l i f necessary

( t y p e i n d i c a t e d on o u r maintenance i n s t r u c t i o n ) .
- F i x t h e brake p i p e and r e l e a s e t h e d i s c brake h y d r a u l i c a l l y . Drive
s l e e v e must be s l i g h t l y t u r n a b l e .
- Mount h y d r a u l i c motor , f i l l motor f l a n g e w i t h A T F - o i l (see
maintenance i n s t r u c t i o n s ) .

Heustraße 1
ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
- I n s e r t rope and f i x i t w i t h t h e c l a m p i n g s c r e w s .
Secure clamping screws a c c o r d i n g l y .
- Check rope w i n c h r e g a r d i n g f u n c t i o n w i t h r u n n i n g motor, e s p e c i a l l y

f u n c t i o n o f t h e h o l d i n g b r a k e ( d i s c b r a k e ) and c o n t r o l o f i n p u t motor.
- F u r t h e r m o r e we p o i n t o u t t o t h e t e c h n i c a l d a t a i n our assembly drawing.

Heustraße 1
ZOLLERN ZOLLERN
VERTRIEBS- WINDENGETRIEBE GETRIEBE
GmbH + Co. Abt. KD
Wartungsanleitunq
Schmierung
Das Z o l l e r n - S e i l w i n d e n p l a n e t e n g e t r i e b e h a t Tauchschmierung.
Ölfüllung ab Werk : AVIA Getriebeöl Hypoid 90 EP.
Bezeichnung : Schmieröl, DIN 51517-CLP 220.
Die öleinfüllmenge i s t a u f dem T y p e n s c h i l d v e r m e r k t . Wird das G e t r i e b e

ohne Öl a u s g e l i e f e r t , i s t m i t einem A u f k l e b e r d a r a u f hingewiesen.
Der M o t o r f l a n s c h i s t nach dem Anbau des Motors m i t ATF - Öl zu füllen.
H i e r z u Verschlußschraube an d e r oleinfülleitung und Verschlußschraube am
M o t o r f l a n s c h bzw. an d e r ölüberlaufleitung e n t f e r n e n . Ölstand i s t knapp
über Windenmitte, öl so lange einfüllen, b i s ölstand durch Ölüberlauf
angezeigt w i r d .
Das a b t r i e b s e i t i g e F l a n s c h l a g e r i s t m i t S c h m i e r f e t t gefüllt.
Fettfüllung ab Werk : AVIA A v i a l i t h 2 EP
Bezeichnung nach DIN: S c h m i e r f e t t , DIN 51825 - KP2K.
Vor Inbetriebnahme i s t das Gegenlager nachzuschmieren, b i s das F e t t am
A b d i c h t p r o f i l bzw. an d e r S p a l t d i c h t u n g a u s t r i t t .
Weitere verwendbare Öl- und F e t t s o r t e n von anderen H e r s t e l l e r n s i e h e

Schmierstoffempfehlung.
Empfehlung für Wartungstermine

Öl-Kontrolle: Wöchentlich.
Nach längerer S t i l l s t a n d z e i t - v o r Wiederinbetriebnahme.
Ölstand : Das Getriebeöl muß b i s z u r MIN./ MAX.-Markierung am
Ölmeßstab eingefüllt s e i n .
Der ölstand d a r f n u r b e i s t i l l s t e h e n d e m G e t r i e b e
geprüft werden.
Ölwechsel : Nach 200, dann a l l e 1000 B e t r i e b s s t u n d e n , mindestens j e d o c h

1 x jährlich.
Ölwechsel möglichst i n betriebswarmen Zustand vornehmen.
Es i s t sehr zu empfehlen, b e i n i e d r i g e n
Umgebungstemperaturen m i t e i n e r erwärmten Teilmenge Neuöl
zu spülen, damit möglicher A b r i e b bzw. V e r u n r e i n i g u n g e n
abfließen können.

Heustraße 1
ZOLLERN ZOLLERN
VERTRIEBS- WINDENGETRIEBE GETRIEBE
GmbH + Co. Abt. KD
Schmierung : wöchentlich, oder v o r Wiederinbetriebnahme des

Gerätes nachschmieren.

Heustraße 1
ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
Maintenance Instructions
Lubrication
The Z o l l e r n - r o p e winch p l a n e t a r y g e a r has s p l a s h e d lubrication.
O i l f i l l i n g ex f a c t o r y : AVIA g e a r o i l Hypoid 90 EP.

C h o i c e a c c o r d i n g t o DIN : DIN 51502.
D e s c r i p t i o n a c c o r d i n g t o DIN: O i l , DIN 51517-CLP 220.
The o i l q u a n t i t y t o f i l l i n i s mentionned on t h e name p l a t e .

I f t h e gear i s d e l i v e r e d w i t h o u t o i l we p o i n t out t o t h a t w i t h a sticker.
The motor f l a n g e has t o be f i l l e d w i t h ATF - o i l a f t e r h a v i n g mounted t h e

motor. T h e r e f o r e remove s e a l i n g s c r e w a t t h e o i l f i l l i n p i p e and s e a l i n g
screw a t t h e motor f l a n g e o r o i l o v e r f l o w p i p e . O i l l e v e l i s a b i t o v e r
the mid of t h e g e a r . F i l l i n o i l u n t i l o i l l e v e l i s i n d i c a t e d by o v e r f l o w .
The f l a n g e b e a r i n g on t h e d r i v i n g s l i d e i s f i l l e d w i t h grease.
G r e a s e f i l l i n g ex f a c t o r y : AVIA A v i a l i t h 2 EP
C h o i c e a c c o r d i n g to DIN : DIN 51502.
D e s c r i p t i o n a c c o r d i n g t o DIN: G r e a s e , DIN 51825-KP2K.
Before t a k i n g into operation grease again flange bearing t i l l grease

emerges a t t h e s e a l i n g p r o f i l e .
Recommendation f o r m a i n t e n a n c e intervals
Oil c o n t r o l : weekly.
A f t e r l o n g e r p e r i o d s of d i s u s e - b e f o r e u s i n g i t a g a i n .
Oil level : The gear o i l has t o be f i l l e d i n up t o t h e min./max. mark a t

t h e o i l s i g h t g l a s s e s . The o i l l e v e l may o n l y be checked
w i t h non-runing gear.
Oil change : a f t e r 200 and t h e n a f t e r 1000 s e r v i c e h o u r s each,

b u t a t l e a s t once a y e a r .
O i l change o n l y w i t h s e r v i c e t e m p e r a t u r e c o n d i t i o n .
I t i s recommended t o r i n s e w i t h a warm p a r t of new o i l

when ambient t e m p e r a t u r e i s low, so t h a t p a r t i c l e s and
d i r t may f l o w o u t .
Greasing : once a week o r b e f o r e t a k i n g rope w i n c h i n t o

operation.

Heustraße 1

ZOLLERN Schmierstoffempfehlung ZOLLERN
VERTRIEBS- für ZOLLERN - G e t r i e b e Getriebe
GmbH + Co. Abt. KD
Schmieröl-Auswahl ! Schmierölauswahl ! S c h m i e r f e t t Auswahl

nach API GL5 ! nach DIN 51502 ! nach DIN 51502
j Schmieröl
SAE 90
! Schmieröl ! Schmierfett
! DIN 51517-CLP 220 !DIN 51825-KP2K
ARAL ! A r a l Getriebeöl ! BG 220 ! A r a l F e t t HLP 2

HYP 90 !
AVIA ! A v i a Getriebeöl ! RSX 220 ! Avia A v i a l i t h 2 EP

Hypoid 90 EP !
BP ! BP Hypogear EP 90 ! GR-XP 220 ! BP Energr. LS EP 2
CASTROL ! C a s t r o l EPX 90 i Alpha SP 220 ! C a s t r o l Spheerol EPL 2

Grease
ELF ! T r a n s e l f Typ B ! R e d u c t e l f SP 220 ! ELF Epexa 2

SAE 90 !
ESSO ! Esso Getriebeöl ! Spartan EP 220 ! Esso Beacon 2 EP

GX-D90 !
FUCHS ! Fuchs Getriebeöl ! Compound 106 ! Fuchs R e n o l i t FEP 2

Renogear Hypoid 90! VG 220 !
GULF ! G u l f M u l t i - P u r p o s e ! EP L u b r i c a n t ! G u l f Crown Grease No.2

Gear L u b r i c a n t ! HD 220 !
SAE 90 !
MOBIL ! Mobilube HD-A 90 ! Mobilgear 630 ! Mobilux 2 EP
SHELL ! S h e l l S p i r a x MB 90! Omala 220 ! S h e l l A l y a n i a EP 2
Ölwechsel- und F e t t s c h m i e r i n t e r v a l l e s i e h e W a r t u n g s a n l e i t u n g .

Heustraße 1
Dok.-Nr.: SCHMIERD.1/TXTKD Seite 1

ZOLLERN RECOMMENDATION FOR LUBRICANTS ZOLLERN
VERTRIEBS- FOR ZOLLERN - GEARS Getriebe
GmbH + Co. A b t . KD
! Choosen a c c o r d i n g ! Choosen a c c o r d i n g ! Choosen a c c o r d i n g

! t o A P I GL5 ! t o D I N 51502 ! t o DIN 51502
! Oil ! Oil ! Grease

! SAE 90 ! DIN 51517-CLP 220 DIN 51825-KP2K
ARAL ! A r a l Gear o i l 1 BG 220 ! A r a l Grease HLP 2

! HYP 90 !
AVIA ! A v i a Gear o i l ! RSX 220 ! A v i a A v i a l i t h 2 EP

! H y p o i d 90 EP !
BP ! BP H y p o g e a r EP 90 ! GR-XP 220 ! BP E n e r g r . LS EP 2
CASTROL ! C a s t r o l EPX 90 ! A l p h a SP 220 . C a s t r o l S p h e e r o l EPL 2

! Grease
ELF ! T r a n s e l f Typ B ! R e d u c t e l f SP 220 . ELF Epexa 2

! SAE 90 !
ESSO ! Esso Gear o i l ! Spartan EP 220 Esso Beacon 2 EP

! GX-D90 !
FUCHS ! Fuchs Gear o i l ! Compound 106 Fuchs R e n o l i t FEP 2

! Renogear H y p o i d 9 0 ! VG 220
GULF ! G u l f M u l t i - P u r p o s e ! EP L u b r i c a n t G u l f Crown G r e a s e No. 2

! SAE 90 !
MOBIL ! M o b i l u b e HD-A 90 ! M o b i l g e a r 630 . Mobilux 2 EP
SHELL ! S h e l l S p i r a x MB 9 0 ! Omala 220 . S h e l l A l v a n i a EP 2
Oil change a n d g r e a s i n g i n t e r v a l s s e e m a i n t e n a n c e instruction.

Heustraße 1
Doc.-No.: SCHMIERE.1/TXTKD Page 1
ZOLLERN ZOLLERN
VERTRIEBS- Anweisung für G e t r i e b e i n s p e k t i o n GETRIEBE
GmbH + Co. Abt. KD
1. I n s p e k t i o n s i n t e r v a l l e
A l l e 1000 B e t r i e b s s t u n d e n , mindestens 1 mal jährlich s o l l t e das
abgelassene Getriebeöl geprüft werden. Für e i n repräsentatives ölmuster
i s t es zweckmäßig, das Öl i n betriebswarmem Zustand abzulassen.
2. Prüfung
Zur Überprüfung, ob im G e t r i e b e e i n e ausreichende ölmenge vorhanden war,
s o l l d i e Menge des abgelassenen Öles m i t d e r v o r g e s c h r i e b e n e n ölmenge
v e r g l i c h e n werden. D i e v o r g e s c h r i e b e n e ölmenge i s t aus dem T y p e n s c h i l d
des G e t r i e b e s oder der W a r t u n g s a n l e i t u n g zu entnehmen.
3. Prüfung a u f Ölfärbung
Wenn das Gebraüchtöl e i n e d u n k l e , schwarze Färbung a u f w e i s t , s i n d im
B e t r i e b Temperaturen von über 100 Grad C. a u f g e t r e t e n . A l s Folge t r i t t
verstärkte A l t e r u n g des Öles a u f , d i e s b e d e u t e t v e r m i n d e r t e
Schmierfähigkeit. Der Ölwechsel muß dann i n kürzeren I n t e r v a l l e n
durchgeführt werden.
Hat d i e ölprobe e i n e trübe Färbung, kann d i e s a u f eingedrungenes Wasser
h i n w e i s e n . E i n s o f o r t i g e r Ölwechsel m i t mehrmaliger gründlicher Spülung
durch Frischöl muß vorgenommen werden. Es i s t zu empfehlen, das G e t r i e b e
zu demontieren und d i e T e i l e a u f Korrosionsschäden zu überprüfen.
4. Prüfung a u f f e s t e F r e m d s t o f f e
Wir empfehlen e i n e Prüfung d e r F r e m d s t o f f e nach DIN 51592.
Die Probe w i r d , g e g e b e n e n f a l l s u n t e r geringem Erwärmen, i n Reinbenzol

gelöst und über e i n benzolbeständiges f e i n p o r i g e s M e m b r a n f i l t e r
f i l t r i e r t . Der Rückstand w i r d gewaschen, g e t r o c k n e t , gewogen und a l s
Gehalt an f e s t e n F r e m d s t o f f e n angegeben.
Gesamtbeurteilung:
Max. zulässiger F r e m d s t o f f - M a s s e r i a n t e i l i s t ca. 0,15 % von d e r
Gesamtölmasse d e r Getriebefüllung. D i e F r e m d s t o f f t e i l e dürfen j e d o c h n u r
aus feinem A b r i e b bestehen ( b i s max. 25 ym). Wird d e r zulässige Wert
n i c h t überschritten kann nach Ölwechsel d e r B e t r i e b des G e t r i e b e s
fortgeführt werden.
Wenn grobkörniger A b r i e b (über 25 ym) oder Abblätterungen von M a t e r i a l

der Zahnflanken f e s t g e s t e l l t werden, i s t unabhängig vom M a s s e n a n t e i l , das
G e t r i e b e zu demontieren. D i e Zahnflanken d e r Zahnräder, insbesondere das
große Sonnenrad d e r A b t r i e b s p l a n e t e n s t u f e i s t d u r c h S i c h t p r o b e zu
überprüfen.

Heustraße 1
ZOLLERN ZOLLERN
VERTRIEBS- Anweisung für Getriebeinspektion GETRIEBE
GmbH + Co. Abt. KD
B e i normalem V e r s c h l e i s s und nach d e r E i n l a u f p e r i o d e s i n d d i e

R a u h i g k e i t s s p i t z e n vom Z a h n f l a n k e n s c h l e i f e n geglättet und d i e
Z a h n f l a n k e n haben e i n e g l a t t e , h e l l e , glänzende Oberfläche.
B e i a l l e n a n d e r e n Merkmalen, w i e Schleifverschleiß, R i e f e n , F r e s s e n ,
Grübchen, Abblätterungen, R i s s e " und p l a s t i s c h e Verformung müssen d i e
Zahnräder g e t a u s c h t werden, bzw. i s t e s dann zweckmäßig, e i n e
Generalüberholung des G e t r i e b e s durchzuführen.

Heustraße 1
Telefon 07586-959-0, T e l e f a x - K u n d e n d i e n s t 07586-959-710, T e l e x 732 218
ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
1. Inspection Intervals
The d r a i n e d gearbox o i l s h o u l d be checked every 1.000 o p e r a t i n g hours,
b u t a t l e a s t once p e r year. I n o r d e r t o o b t a i n a r e p r e s e n t a t i v e o i l
sample, t h e o i l should be d r a i n e d w i t h t h e gear box a t o p e r a t i n g
temperature.
2. .Checking t h e Drained O i l
I n o r d e r t o check whether t h e r e was a s u f f i c i e n t q u a n t i t y o f o i l i n t h e
gearbox, t h e q u a n t i t y o f o i l d r a i n e d has t o be compared w i t h t h e q u a n t i t y
p r e s c r i b e d . The p r e s c r i b e d o i l q u a n t i t y i s i n d i c a t e d on t h e gearbox
r a t i n g p l a t e o r s p e c i f i e d i n t h e maintenance i n s t r u c t i o n s .
3. Checking f o r O i l D i s c o l o u r a t i o n
I f t h e used o i l d i s p l a y s a dark, b l a c k c o l o u r i n g , t h i s i n d i c a t e s t h a t
temperatures o f over 100 degrees C. have o c c u r r e d d u r i n g o p e r a t i o n . As a
consequence, more r a p i d ageing o f t h e o i l o c c u r s , causing reduced
l u b r i c a t i n g p r o p e r t i e s . The o i l change must t h e n be c a r r i e d o u t a t more
frequent i n t e r v a l s .
I f t h e o i l sample has a c l o u d y c o l o u r i n g , t h i s can i n d i c a t e t h e
p e n e t r a t i o n o f water.
An immediate o i l change must be performed and t h e gearbox f l u s h e d o u t
t h o r o u g h l y s e v e r a l t i m e s w i t h f r e s h o i l . I t i s t o be recommended t h a t
the gearbox i s disassembled and t h e p a r t s examined f o r c o r r o s i o n .
4. Checking f o r S o l i d F o r e i g n M a t t e r
We recommend t o check f o r f o r e i g n substances r e g a r d i n g DIN 51592.
The sample w i l l be d i s s o l v e d i n pure b e n z o l , i f necessary warm up a
l i t t l e , and t h e n f i l t e r i t t h r o u g h a benzol r e s i s t a n t , f i n e - p o r e d
membrane f i l t e r . The r e s t w i l l be washed, d r i e d , weighed and i n i c a t e d as
amount o f s o l i d f o r e i g n substances.
O v e r a l l Assessment:
The max. p e r m i s s i b l e w e i g h t o f f o r e i g n m a t t e r i s approx. 0.15 % o f t h e
t o t a l w e i g h t o f o i l i n t h e gearbox. However, t h e f o r e i g n m a t t e r must
c o n s i s t o n l y o f f i n e a b r a s i o n (up t o max. 25 ym). I f t h e p e r m i t t e d v a l u e
i s n o t exceeded, t h e gearbox can c o n t i n u e t o be o p e r a t e d a f t e r t h e o i l
change.
I f coarse a b r a s i o n (above 25 ym) o r f l a k e s o f m a t e r i a l from t h e p r o f i l e s
of t h e gear t e e t h a r e d i s c o v e r e d , t h e gearbox must be disassembled,
i r r e s p e c t i v e o f t h e amount o f f o r e i g n m a t t e r . The p r o f i l e s o f t h e gear

Heustraße 1

ZOLLERN ZOLLERN
GmbH + Co. Abt. KD
wheels, i n p a r t i c u l a r t h e l a r g e sun wheel o f t h e o u t p u t p l a n e t a r y gear

s e t , should be i n s p e c t e d v i s u a l l y . W i t h normal wear and a f t e r t h e
r u n n i n g - i n p e r i o d , t h e rough peaks s h o u l d have been smoothed by t h e
f r i c t i o n between t h e t o o t h p r o f i l e s and t h e p r o f i l e s should have a
smooth, b r i g h t , s h i n y s u r f a c e .
I f any o t h e r c h a r a c t e r i s t i c s a r e d e t e c t e d , such as wear due t o g r i n d i n g ,

s c o r e s , s c u f f s , p i t s , f l a k i n g , cracks o r p l a s t i c d i s t o r t i o n , t h e gear
wheels should be r e p l a c e d and/or a g e n e r a l o v e r h a u l o f t h e gearbox
carried out.

Heustraße 1
Doc-No.: ANWEISE1/TXTKD . Page 2
ZOLLERN Anzugsmoment für B e f e s t i g u n g s s c h r a u b e n . ZOLLERN
VERTRIEBS- T i g h t e n i n g t o r q u e s f o r screws. GETRIEBE
GmbH + Co. Moment de serrage pour v i s de f i x a t i o n (mN). Abt. KD
Pares de a p r i e t e p a r a t o r n i l l o s de fijación.
Festigkeitsklassen (Reibungszahl 0,125)

strength-class (frictioncoefficient)
Classe de r e s i s t a n c e ( c o e f f i c i e n t de f r i c t .
Clases de r e s i s t e n c i a ( c o e f i c c i e n t e de f r i c .
8.8 10.9 12 .9
M 4 2,7 Nm 3,8 Nm 4,6 Nm
M 5 5,5 Nm 8,0 Nm 9,5 Nm
M 6 9,5 Nm 13,0 Nm 16,0 Nm
M 8 23,0 Nm 32,0 Nm 39,0 Nm
M 10 46,0 Nm 64,0 Nm 77,0 Nm
M 12 80,0 Nm 110,0 Nm 135,0 Nm
M 14 = 125,0 Nm 180,0 Nm 215,0 Nm
M 16 = 195,0 Nm 275,0 Nm 330,0 Nm
M 18 = 270,0 Nm 390,0 Nm 455,0 Nm
M 20 = 385,0 Nm 540,0 Nm 650,0 Nm
M 22 = 510,0 Nm 720,0 Nm 870,0 Nm
M 24 = 660,0 Nm 930,0 Nm 1100,0 Nm
M 27 = 980,0 Nm 1400,0 Nm 1650,0 Nm
M 30 = 1350,0 Nm 1850,0 Nm 2250,0 Nm
Schrauben g e s i c h e r t m i t L o c t i t e Typ 242.

Secured by L o c t i t e Type 242.
F r e i n de v i s p a r L o c t i t e Type 242.
T o r n i l l o s asegurados con L o c t i t e Tipo 242.
Verbindungsflächen an den G e t r i e b e t e i l e n m i t L o c t i t e Typ 640 a b g e d i c h t e t
F i t t i n g s u r f a c e s s e a l e d by L o c t i t e Type 640.
Les s u r f a c e s des elements de f i x a t i o n s o n t assurées p a r L o c t i t e Type 640.
S u p e r f i c i e s de u n i o n hermetizadas con L o c t i t e Tipo 640.
Planflächen an d e r Haltebremse m i t L o c t i t e Type 573 a b g e d i c h t e t .
S u r f a c i n g on b r a k e sealed by L o c t i t e Type 573.
Les s u r f a c e s du f r e i n de r e t e n u e sont etanches p a r L o c t i t e Type 573.
S u p e r f i c i e s p l a n a s en e l f r e n o de retención hermetizadas con L o c t i t e
Tipo 573.
Versehraubungsgewinde d e r R o h r l e i t u n g e n und d i e Verbindungsfläche des
A n t r i e b s m o t o r s zum G e t r i e b e m i t L o c t i t e Typ 572 a b g e d i c h t e t .
Screwing o f t h e t u b i n g and t h e c o n n e c t i o n s u r f a c e s o f t h e d r i v i n g motor
t o t h e gear a r e s e a l e d w i t h L o c t i t e t y p e 572.
1
Raccord a v i s des c o n d u i t e s e t l a s u r f a c e du moteur d e n t r a i n e m e n t au
réducteur o n t e t e etanches p a r L o c t i t e t y p e 572.
Rosca d e l r a c o r de l o s tubos y l a s u p e r f i c i e de u n i o n d e l motor de
accionamiento con e l engranaje están estanqueizadas con Loctité
Tipo 572.
A n w e n d e r v o r s c h r i f t e n d e r Firma L o c t i t e beachten.
Note a p p l i c a t i o n i n s t r u c t i o n s o f L o c t i t e .
F a i t e s a t t e n t i o n aux i n s t r u c t i o n s d ' u t i l i s a t i o n de L o c t i t e .
Tenganse en cuenta l a s i n s t r u c c i o n e s de utilización dadas p o r L o c t i t e .

Heustraße 1
Doc.-No.: ANZUGSM5/TXTKD Page 1
M E R K B L A T T
über d i e Aufrechterhaltung der B e t r i e b s b e r e i t s c h a f t

von Seilwinden und Drehwerksgetrieben
1.) E i n l e i t u n g
Bei der konstruktiven Auslegung und Berechnung von Kränen w i r d eine Gesamt-
Gebrauchsdauer (Lebensdauer) zu Grunde gelegt. Die verwendeten Aggregate,
wie' u.a. Seilwinden und Drehwerksgetriebe, werden e b e n f a l l s unter Berücksich-
t i g u n g der Einschaltdauer und der Belastungsart ( L a s t - K o l l e k t i v ) auf eine
z e i t l i c h begrenzte, t h e o r e t i s c h e Lebensdauer dimensioniert. Wenn e i n Kran oder
eine Seilwinde z.B. m i t einem härteren B e l a s t u n g s k o l l e k t i v betrieben w i r d a l s
für d i e Auslegung angenommen, kann d i e Gesamt-Gebrauchsdauer stark verkürzt
werden. Auch d i e Betriebstemperatur (» öltemperatur) hat z.B. e b e n f a l l s einen
sehr starken Einfluß auf d i e Schmierfähigkeit und Lebensdauer des Öles und
damit auf die Lebensdauer eines Planetengetriebes.
Zur Aufrechterhaltung der B e t r i e b s s i c h e r h e i t müssen deshalb vom Kranbetreiber,

neben der gründlichen Wartung, b e r e i t s vor Erreichen der theoretischen Gesamt-
Gebrauchsdauer r e c h t z e i t i g vorbeugende "Instandhaitungs-Maßnahmen" e i n g e l e i t e t
werden.
2.) Vorbeugende Instandhaltung
2.1) VerschIeIßkontro11e PIanetengetr i ebe
In unserer "Anweisung für Getriebe lnspektionen" haben w i r w i c h t i g e Hinweise

bezüglich ölfärbung und f e s t e Fremdstoffe gegeben bzw. Konsequenzen aus dessen
Ergebnissen empfohlen.
Zwischenzeitlich g i b t es gut p r a k t i k a b l e Möglichkeiten, k u r z f r i s t i g genaue

ölanalyseo beim " S p e z i a l i s t e n " durchführen zu lassen.
Fa. WEARCHECK GmbH, 83098 Brannenburg, i s t eine unabhängige Familiengesellschaft,

die mit modernsten Analysen-Automaten und zugeschalteter Datenbank Innerhalb
von 2-3 Tagen ölanalysen durchführt.
Die ölanalyse g i b t Aufschluß über Menge und A r t von Verschleißmetallen,

A d d i t i v e , Verunreinigungen und öl zustand, dessen Gesamtergebnis nochmals
allgemeinverständlich I n t e r p r e t i e r t wird.
WEARCHECK GmbH a r b e i t e t im Verband und in ständigem Erfahrungsaustausch mit dem

WEARCHECK-Labor in USA, Kanada, England, Südafrika, A u s t r a l i e n , Belgien und
Spanien.
(Nähere Hinweise erhalten S i e von Wearcheck

Tel. 08034-1690 - Fax. 08034-1699)
- 2-
- 2 -
2.2) V e r s c h l e i B k o n t r o l l e Z a h n p r o f i l W e l l e
Hvdrau11kmotor/AntrIeb P I a n e t e n q e t r I e b e
Im Z a h n p r o f i l b e i d e r T e i l e e n t s t e h e n d u r c h Schwingungen k l e i n s t e R e l a t i v -
bewegungen, d i e zum Verschleiß ( R e i b k o r r o s i o n , Passungsrost) führen können.
Insbesondere b e i extremen B e t r i e b s b e d i n g u n g e n , z.B. G r e i f e r b e t r i e b , C o n t a i n e r -
b e t r i e b m i t hoher V o l l a s t e i n s c h a l t d a u e r usw., kann nach längerer B e t r i e b s d a u e r
s t a r k e r Verschleiß a u f t r e t e n . D i e r e s t l i c h e n v e r b l e i b e n d e n schmalen Z a h n p r o f i l e
können u.U. das v o l l e Motormoment n i c h t mehr übertragen bzw. d i e Zähne werden
abgeschert.
Deshalb w i r d d r i n g e n d empfohlen, spätestens nach ca. 3000 B e t r i e b s s t u n d e n den

Verschleiß d e r Z a h n p r o f i l e durch Demontage d e r Ölmotoren zu prüfen. Wenn k e i n
oder nur g e r i n g e r Verschleiß f e s t g e s t e l l t wurde, s o l l t e d i e s e Prüfung i n an-
gemessenen Zeiträumen (z.B. jährlich) w i e d e r h o l t werden, um e i n e n genaueren
Aufschluß über den Verschleißfortschritt zu e r f a h r e n .
S o l l t e durch Verschleiß, gegenüber dem Neuzustand, mehr a l s ca. 30% d e r Zahn-

b r e i t e abgetragen s e i n , muß e i n Austausch d e r T e i l e e r f o l g e n .
In diesem F a l l e empfehlen w i r den Einbau e i n e r öl geschmierten Z a h n p r o f i I - V e r -

bindung. Den hierfür e r f o r d e r l i c h e n Umbausatz e r h a l t e n S i e b e i Angabe des
G e t r i e b e t y p e s und d e r Serien-Nummer b e i u n s e r e r S e r v i c e - A b t e i l u n g .
2.3) Verschleißkontrolle S e i I t r o m m e M a g e r
Bei der m o t o r s e I t i g e n S e i I t r o m m e I l a g e r u n g werden r e i c h l i c h d i m e n s i o n i e r t e

Nadellager, f l a n s c h s e i t l g P e n d e l r o l l e n l a g e r verwendet. Für d i e Lebensdauer
d i e s e r Wälzlager I s t d i e regelmäßige Nachschmierung entsprechend den v o r g e -
schriebenen S c h m i e r i n t e r v a I I e n von e n t s c h e i d e n d e r Bedeutung.
Bei d e r m o t o r s e i t i g e n Lagerung w i r d d e r Raum zwischen i n n e r e r D i c h t u n g und

äußerer L i p p e n d i c h t u n g m i t A l t f e t t gefüllt. B e i d e r gegenüberliegenden
F l a n s c h l a g e r u n g b i l d e t das ausgepreßte A l t f e t t e i n e n F e t t k r a g e n . E i n e U n t e r -
suchung d i e s e s A l t f e t t e s h i n s i c h t l i c h Färbung, A b r i e b und F r e m d s t o f f e l i e f e r t
frühzeitig w i c h t i g e Hinwelse über den Zustand und Verschleiß des Lagers. Eine
zusätzliche Überprüfung des L a g e r s p i e l e s g i b t e b e n f a l l s Aufschluß über einen
möglichen Verschleiß des Lagers.
Das normale S e i I t r o m m e I l a g e r s p i e l beträgt zwischen 0,2 - 0,4 mm j e nach S e i l -
windengröße.
Achtung:
Bei w e i t f o r t g e s c h r i t t e n e m Verschleiß des m o t o r s e i t i g e n S e i I t r o m m e I l a g e r s e n t -
stehen zusätzliche, erhöhte Kräfte an d e r Schraubverbindung zwischen S e i l t r o m m e l
und P l a n e t e n g e t r i e b e .
- 3 -
3.) V o r t e i l e f ü r den G e r ä t e - B e t r i e b e r :
Wertvolle, f r ü h z e i t i g e Informationen ü b e r den Zustand der Planetengetriebe

und Sei ItrommeIlagerung lassen l a n g f r i s t i g e Planungen und Dispositionen
f ü r preiswerte Instandsetzungen vor dem Maschinenausfall zu. Teure S t i l l -
standzeiten zu ungeeigneten Zeitpunkten werden vermieden.
Sparen S i e Kosten und Ä r g e r , e r g r e i f e n S i e Maßnahmen
zur vorbeugenden Instandhaltung 1

S P E C I F I C A T I O N
for maintaining the operating condition of

rope w i n c h e s and gear boxes
1.) I n t r o d u c t i o n
The c o n s t r u c t i v e i n t e r p r e t a t i o n and c a l c u l a t i o n o f cranes J s based on a t o t a l

o p e r a t i o n p e r i o d ( l i f e t i m e ) . The used a g g r e g a t e s such as rope winches and gear
boxes are a l s o dimensioned t o a t e m p o r a r y l i m i t e d , t h e o r e t i c a l l i f e t i m e con-
s i d e r i n g t h e i r o p e r a t i n g p e r i o d and k i n d o f l o a d i n g ( l o a d c o n t r o l ) . In case a
c r a n e or a rope winch i s o p e r a t e d by g r e a t e r loads t h a n dimensioned, t h i s may
considerably shorten the t o t a l o p e r a t i o n p e r i o d . Also the o p e r a t i o n temperature
(=• o i l temperature) has g r e a t i n f l u e n c e t o l u b r i c i t y and o i l l i f e t i m e and so t o
t h e l i f e t i m e o f t h e p l a n e t a r y gear.
For m a i n t a i n i n g t h e o p e r a t i n g s e c u r f t y , t h e c r a n e o p e r a t o r has - b e s i d e s t h e
c a r e f u l maintenance - t o t a k e p r e v e n t i v e "maintenance measures" i n t i m e ,
b e f o r e t h e t h e o r e t i c a l t o t a l o p e r a t i o n p e r i o d w i l l be reached.
2.) P r e v e n t i v e maintenance
2.1) Wear c o n t r o l o f p l a n e t a r y g e a r
Our " I n s t r u c t i o n f o r gear I n s p e c t i o n " g i v e s i m p o r t a n t r e f e r e n c e s as t o o i l

c o l o r and s o l i d i m p u r i t i e s r e s p . recommends consequences of t h e i r r e s u l t s .
Meanwhile t h e r e are p r a c t i c a b l e p o s s i b i l i t i e s t o I n s t r u c t immediate e x a c t o i l

analysises at " s p e c i a l i s t s " .
Messrs. WEARCHECK GmbH, 83098 Brannenburg, i s an Independent f a m i l y company

who makes o i l a n a l y s i s e s w i t h i n 2-3 days w i t h l a t e s t apparatuses and connected
d a t a bank.
The o i l a n a l y s i s g i v e s e x p l a n a t i o n on q u a n t i t y and t y p e of a b r a s i o n m e t a l s ,
a d d i t i v e s , i m p u r i t i e s and o i l s t a t u s . I t s t o t a l r e s u l t w i l l be e x p l a i n e d
g e n e r a l l y i n t e l l i g i b l e once more a f t e r w a r d s .
WEARCHECK GmbH i s w o r k i n g In a s s o c i a t i o n and s t e a d y exchange o f e x p e r i e n c e w i t h

WEARCHECK Labours i n USA, Canada, Great B r i t a i n , South A f r i c a , A u s t r a l i a ,
Belgium and Spain.
(For f u r t h e r d e t a i l s c o n t a c t Wearcheck - Phone 08034-1690 - Fax 08034-1699)
- 2 -
- 2 -
2.2) Wear control tooth profile shaft

hydraulic motor/drive planetary gear
Oscillations cause smallest relative movements in the tooth profile which may
imply their wear (fretting corrosion). Especially under extreme working conditions,
e.g. service with grabs, containers with high full load operation etc., strong
wear may occur after a longer service period. The remaining weakened cross-
sections of the tooth profiles may probably no more transfer the full motor
torque resp. the teeth are sheared off.
Therefore we recommend to dismantle the oi I motors and check the wear of the
tooth profile after about 3000 working hours. In case there is no or less wear,
this inspections should be repeated in adequat periods (e.g. annually) in order
to get an exact information concerning the progress of wear.
In case such wear should have caused a reduction of the tooth-thickness of more
than appr. 30% against to new ones, the parts must be exchanged.
In this case we recommend to mount an oil lubricated tooth profile connection.

You can get this conversion-set from our service department by indicating them
the gear type and its serial number.
2.3) Wear control cable drum bearing

For the cable drum bearing on the motor side ample dimensioned needle bearings
and self-aIigning roller bearings on flange side are used. It is very important to
grease them regularly according to the indicated greasing intervals.
Regarding the bearing on motor side the space between Inner seal and outer lip
seal is filled with old grease. At the opposite flange bearing, the extruded
old grease builds up a grease collar. An Inspection of this old grease concerning
color, abrasion and foreign materials gives important references about the
status and wear of the bearing early in time. An additional inspection of
bearing clearance gives references concerning a probable wear of It. The usual
cable drum bearing clearance is"0,2 - 0,4 mm, depending on the rope winch size.
AttentIon:
In case the cable drum bearing on motor side is much worn, there occur additional
elevated forces at the screw connection between cable drum and planetary gear.
- 3 -
- 3 -
3. ) Advantages Tor the Operator»
Useful Information in time concerning the condition of planetary gear and

cable drum bearing means long-termed plannings and disposals f o r reasonable
repairs before t h e i r t o t a l breakdown. Expensive periods of disuse t o un-
suitable times can so be avoided.
Avoid expenses and worry - take measures
t o preventive maintenance !
C A R E AND MAINTENANCE OF WIRE R O P E S
TABLE OF CONTENTS
1 Types of Wire Ropes to be Used
2 Unloading Wire Ropes
3 Storing Wire Ropes
4 Mounting Wire Ropes

4.1 Unwinding from the Coil
4.2 Reeling Off
4.3 Mounting the Wire Rope
4.4 Rereeling onto the Rope Drum
4.5 Reeving a New Rope
4.6 Winding up under Load
4.7 Cutting Wire Ropes
5 Maintaining Wire Ropes

5.1 Re-Lubricating Wire Ropes
5.2 Cleaning Wire Ropes
5.3 Removing Broken Wires
5.4 Cutting off, Shifting or Turning Wire Ropes
6 Inspecting Wire Ropes

6.1 Replacement Criteria of Wire Ropes
6.2 Which Parts of a Wire Rope are to be Inspected?
6.3 Determination of the Number of Broken Wires
6.4 Determination of Wire Rope Diameter
6.5 Checking the Structural Strength of the Wire Rope
6.6 Inspecting Rope Sheaves and Rope Drums
6.7 Rope Thimble Replacement
BAUER
CARE AND MAINTENANCE OF WIRE ROPES
Types of Wire Ropes to be Used
When wire ropes are worn they are to be replaced by new wire ropes of the same type,
with the same nominal diameter, the same rated strength as well as the same type and
direction of lay of strand as the original ropes.
Unloading Wire Ropes
To prevent damage when unloading wire ropes, we recommend lifting coiled rope with a
textile strap and inserting a rod through the shaft of reels before lifting (see fig. 1).
JASWAA004
ftSWAAOOg
Fig. 1 ASWAA003
A
Lifting coils and reels with a fork lift truck or a lifting hook (see fig. 2)
without any auxiliary devices and dropping coils or reels from the trans-
port vehicle may cause irreparable damage to the outer layers of the wire
CAUTION rope.
1
BAUER
3 Storing Wire Ropes
Wire ropes are to be stored in clean, cool and dry places. To avoid ground contact coils
and reels are to be stored on pallets (see fig. 3).
If the only possible place to store coils and reels is outdoors, wire ropes must be covered
so as to protect against rain. A layer of sackcloth prevents damage by condensation water
(see fig. 4).
2
4 Mounting Wire Ropes
4.1 Unwinding from the Coil
Wire ropes on coils can be unwound either with a rotary plate or by rolling them off on the
ground (see fig. 5).
A
To prevent sand etc. from sticking to the rope's lubricant the ground
should be clean. Sand and dirt may cause damage to the rope during
operation.
CAUTION
lASWAAOOT) jASWAAQpg
Fig. 5
4.2 Reeling Off
It Is not practical to roll off the wire rope immediately onto the ground, because the length
of wire unwound in this way does not correspond to the length rolled off at the reel and so,
the wire rope is always dragged behind (see fig. 7).
Fig. 7 AswAAoni
Do not unwind wire ropes to the side of the coil or reel under any
circumstances (see fig. 8).
CAUTION
BAUER
Winding wire rope off sidewards causes the rope to twist, which eventually alters the load
distribution in the rope.
Wire rope wound off to the side from a coil or reel will resist the twisting force exerted upon
it and form loops. When a rope in this state is under load the loops straighten out due to
force and kinks are thus formed (see fig. 9). A kink is an irreparable deformation and
reduces the rope force by 15 to 20 %.
Abb. 9 frswAAoi4
Wire ropes with kinks are not operationally reliable and must be discar-
ded.
CAUTION
Never pull a loop out of a rope by force but twist the rope to unwind and straighten the loop
while the rope is not under tension.
5
4.3 Mounting the Wire Rope
WARNING!
Always wear working gloves when handling wire ropes.
Before mounting new wire ropes, it is imperative to observe the following instructions:
• Wire ropes must be free of corrosion, damage and dirt.
• The new wire rope to be mounted must have the same rope drive as the original rope.
Special attention is to be paid to the rope end mounts. Make sure that the new wire
rope is anchored in the end mounts in exactly the same way as the original rope. It is
strictly prohibited to make any alterations or supplements.
• If the new rope is cut off from a rope supply, ensure that the strands and wires do not
untwist and distort at the rope ends, unless this is necessary for mounting the rope.
• Before installing a new wire rope, make sure that the grooves in the rope drums and
rope sheaves match the diameter of the rope.
• Before operation with the new wire rope, make sure that it is correctly reeved and
properly fit into the grooves of the rope drums and rope sheaves. Check the rope for
correctness by moving it a few times with little load for test purposes. The load may
not exceed 10% of the full load.
• After a new wire rope has been installed, all parts connected to the rope drive, such
as overhoist limiters, overload protection devices and rope hold-down rollers, are to
be checked for safe and working order.
• During the first weeks after a new wire rope has been installed, the wire rope and the
rope end mounts are to be inspected more frequently than usual.
There are different ways of mounting a new wire rope depending on the kind of appliance
and type of rope drive used:
- Remove old wire rope and then mount the new wire rope.
- Install new wire rope using the old rope for help.
- Install new wire rope using an auxiliary rope for help.
The user has to decide whether the rope is to be reeved through all rope guides of the
device or first rereeled directly from the coil or reel onto the rope drum and then reeved by
hand or with an auxiliary rope.
BAUER
4.4 Rereeling onto the Rope Drum
Each wire rope is manufactured with a bending line. Make sure that the correct bending
line is maintained when the wire rope is rereeled from the reel onto the rope drum (see
fig. 10).
Fig. 10 ASWAA013
8
4.5 Reeving a New Wire Rope with the Old Rope or with an Auxiliary Rope
The new wire rope can be connected to the old wire rope or an auxiliary rope either by
means of welded eyes, which are joined together with strands or thinner ropes, or a rope
braiding (see fig. 12).
We recommend the use of a non-spinning wire rope as auxiliary rope. If a conventional

wire rope is used make sure that it has the same direction of lay as the new rope.
Make sure that the old wire rope or the auxiliary rope do not cause the
new wire rope to spin. Use a rope swivel if necessary.
CAUTION
Because welded connections are rigid, it is not advisable to weld the wire ropes together.
1
IASWAA0H 1HSWAA016I
Fig. 12
4.6 Winding up under Load
In the case of multiple layer winding on the rope drum it may be necessary to initially tension
the wire rope.
The initial tension should be approx. 1 to 2 % of the wire rope's breaking load.
Initial tension is produced by braking the flange of the reel with a wooden plank (see fig.
13) or by operating a brake sheave mounted to the outside of the reel (see fig. 14). The
braking strings are provided by the rope manufacturer.
A
Never generate initial tension by clamping the rope, e.g. by passing the
rope between wooden clamps, for this may lead to irreparable deforma-
tions (see fig. 15).
CAUTION
Fig. 15 ASWAA021I
10
4.7 Cutting Wire Ropes
Wire rope scissors can be used to cut wire ropes with a diameter of up to 8 mm. For larger
wire rope diameters mechanical or hydraulic cutters are available, but normally a right
angle grinder is used.
It is imperative to carefully bind the ropes on both sides of the point to be cut so as to
prevent the rope ends from springing open or the lengths of lay from being altered.
Wire ropes are to be bound with iron wire.
We recommend to proceed as follows (see

fig. 16):
a) * Mark the point of separation with chalk or

adhesive tape.
* Span the binding wire horizontally along the

rope at a length of 4 times the wire rope
diameter.
* Wind the binding wire around the wire rope

from the point of separation.
b) Tightly wind the binding wire around the wire

rope until the binding wire is 3 times the length
of the wire rope's diameter.
c) Twist the two wire ends together with pliers.
d) * Cut the cabled binding wire ends with pliers

to the length of the wire rope's diameter.
* Drive the wire ends carefully into a gap

between two outer strands of the wire rope.
Fig. 16 j4SWAA02g
* Cut the wire rope with a right angle grinder.
11
5 Maintaining Wire Ropes
Wire ropes are to be maintained at regular intervals as stated in the regulations of the host
country. The maintenance and checks to be carried out depend on the type of lifting gear,
its application and the type of rope used.
Regular maintenance helps to increase a wire rope's service life considerably.
5.1 Re-Lubricating Wire Ropes
Wire ropes and especially the bending areas at drums and sheaves are to be lubricated
regularly at intervals according to the operating conditions.
Lubrication reduces friction and possible corrosion.
The lubricants used must be compatible with the lubricant already in the
wire rope.
Oils and greases with certain additives may penetrate to the innermost
parts of the rope.
NOTE
5.2 Cleaning Wire Ropes
Wire ropes with a heavily-dirtied exterior should be cleaned from time to time.
This is especially true for wire ropes onto which chemically reacting material may settle
and which are used in heavily abrasive conditions.
12
BAUER
5.3 Removing Broken Wires
If ends of broken wires, which may damage adjacent wires, are detected during inspection
remove them as follows:
Bend the wire end repeatedly backward and forward with your fingers or a tool until the
wire breaks at the point where it is bonded into the structure of the rope (see fig. 18).
13
5.4 Cutting off, Shifting or Turning Wire Ropes
The service life of parts of wire ropes which are subject to heavy stress or wear can be
considerably Increased by taking one the following measures:
— In the case of heavy stress on the drum, where the rope has to climb from the first to
the second layer, the rope can be shortened so as to shift the stress onto a different
part of the wire rope.
— In the case of heavy wear on the drum, where a rope line contacts the adjacent winding
and is diverted sidewards, the parts of rope worn and stressed in this way can be moved
to another place by shifting the rope several times.
— In the case of each half of the rope being stressed and worn very differently, service
life may be considerably Increased by turning the wire rope.
14
6 Inspecting Wire Ropes
WARNING!
Wire ropes are consumables with a limited service life. During its service
life many characteristics and features of a wire rope are subject to
change. Therefore it is essential to comply to the following regulations..
• Wire ropes and wire rope end mounts are to be checked daily for possible damages
and deformations, especially those parts of wire rope contacting the device.
• Wire ropes are to be checked regularly by skilled experts for operational safety.
• Inspections are to be carried out frequently enough to allow possible damages to be

detected on time. Therefore the inspection intervals during the first weeks after
installment and after the first wire breaks have been detected should be shorter than
usual.
• In the case of extraordinary wear or stress and of suspected but invisible damage,
inspections should be carried out more frequently.
• Wire ropes must be inspected after long-term standstills (3 months or more), every
time the drilling rig is put into service on a new site for the first time and after any
accidents or damages involving the rope drives.
• When inspecting wire ropes special attention is to be paid to those parts which
frequently run over rope sheaves and are near anchors or mounts. Regular inspection
helps to detect possible wire breaks early.
• Where plastic sheaves or metal sheaves with plastic lining are used, inspections are
to be carried out at shorter intervals.
• Special attention is to be paid to those parts which are not or only poorly greased.
• Rope sheaves, rope drums and compensation rollers are to be inspected as required,
however at least once a year and after every installation of a new wire rope.
• The inspection results are to be recorded in an inspection book so as to maintain a

complete log of the checks carried out at regular intervals.
16
6.1 Replacement Criteria of Wire Ropes
The replacement criteria of wire ropes are defined by the ISO stand-
ard 4309. The operational safety of wire ropes can be determined accor-
ding to the following criteria:
NOTE
a) Type and number of wire breaks

b) Wire breaks at the end of a wire rope
c) Position of wire breaks
d) Intervals of time between wire breaks occurring
e) Strand breaks
f) Reduction in rope diameter (necking)
g) Reduction in rope elasticity
h) External and internal wear
i) External and internal corrosion
j) Wire rope deformations
k) Rope deformations by heat or sparks
I) Elongation of the rope over a period of time.
• A skilled expert is to determine the operating safety of a wire rope according to the
criteria listed above.
• Most rope defects are a result of several factors.
• It is essential to check whether a defect in the rope has been caused by a defective
device.
If this is the case the defective device is to be repaired before installing a new rope.
WARNING! I
For the sake of safety, wire ropes which fulfil one or more of the following
replacement criteria are to be discarded.
Failing to replace faulty wire ropes may cause serious damage and may
lead to serious or even fatal accidents.
17
a) Type and Number of Wire Breaks
• With wire ropes of 6 and 8 strands wire breaks occur mostly on the surface.
• With multi-strand wire ropes wire breaks occur mostly in the interior of the rope and
are therefore unrecognizable.
• In Tables 1 and 2 the factors mentioned above are taken into account.
• The replacement criteria of rotation-resistant ropes is also to be determined according

to the wire rope construction, the date of installation and the kind of application.
• Table 2 deals with rotation-resistant wire ropes.
WARN1NG1
At the latest, a wire rope is to be discarded when the number of wire
breaks detected corresponds to the number indicated in the table.
In Tables 1 and 2 the columns for the drive gear groups M1 and M2 are
relevant.
NOTE
18
Table 4 - 1 0 Replacement state of wear of wire cables due to wire breaks
Number of visible wire breaks during replacement state of wear
Number of load-bearing Drive gear groups Drive gear groups

wires in the outside M1, M2, M3 and M4 M5, M6, M7 and M8
strands of the wire ca-
ble 1
Crosslay Long lay Crosslay Long lay
at a length of at a length of at a length of at a length of
n 6d 30d 6d 30d 6d 30d 6d 30d
50 2 4 1 2 4 8 2 4
51 to 75 3 6 2 3 6 12 3 6
76 to 100 4 8 2 4 8 16 4 8
•101 to 120 5 10 2 5 10 19 5 10
121 to 140 6 11 3 6 11 22 6 11
141 to 160 6 13 3 6 13 26 6 13
161 to 180 7 14 4 7 14 29 7 14
181 to 200 8 16 4 8 16 32 8 16
201 to 220 9 18 4 9 18 35 9 18
221 to 240 10 19 5 10 19 38 10 19
241 to 260 10 21 5 10 21 42 10 21
261 to 280 11 22 6 11 22 45 11 22
281 to 300 12 24 6 12 24 48 12 24
above 300 2
0.04.n 0.08.n 0.02.n 0.04.n 0.08.n 0.16.n 0.04.n 0.08.n
Filler wires are not deemed as load-bearing.

In the case of wire cables with multiple strand plies only the strands of the outermost strand
ply are deemed to be "outside strands".
In the case of wire cables with steel reinforcement the reinforcement should be regarded as
an inner strand.
The figures calculated should be rounded off.
With cable designs with especially thick wires in the outside turn of the
outside strands, e.g. round strand cable 6x19 core in accordance with
DIN 3058 or round strand cable 8x19 core in accordance with DIN 3062,
the number of visible wire breaks for the replacement state of wear is to
NOTE
be assumed to be 2 lines lower than as given in the tabular values.
19
Table 2 Number of visible wire breaks in rotation-resistant wire ropes, running on steel
sheaves
Number of visible wire breaks

Drive gear groups Drive gear groups
M1, M2, M3 and M4 M5, M6, M7 and M8
on a length of on a length of
6d 30 d 6d 30 d
2 4 4 8
b) Wire Breaks at the End of a Wire Rope
— Wire breaks at the end of a wire rope are an indication of high stress and incorrect
mounting of the rope end.
- If the wire..rope is to be used further the rope end should be cut off and a new rope end
mount installed.
c) Position of Wire Breaks
— If wire break clusters occur, the wire rope is to be discarded immediately.
- In the case of wire break clusters occurring on a length of less than 6 times the wire
rope's diameter or if the wire clusters occur on a single strand, the wire rope is to be
discarded, even if the number of broken wires is less than indicated in Tables 1 and 2.
d) Intervals of Time between Wire Breaks Occurring
- As a rule, it takes some time for wire breaks to occur, but they then rapidly increase.
Once a wire break has been detected, the rope is to be checked regularly and
thoroughly so as to watch the development of wire breaks and to determine the
condition of the rope with regards to replacement.
e) Strand Breaks
The wire rope is to be immediately discarded when a whole strand breaks.
f) Reduction in Rope Diameter due to Changes in the Wire Rope's Core
- There are various reasons for changes in the wire rope's core causing a reduction in
the rope diameter:
* Internal wear and notches
* Internal wear by friction and flexion
* Degradation of core's fibre structure
* Fracture of a steel core
* Fracture of inner layers of multiple layer constructions.
- Rotation-resistant wire ropes are to be discarded when their nominal diameter is

reduced by 3 % due to one of the above reasons. Other wire ropes are to be replaced
when their diameter is reduced by 10%.
- The wire ropes are to be discarded even if no wire fractures are visible.
g) Reduction in Rope Elasticity
— A reduction in elasticity is not easy to detect and should therefore be determined by a

skilled expert.
- For the sake of safety, a wire rope is to be discarded when the elasticity is reduced
resulting from one of the following reasons:
* Reduction in the wire rope's diameter

* Elongation of the rope
* Reduction in the gaps between the wires and strands resulting from compression
* Fine, brown powder emerging from between the strands
* The wire rope is noticeably stiffer, although no wire fractures are visible. The wire
rope's diameter is reduced more than expected with normal wear.
21
h) External and Internal Wear
— Abrasion is evoked by the strands and wires coming into contact when under pressure,
by the wire rope bending, by movements of wire rope in rope sheaves and by the rope
being dragged along the ground.
— Wear is encouraged by lack of lubricant, false lubrication and dirt or large-grained sand.
— A reduction in the wire rope's diameter due to wear leads to a reduction of the rope's
carrying force.
— When the diameter of a wire rope has been reduced by 7 % or more resulting from
external wear, it is to be discarded, even if no wire fractions can be detected.
i) External and Internal Corrosion
— Corrosion is promoted by operation under aggressive environmental conditions.
— Corrosion causes the metal profile to diminish and thus leads to a reduction of the rope's
breaking strength.
— Corrosion also leads to the development of uneven surfaces which may start to break
when under load.
• External Corrosion
Corrosion of outer wires can be detected by visual inspection.
• Internal Corrosion
It is difficult to detect internal corrosion. However, the following characteristics of a rope

may point to internal corrosion:
* Changes in the wire rope's diameter:

The wire rope's diameter may be reduced at spots running over sheaves.
The diameter of idle wire ropes may also increase resulting from rust beneath the
outer strands.
* A reduction in the gaps between the outer layers of strand, possibly in combination
with wire fractures in the strands.-
22
- In the case of suspected internal corrosion the wire rope is to be inspected by a skilled
expert.
If the suspicion is confirmed the wire rope is to be immediately discarded or replaced.
j) Wire Rope Deformations
Wire rope deformations are visible changes to the rope structure caused by excessive
strain or damages. The various forms of deformation are grouped according to their
appearance as follows:
1. Corkscrewing
A wire rope must be discarded when the pinch of a corkscrewing deformation reaches a
height corresponding to 1/3 of the rope's diameter, because an increase in the wear and
in the number of wire fractures is expected. Corkscrewing deformations are measured
without load.
pjg_ -|g IASWAA031I
2. Basketing
Basketing deformations are caused when the rope is extended by force and the outer
strands are thus forced to change their position in the rope.
When the slack rope is suddenly strained, the outer strands extend while the inner strands
remain the same.
Wire ropes with basketing are to be immedi-

ately discarded.
Fig. 20 |ASWAA03q
23
3. Protrusion of Strands
Torsional unbalance may lead to the protrusion of strands from the rope structure.
Wire ropes with protruding strands are to be discarded immediately.
Fig. 21 ASWAA0271
•>
4. Protrusion of Wires
Shock loading may lead to Individual wires or groups of wire protruding from the rope
structure and forming loops.
If the rope's structure is noticeably modified by protruding wires, the rope is to be discarded.
pjg 22 ASWAA033
5. Local Increase In "Rope Diameter
A local increase in the rope diameter is caused when the core is twisted and the outer
strands are thus forced outwards from their correct location.
The wire rope is to be discarded when a noticeable local increase in the rope diameter
occurs.
jASWAA02E|
6. Local Reduction in Rope Diameter
A local reduction in the rope's diameter may be caused by a core fracture, in which case
the outer strands slip into the place where the core has broken. Special attention is to be
paid to those parts of the rope which are near the end mounts.
The wire rope is to be discarded when a noticeable local reduction in the rope diameter
occurs.
Fjq. 24 iftswAA03q
25
7. Flattenings
Flattenings of the rope structure are caused when the wire rope is crushed. Flattenings
cause an increase in wire breaks.
Flattenings can also be caused by the incorrect reeling of ropes onto drums.
Wire ropes with strong flattenings are to be discarded.
Fig. 25 ASWAA037I
8. Kinks
Kinks are deformations which are caused when a wire rope with loops is pulled straight.
Wire ropes with kinks are to be discarded .immediately.

9. Pinches
Pinches are caused by forceful external influences.

Wire ropes with kinks are to be discarded immediately.
Fig. 27 iASWAA03S|
k) Rope Deformations by Heat or Sparks
When wire ropes are exposed to temperatures exceeding 300 C their breaking strength
is noticeably reduced. Discolouration of the wire rope indicates exposure to excessive
heat.
Wire ropes damaged through exposure to excessive heat are to be discarded.
I) Service Life
Employees with enough experience in wire ropes may determine when a rope is to be
replaced. However, the above-listed criteria are critical.
27
6.2 Which Parts of a Wire Rope are to be Inspected?
• As a rule, the full length of the wire rope is to be inspected.
• Special attention is to be given to the following parts:
— Rope end mounts.

— Parts of the wire rope which run through rope blocks or over rope sheaves, especially
those which always run over the sheaves under load.
— Parts which run over compensation rollers.
— Parts which are subject to wear by external friction.
— Parts which are subject to corrosion and fatigue.
— Parts which are exposed to heat.
• Rope end mounts

The parts at the rope end mounts are to be specially checked for wire breaks and
corrosion.
The end mount itself is to be checked for deformation and wear.
The inspection results should be written down to ensure comparative

values for later inspections.
NOTE
6.3 Determination of the Number of Broken Wires
To be able to determine the exact number of wire breaks, the whole wire rope is to be
checked to find the place with the most wire breaks.
Dirty wire ropes are to be cleaned thoroughly before starting the inspection.
To determine the number of broken wires proceed as follows:
- Mark the piece of rod with the highest number of wire breaks at a length corresponding
to 30 times the wire rope's diameter.
Where wire break clusters or local damages are found the wire rope is to be marked
additionally at a length corresponding to 6 times the wire rope's diameter.
- Count the wire breaks within the marked areas either by inspecting the wire rope visually
or by feeling for the breaks and write the results down.
- Compare the number of wire breaks found to the permissible number of wire breaks
according to ISO 4309 (see section 6.1 .a).
29
BAUER
6.4 Determination of Wire Rope Diameter
To be able to calculate tolerances and later reductions in diameter, a wire rope is to be

measured several times when it is delivered fresh from the factory.
To receive the correct diameter value, the wire rope's hypersurface, i.e. the distance from
one strand summit to another strand summit is to be measured (see fig. 28 a).
When the wire rope's diameter is measured across gaps, the result will be incorrect (see
fig. 28 b).
When the number of outer strands is even (4-, 6-, 8-, 10-,...strand) a normal calliper gauge
may be used.
With wire ropes whose number of outer strands is uneven (3-, 5-, 7-, 9-,...strand) we
recommend the use of a calliper gauge with broad measuring surfaces, because strand
summit and gap are opposite each other.
So as to detect oval deformations of the wire rope it is necessary to measure the rope's
diameter at one point and then turn the calliper gauge.90 and measure the rope again at
the same point.
30
6.5 Checking the Structural Strength of the Wire Rope
The strength of a wire rope can be checked by inserting a screw driver into two outer
strands and trying to make a gap without using any force.
If a wire rope does not strongly resist or even allows the screw driver to be pushed through,
the wire rope's structure is too loose.
The strength of the outer wires of strand can be checked in the same way.
Bending or lifting the outer strands with the screw driver may cause
damage to the rope.
CAUTION
31
6.6 Inspecting Rope Sheaves and Rope Drums
The grooves in the rope sheaves and rope drums should be smooth and have a diameter
of 1.06 to 1.08 times the nominal diameter of the wire rope in the groove base.
Fig. 29 aswAA03q
Groove gauges are used to check the groove diameter.

Self-made circular gauges are advantageous, because they can be manufactured to fit the
required diameter exactly.
When checking the groove diameter, the depth of the groove base and its surface quality
should be inspected too.
Cavities and other alterations to the surface of the groove base and at
the groove flanks tremendously reduce a wire rope's service life. When
the wire rope is replaced the sheaves are to be replaced too. '
CAUTION
Stress marks on the groove flanks often indicate an excessive deviation angle of the wire
rope in comparison to the sheave level. The deviation angle with non rotation-resistant
wire ropes should not exceed 4 degrees. With rotation-resistant wire ropes 1.5 degrees
should be the maximum deviation.
32
6.7 Rope Thimble Replacement
The thimbles used on the wire ropes of BAUER Drilling Rigs are jointless one-piece die
cast thimbles conforming to DIN 3091.
Thimble material: GTW-40 (malleable cast iron)

GGG-40 (spheroidal graphite cast iron)
Design and dimensions:
. c . b
d i
Fig. 30 IAAAAA020I
Table 3 Thimble selection guide for liftcrane rope (sizes are in mm)
s = nominal size = 20 22 24 26 28 30 34 36 38 42
max. rope dia.
di = finished eye 40 50 40 50 60 60 80 80 80 80
dia., with a tolerance
space of D10
33
Table 4 Dimensions, tolerances and weights (sizes are in mm)
d d1
Nominal Finis hed

a b Raw
size = dimerision,
dimen-
max. with 010 Weight
sion
rope dia. toier ance c h S1
M h2 ri r2 s2
kg1)
Margi- Margi-
nal nal
devia- devia- from to
tions tions
± +
20 22 0.6 31 0.6 35 40 50 100 13.5 161 32 200 6 20 7 1.61

22 24 0.6 335 0.6 38 43 55 110 15 177 35 220 7 22 7.5 2.11
24 26 0.8 36 0.8 41 46 60 120 16.5 193 38 240 7 24 8 2.71
26 29 0.8 39.5 0.8 44 49 65 130 18 209 42 260 8 26 9 3.55

28 31 0.8 42 0.8 47 52 70 140 20 224 45 280 8 28 10 4.2
32 35 0.8 47 0.8 53 58 80 160 23 256 51 320 10 32 11 6.3
36 40 1 53 1 59 65 90 180 26 288 58 360 11 36 13 8.84

40 44 1 58 1 65 71 100 200 29 320 64 400 12 40 14 11
44 48 1 63 1 70 76 110 220 32 352 70 440 13 44 15 15
1) Weight is based on a density of 7.8 and a bore of d l = raw dimension
Material strength requirement
No visible crack, deformation or other damage in the material of the jointless thumble must
result when the thumble is loaded to the breaking point of a rope having a rated wire
breaking strength of 1960 N/sq.mm.

Bauer Spezialtiefbau GMBH D-86522 Schrobenhausen - Postfach 12 60 - Germany Phone: Germany + 8252/97-0 Fax: Germany + 8252/97-13 59

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Bauer Spezialtiefbau GMBH D-86522 Schrobenhausen - Postfach 12 60 - Germany Phone: Germany + 8252/97-0 Fax: Germany + 8252/97-13 59

Uploaded by

Copyright:

Available Formats

Instruction Manual

BAUER BG22 BAUER

BAUER SPEZIALTIEFBAU GmbH

2 Technical Data 2-1

4 Putting Into Service - Mounting - Dismounting - Transport . . .4-1

4.12 Transportation 4-37

5 Service and Maintenance 5-1

CAREFULLY READ THE WHOLE MANUAL THROUGH BEFORE YOU BEGIN.

Edited and published by BAUER SPEZIALTIEFBAU GmbH, 1996

© Copyright by BAUER SPEZIALTIEFBAU GmbH Schrobenhausen, Germany.

HOW TO USE THE MANUAL

To find information quickly

Read the following pages to understand the arrangement of the manual.

Numbering of Tables and Figures

Numbering of Items in a Figure

Reference to a section: ... (see sect. 3.1.1)

Warning is used to warn whenever incorrect observance or non-obser-

W Note is used to highlight a procedure and is in general a work facilitation.

How to reach the BAUER Service Centre

• Phone: Germany +82 52/97 - 25 86

• Fax: Germany +82 52/97 - 25 87

If your ever need to call up BAUER'S after-sales service in Schrobenhau-

• For possible check backs by BAUER:

— Contact person; Phone / Fax:

— Description of how to get to the site

UK Suisse Thailand Mexico

Portugal Spain China Peru

Bulgaria China Chile

Italy Jordan Korea

Greece Syrien Malaysia South-Africa

Turkey Iran Japan

Fig. 1/1 [BFASE0021

Special feature: Special feature: Special feature:

Fig. 1/2 BG 15 Drilling rig IBFASEOOSI

1.2.1 Rotary Drive

Rotary head = KDK 220

Two planetary gears enable switching between two modes:

The compression springs (5) of the

The cardanic joint (3) transfers the

Fig. 1/3 KDK 220 I BFASEIQ 3|

Planetary gears enable switching between two modes:

Fig. 1/4 IBFASE202I

The rake of the mast determines the

The distance between the bore axis

Fig. 1/5 Mast IBFASEECMI

The upper or Upper guide sheave The cylinder

Crowd winch •' i W

Lower guide sheave Lfl

Fig. 1/7 Masthead

1.2.5 Backstay Cylinders

Fig. 1/8 Twin backstay cylinders IBFASE035

1.2.7 Main and Auxiliary Winch

1.3.1 Design of the Base Machine

The tension of the crawler chains can be adjusted hydraulically.

The base machine is equipped with a water-cooled Caterpillar diesel engine.

To improve operating safety, limit switches monitor various functions:

Table 1 - 1 Limit switches

Fig. 1/12 IBFASE037I

2.1 DIMENSIONED DRAWING

Fig. 2/1 IBFASE038I

B Lower edge, rotary drive in highest

C Lower edge, mast (without mastfoot

Fig. 2/2 Dimensioned drawing of continuous