1770 BG24H en 0000468054 GZ

Instruction Manual
BG 24 H
BU757500.wmf
Keep this manual also for future use!
BAUER Maschinen GmbH

P.O. Box 12 60  D-86522 Schrobenhausen  Germany
Phone: +49 8252 97-0  Fax: +49 8252 97-1359
INTRODUCTION
This manual has been made for operators and maintenance personnel.
Before putting the equipment in operation, please:
Carefully read through the whole Instruction Manual and

Safety Information Book supplied with the equipment
They must be kept with the equipment and be accessible at all times!
In the Instruction Manual you will find a detailed description of the equipment, guide-
lines for transporting and putting into operation, comprehensive instructions for operat-
ing and troubleshooting and information on service and maintenance.
Technical data, dimensions and weights relate to the date of print of the manual. They
may differ slightly to those on your version of equipment, 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 equipment is fitted, and can consequently not form grounds for complaint.
The equipment shall be used only for the purposes specified in this manual.
As you will understand, the manufacturer of the equipment cannot be held responsible
for any damage caused by misuse, abuse or neglect.
The Safety Information Book supplied with this equipment comprises instructions and
regulations for the safe handling of this type of equipment and must be observed by all
means.
Also to be observed are the documents for components found in the appendices of this
manual and also all other documents supplied with the equipment.
This manual was edited and published by

BAUER Maschinen GmbH  P.O. Box 12 60  D-86522 Schrobenhausen
© Publisher’s copyright:
No part of this manual may be reproduced or translated or made available to third
parties without the express permission from the publisher.
BG 24 H / 2008 I
TABLE OF CONTENTS
INTRODUCTION............................................................................................................................................I
TABLE OF CONTENTS................................................................................................................................II
ABOUT THE MANUAL............................................................................................................................. VIII
NAMEPLATES............................................................................................................................................. X
AFTER SALES SERVICE........................................................................................................................... XI
WARRANTY TERMS................................................................................................................................. XII

WARRANTY CLAIM.................................................................................................................................. XIV
1 DESCRIPTION .......................................................................................................................1 - 1
1.1 EQUIPMENT APPLICATIONS...............................................................................................1 - 1
1.2 COMPONENTS......................................................................................................................1 - 2
1.2.1 Basic Rig / Kelly Equipment ...................................................................................................1 - 2
1.2.1.1 Components Overview ...........................................................................................................1 - 2
1.2.1.2 Components Description ........................................................................................................1 - 3
1.2.2 CFA Equipment ......................................................................................................................1 - 4
1.2.2.1 Components Overview ...........................................................................................................1 - 4
1.2.2.2 Components Description ........................................................................................................1 - 5
2 SAFETY .................................................................................................................................2 - 1
2.1 GENERAL SAFETY REQUIREMENTS .................................................................................2 - 1
2.2 EQUIPMENT SAFETY ...........................................................................................................2 - 1
2.3 MAJOR HAZARDS.................................................................................................................2 - 1
2.4 SAFETY DEVICES.................................................................................................................2 - 2
2.4.1 Emergency Stop .....................................................................................................................2 - 2
2.4.2 Pilot Control Safety Stick........................................................................................................2 - 2
2.4.3 Fire Extinguisher ....................................................................................................................2 - 2
2.4.4 Medical Box ............................................................................................................................2 - 3
2.4.5 Emergency Exit ......................................................................................................................2 - 3
2.4.6 Limit Switches.........................................................................................................................2 - 4
2.4.7 Work Platforms on Upper Carriage, at Rotary Drive or Masthead (Optional)........................2 - 5
2.5 STABILITY..............................................................................................................................2 - 6
2.5.1 Guidelines for Stability............................................................................................................2 - 6
2.5.1.1 Conditions for Operation ........................................................................................................2 - 6
2.5.1.2 Conditions for Onsite Travelling .............................................................................................2 - 6
2.5.2 Stability of BG 24 H # 1770 - Kelly BK 25/394/3/33 ...............................................................2 - 7
2.5.2.1 Load Capacity Chart...............................................................................................................2 - 7
2.5.2.2 Weights / Centres of Gravity - Drill Distance 3.50m...............................................................2 - 8
2.5.2.3 Weights / Centres of Gravity - Drill Distance 4.50m...............................................................2 - 9
2.5.3 Stability of BG 24 H # 1770 - CFA Ø 750 mm......................................................................2 - 10
2.5.3.1 Load capacity chart ..............................................................................................................2 - 10
2.5.3.2 Weights / Centres of Gravity - Drill distance 3.50m .............................................................2 - 11
2.5.3.3 Weights / Centres of Gravity - Drill distance 4.00m .............................................................2 - 12
2.6 PERMISSIBLE WIND SPEED..............................................................................................2 - 13
BG 24 H / 2008 II
3 TECHNICAL SPECIFICATIONS ...........................................................................................3 - 1
3.1 DIMENSIONS.........................................................................................................................3 - 1
3.1.1 Kelly Equipment BK 25/394/3/33............................................................................................3 - 1
3.1.2 CFA Equipment ......................................................................................................................3 - 2
3.2 EQUIPMENT SPECIFICATIONS ...........................................................................................3 - 3
3.3 ROTARY DRIVE SPECIFICATIONS .....................................................................................3 - 5
3.3.1 Rotary Drive, Shiftable ...........................................................................................................3 - 5
3.4 DRILLING SPECIFICATIONS................................................................................................3 - 7
3.4.1 Kelly Equipment......................................................................................................................3 - 7
3.4.2 CFA Equipment  750 ...........................................................................................................3 - 8
3.5 ROPE SPECIFICATIONS ......................................................................................................3 - 9
3.5.1 Main Rope ..............................................................................................................................3 - 9
3.5.2 Auxiliary Rope ......................................................................................................................3 - 10
3.5.3 Crowd Ropes........................................................................................................................3 - 11
3.6 NOISE EMISSION................................................................................................................3 - 12
3.7 TEMPERATURE CONDITIONS ..........................................................................................3 - 12
3.8 EXPOSURE TO VIBRATION ...............................................................................................3 - 12
4 CONTROLS AND INDICATORS...........................................................................................4 - 1

4.1 CAB ........................................................................................................................................4 - 1
4.2 BASE MACHINE CONTROL CONSOLE...............................................................................4 - 2
4.3 CONTROL PANEL 1 ..............................................................................................................4 - 3
4.4 CONTROL PANEL 2 ..............................................................................................................4 - 4
4.5 B-TRONIC SYSTEM ..............................................................................................................4 - 5
4.6 REMOTE CONTROL FOR CASING OSCILLATOR (OPTIONAL) ........................................4 - 6
5 OPERATION ..........................................................................................................................5 - 1
5.1 TRAVEL..................................................................................................................................5 - 1
5.1.1 To Select the Travel Mode .....................................................................................................5 - 1
5.1.2 To Travel and Steer................................................................................................................5 - 1
5.2 UPPERCARRIAGE SWING ...................................................................................................5 - 2
5.2.1 Swing Brake ...........................................................................................................................5 - 2
5.2.2 Swing Control .........................................................................................................................5 - 2
5.3 MAST REPOSITIONING........................................................................................................5 - 3
5.3.1 Mast Auto Reset to Vertical....................................................................................................5 - 3
5.3.2 Mast Repositioning by Manual Control ..................................................................................5 - 4
5.3.2.1 To Adjust the Mast Inclination ................................................................................................5 - 4
5.3.2.2 To Adjust the Drill Distance ....................................................................................................5 - 5
5.4 MAST PROP CONTROL........................................................................................................5 - 6
5.5 TRAVELLING WITH THE RIG ...............................................................................................5 - 6
5.5.1 Travelling over Level Ground .................................................................................................5 - 6
5.5.2 Travelling Up and Down Slopes.............................................................................................5 - 7
5.5.2.1 With Raised Mast without Drilling Equipment ........................................................................5 - 7
5.5.2.2 With Lowered Mast.................................................................................................................5 - 7
5.5.3 Raising the Mast - with Rotary Drive and Kelly ......................................................................5 - 8
5.5.4 Lowering the Mast - with Rotary Drive and Kelly .................................................................5 - 10
5.6 ROTARY DRIVE CONTROL................................................................................................5 - 12
5.6.1 With Kelly Equipment (Rotary Drive Shiftable).....................................................................5 - 12
5.6.2 With CFA Equipment............................................................................................................5 - 13
5.6.3 Torque Reduction by Key-Operated Switch.........................................................................5 - 14
5.6.4 Additional Functions .............................................................................................................5 - 15
5.6.4.1 To Operate with "Freewheel" (optional) ...............................................................................5 - 15
BG 24 H / 2008 III
5.6.4.2 To Operate with Torque Amplifier ........................................................................................5 - 15
5.7 WINCH CONTROL...............................................................................................................5 - 16
5.7.1 Lifting / Lowering ..................................................................................................................5 - 16
5.7.2 To Operate with Freewheel ..................................................................................................5 - 17
5.7.3 To Operate with "Slack Rope Switch-Off" ............................................................................5 - 18
5.8 DEPTH MEASURING CONTROL........................................................................................5 - 19
5.8.1 To Reset the Depth Measuring ............................................................................................5 - 19
5.8.2 To Interrupt the Depth Measuring ........................................................................................5 - 19
5.9 CROWD CONTROL.............................................................................................................5 - 20
5.9.1 Basic Functions ....................................................................................................................5 - 20
5.9.1.1 Moving the Crowd Sledge Down / Up ..................................................................................5 - 20
5.9.1.2 To Switch On Fast Crowd ....................................................................................................5 - 21
5.9.2 Special Functions .................................................................................................................5 - 22
5.9.2.1 Which Crowd Functions for Which Drilling Methods? ..........................................................5 - 22
5.9.2.2 Crowd Pressure Adjustment ................................................................................................5 - 23
5.9.2.3 Crowd Speed Adjustment.....................................................................................................5 - 24
5.9.2.4 Pulling by Crowd + Reeved Main Rope ...............................................................................5 - 25
5.9.2.5 Drilling Assistant in Kelly Operations ...................................................................................5 - 26
5.9.2.5.1 How to Control......................................................................................................................5 - 26
5.9.2.6 Drilling Assistant in CFA Operations ....................................................................................5 - 28
5.9.2.6.1 How to Control......................................................................................................................5 - 28
5.9.2.6.2 Presetting for the Drilling Assistant in CFA ..........................................................................5 - 30
5.9.2.7 Drilling Assistant in FDP Operations ....................................................................................5 - 31
5.9.2.7.1 How to Control......................................................................................................................5 - 31
5.9.2.7.2 To Assess the Strength (Penetration Rate) of the Soil ........................................................5 - 33
5.9.2.7.3 Presetting for the Drilling Assistant in FDP ..........................................................................5 - 34
5.9.2.8 Pulling Assistant Operation ..................................................................................................5 - 35
5.9.2.8.1 How to Control......................................................................................................................5 - 35
5.9.2.8.2 Presetting for the Pulling Assistant ......................................................................................5 - 37
5.9.3 To Use the Main Winch in Combination with Crowd............................................................5 - 40
5.10 AUGER CLEANER CONTROL (OPTIONAL) ......................................................................5 - 41
5.11 CENTRAL LUBRICATION CONTROL.................................................................................5 - 42
5.12 EMERGENCY CONTROL....................................................................................................5 - 43
5.12.1 Emergency Control of Engine Speed...................................................................................5 - 44
5.13 COMPRESSOR OPERATION (OPTIONAL) .......................................................................5 - 45
6 START-UP / SHUT-DOWN....................................................................................................6 - 1
6.1 START-UP..............................................................................................................................6 - 1
6.1.1 Initial Start-Up.........................................................................................................................6 - 1
6.1.2 Visual Inspection before Starting ...........................................................................................6 - 1
6.1.3 Daily Start-Up .........................................................................................................................6 - 2
6.1.3.1 Starting the Equipment...........................................................................................................6 - 2
6.1.3.2 Selecting the Work Application ..............................................................................................6 - 3
6.1.4 Safety Tests before Starting to Work .....................................................................................6 - 4
6.1.4.1 Checking the Emergency STOP ............................................................................................6 - 4
6.1.4.2 Checking the Pilot Control Safety Stick..................................................................................6 - 4
6.1.4.3 Checking the End Limiters .....................................................................................................6 - 5
6.2 SHUT-DOWN .........................................................................................................................6 - 6
6.2.1 Daily Shut-Down.....................................................................................................................6 - 6
6.2.2 Shut-Down for a longer Period...............................................................................................6 - 6
7 RIGGING / DE-RIGGING .......................................................................................................7 - 1

7.1 GUIDELINES FOR RIGGING AND DE-RIGGING.................................................................7 - 1
7.2 WAX REMOVAL.....................................................................................................................7 - 2
BG 24 H / 2008 IV
7.3 EXTENDING THE CRAWLERS ...........................................................................................7 - 3
7.4 MOUNTING THE COUNTERWEIGHT ..................................................................................7 - 4
7.5 ASSEMBLY OF MAST ...........................................................................................................7 - 6
7.5.1 Mounting the Masthead..........................................................................................................7 - 6
7.5.1.1 Folding Out the Upper Mast Extension ..................................................................................7 - 7
7.5.2 Raising the Mast – without Rotary Drive and Kelly ................................................................7 - 8
7.5.3 Mounting Supporting Clamps .................................................................................................7 - 9
7.6 ASSEMBLY OF WORK ATTACHMENTS............................................................................7 - 10
7.6.1 Assembly of Kelly Equipment...............................................................................................7 - 10
7.6.1.1 Mounting the Rope Swivel....................................................................................................7 - 10
7.6.1.2 Mounting Extension Frame to Crowd Sledge (optional) ......................................................7 - 11
7.6.1.3 Mounting the Rotary Drive....................................................................................................7 - 12
7.6.1.4 Mounting the Kelly................................................................................................................7 - 13
7.6.1.5 Mounting Kelly Guidance (optional) .....................................................................................7 - 15
7.6.2 Assembly of CFA / FDP equipment .....................................................................................7 - 17
7.6.2.1 Mounting a Wedge (only with CFA-V)..................................................................................7 - 17
7.6.2.2 Retrieving the Main Rope.....................................................................................................7 - 18
7.6.2.3 Mounting Concreting Kelly ...................................................................................................7 - 18
7.6.2.4 Mounting Concreting Kelly CFA-V .......................................................................................7 - 19
7.6.2.5 Mounting Concreting Head CFA ..........................................................................................7 - 20
7.6.2.6 Mounting Concreting Head CFA-V.......................................................................................7 - 20
7.6.2.7 Mounting Torque Support.....................................................................................................7 - 21
7.6.2.8 Mounting Torque Support.....................................................................................................7 - 21
7.6.2.9 Mounting Holding Bracket for Concrete Hose......................................................................7 - 22
7.6.2.10 Connecting Concrete Pressure Gauge ................................................................................7 - 22
7.6.2.11 Mounting CFA Auger............................................................................................................7 - 23
7.6.2.12 Mounting the Tubes and the Full Displacement Head (FDP) ..............................................7 - 26
7.6.2.13 Mounting Auger Guidance ...................................................................................................7 - 27
7.6.2.14 Mounting CFA Auger Cleaner ..............................................................................................7 - 28
7.6.2.15 Mounting the FDS Tube Guide ............................................................................................7 - 29
7.6.2.16 Installing Main Rope for "CFA with Main Winch" Mode .......................................................7 - 30
7.6.2.17 Mounting Crossbeam to Rotary Drive for "CFA with Main Winch" Mode ............................7 - 31
7.7 DISASSEMBLY OF WORK ATTACHMENTS......................................................................7 - 32
7.7.1 Disassembly of Kelly Equipment..........................................................................................7 - 32
7.7.1.1 Removing the Kelly ..............................................................................................................7 - 32
7.7.1.2 Removing the Rotary Drive ..................................................................................................7 - 32
7.7.2 Disassembly of CFA Equipment ..........................................................................................7 - 33
7.7.2.1 Removing CFA Auger Cleaner.............................................................................................7 - 33
7.7.2.2 Removing the Auger Guidance ............................................................................................7 - 33
7.7.2.3 Removing CFA Auger ..........................................................................................................7 - 34
7.7.2.4 Removing Torque Support ...................................................................................................7 - 35
7.7.2.5 Removing Concreting Head CFA-V .....................................................................................7 - 35
7.7.2.6 Removing the Concreting Head ...........................................................................................7 - 36
7.7.2.7 Removing Concreting Kelly CFA-V ......................................................................................7 - 36
7.7.2.8 Removing Concreting Kelly ..................................................................................................7 - 37
7.7.2.9 Removing the Wedge (only with CFA-V) .............................................................................7 - 38
7.8 DISSASSEMBLY OF THE MAST ........................................................................................7 - 39
7.8.1 Removing the Supporting Clamps .......................................................................................7 - 39
7.8.2 Lowering the Mast - without Rotary Drive and Kelly ............................................................7 - 40
7.8.3 Lowering the Masthead ........................................................................................................7 - 41
7.8.4 Folding in the Upper Mast Extension ...................................................................................7 - 42
7.9 REMOVING THE COUNTERWEIGHT ................................................................................7 - 43
7.10 RETRACTING THE CRAWLERS.......................................................................................7 - 45
8 TRANSPORT .........................................................................................................................8 - 1
BG 24 H / 2008 V
8.1 SAFETY GUIDELINES FOR TRANSPORT...........................................................................8 - 1
8.2 MEASURES TO TAKE FOR TRANSPORT...........................................................................8 - 2
8.3 DRIVING ON / OFF A LOWLOADER ....................................................................................8 - 3
8.4 LIFTING POINTS ...................................................................................................................8 - 4
8.5 TYING DOWN ........................................................................................................................8 - 5
8.6 TRANSPORT DATA...............................................................................................................8 - 6
9 MAINTENANCE.....................................................................................................................9 - 1
9.1 SAFETY GUIDELINES FOR MAINTENANCE.......................................................................9 - 1
9.2 MAINTENANCE INTERVALS ................................................................................................9 - 2
9.3 MAINTENANCE PLAN...........................................................................................................9 - 3
9.3.1 Entire Equipment....................................................................................................................9 - 3
9.3.2 Components ...........................................................................................................................9 - 4
9.3.3 Work Equipment.....................................................................................................................9 - 7
9.3.4 Uppercarriage.........................................................................................................................9 - 8
9.3.5 Undercarriage.........................................................................................................................9 - 9
9.3.6 Optional Equipment..............................................................................................................9 - 10
9.4 LUBRICATION PLAN...........................................................................................................9 - 11
9.5 MAINTENANCE DURING LONGER PERIODS OF STANDSTILL .....................................9 - 12
9.6 HYDRAULIC SYSTEM.........................................................................................................9 - 13
9.6.1 Hose Assemblies..................................................................................................................9 - 13
9.6.2 Hydraulic Cylinders ..............................................................................................................9 - 14
9.6.3 Filter Replacement ...............................................................................................................9 - 15
9.7 WINCHES.............................................................................................................................9 - 16
9.7.1 Checking the Oil Level .........................................................................................................9 - 16
9.7.2 Changing Gear Oil................................................................................................................9 - 17
9.8 WIRE ROPE ACCESSORIES..............................................................................................9 - 18
9.8.1 Rope Swivel..........................................................................................................................9 - 18
9.8.2 Rope Hold-Down Rollers......................................................................................................9 - 19
9.8.3 Rope Fasteners, Thimbles and Sockets ..............................................................................9 - 19
9.8.4 Rope Sheaves ......................................................................................................................9 - 20
9.8.4.1 Greasing Rope Sheaves ......................................................................................................9 - 20
9.8.4.2 Checking Rope Sheaves......................................................................................................9 - 21
9.9 ROTARY DRIVE ..................................................................................................................9 - 22
9.9.1 Routine Inspection................................................................................................................9 - 22
9.9.2 Checking the Oil Level .........................................................................................................9 - 23
9.9.2.1 Main Gear.............................................................................................................................9 - 23
9.9.3 Changing the Oil...................................................................................................................9 - 24
9.9.4 Oil Sampling .........................................................................................................................9 - 27
9.9.5 Hollow Shaft Mounting Bolts ................................................................................................9 - 28
9.9.6 Kelly Driver and Guide Flange .............................................................................................9 - 29
9.9.6.1 Checking the Mounting Bolts ...............................................................................................9 - 29
9.9.6.2 Checking Driver Strips for Wear...........................................................................................9 - 30
9.9.7 Cardan Joint .........................................................................................................................9 - 31
9.9.8 Sledge Sliding Strips ............................................................................................................9 - 31
9.9.9 Greasing the Shaft Seal Ring...............................................................................................9 - 32
9.10 CRAWLER TRACK ASSEMBLIES ......................................................................................9 - 33
9.10.1 Routine Inspection................................................................................................................9 - 33
9.10.2 Crawler Tracks .....................................................................................................................9 - 34
9.10.2.1 To Check the Track Tension ................................................................................................9 - 34
9.10.2.2 Adjusting Crawler Track Tension .........................................................................................9 - 34
9.10.3 Checking Mounting Bolts......................................................................................................9 - 36
9.10.4 Crawler Drive Gears.............................................................................................................9 - 37
BG 24 H / 2008 VI
9.10.4.1 Checking the Oil Level .........................................................................................................9 - 37
9.10.4.2 Changing the Oil...................................................................................................................9 - 37
9.10.5 Adjusting Crawler Crossbeam Play......................................................................................9 - 38
9.11 BOLTED CONNECTIONS ...................................................................................................9 - 39
9.12 CENTRAL LUBRICATION SYSTEM ...................................................................................9 - 40
10 LUBRICANTS / TABLES.....................................................................................................10 - 1
10.1 LUBRICANTS.......................................................................................................................10 - 1
10.1.1 General.................................................................................................................................10 - 1
10.1.2 Lubricant Table.....................................................................................................................10 - 2
10.1.3 Lubricant Guide ....................................................................................................................10 - 4
10.1.3.1 List of Approved Gear Oils, Petroleum – CLP .....................................................................10 - 4
10.1.3.2 List of Approved Gear Oils, Petroleum – API.......................................................................10 - 5
10.1.3.3 List of Approved Gear Oils, petroleum – ATF ......................................................................10 - 6
10.1.3.4 List of Approved Gear Oils, Synthetic – CLP PG .................................................................10 - 7
10.1.3.5 List of Approved Hydraulic Oils, Petroleum – HVLPD .........................................................10 - 8
10.1.3.6 List of Approved Gear Oils, Synthetic – CLP HC .................................................................10 - 9
10.1.3.7 List of Approved engine oils – API CI-4 .............................................................................10 - 10
10.1.3.8 List of Approved Engine Oils, Petroleum – API CF-4 ........................................................10 - 11
10.1.3.9 List of Approved Greases, Petroleum – KP2N...................................................................10 - 12
10.1.3.10 List of Approved Engine Oils, Synthetic – API CF .............................................................10 - 13
10.1.3.11 List of Approved Hydraulic Oils, Fixed – HEES - unsaturated Ester .................................10 - 14
10.1.3.12 List of Approved Hydraulic Oils, Fixed – HEES - saturated Ester .....................................10 - 15
10.2 BOLT TORQUE VALUES ..................................................................................................10 - 16
10.3 CONVERSION TABLE.......................................................................................................10 - 17
BG 24 H / 2008 VII
ABOUT THE MANUAL
This manual is made for
Equipment model: BG 24 H
Construction number: 1770
Construction year: 2008
Date of 1st operation: .. / .. / ....
Certification: CE
This manual was published in
11.2008
The chapters of this manual
1 DESCRIPTION
2 SAFETY
3 TECHNICAL SPECIFICATIONS
4 CONTROLS AND INDICATORS
5 OPERATION
6 START-UP / SHUT-DOWN
7 RIGGING / DE-RIGGING
8 TRANSPORT
9 MAINTENANCE
10 LUBRICANTS / TABLES
11 EXTRA EQUIPMENT (OPTIONAL)
APPENDICES
G:\...\1770_BG24H_en_0000468054
BG 24 H / 2008 VIII
Symbols used in this manual
DANGER!
"Danger!" is used to identify an immediate hazard that can result in

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

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

moderate injury and / or damage to the equipment if the instructions
CAUTION given in the manual are ignored or not correctly followed.
"Note" is used to highlight an operation, assembly or maintenance

procedure. In general, observance of the information here will facilitate
NOTE the work.
BG 24 H / 2008 IX
NAMEPLATES
Nameplates on the equipment
Assembly Location Nameplate

Total equipment In front of cab Bauer Maschinen GmbH
D - 86522 Schrobenhausen Made in Germany
Gerätetyp Trägergerät
type base carrier
nächste Prüfung Baujahr Bau - Nr. Inv. - Nr.
year of manufacture serial No Inv. No
Rückzugkraft Vorschubkraft
1 kN kN
12 2 pulling force pushing power
91011
345
2001 max. Druck Betriebsdruck
max. pressure
bar working pressure
bar
678
Gesamtgewicht Arbeitspannung
total weight
kg working voltage
V
Sachkundigenprüfung CE - Zeichen Motorleistung Frequenz
expert test CE sign engine power
kW frequency
Hz
B0000551.wmf
BG 24 H / 2008 X
AFTER SALES SERVICE
How to reach the Service Centre
Phone +49 8252 97-2586

Fax +49 8252 97-2587
Whenever you consult the Service Centre, please give the following in-
formation so your inquiry can be dealt with more quickly.
NOTE
Equipment description
– Name of model:
– Construction number:
– Number of operating hours:
Description of damage
– Date (DD.MM.YY):
– Cause of damage (if identifiable):
– Course of events leading to damage:
For possible check-backs
– Name of person to contact, phone / fax:
Description of site
– Name of site:
– Address (post code, town, street):
– Route description for a mechanic (as necessary):
BG 24 H / 2008 XI
WARRANTY TERMS
The warranty terms listed in the following apply to all equipment sold by the BAUER
company.
 Warranty Period: The warranty period is either

– 12 months starting with the date of commissioning, or
– in accordance with contractual agreements.
 Commencement: – The warranty comes officially into effect when the equip-
ment is put to the initial operation at the Client‘s, a process
which must be recorded in the "Commissioning Certificate"
and verified by the signatures of both the Client and a
representative of BAUER. In any event, the warranty shall
come into effect no later than 1 week after delivery.
 Warranty terms – Original BAUER spare parts must be used throughout the
and conditions: warranty period.
– Components and operating systems must not be dis-
mantled or repaired at any time during the warranty period
without proper authorisation.
– Any faults must be notified to BAUER in writing on the
appropriate "Warranty Claim" form within 24 hours after
their occurrence.
– The Client or Operator of the BAUER equipment agrees to
carry out all services throughout the warranty period within
the specified service intervals in full compliance with the In-
struction Manual.
– Any work (servicing, repairs etc.) carried out on the equip-
ment must be recorded in the Maintenance and Repair Log
provided for this purpose with each item of equipment.
 Warranty – Improper use or operation (misuse) of the equipment.

exclusions: – Failure to adequately maintain or service the equipment
causing breakdowns and damage.
– Repairs which have been carried out improperly.
– Unauthorised modifications or alterations to the equipment.
– Forceful physical damage.
– Damage resulting from incorrect or improper operation.
– All normal wear and tear.
NOTE:
Wear and tear parts include drilling tools, kelly bars, ropes
etc.
Damages resulting from manufacturing faults shall, how-
ever, be dealt with on a warranty basis.
BG 24 H / 2008 XII
A) Liabilities and Responsibilities of BAUER
– BAUER will supply spare parts required for carrying out repairs to BAUER
equipment under warranty to the Client.
– Spare parts will be delivered c.i.f. (cost, insurance, freight) to the Client.
– If necessary, BAUER will also provide personnel for carrying our repairs under
warranty.
Any defective parts replaced under warranty shall become the property of
BAUER.
BAUER shall determine whether defective parts are to be returned to their
factory at Schrobenhausen, Germany. Transport costs for re-
NOTE deliveries will be paid by BAUER Maschinen GmbH (after sales
service).
– Redeliveries / Deadlines
Concerning requested redeliveries the following deadlines are valid from the date
of arrival of the new parts on the jobsite in the assignment country until arrival of
the damaged parts in Schrobenhausen.
– Redeliveries via air freight: 4 weeks

– Redeliveries via sea freight: 4 months
If the damaged parts, which are redelivered via sea freight, are not redelivered in
time due to the jobsite situation, the after sales service department has to be in-
formed correspondingly, at the latest 6 weeks before expiry of the deadline.
Concerning redeliveries via air freight, an extension of the deadline is principally
not possible.
In case requested redeliveries are not returned within the agreed time period, the
corresponding open amounts according to the sales invoice have to be paid by
the respective customer.
B) Liabilities and Responsibilities of the Client
– Any customs duties payable in the country of destination for a consignment of

spare parts supplied under warranty shall be the responsibility of the Client.
– Local transport to a final destination (construction site) in connection with a war-
ranty claim shall also be the responsibility of the Client.
– Full and meticulous compliance with all operating instructions and observance of
proper operating procedures for all equipment.
– Full compliance with the specified and necessary service schedule.
– Entering and maintaining full and comprehensive records in the Maintenance and
Repair Log.
BG 24 H / 2008 XIII
To: BAUER Maschinen GmbH
After Sales Service Department
P.O. Box 12 60
86522 Schrobenhausen, Germany
Phone +49 8252 97-2586
Fax +49 8252 97-2587
From (Customer, Agent):
Phone: Fax:
Total number of pages of claim:
WARRANTY CLAIM
1. Product specifications
Equipment: Constr. no.: Constr. year: Operating hours:
Current location of the equipment, postal address:
Date of commissioning: Date of damage:
2. Description of damage
Please describe damaged parts and state their material number
Name of damaged part Material no. Construction no.
Note (symptoms/malfunctions, causes, position of damaged parts):
3. Delivery of new parts and repair

Replacement of damaged parts from customer's own stock?
Replacement of damaged parts by ordering from after sales service?
Shipment (by courier, air or sea freight):
Delivery address:
Information for a proforma invoice:
Replacement work by customer, agent? Yes No
Estimated working time (hrs): Estimated additional costs:
Date Name of claimant Signature Company

(please print)
4. For internal use only (to be filled in by BAUER)

Subject to warranty? Yes No
If yes, give order number: If no, give reasons:
Further reports:
Further actions:
01/2003
Return of damaged parts by:

Estimated working time (hrs):
910.396.2
(Signed by authorized BAUER employee)

An: BAUER Maschinen GmbH
Abteilung Kundendienst
Postfach 12 60
86522 Schrobenhausen
Tel. +49 8252 97-2586
Fax +49 8252 97-2587
E-Mail KVT@bauer.de
Personalanforderung / Staff request
Von Firma / Company:
Besteller / Ordered by: Tel.:
Fax:
Bestell-Nr. / Order no.: e-mail:
Gerät / Ausrüstung /
Equipment: Attachment:
Betriebsstd. /
Bau-Nr. / Serial no.:
Working hours:
Standort des Geräts / Location of machine:
Ansprechpartner Baustelle / Baustellentelefon /

Contact person jobsite: Jobsite phone no.:
Zielflughafen / Airport of destination:
Datum des gewünschten Einsatzes / Date of requested assignment:
Gewünschtes Personal / Requested staff: Mechaniker Elektriker Einweiser

mechanic electrician operator
Voraussichtliche Dauer / Estimated duration:

Auszuführende Arbeiten / Works to be carried out:
Besonderheiten / Special requirements:
Ersatzteile / Spare parts:
Kommunikation auf der Baustelle /Communication on jobsite:
deutsch/German englisch/English Landessprache/Language of country
Datum / Date: Unterschrift / Signature:
BAUER Maschinen GmbH  86529 Schrobenhausen  Tel. 0 82 52/97-0 sra 910.097.1+2BMA 08/2008
DESCRIPTION
1 DESCRIPTION
1.1 EQUIPMENT APPLICATIONS
The equipment is designed and intended for the following applications only:
Area of application In short Allowed

Drilling with Kelly equipment Kelly Yes
Drilling with Continuous Flight Auger equipment CFA Yes
Drilling with Front-of-Wall equipment FOW No
Drilling with Twin Rotary Drives equipment TRD No
Drilling with Triple Auger ("Mixed-in-Place") equip-
MIP No
ment
Piling with Vibrator equipment No
Drilling with High Pressure Injection equipment HPI No
Drilling with Full Displacement System equipment FDS No
Drilling with Soil Stabilization equipment CSV No
Drilling with Soil Mixing equipment No
Observance of the instruction manual and all the documents supplied with the equip-
ment is also considered part of the intended application.
Using the equipment in another or a further application than those stated here is not
permitted and will be considered misuse.
Hence it is strictly forbidden to use the equipment as a liftcrane or for grading jobs or as
a personal hoist.
The manufacturer does not assume any responsibility for damages resulting from mis-
use of the equipment.
BG 24 H / 2008 1-1
DESCRIPTION
1.2 COMPONENTS
1.2.1 Basic Rig / Kelly Equipment
1.2.1.1 Components Overview
Basic Rig
1 Boom
16
2 Boom cylinders 21
3 Swing mechanism
4 Crawler drives
5 Counterweight 11
6 Main winch
7 Main rope
8 Auxiliary winch 22
9 Auxiliary rope
10 Wedge * 46
11 Masthead tilting cylinder
12 Kinematic triangle * 13
13 Mast (upper section / lower section)
14 Mast prop
15 Mast pivot
16 Masthead
43
17 Mast extension (upper) 45
18 Mast extension (lower) 41 26
19 Backstay cylinders
20 Uppercarriage 44
21 Rope swivel 42
22 Crowd rope tensioning cylinder
23 Supporting boom * 19
24 Supporting trestle
25 Undercarriage 40
27
26 Crowd sledge 29
27 Crowd ropes (upper / lower) 9
28 Thrust rod * 15 7
29 Crowd winch 8
30 Crowd cylinder * 12
23
Kelly equipment 2
1
40 Drilling tool
6 20
41 Rotary drive
42 Casing drive adapter
5
43 Shock absorber 14
44 Cardan joint 3
45 Kelly drivers 4
46 Kelly bar
BK513510.wmf
*) does not exist with this version
BG 24 H / 2008 1-2
DESCRIPTION
1.2.1.2 Components Description
Table Basic rig components description

Component Description / Function
Is a movable link from the machine to the mast
Boom
pivot.
Are movable connections of the boom to the ma-
Boom cylinders chine. They enable adjustment of the machine's dis-
tance to the bore.
Swing mechanism Enables rotation of the uppercarriage to both sides.
Crawler drives Drive the two crawlers forward and reverse.
Counterweights Render stability to the equipment.
Main winch with main rope Is used as a hoist for the kelly.
Auxiliary winch with auxiliary rope Is used for rigging operations and load handling.
Wedge Allows changing the distance from mast to bore.
Kinematic triangle (H) Enables parallel repositioning of the mast.
Mast (upper section / lower section) Provides guidance for the crowd sledge.
Mast prop Supports the rig during withdrawal of the drilling tool.
Mast pivot Is a swivel link between the mast and the boom.
Masthead Houses sheaves which guide ropes over the mast.
Mast extension (intermediate) Enables use of longer drilling tools.
Mast extension (lower) Allows the crowd sledge be positioned further down.
Are movable supports of the mast. They raise and
Backstay cylinders lower the mast and allow adjustment of the inclina-
tion of the mast.
Uppercarriage Houses the engine, hydraulic system and controls.
Rope swivel Prevents rope twist.
Crowd rope tensioning cylinder (S) Stresses the crowd ropes.
Supporting boom (H) Enables parallel repositioning of the mast.
Supporting trestle (V) Is a mount for the backstay cylinders.
Carries the rig and moves it from one drilling spot to
Undercarriage
the next.
Runs up and down the mast while carrying the ro-
Crowd sledge
tary drive and drilling tool.
Crowd ropes (upper / lower) (S) Transfer force from crowd winch to crowd sledge.
Thrust rod (Z) Is a distance keeper for the crowd cylinder.
Crowd winch (S) Generates the crowd forces.
Crowd cylinder (Z) Generates the crowd forces.
Z) for rig fitted with cylinder crowd V) for mast lowering to the front
S) for rig fitted with rope crowd H) for mast lowering to the rear
BG 24 H / 2008 1-3
DESCRIPTION
1.2.2 CFA Equipment (optional)
1.2.2.1 Components Overview
1 Concreting kelly extension 2

2 Concreting swivel head
3 Wedge
4 Continuous flight auger (CFA)
5 Auger cleaner
6 Rope crossbeam
(for CFA with main winch only)
1
3
BJ535500.wmf
BG 24 H / 2008 1-4
DESCRIPTION
1.2.2.2 Components Description
Table CFA equipment components description
Component Description / Function

Transmits torque from rotary drive to drilling tool
and conveys slurry from the concreting head into
Concreting kelly extension the CFA auger.
Allows increasing the drilled depth by as much as
the length of the concreting kelly extension.
Guides slurry into the rotating concreting kelly.
Concreting swivel head
Is fitted with a concrete pressure gauge.
Wipes off soil from the auger flight during with-
Auger cleaner
drawal and serves as a guidance of the auger.
Is pinned to the rotary drive and has a rope
sheave to reeve the main rope, the end of which
Rope crossbeam is anchored to the masthead.
Serves for use of the main winch force to sustain
the crowd system in pulling the auger.
Is a hollow stem with a continuous flight auger
which cuts and transports soil and through which
CFA auger
the bore may be filled with slurry during the with-
drawal.
BG 24 H / 2008 1-5
SAFETY
2 SAFETY
2.1 GENERAL SAFETY REQUIREMENTS

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

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

– In drilling applications, the equipment operates with rotating tools. Being caught by a
rotating part is mortal.
– In vibrator applications, the equipment operates with high-frequency oscillating tools.
Getting knocked down by a component thereof is mortal.
– The stability of the equipment must not be endangered. Exceeding the rig's capacity
or operating with faulty end-limiters can make the equipment fall violently causing se-
vere personal injury or even loss of life.
– Never remove equipped safety devices or render them out of order.
– Be observant of oil spills from the hydraulic system. If there is a spill, find the cause
and repair it. Oil spraying with high pressure from a leak in the hydraulic system can
cause severe burns and poisoning.
– The cooling system gets very hot from operation. Coming in touch with components
containing coolant can cause burns.
– Engine, gear and hydraulic oils get very hot from operation. Touching a component
containing such an oil can cause burns.
– Be sure the equipment is properly shut down before you begin a maintenance, repair
or cleaning job on it: Set all controls to Off, stop the engine and set the battery main
switch to Off position.
– To prevent abuse and unauthorised starting of the equipment, shut it down, remove
the ignition key and lock the cab whenever you leave the equipment unattended.
BG 24 H / 2008 2-1
SAFETY
2.4 SAFETY DEVICES

2.4.1 Emergency Stop
In an emergency!!
Press the Emergency STOP button (1)!!

All equipment functions will promptly come 1 Emergency Stop
NOT-AUS
to a stop.
To re-start, pull the depressed Emergency

STOP button.
B0000819.wmf
2.4.2 Pilot Control Safety Stick
With the safety stick (1), the operator must 1.1

shut off the pilot control before leaving the
driver's seat. With the stick in the "Off" posi-
tion, all hydraulic functions are blocked. 1.2
Pilot control On: Emergency Stop
NOT-AUS
Stick moved to position (1.1)
Pilot control Off:

Stick moved to position (1.2)
B0000820.wmf
2.4.3 Fire Extinguisher
Machine with an engine power of < 200 kW

is equipped with one fire extinguisher / Ma-
chine with an engine power of > 200 kW
has two fire extinguishers.
Their location in or on the machine is identi-
fied with a decal (see fig.).
Personnel must recapitulate the text on fire

extinguishers from time to time to be famil-
iar with their use. B0000506.wmf
BG 24 H / 2008 2-2
SAFETY
2.4.4 Medical Box
A First Aid medical box is found in the op-

erator’s cab. Its location is identified with a
decal (see fig.).
B0000562.wmf
2.4.5 Emergency Exit
Whenever the normal exit from the cab is

blocked, the operator can use the equipped
emergency hammer (see fig.) to smash a
window.
The hammer is found in the upper corner

behind the operator’s seat.
GAALM055.wmf
BG 24 H / 2008 2-3
SAFETY
2.4.6 Limit Switches
Table Limit switches
Name Function HS 1
Monitors backward inclination of mast. HS 2
ES 1 Switches off "Rotary drive rotation" and

"Crowd" when activated.
ES 2 Limits mast inclination to left.
Monitors the max. permissible distance
ES 3 to the bore.
or Switches off "Rotary drive rotation" and
B 39 "Crowd" when activated.
Notice: B 39 is programmable.
ES 4 Limits mast inclination to right.
Stops lifting by the main winch before
HS 1
load may hit the masthead.
Stops lifting by the auxiliary winch before ES 2 / ES 4
HS 2 load may hit the masthead. ES 1
B 39
BJ318506.wmf
BG 24 H / 2008 2-4
SAFETY
2.4.7 Work Platforms on Upper Carriage, at Rotary Drive or Masthead (Optional)
WARNING!
Danger of falling!
None of the platforms must be loaded beyond max. 200 kg.
Stairways, treads, handrails, ladders, platforms etc. must be maintained
free of mud, grease, snow and ice to permit personnel safe access.
When transferring from mast to work platform and vice versa, the fitter
must be secured at all times by a safety harness. The fitter may unfas-
ten the safety harness only after having reached the enclosed work
platform. He then disengages the safety harness from the ladder and
fastens it to the railings of the work platform. Prior to leaving the work
platform, the fitter disengages his safety harness from the railings and
fastens it from within the enclosed platform to the safety guide rail at-
tached to the mast. On the upper carriage, the harness will be snapped
to the loops provided there.
If a lifting platform is used, it must comply with the safety standards for
personal hoists.
Work platforms at the rotary drive:
The work platforms must not be used as a personnel hoist, i.e. if the
rotary drive has to be repositioned during rigging, then the fitter must
climb down on the ladder attached to the mast with the safety harness
securely fastened to the ladder.
For work on a platform at the rotary drive, the fitter takes the key from
the free-fall lock in the cab with him, to prevent accidental release of the
free-fall during the work.
BG 24 H / 2008 2-5
SAFETY
2.5 STABILITY
2.5.1 Guidelines for Stability
Rig capacity charts are calculated in compliance with the European standard EN 791.
WARNING!
Rig tipping hazard!

The conditions listed in the following must be observed in order that the
stability of the rig is guaranteed.
2.5.1.1 Conditions for Operation
– Rig angles and loads on main rope, auxiliary rope and crowd given in the capacity
charts are maximum values which must not be exceeded for safety reasons.
– The specified loads apply only when not combined and not used on an altered setup
of equipment.
– Machine on firm and level surface. National safety codes and guidelines observed
concerning the soil and working platform conditions.
– Uppercarriage held stationary with crowd and main rope load.
– Slow swing of uppercarriage with load on auxiliary rope.
– No diagonal pull.
Pulling and pushing forces of the winches / crowd cylinder and the pre-
sent centre of gravity (position of the work attachments) are factors
which have additional influence on the rig’s stability.
NOTE The loads given in the capacity charts take into consideration the most
adverse position of the components.
2.5.1.2 Conditions for Onsite Travelling
– Uppercarriage in line with undercarriage.

– Work attachments and movable loads kept as close to the ground as possible.
– Mast vertical.
– No abrupt movements.
BG 24 H / 2008 2-6
SAFETY
2.5.2 Stability of BG 24 H # 1770 - Kelly BK 25/394/3/33
2.5.2.1 Load Capacity Chart
Valid only for Mast extension 2.0 m 1.1 to

Counterweight 10.00 to
Kelly BK 25/394/3/33 5.9 to
Casing drive adapter  1300 mm 1.48 to
Drilling tool  1180 mm 1.85 to
Conditions for operation Crowd sledge stroke limiter mounted (max. stroke: 9155 mm)
B0000689.wmf Max permissible load / max ground pressure**
B00005003.wmf
B00005002.wmf Min drill distance*: 3.50 m Max drill distance*: 4.50 m
Auxiliary 8.0 to 5.0 to
rope 415 kPa 600 kPa
Main 20.0 to 18.0 to

33.0 to 16.0 to
Crowd
525 kPa 590 kPa
α = 5° α = 5°
Auxiliary β = 3° 8.0 to β = 3° 7.0 to
rope γ = 0° 545 kPa γ = 0° 1035 kPa
δ = 360° δ = 90°
α = 5° α = 5°
Main β = 3° 20.0 to β = 3° 20.0 to
rope γ = 15° 415 kPa γ = 15° 720 kPa
δ = 360° δ = 90°
α = 5° α = 5°
β = 3° 33.0 to β = 3° 31.0 to
Crowd
γ = 15° 525 kPa γ = 15° 1230 kPa
δ = 360° δ = 90°
α = 5° α = 5°
β = 3° β = 3°
rope γ = 0°
545 kPa
γ = 0°
1035 kPa
α = 5° α = 5°
Main 20.0 to 14.0 to
β = 3° β = 3°
rope γ = 15°
405 kPa
γ = 15°
720 kPa
α = 5° α = 5°
β = 3° 33.0 to β = 3° 12.0 to
Crowd
515 kPa 1230 kPa
γ = 15° γ = 15°
Max travel gradability /

5° / 330 kPa 3° / 485 kPa
max ground pressure
*) Drill distance = Centre distance from machine to drilling tool
**) Max value of ground pressure as calculated in conformance with DIN EN 791 (issue 1995)
BG 24 H / 2008 2-7
SAFETY
2.5.2.2 Weights / Centres of Gravity - Drill Distance 3.50m
Valid only for Drill distance* 3.50 m
Weight Xres Zres

Assembly group
[kN] [m] [m]
Completely equipped drilling rig 843.97 0.57 5.22
B0000919.wmf
Undercarriage with connections to CO 230.0 0.00 0.51

B0000920.wmf
Uppercarriage with BAUER attachments,

with crowd sledge
with counterweights
454.22 -0.15 5.32
without work equipment
without undercarriage
without rotary drive
B0000921.wmf
Rotary drive KDK 232 S 51.00 3.31 11.8

with kelly driver
Casing drive adapter Ø 1300 14.8 3.51 10.0
Kelly BK 25/394/3/33 59.0 3.51 14.7
Drilling bucket Ø 1180 18.15 3.51 7.2
Filling (90 % Density 1.7 kg/dm3) 16.8 3.51 7.2
B0000922.wmf
Undercarriage Dimension Z
[m]
X A
Length of crawler tread A 4.54
Track gauge, extended S 3.70
B
Width of track pads B 0.70

S
B0000929.wmf
BG 24 H / 2008 2-8
SAFETY
2.5.2.3 Weights / Centres of Gravity - Drill Distance 4.50m
Weight Xres Zres

Assembly group
[kN] [m] [m]
B0000919.wmf

B0000920.wmf

with crowd sledge
with counterweights
454.22 0.34 5.32
B0000921.wmf

with kelly driver
Casing drive adapter Ø 1300 14,8 4.52 10.0
Kelly BK 25/394/3/33 59.0 4.52 14.7
Drilling bucket Ø 1180 18.15 4.52 7.2
Filling (90 % Density 1.7 kg/dm3) 16.8 4.52 7.2
B0000922.wmf
Undercarriage Dimension Z
[m]
X A
Length of crawler tread A 4.54
Track gauge, extended S 3.70
B
Width of track pads B 0.70

S
B0000929.wmf
BG 24 H / 2008 2-9
SAFETY
2.5.3 Stability of BG 24 H # 1770 - CFA Ø 750 mm (optional)
2.5.3.1 Load capacity chart
Valid only for Mast extension 2.0 m 1.10 to

Counterweight 6 +2 +2 to
Continuous flight auger Ø 750 mm 4.14 to
Kelly extension 8m / concreting head 1.8 to + 0.32 to
Auger cleaner 3.5 to
Conditions for operation -
B0000689.wmf Max permissible load / max ground pressure**
B00005003.wmf
B00005002.wmf Min drill distance*: 3.50 m Max drill distance*: 4.00 m
Main
rope 49.0 to 32.5 to
+ 625 kPa 580 kPa
Crowd
α = 5° α = 5°
Auxiliary β = 3° 8.0 to β = 3° 8.0 to
rope γ = 0° 620 kPa γ = 0° 885 kPa
δ = 90° δ = 90°
Main α = 5° α = 5°
rope β = 3° 73.0 to β = 3° 53.5 to
+ γ = 15° 950 kPa γ = 15° 1215 kPa
Crowd δ = 90° δ = 90°
α = 5° α = 5°
β = 3° β = 3°
rope -- kPa -- kPa
γ = 0° γ = 0°
Main α = 5° α = 5°
rope β = 3° 50.0 to β = 3° 25.0 to
+ γ = 15° -- kPa γ = 15° -- kPa
Crowd
Max travel gradability /

4° / 390 kPa 2° / 475 kPa
max ground pressure
**) Max value of ground pressure as calculated in conformance with DIN EN 791 (issue 1995)
BG 24 H / 2008 2 - 10
SAFETY
2.5.3.2 Weights / Centres of Gravity - Drill distance 3.50m
Weight Xres Zres

Assembly group
[kN] [m] [m]
B0000919.wmf
B0000920.wmf
with crowd sledge
with counterweights
454.22 -0.15 5.51
B0000921.wmf
with kelly driver
Continuous flight auger Ø 750 mm 18.23 41.4 3.5 9.62
m
Concreting Kelly extension 394/254 8m 22.0 3.5 24.04
Wedge 23° for CFA on masthead 0.76 2.41 22.16
Holding bracket for concrete hose on 1.4 3.15 20.93
KDK
Concreting swivel head 3.2 3.65 29.79
Torque support complete 8m 5.0 3.5 24.54
Concrete hose filled. 5.0 3.1 17.3
Rope crossbeam 6.0 2.92 22.0
Auger guidance - - -
Auger cleaner 35.0 3.08 2.12
Filling of continuous flight auger - - -
B0000922.wmf
BG 24 H / 2008 2 - 11
SAFETY
2.5.3.3 Weights / Centres of Gravity - Drill distance 4.00m
Weight Xres Zres

Assembly group
[kN] [m] [m]
B0000919.wmf
B0000920.wmf
with crowd sledge
with counterweights
445.22 0.09 5.11
B0000921.wmf
with kelly driver
Continuous flight auger Ø 750 mm 18.23 4.41 4.0 9.62
m
Concreting Kelly extension 394/254 8m 22.0 3.9 24.04
Wedge for CFA on masthead 0.76 2.91 22.16
Holding bracket for concrete hose on 1.4 3.65 20.16
KDK
Concreting swivel head 3.2 4.15 29.79
Torque support complete 8m 5.0 4.00 24.54
Concrete hose filled. 5.0 3.6 17.3
Rope crossbeam 6.0 3.42 22.0
Auger guidance - - -
Auger cleaner 3.5 3.58 2.12
Filling of continuous flight auger - - -
B0000922.wmf
BG 24 H / 2008 2 - 12
SAFETY
2.6 PERMISSIBLE WIND SPEED
The place to measure the wind speed is at the masthead:
Max. permissible wind speed for equipment operation Barrier effect

m/s km/h miles/h Beaufort ktn
20 72 45 8 39 250 (N/m²)
WARNING!
Rig tipping hazard!

Shut down the equipment before the value is exceeded.
● Remove attached drilling tool(s) and suspended load.

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

Wind force Wind speed
Wind effects
Beaufort English m/s km/h
0 calm 0 - 0.2 less than 1 Smoke rises straight in the air, sea is calm-glassy
1 light air 0.3 - 1.5 1-5 Smoke drifts but vanes remain still, sea is rippled
2 light breeze 1.6 - 3.3 6 - 11 Wind can be felt on your face, leaves rustle, sea
has wavelets
3 gentle breeze 3.4 - 5.4 12 - 19 Leaves and thin twigs move, pennants stretch,
wave crests begin to break
4 moderate 5.5 - 7.9 20 - 28 Dust and paper lift, twigs and branchlets sway,
breeze waves are growing in length, scattered white-
caps
5 fresh breeze 8 - 10.7 29 - 38 Small trees begin to sway, waves are white-capped
all over the sea
6 strong breeze 10.8 - 13.8 39 - 49 Sturdy branches move, wires sing, umbrellas are
hard to handle, sea is rough, crests break
7 near gale 13.9 - 17.1 50 - 61 Whole trees swaying, walking towards the wind is
difficult, sea is very rough, foam on crests
8 gale 17.2 - 20.7 62 - 74 Branches break off, walking outdoor is extremely
difficult, waves are high, spray from crests
9 strong gale 20.8 - 24.4 75 - 88 Minor damage to buildings (roof tiles and chim-
ney hoods are ripped off), on the sea waves are
very high and the visibility is obstructed by spray
BG 24 H / 2008 2 - 13
TECHNICAL SPECIFICATIONS
3 TECHNICAL SPECIFICATIONS
3.1 DIMENSIONS
3.1.1 Kelly Equipment BK 25/394/3/33
Dimensions in [mm]
23840
22070
21790
2000
1000
13715
12905
12544
16400
8864
8075
5875
9155
3389
2010
3510
1660
1550
1180
0
291 4540
5503
3507 - 4517 R 3562
BU1550501.wmf
BG 24 H / 2008 3-1
3.1.2 CFA Equipment (optional)
Dimensions in [mm]
30037
29083
8050
8000
24157
22070
21370
2000
21069
19715
18787
ø 750
16400
16840
18230
1000
2875
2010
2445
3270
1665
1550
557
1180
275
0
4540
5503
3508 - 4151 R 3562
BU1550502.wmf
BG 24 H / 2008 3-2
3.2 EQUIPMENT SPECIFICATIONS
Base Machine
Uppercarriage
Type BS 70/C
Serial number 70.6.936
Engine
Type CAT C 9
Serial number MBD 08225
Output 261 kW
Speed 1850 rpm
Undercarriage
Type UW 80 C
Serial number 8015
Width over crawlers 3000 - 4400 mm
Length of crawlers 5502 mm
Width of track pads 700 mm
Mast Inclination
During operation without work equipment
forward 5°
backward 15°
to left 3°
to right 3°
During operation with work equipment
See load capacity chart
Operating Range
See load capacity chart
Working Weight
With:
-Kelly BK 25/394/3/33 approx. 84.5 tonnes

-CFA Ø 750 wih kelly extension and auger cleaner approx. 85.5 tonnes
BG 24 H / 2008 3-3
Main Winch
Type 77 WH 102/12
Serial number 60668
Pulling force (1st layer) 200 kN
Rope diameter 28 mm
Rope length 72 m
Rope speed 102 m/min
("lifting" with 10 kN load)
Auxiliary Winch
Type ZHP 4.22 1000328

Serial number 788
Pulling force (1st layer) 80 kN
Rope diameter 20 mm
Rope length 50 m
Rope speed 55 m/min
("lifting" with 10 kN load)
Crowd Cylinder
Stroke of crowd sledge 0000 mm

Max. pushing force 000 kN
Max. pulling force 000 kN
Reduced pulling force (optional) 000 kN
Crowd speed:
"Fast crowd" up 00 m/min
"Fast crowd" down 00 m/min
"Slow crowd" up 00 m/min
"Slow crowd" down 00 m/min
Crowd Winch
Type ZHP 4.26. 1001908

Serial number 323
Max. stroke of crowd sledge 17620 mm
Max. pushing force 200 kN
Max. pulling force 330 kN
Rope diameter 24 mm
Length of upper / lower rope 69 m
62 m
Crowd speed:
"Fast crowd" up 26.5 m/min
"Fast crowd" down 27.5 m/min
"Slow crowd" up 6.7 m/min
"Slow crowd" down 6.7 m/min
BG 24 H / 2008 3-4
3.3 ROTARY DRIVE SPECIFICATIONS

3.3.1 Rotary Drive, Shiftable
Pth = 208 kW
Qth = 2 x 250 l/min
1st gear 2nd gear

i = 152.45 i = 69.69
250 120
233
110
225 106
100
200
194
90
175
Drehmoment / Torque M [kNm]
80
150 70
125 60
50
100
40
75
74 34
30
50
20
25 10
0 0
9 27 22 59
0 5 10 15 20 25 30 0 10 20 30 40 50 60 70
Drehzahl n [1/min] / Speed n [rpm] Drehzahl n [1/min] / Speed n [rpm]
BU710502.wmf BU710504.wmf
BG 24 H / 2008 3-5
1st
gear (reduced torque)
i = 152.45
200
161
150
134
100
74
50
0
12 27
0 5 10 15 20 25 30
Drehzahl n [1/min] / Speed n [rpm]
BU710503.wmf
BG 24 H / 2008 3-6
3.4 DRILLING SPECIFICATIONS

3.4.1 Kelly Equipment
L1
Dimensions [mm]
L1 21790
L2 12544
L3 3389
A max. 18311
Hd 8864
A
Bore diameter [mm]
L2
uncased 1700
cased 1400
Casing length
without CO Hw – 0.5 m
with CO Hw – 1.5 m
L3
Hd
Hw
Drilling depth / Kelly specifications

locked unlocked
kelly kelly
kelly type without with without with
CO CO CO CO Weight
A [m] B [m] B1 [m] Hw [m] T [m] T [m] T [m] T [m] [to]
BK 25/394/3/33 13.72 36.20 35.96 5.88 34.77 33.27 35.01 33.51 5.90
B
Notice: Drilling depth specifications are based on min. operating radius of mast.
With max. operating radius the drilling depth increases by 0.3 m.
A: Length of retracted kelly

A max.: Max lifted length of kelly
B / B1: Length of extended kelly unlocked / locked
T: Max. possible drilling depth
Hw: Maximum height to drilling tool
Hd: Maximum height to casing drive adapter
W L1: Highest possible position of kelly lifting eye
L2: Highest possible position of kelly driver upper edge
L3: Lowest possible position of kelly driver upper edge
BJ608503.wmf W: Length of drilling tool: 2.2 m
CO: BAUER Casing Oscillator
BG 24 H / 2008 3-7
3.4.2 CFA Equipment  750 (optional)
Dimensions [mm]
L 18000
L1 28570
Max. bore diameter 750
Crowd / Pulling force [kN]

Crowd force 330
Pulling force (unreeved) 530
Pulling force (reeved) 730
L1
BV778502.wmf
Drilling depth [m]

Without With With
kelly extension kelly extension kelly extension
unlocked locked
With auger guide - - -
With auger cleaner 16.25 24.25 24.30
BG 24 H / 2008 3-8
3.5 ROPE SPECIFICATIONS

3.5.1 Main Rope
Ready-made length 72 m
Nominal diameter 28.00 mm

Permissible deviation + 4.00 %
Weight per meter 4.05 kg/m
Nominal wire strength 1960.00 N/mm2
Fill factor 0.77
Spinning loss factor 0.78 - 0.80
Nominal aggregate breaking load 887.10 kN
Minimum breaking load 713.00 kN
Diameter of outer wires 1.50 mm
Total metal cross section 453.00 mm2
Total number of wires 224
Number of load-bearing wires
(outer strands) 105
Rope structure 16x(6+1)+5x(6+1)+5x(6+1)+5x(6+1)+SE(6+1)

Rope core Steel core (SC)
Wire surface Galvanized Drawn out
Lay and direction Regular-lay, right
Characteristics Low-stress
Corrosion protection Steel core greased
Rope description All strands of superfill design (compacted)

Features Very good coiling characteristic
Non-rotation, radially elastic, with plastic
coated steel core
BG 24 H / 2008 3-9
3.5.2 Auxiliary Rope
Ready-made length 50 m

Permissible deviation + 4.00 %
Nominal wire strength 1960 N/mm2
Fill factor 0.750
Spinning loss factor 0.835
Diameter of outer wires 1,10 mm
Total metal cross section 226,70 mm²
(outer strands) 105
Rope structure 16* (6+1)+5x(6x1)+5x(6+1)+5x(6+1)+SE(6+1)

Rope core Steel core(SC)
Wire surface Bright
Lay and direction Regular-lay , right
Corrosion protection Steel core greased
Rope description All strands of superfill design (compacted)

Features Very good coiling characteristic
Non-rotation, radially elastic, with plastic
coated steel core
BG 24 H / 2008 3 - 10
3.5.3 Crowd Ropes
Ready-made length upper rope 69 m

lower rope 62 m

Permissible deviation + 3.00 % - 4.00 %
Nominal wire strength 1960.00 N/mm2
Fill factor 0.647
Spinning loss factor 0.830
Diameter of outer wires 1.29 mm
Total metal cross section 292.57 mm2
(outer strands) 216
Rope structure 6x(14+7+7+7+1)+IWRC=6x(6+1)+7

Rope core Steel core
Wire surface Bright
Lay and direction Regular-lay, left
Corrosion protection Greased
Rope description Outer wires compacted

Features prestressed, rotation resistant
BG 24 H / 2008 3 - 11
3.6 NOISE EMISSION
1. Inside Cab
Measurement made in accordance with ISO 6394
Sound-pressure level in cab LpAI = 76.0 dB(A)
2. Outside
Measurements made in accordance with DIN 45635 T.33
Average sound-pressure level LpA = 82.0 dB(A)

Sound-power level LWA = 112.0 dB(A)
3.7 TEMPERATURE CONDITIONS
The equipment can be used in outdoor temperatures ranging from -20° to +40° C
(-4 to +104 F).
For use at temperatures outside the specified range the manufacturer must be con-
sulted.
3.8 EXPOSURE TO VIBRATION
The operator’s exposure to vibration acceleration during operation with this equipment
is less than 0.5 m/s².
BG 24 H / 2008 3 - 12
CONTROLS AND INDICATORS
4 CONTROLS AND INDICATORS
4.1 CAB
1.5
1.3
1.1 2.1 3
5
22
21 4
20 4
5 6
26
27
7
2
8
1
9
10
0
28
19 1.2 2.2 6
18 1.4 2.3 7
1.6
15.7 17/17.1 8/8.1 10.7
13
15.5 9/9.1 10.5
15.1 10.1
15.3 15.4 16 10.3 10.4

5 6
4
3
7
2
8
1
9
0
10
15.9 15.10 4 5 6
10.9 10.10
3
7
2
8
1
9
0
10
23
11
5
10.2
4 6
15.2
3
7
2
14.1
1
9
0
10
15.6 10.6
15.8 14.2 10.8
24
25
29
0 0 0 0 0 0 00
12
BU1447502.wmf
1.1 Left crawler travel forward 12 Engine ignition On / Off
1.2 Left crawler travel reverse 13 Heater control
1.3 In CO mode: Tube lower* 14.1 Crowd pressure adjustment
1.4 In CO mode: Tube lift* 14.2 In FDP /CFA mode:
1.5 In CO mode + Clamping cylinders selected: Crowd speed adjustment
Tube unclamp* 15.1 Winch 1/2 down
1.6 In CO mode + Clamping cylinders selected: 15.2 Winch 1/2 up
Tube clamp* 15.3 Uppercarriage swing to left
2.1 Right crawler travel forward 15.4 Uppercarriage swing to right
2.2 Right crawler travel reverse 15.5 Rigging mode + Backstay cylinders selected:
2.3 In CO mode: Oscillate* Left backstay cylinder extend
3 Free-fall / Freewheel release 15.6 Rigging mode + Backstay cylinders selected:
4 Free-fall / Freewheel mode On / Off Left backstay cylinder retract
5 Indication: Free-fall / Freewheel released 15.7 Not used
6 Crowd fast mode On 15.8 Not used
7 Horn On 15.9 Not used
8 In Kelly mode: To dump spoil 15.10 Not used
8.1 In CFA mode: Auto pull On 16 Emergency STOP
9 In Kelly / CFA / FDPmode: 17 Auger cleaner retract / extend
Rotary drive fast mode On / Off 17.1 Not used
9.1 Not used 18 Swing brake unlock
10.1 Crowd down 19 Swing brake lock
10.2 Crowd up 20 Free-fall / Freewheel release
10.3 In Kelly / CFA / FDP mode: 21 Pilot control On / Off
Rotary drive rotate right 22 Rope retract force control
10.4 In Kelly / CFA / FDP mode: 23 Freewheel retract control main whinch
Rotary drive rotate left 24 Central lubrication system On / Flashing code
10.5 Rigging mode + Backstay cylinders selected: 25 Warning: Central lubrication system fault
Right backstay cylinder extend 26-28 Not used
10.6 Rigging mode + Backstay cylinders selected: 29 Central lubrication system switch On / Off
Right backstay cylinder retract
10.7 Rigging mode + Boom cylinders selected: FDP = Full Displacement Piling
Boom cylinders retract CFA = Continuous Flight Auger
10.8 Rigging mode + Boom cylinders selected: CO = Casing Oscillator
Boom cylinders extend * = not used in this version
10.9 Not used
10.10 Not used
11 Engine speed adjustment
BG 24 H / 2008 4-1
4.2 BASE MACHINE CONTROL CONSOLE
1 Indicator: Freewheel / Free-fall released

2 Rope retract force adjustment
3 Freewheel / Free-fall mode On / Off 4
4 Diagnostic system monitor
5 Check battery charging
6 Check fuel level 5 6 7 8
7 Check coolant temperature n
min
9 10 11 12
8 Check engine oil pressure
9 Check hydraulic oil temperature
10 Check engine speed 1 13 14 15 16 17
11 Check operating hours 18 19 20 21 22
12 Clock
13 Indicator: Swing brake locked
14 Warning: Air filter contaminated
5 6
4
1 2 3
7
2
8
1
9
10
0
15 Warning: Hydraulic oil return line filter
contaminated
46 45 44
16 Pilot oil filter contaminated
17 Not used
18 Warning: Coolant temperature too high 24 25
19 Warning: Coolant level too low
20 Indicator: Valve on hydraulic tank closed 29 30
21 Warning: Hydraulic oil level too low
22 Not used
23 Right control lever
24 Front light On / Off 23
25 Rear light On / Off
26 Not used
27 Not used
28 Wiper interval adjustment
29 Front window wipe On / Off 28 41
30 Roof window wipe On / Off
31 Air conditioning On / Off 35
32 Not used
33 Not used
34 Not used 31
35 Engine idling automatic On / Off
36 Load limit sensing control
36
Manual / Automatic
37 Warning: Engine diagnostic 37
Red indication = Switch engine off!
Yellow indication = Observe flash code 40
39 Electrical socket
40 Ventilator On / Off
41 Engine speed adjustment
43 39
000000 00
42 Engine ignition On / Off

43 Hourmeter: Operating hours
44 Not used 42
45 Not used
46 Not used B0000763.wmf
BG 24 H / 2008 4-2
4.3 CONTROL PANEL 1
Masthead position Mast prop cylinder

tilt setup retract extend
Winch Boom Backstay cylinder Extendable crawlers

rigging Rigging Derigging extend extend retract extend
extend
Mast Boom Backstay Boom Backstay cylinder Winch

Auto reset cylinders cylinders retract retract retract Main Aux
AT 1 2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B0000885.wmf
1 Rotary drive high torque 14 In drilling mode:

and high speed select Right backstay cylinder extend
2 Rotary drive high torque 15 Extendable crawlers retract
and reduced speed select 16 Extendable crawlers extend
3 Rotary drive reduced torque 17 Set mast automatically vertical
and high speed select 18 In rigging mode:
4 Rotary drive low torque Boom cylinders operation
and maximum speed select ** (+ right control lever)
5 Masthead tilt to transport 19 In rigging mode:
6 Masthead setup to operation Backstay cylinders operation
7 Mast prop retract (+ left + right control lever)
8 Mast prop extend 20 In drilling mode: Boom retract
9 Rigging mode: 21 In drilling mode:
Winch operation select Left backstay cylinder retract
10 Rigging mode select 22 In drilling mode:
11 Derigging mode select Right backstay cylinder retract
12 In drilling mode: Boom extend 23 Winch 1 (main winch) select
13 In drilling mode: 24 Winch 2 (auxiliary winch) select
Left backstay cylinder extend
* not used in this version
** not used with constant rotary drive
BG 24 H / 2008 4-3
4.4 CONTROL PANEL 2
Casing Depth Compressor

Travel Lock
oscillator interrupt On
Auto
CO casing
drive
Lower mast extension

lower raise
Casing oscillator Rope tensioner

CO
unlock lock clamping cyl. retract extend
KDK
Freewheel
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
BU12845003.wmf
1 Travel mode select * 15 In FOW mode:

2 CO mode select * Indicator: Casing tube high torque *
3 Auto casing drive lock / unlock * 16 In FOW mode:
Indicator: Drill auger high torque *
4 Generator On / Off *
17 In CO mode:
5 In Kelly-/CFA- /FDS mode:
Casing oscillator unlock *
Drilling assistant On / Off
18 In CO mode:
6 IN CFA-/FDS mode:
Casing oscillator lock *
Pulling assistant On /Off
19 In CO mode:
7 Depth measuring interrupt
Clamping cylinders select *
8 Compressor On / Off
20 Not used
9 Mast extension lowering 21 In CO mode*:
10 Mast extension raising Rotary drive freewheel On / Off
11 Air valve Open * 22 In FOW/TRD mode*:
12 Air valve Close * Selector: Casing tube rotate /
13 In FOW/TRD mode: Uppercarriage swing *
Casing tube ahead * 23 Crowd rope tension
14 In FOW/TRD mode: 24 Crowd rope slacken
Drill auger ahead *
* not used in this version
BG 24 H / 2008 4-4
4.5 B-TRONIC SYSTEM
For details on the B-Tronic System, please refer to the supplementary documentation
supplied with the equipment.
BG 24 H / 2008 4-5
4.6 REMOTE CONTROL FOR CASING OSCILLATOR (OPTIONAL)
1.1 2.1
1.3 2.3
1.2 2.2
4
3.1 3.2
B0000668.wmf
1.1 Tube unclamp

1.2 Tube clamp
1.3 Oscillate
2.1 Tube lift
2.2 Tube lower
2.3 Automatic press mode On
3.1 Casing oscillator unlock
3.2 Casing oscillator lock
4 In automatic press mode:
pressure adjust
BG 24 H / 2008 4-6
OPERATION
5 OPERATION
5.1 TRAVEL
5.1.1 To Select the Travel Mode
The "Travel" mode comes on automatically when the machine is started.
With machines equipped with provisions for 3 4

a casing oscillator, however, a selection must
be made between "Travel" or "Casing Oscil-
lator" mode to begin with:
To select "Travel":
● Press button (1). CO
Indicator light (3) glows.
To select "Casing Oscillator":

● Press button (2). 1 2
BK331518.wmf
Indicator light (4) glows.
5.1.2 To Travel and Steer
Initial position: Crawler drive wheels to the rear
B0000552.wmf
BG 24 H / 2008 5-1
OPERATION
5.2 UPPERCARRIAGE SWING

5.2.1 Swing Brake
The swing brake serves to arrest the uppercarriage against rotation during operation.
Risk of damaging components!

The swing brake may be applied only when the uppercarriage has come
CAUTION to a stop.
Swing brake lock:

● Press button (19);
indicator light (30) comes on. 30
19
18
Swing brake unlock:
● Push button (18);
15.3 15.4
indicator light (30) goes out.
B0000798.wmf
5.2.2 Swing Control
Uppercarriage swing to left:

● Unlock swing brake.
● Move control lever (15) to left (15.3) from centre.
Uppercarriage swing to right:

● Unlock swing brake.
● Move control lever (15) to right (15.4) from centre.
Letting the lever return to centre makes the swing slowly come to a stop, in hydraulic
way. A quicker stop can be implemented by carefully moving the lever in the opposed
direction.
BG 24 H / 2008 5-2
OPERATION
5.3 MAST REPOSITIONING

The mast must be parallel to the drilling axis at all times!
During drilling operation – and especially so in casing oscillator applica-
tions – it is important to watch the inclination of the mast on the opera-
CAUTION tor’s screen. Should the inclination change, due to the forces, the mast
must be repositioned to the original inclination.
5.3.1 Mast Auto Reset to Vertical

Neither the mast prop nor components of the drilling equipment may be
CAUTION in touch with the ground when the "Mast Auto Reset" is actuated.
AT
● Press button and hold on.
The mast sets to vertical position.

Releasing the button too soon stops the action.
The mast will first set to vertical position in the X axis and then, after a
pause, in the Y axis.
NOTE
BG 24 H / 2008 5-3
OPERATION
5.3.2 Mast Repositioning by Manual Control
5.3.2.1 To Adjust the Mast Inclination
– In Drilling Mode
The rigging modes , and are not

selected:
● Extend left backstay cylinder by
● Extend right backstay cylinder by
● Retract left backstay cylinder by
● Retract right backstay cylinder by
– In Rigging Mode
Rigging mode or is selected:
● Select backstay cylinder operation by B0000570.wmf
Lowering the mast:

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

● Move left / right control lever forward
BG 24 H / 2008 5-4
OPERATION
5.3.2.2 To Adjust the Drill Distance
– In Drilling Mode
The rigging modes , and not se-

lected.
Increasing the machine’s distance to the bore:
● Retract boom cylinders by
Decreasing machine’s distance to the bore:
● Extend boom cylinders by
– In Rigging Mode
Rigging mode or is selected.

B0000571.wmf
● Select boom cylinder operation by
Retracting the boom cylinder:

● Move right control lever forward.
Extending the boom cylinder:

● Move right control lever back.
BG 24 H / 2008 5-5
OPERATION
5.4 MAST PROP CONTROL
The mast prop must be fully extended when strong forces result from the extraction of
the tool.
To extend the mast prop:

● Press button (2) and hold on.
To retract the mast prop:

● Press button (1) and hold on.
Releasing one of these buttons too soon interrupts

the action. 1 2
BK331528.wmf
5.5 TRAVELLING WITH THE RIG

5.5.1 Travelling over Level Ground
Risk of accident due to driver’s obstructed round-view from the cab.

The driver of the rig must be assisted by a signalman during travel.
CAUTION
● Provide an obstacle free travel path.

● Adjust the uppercarriage in line with the crawlers and apply the swing brake.
● Lower work attachments and movable loads as close to the ground as possible.
● Set the mast in position of minimum working range.
● Set the mast vertical.
● Travel on firm and level surfaces only.
● Avoid making abrupt movements.
BG 24 H / 2008 5-6
OPERATION
5.5.2 Travelling Up and Down Slopes
5.5.2.1 With Raised Mast without Drilling Equipment
Tipping hazard!
Observe all instructions found in sect. "Travelling over level ground"!
CAUTION
Tipping hazard!
Max. permissible gradient is (15°).
Travel straight to the grade only. Never zigzag or traverse!
CAUTION
● Arrange the machine to carry the mast

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

shown here:
B0000704.wmf
5.5.2.2 With Lowered Mast
Tipping hazard!
Observe all instructions found in sect. "Travelling over level ground"!
CAUTION
Tipping hazard!
Max. permissible gradient is 15°.
Travel straight to the grade only. Never zigzag or traverse!
CAUTION
● Travel up or down a slope in the manner shown here:
B0000536.wmf
BG 24 H / 2008 5-7
OPERATION
5.5.3 Raising the Mast - with Rotary Drive and Kelly
Initial situation (see fig.)

BK000508.wmf
2
● Extend boom cylinders (1) half way.
1 5
BK000507.wmf
● By extending the backstay cylinders,

raise the mast to about 45°.
● Elevate the kelly by the main winch.
If the kelly is locked in the rotary drive:
Select "Winch rigging" mode- Hold "Re-
set depth " button depressed while turn-
ing the rotary drive counter-clockwise.
BK000504.wmf
● Extend backstay cylinders (2) com-

pletely.
BK000506.wmf
BG 24 H / 2008 5-8
OPERATION
● Extend boom cylinders (3) completely.

● Mount supporting clamps on boom cyl-
inders.
It is not allowed to operate

the rig without supporting
clamps mounted on the
boom cylinders! Supporting
CAUTION clamps prevent inadmissi-
ble working radius.
● Tension the crowd ropes.
BK000505.wmf
BG 24 H / 2008 5-9
OPERATION
5.5.4 Lowering the Mast - with Rotary Drive and Kelly
Risk of damaging the equipment and components!

Laying down the mast fitted with complete drilling equipment is allowed
only where the total wight of the kelly bar + drilling tool + casing drive
adapter does not exceed the following values.
BG 24 H without mast extension: 11.0 tonnes
BG 24 H with 2 m mast extension: 10.0 tonnes
CAUTION BG 28 H without mast extension: 8.0 tonnes
BG 28 H with 2 m mast extension: 7.0 tonnes
BAUER does not assume any liability for damage resulting from non
observance of the weight specified here!
Initial position (see fig.)
● Remove supporting clamps (3) from

boom cylinders.
● Run the crowd sledge (4) fitted with
kelly down until the lower end of the
casing drive adapter is in line with the
lower end of the mast.
Elevating the crowd sledge

fitted with drilling equipment
onto upper section of mast 3
CAUTION endangers the stability of the
rig.
BK000505.wmf
● Retract boom cylinders (3) until the

mast has been lowered to slightly
above the ground. 2
BK000506.wmf
BG 24 H / 2008 5 - 10
OPERATION
● Retract backstay cylinders (2) until the

mast has been tilted backward to about
45°.
● Let the kelly slip through the rotary drive

as far as possible, taking care that lock-
ing pockets on the kelly stay clear of
driver strips in the rotary drive.
BK000504.wmf
● Retract backstay cylinders (2) com- 2

pletely.
● Release main and auxiliary rope (5) ten- 1 5

sion. Spool out sufficient length of rope,
until the ropes are slack enough to allow BK000507.wmf
the mast to be laid down on the upper-

carriage.
● Lay the mast down:

Retract boom cylinders (1) completely.
When laying down the mast in the sup-
port on the uppercarriage pay attention BK000508.wmf
to correct position of ropes and hoses.
BG 24 H / 2008 5 - 11
OPERATION
5.6 ROTARY DRIVE CONTROL

Operational functions
Under no load: The rotary drive rotates at the adjusted max speed
Under load: The higher the required torque the slower the rotating speed
Control:
Risk of damaging drill string components!
The "High torque" must not be switched on if the drill string components
(kelly bar, continuous flight auger) are not capable of transmitting it.
CAUTION If that is the case, use the "Reduced torque" instead of the "High torque"!
Symbols on control buttons stand for Torque (Y-axis) - Rotary

speed (X-axis) - Diagrams.
NOTE The initial placing of the drill string should be performed under low torque
in order that sufficient force be still at hand, if the auger gets stuck.
Observe the torque indicating bar on the screen during the performance.
For placing the drill string and drilling in rock, a "Reduced speed" function
is provided.
5.6.1 With Kelly Equipment (Rotary Drive Shiftable)

8
9
31 32 33 34 10
B0000895.wmf
Function Control
To select high torque (1st gear) (with rotary drive out of motion)
– with high speed: Press button (31)
– with reduced speed: Press button (32)
– and to shift between high and reduced speed: Press button (9)
To select reduced torque (1st gear): Press button (33)
To select low torque (2nd gear) (with rotary drive out of motion only)
– with max speed: Press button (34)
To accelerate or decelerate rotation: Move control lever (10) away from or back to centre
To rotate counter-clockwise: Move control lever (10) to right
To rotate clockwise: Move control lever (10) to left
To dump spoil (abrupt stopping clockwise rota- Move control lever (10) to left and press button (8)
tion):
BG 24 H / 2008 5 - 12
OPERATION
5.6.2 With CFA Equipment

8
9
31 32 33 34 10
B0000895.wmf
Function Control
To select high torque (1st gear) (with rotary drive out of motion only)
– with high speed: Press button (31)
– with reduced speed: Press button (32)
– and to shift between high and reduced speed: Press button (9)
To select reduced torque (1st gear): Press button (33)
To select low torque (2nd gear) (with rotary drive out of motion only)
– with max speed: Press button (34)
To accelerate or decelerate rotation: Move control lever (10) away from or back to centre
To rotate counter-clockwise: Move control lever (10) to right
To rotate clockwise: Move control lever (10) to left
BG 24 H / 2008 5 - 13
OPERATION
5.6.3 Torque Reduction by Key-Operated Switch
The torque reduction is an overload protection for drill string components (kelly rods and joints
of auger sections and FDP tube sections) not capable of transmitting the full torque of the rotary
drive.
To switch the torque reduction On: 1
● Turn the key-operated switch (1) in the control

cabinet to position "I".
B0000904.wmf
Enabled control functions: - - + +
In kelly mode
Although the torque reduction is on, activation of the full torque is still possi-
ble for operations with the casing driver.
Precondition: The load on the main rope is at least 1 tonne
To activate the full torque for the casing driver: min.

1 to
1 2 3 4
● Press button (8).  Light (1) blinks.
● Spool in at least one meter of main rope,
i. e. kelly is hanging freely suspended on
the rope.  Light (1) shines.
8 7 6 5
The full torque will be deactivated again as B0000903.wmf
soon as the main rope is spooled out.
min.
1m
B0000910.wmf
BG 24 H / 2008 5 - 14
OPERATION
5.6.4 Additional Functions
5.6.4.1 To Operate with "Freewheel" (optional)
This is a function that permits the rotary drive to coast freely, enabling additional opera-
tion with a casing oscillator without having to remove the casing tube from the casing
drive adapter.
Risk of damaging the rotary drive!

When using a casing oscillator, the freewheel function of the rotary drive
must be activated or the casing tube must be disengaged from the casing
CAUTION drive adapter.
2
"Freewheel" activation:
● Press button (1).
Indicator light (2) glows. CO
"Freewheel" deactivation:
KDK
● Press button (1). Freewheel
Indicator light (2) does not glow.
1
B0000697.wmf
5.6.4.2 To Operate with Torque Amplifier (optional)
The equipped BAUER torque amplifier doubles the torque generated by the rotary
drive.
Danger of damaging the swing mechanism, the swing brake or the mast
pivot!
Release the swing brake when the torque input in the amplifier exceeds
CAUTION 50 % of the max. torque output of the rotary drive.
To use the torque amplifier:

● Align the mast at the drilling spot.
● Apply the swing brake.
● With reduced torque (max. 50 %), screw the borehole casing into the ground by
about 3 - 4 m. From this depth on it can be guaranteed that the casing will remain
plumb.
● Release the swing brake and sink the casing by reversible operation with the rotary
drive.
BG 24 H / 2008 5 - 15
OPERATION
5.7 WINCH CONTROL

5.7.1 Lifting / Lowering
Risk of damaging the winches!

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

Hoist limiters are out of function during rigging operations so that the
CAUTION winches must be controlled with great care.
In Drilling mode In Rigging mode
● Set all Rigging controls to OFF. ● Select "Winch rigging" mode:
Lamp in buttons , and Lamp in button glows.
do not glow.
Winch selection:
1
● Press button for Main winch or
2
● press button for Auxiliary winch.
Control of selected winch
B0000702.wmf
BG 24 H / 2008 5 - 16
OPERATION
5.7.2 To Operate with Freewheel (optional)
The freewheel function enables the main winch to automatically follow the drilling pro-
gress and prevents the drilling tool getting stuck in soft soil formations.
Preconditions for release of freewheel 4

function: 5
– Load on rope is maximum: 2.0 tonnes 4
5 6
1
3
7
2
8
1
7
9
10
0
Freewheel activation:
● Turn key-operated switch (1) to position 2
of Freewheel mode "On". Emergency Stop
NOT-AUS
● Press foot switch (4) all way down and

4 5 6
7
2
8
1
9
10
0
5 6
4
7
hold on.
8
6
9
10
0
● Briefly press button (3).
00000000
 Freewheel is released! Indicator

BJ637501.wmf
(5) glows.
The rope will first automatically tension (by up to approx. 500 kg), en-
suring tipped swivel raises to upright. This avoids damage resulting to
NOTE the rope.
Freewheel speed setting:

● By potentiometer (6), set the freewheel speed such that the operating pressure at the
rotary drive will not exceed 200-250 bar during the drilling progress. This prevents the
drilling tool getting stuck.
Potentiometer setting Freewheel speed

0 Max
10 0
If the potentiometer is set to max, the winch will stop and the indication (5) go out. In
this case, turning the potentiometer back slightly will make the freewheel release again.
Freewheel deactivation:
● Release the foot switch.
● Or, lift / lower by the winch control lever.
● Turn the key-operated switch (1) back to position of Freewheel mode "Off".
BG 24 H / 2008 5 - 17
OPERATION
5.7.3 To Operate with "Slack Rope Switch-Off"
The "switch-off" here is a function that enables power-controlled and slack-free unspool-
ing of rope from the main winch.
To activate the slack rope switch-off:
● Turn potentiometer (7) to right past the 4

switch-point. 5
● Set potentiometer (7) to the desired rope
1
retraction force (= the value at which the 3
4 5 6
7
2
8
1
7
9
10
0
winch is to stop unspooling rope).
Potentiometer setting Retraction force [to] 2

1 0
Emergency Stop
NOT-AUS
5 6
4
7
2
8
1
9
0
10
5 6
4
7
10 2.0
8
6
9
10
0
0 0 0 00 0 00
BJ637501.wmf
Power-controlled unspooling of rope:
● Push left control lever forward, until load lands on solid surface.
If slack rope creates, the main winch will stop and the following message appears on
the screen:
Main winch slack rope switch-off
From now on, activation of the "Freewheel" function of the main winch
(see separate sect.) can be used to continue the automatic slack-free
NOTE unspooling of rope.
To deactivate the slack rope switch-off:
● Turn potentiometer (7) to left up to stop.
BG 24 H / 2008 5 - 18
OPERATION
5.8 DEPTH MEASURING CONTROL

5.8.1 To Reset the Depth Measuring
● Place drilling tool in desired position.

● Press button "RESET" on display , to reset the depth indicator to "0".
The depth measuring may be reset to zero at any time.

NOTE
5.8.2 To Interrupt the Depth Measuring
In CFA applications, the depth measuring must be interrupted every time the drill string
is extended with a new section:
● Press button to interrupt the depth measuring.

● Press the button anew to re-start the depth measuring.
BG 24 H / 2008 5 - 19
OPERATION
5.9 CROWD CONTROL

Do not use the boom cylinders to boost the crowd system. Or, the crowd system
will be overloaded and the drilling axis distorted.
CAUTION
5.9.1 Basic Functions
5.9.1.1 Moving the Crowd Sledge Down / Up
Function Control
To move the crowd sledge down: Push control lever (10) forward. 10
p
To move the crowd sledge up: Pull control lever (10) back.
5 6
4
7
2
8
1
9
10
0
v
5 6
4
7
2
8
1
9
10
0
To control the crowd speed: The speed changes with the
amount of lever movement (10).
BM000502.wmf
Risk of damaging the kelly!

When extending or retracting the kelly, reduce the
CAUTION crowd speed in areas of locking recesses (1).
BM000503.png
BG 24 H / 2008 5 - 20
OPERATION
5.9.1.2 To Switch On Fast Crowd
Application: In all drilling methods
Risk of damaging the kelly!

Do not switch the "Fast crowd" on
– when the kelly is locked,
– for locking the kelly,
– when retracting or extending the kelly,
CAUTION
– during drilling.
Only switch the "Fast crowd" on when at idle stroke.
Function Control 6
To switch "Fast crowd" On: Press button (6) and keep it 10

pressed. p
Move control lever (10) straight

4 5 6
7
2
8
1
9
10
0
v
5 6
4
7
2
8
1
9
10
0
forward-backward from centre.
BM000504.wmf
The switch-on of the "Fast crowd" will not respond when the "Drilling Assistant" or
"Pulling Assistant" or "Crowd + Main winch" is on.
NOTE
BG 24 H / 2008 5 - 21
OPERATION
5.9.2 Special Functions
5.9.2.1 Which Crowd Functions for Which Drilling Methods?
Drilling-
method CFA FDP
TRD
Kelly CFA with FDP with TRD SMW CSM FOW ROB RSV
BTM
Crowd MW MW
function
Manually controlled functions
Adjustment of
crowd pres- x x x x x x x
sure
Adjustment of
x x x x x x
crowd speed
Pulling by
crowd + main x x
winch
Program sustained functions
Drilling
assistant with x
kelly
Drilling
assistant with x x x x
CFA
Drilling
assistant with x x
FDP
Pulling
x x x x x x
assistant
BG 24 H / 2008 5 - 22
OPERATION
5.9.2.2 Crowd Pressure Adjustment
Application: In all drilling methods.

Function: To operate with reduced crowd pressure on the drilling tool.
Practice: The operator adjusts an exact crowd pressure which he can then maintain with-
out having to permanently readjust by sensitive movements with the control
lever.
10
14.1
p p
max. 4
5 6
min. 4
5 6
3
7
2
8
3
9
10
0
v
2
8
1
5 6
4
10
0
7
2
8
1
9
10
0
BM000505.wmf
BM000506.png
Control Indicators
Black piston in the display shows the adjusted
Adjust by potentiometer (14.1)
value in %
and control by forward lever movement (10).
(only displayed in the kelly drilling method)
BG 24 H / 2008 5 - 23
OPERATION
5.9.2.3 Crowd Speed Adjustment
Applicable to drilling methods

CFA FDP
TRD
BTM
MW MW
Function: To operate with reduced up and down crowd speed.
Practice: The operator adjusts an exact crowd speed which he can then maintain without
having to permanently readjust by sensitive movements with the control lever.
10
14.2
p
v 4
5
6
3
7
2
8
1
9
10
0
max. 4
5 6
min. 4
5 6
3
7
2
3
8
7
9
10
0
2
8
1
9
10
0
BM000507.wmf BM000508.png
Control Indicators
1 (grey)* = optimal speed

Adjust by potentiometer (14.2) and control by 2 (white) = actual speed
forward-backward lever movement (10). 3 (red)* = divergence from the optimal speed
4 (green)* = optimal range
* Indicators 1, 3 and 4 are computed by the program in dependence on the

equipment specific presets entered in the Drilling Assistant menu.
NOTE The indicators 1, 3 and 4 are not displayed in the FDP drilling method.
BG 24 H / 2008 5 - 24
OPERATION
5.9.2.4 Pulling by Crowd + Reeved Main Rope
Applicable to drilling methods
CFA FDP
TRD
Kelly CFA with FDS with TRD SMW CSM FOW ROB RSV
BTM
MW MW
Practice: The operator uses both the crowd winch and the main winch in pulling the drill
string.
15 10
p
5 6
4
3
7
2
8
1
9
10
0
v
5 6
4
3
7
2
8
1
9
0
10
BM000509.wmf
Control Indicator
Pull both control levers (10) and (15)
-
simultaneously back from centre.
Only feasible with extended mast prop.
NOTE
BG 24 H / 2008 5 - 25
OPERATION
5.9.2.5 Drilling Assistant in Kelly Operations
Program sustained function applicable to drilling methods

CFA FDS
TRD
Kelly CFA with FDS with TRD SMW CSM FOW ROB RSV
BTM
MW MW
Aim: Optimally torque-oriented crowd pressure on the drilling tool.

Function: The crowd pressure is regulated by the program in dependence on the oil pres-
sure to the rotary drive.
Practice: After initial drilling, the operator switches the Drilling Assistant on leaving the re-
gulation of the crowd pressure to the program.
5.9.2.5.1 How to Control
Depth
interrupt
● Press button (5) on the control panel.

 Lamp (5) glows. Concrete valve Air valve Auger to casing adjustment
open close open close
Winch Rope tensioner

Mud-hopper retract extend
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
BM1097522.wmf
10
● Push control lever (10) forward for crowd + left
for rotation.
p p
14.1 4
5 6
3
The regulation is influenced by the

5 6
2
4
8
1
9
10
0
3
v
2
8
1
5
9
4 6
3
7
2
10
0
8
1
value adjusted by the potentiome-

0
10
NOTE ter (14.1).
BM000510.wmf
Displays on the screen:
V = Crowd pressure in bars and %

KDK = Rotary drive pressure (torque) in bars
and %
BM000511.png
BG 24 H / 2008 5 - 26
OPERATION
Example:
The program regulates the crowd

pressure in dependence on the pres-
sure at the KDK.
(KDK = Rotary drive)
BM000512.png
KDK pressure = 275 bars  Crowd pressure V = 50 %
Whenever the pressure at the KDK

gets too high, the program regulates
the crowd pressure down to 0.
The drilling tool can cut itself free. BM000511.png
The crowd pressure rises again.
BM000513.png
BG 24 H / 2008 5 - 27
OPERATION
5.9.2.6 Drilling Assistant in CFA Operations

CFA FDP
TRD
BTM
MW MW
Aim: To achieve optimal filling of the drill auger in avoidance of a "corkscrew" effect.
Function: The drilling down speed is regulated by the program in dependence on the rota-
tion speed of the rotary drive.
Practice: After initial drilling and presetting, the operator switches the Drilling Assistant on
leaving the regulation of the crowd speed to the program.
● Enter the required presets for the Drilling Assistant Depth

interrupt
(see sect. "Presetting for the Drilling Assistant in

CFA"). Concrete valve Air valve Auger to casing adjustment

● Press button (5) on control panel 2. 3
1 2 3 4 5 6 7 8
 Lamp (5) blinks. 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
BM1097522.wmf
BG 24 H / 2008 5 - 28
OPERATION
Using the Assistant at maximal "Penetration rate " (in mm per revolution):
10 8.1
● Push control lever (10) forward to max for crowd +
left for rotation.
p
5 6
4
● Shortly press button (8.1) on the control lever.
7
2
8
1
9
10
0
v
5 6
4
7
2
8
1
9
10
0
BM000514.wmf
10
 Lamp (5) on the control panel glows.
p
 By the lever (10) moved left only,

5 6
4
7
2
8
1
9
0
10
v
4 5 6
7
2
8
1
9
just control the rotation.
10
0
BM000515.wmf
 The program drills down at maximal consistent pe-

netration rate.
 The yellow line denoting the "Penetration rate" (1)
runs along the red nominal line.
BM000543.png
Using the Assistant at lower "Penetration rate" (in mm per revolution):
● Push control lever (10) forward for crowd + left for 10 8.1
rotation.
● When the optimal crowd speed has been gained, 4
5 6
p
3
7
2
8
1
9
10
0
shortly press button (8.1) on the control lever.

5 6
4
3
7
2
8
1
9
10
0
 The attained crowd speed is stored. BM000514.wmf
10
 Lamp (5) on the control panel glows.
p
 By the lever (10) moved left only,

5 6
4
3
7
2
8
1
9
0
10
v
4 5 6
3
7
2
8
1

0
10
BM000515.wmf
 The program drills down at a lower consistent pe-

netration rate.
 The yellow line denoting the "Penetration rate" (1)
runs parallel to the red nominal line.
BM000544.png
BG 24 H / 2008 5 - 29
OPERATION
8.1
To deactivate the Drilling Assistant in CFA: 10
● Shortly press button (8.1) anew. 4 5 6

p
7
2
8
1
9
10
0
v
5 6
4
7
2
8
9
1
10
0
 Lamp (5) on the control panel blinks. Depth
interrupt
Or
Concrete valve Air valve Auger to casing adjustment
● let the control lever return to neutral, open close open close
or
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
● switch off by button (5) on control panel 2. BM000518.wmf 17 18 19 20 21 22 23 24
 Lamp (5) on the control panel goes out. BM1097522.wmf
5.9.2.6.2 Presetting for the Drilling Assistant in CFA
● Switch on drilling .
● Select Crowd assistant .
● Open up the CFA drilling assistant adjustment
menu.
BM000545.png

● Enter by the required values.
 These will be used by the program to determine the

" Penetration rate " in [mm/revolution].
BM000546.png
 The determined max penetration rate is denoted by

a red line (1) in the diagram on the operating screen
and will serve as a bearing for an optimal crowd
speed.
BM000547.png
BG 24 H / 2008 5 - 30
OPERATION
5.9.2.7 Drilling Assistant in FDP Operations

CFA FDP
TRD
BTM
MW MW
Aim: To ensure that a certain min rpm is maintained by the rotary drive in the pro-
gress of the drilling.
Moreover, it offers assessment of the strength (penetration resistance) of the
soil enabling the length of the pile being adapted correspondingly.
Function: Whenever the rotation speed drops below a min rpm, the program will throttle
the crowd speed.
Practice: After initial drilling and presetting, the operator switches the Drilling Assistant on
leaving the regulation of the crowd speed to the program.
● Enter the required presets for the Drilling Depth

interrupt
Assistant (see sect. "Presetting for the Drilling

Assistant in FDP").
● Press button (5) on control panel 2. Winch Rope tensioner

 Lamp (5) blinks.

3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
BM1097522.wmf
Mast prop cylinder

retract extend
 The function (2) on control panel 1 is

selected (meaning "reduced rotation speed"). Winch
rigging Rigging Derigging Boom
extend
Backstay cylinder
extend extend
Extendable crawlers
retract / extend
Mast Backstay Boom Backstay cylinder Winch

reset cylinders retract retract retract Main Aux
AT 1 2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B0000896.wmf
Continued
BG 24 H / 2008 5 - 31
OPERATION
Control continued
● Push control lever (10) forward for crowd +
10 8.1
left for rotation.
14.2
 The operator controls both the crowd v 4
5 6
p
7
speed and the rotation speed. However,
8
1
9
0
10
v
max. min.
5 6 5
4 4 6
7
3
8
7
9
10
0
2
8
1
9
the program will throttle the crowd speed
10
0
when the rotation speed drops below the
min rpm. BM000522.wmf
The crowd speed is influenced by

the value adjusted by the potenti-
NOTE ometer (14.2).
● Shortly press button (8.1) on the control 8.1

10
lever.
p
5 6
4
7
2
8
1
9
10
0
v
5 6
4
7
2
8
1
9
10
0
 Lamp (5) on control panel 2 glows.
 The crowd speed attained by the amount BM000523.wmf
of lever (10) movement is stored.
● By the lever (10) moved left only,

 The program keeps the crowd speed con-
sistent, however will throttle the crowd
speed when the rotation speed drops be-
low the min rpm.
BM000548.png
8.1
To deactivate the Drilling Assistant in FDP: 10
p
● Shortly press (8.1) anew.

4 5 6
3
7
2
8
1
9
0
10
v
5 6
4
3
7
2
8
1
9
10
0
 Lamp (5) on the control panel blinks. BM000518.wmf
The stored crowd speed is deleted. Depth

interrupt
Or
● let the control lever (10) return to neutral,
or Winch
Mud-hopper
Rope tensioner
retract extend
1 2 3 4 5 6 7 8
● switch off by button (5) on the control panel.
9 10 11 12 13 14 15 16
 Lamp (5) goes out. 17 18 19 20 21 22 23 24
BM1097522.wmf
BG 24 H / 2008 5 - 32
OPERATION
5.9.2.7.2 To Assess the Strength (Penetration Rate) of the Soil
Example:
1 Borderline to bearing layer as determined from
the subsoil investigation
2 Estimated length of piles
ye l l o w Layer of insufficient bearing capacity
g r e y Layer of sufficient bearing capacity
r e d Zone of insufficient bearing capacity as not

detected by the subsoil investigation
g r e e n Pile lengths adapted to the prevailing bearing

capacity of the subsoil
BM000525.png
The lower the penetration rate

(strength of the soil)
the further left the yellow curve.

After arrival in the bearing layer, the yellow curve


will run across the red line over several meters.
Parallel thereto, the curve of the torque in Ma
must keep close to 100 %. 
BM000526.png
BM000549.wmf
BG 24 H / 2008 5 - 33
OPERATION
5.9.2.7.3 Presetting for the Drilling Assistant in FDP
● Switch on drilling .
● Open the FDP drilling assistant adjust-
ment menu.
BM000550.png

● Enter by the required values as fol-

lows.
─ For " Nominal value penetration resistance

",
enter from experience: 8000
BM000551.png
 In the diagram on the operating screen the

entered value of " Nominal value penetra-
tion resistance " appears as a red line (1).
BM000530.png
─ For " Min rpm " ,

enter as recommended: 8.
Or
switch the reduced rotation speed function on by button , rotate with the KDK idling,
read the rpm off the operating screen, deduct 1 (n -1) and enter the resulting value.
BG 24 H / 2008 5 - 34
OPERATION
5.9.2.8 Pulling Assistant Operation

CFA FDP
TRD
BTM
MW MW
Aim: To produce a homogenous pile of an optimal quantity of concrete.
Function: The program regulates the pulling speed in dependence on the concrete quan-
tity and concrete pressure.
Practice: The operator switches the Pulling Assistant on leaving the regulation of the pull-
ing speed to the program.
● Enter the required presets for the Pulling Depth

interrupt
Assistant (see sect. "Presetting for the Pull-

ing Assistant).
● Press button (6) on control panel 2.

 Lamp (6) blinks.

3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
BM1097522.wmf
Mast prop cylinder

retract extend
 The function (2) on control panel 1 is

selected (meaning "reduced rotation speed"). Winch
rigging Rigging Derigging Boom
extend
Backstay cylinder
extend extend
Extendable crawlers
retract / extend
Mast Backstay Boom Backstay cylinder Winch

reset cylinders retract retract retract Main Aux
AT 1 2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B0000896.wmf
Continued
BG 24 H / 2008 5 - 35
OPERATION
Control continued
● Pull control lever (10) back. 8.1
10
● Shortly press button (8.1) on the control p
lever.
4 5 6
7
2
8
1
9
10
0
v
4 5 6
7
2
8
1
9
10
0
 Lamp (6) at on control panel 2 glows. BM000531.wmf
 The program regulates the pull-up speed

in dependence on both the quantity and
the pressure of the concrete.
BM000552.png
Switching the concrete pump off:

When the pile has been built-up to the blue line (1), the con-
crete pump can be switched off, since the quantity of concrete
contained in the pipe is sufficient for the rest of the pile.
The blue line appears in the diagram after a short pull by the
control lever (10).
Precondition: The value of " Concreting pipe quantity " has
been entered into the " Crowd assistant " menu.
BM000533.png
To deactivate the Pulling Assistant: 10 8.1
● Shortly press button (8.1) anew. 4

5 6
p
3
7
2
8
1
9
10
0
 Lamp (6) on the control panel blinks.

5 6
4
3
7
2
8
1
9
0
10
BM000518.wmf
Or Depth
interrupt
● let the control lever (10) return to neutral,

or

● switch off by button (6) on the control panel. 3
 Lamp (6) goes out.

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
BM1097522.wmf
BG 24 H / 2008 5 - 36
OPERATION
5.9.2.8.2 Presetting for the Pulling Assistant
● Switch on to concrete .
● Open the Pulling assistant adjustment
menu
BM000553.png

● Enter by the required values as fol-
lows.
─ For " Set piston stroke ",
enter in Litres the quantity delivered by one
stroke of the concrete pump.
─ For " Pile diameter ",
enter in Millimetres the diameter of the pile to
be produced.
The program will use this value to calculate
the concrete consumption.
BM000554.png
─ For " Concreting pipe quantity ",
enter in Litres the capacity of the concreting
pipe.
─ For " Rated increased consumption ",

enter in dependence on the prevailing soil
conditions the % of consumption to be added
(see red area in fig. right) in order that a suffi-
cient quantity of installed concrete be guaran- +%
teed.
BM000536.png
BG 24 H / 2008 5 - 37
OPERATION
─ For " No. of strokes per depth interval ",

enter the number of strokes by the concrete pump
that makes the yellow bars in the diagram reach the
red line. This adapts the height of the bars to the
scale of the depth.
The display helps the operator to control the pull-up
where the Pulling Assistant is not used.
The two examples right show 2 and 4 pump strokes
respectively per depth interval until the nominal quantity
(red line) is obtained
The fewer the number of strokes en- BM000537.png BM000538.png
tered the quicker can the operator ob- Entry: 2 strokes Entry: 4 strokes
serve whether the pull-up speed is
NOTE correct.
─ For Pull process threshold value ",

enter in Bars the minimum value of concrete pres-
sure Pstart for start of pulling.
Not until this value has been obtained will the red
line (1) appear in the diagram.
BM000530.png
p
start
BM000539.png
─ For " Depth at circumfusion ",

enter in Meters the depth (s) at which the concrete
pressure will collapse (p = 0 bar). p= 0 bar s
The program will use the entered value to determine
from where on the concrete pressure is no more to
be considered and the Pulling Assistant be regulated
by the concrete quantity alone.
BM000540.png
BG 24 H / 2008 5 - 38
OPERATION
─ For " Min pressure at pulling assistant ",

enter in Bars the minimum concrete pressure (pmin)
that must be maintained for the Pulling Assistant.
Whenever the pressure drops below the entered value,
the pulling procedure will stop until the concrete pres-
sure has built-up again.
p
If the concrete pressure is not to be min
considered at all in the production of
NOTE the pile, just enter "0" here.
BM000541.png
BG 24 H / 2008 5 - 39
OPERATION
5.9.3 To Use the Main Winch in Combination with Crowd
Danger of damaging the slewing ring and undercarriage by overloading!

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

– where the rig is equipped with a mast prop which is fully extended, and
– where the attached tool string has the appropriate provisions (e.g. a defined stop for
the kelly on the casing drive adapter, in kelly applications)
Equipment fitted with a mast prop may have a monitoring automatic

which stops the main winch from pulling during crowd as soon as a cer-
tain value of the combined forces is exceeded.
NOTE Where there is no such monitoring automatic, the operator himself is
responsible for not endangering the capacities of the rig when forces
sum up.
BG 24 H / 2008 5 - 40
OPERATION
5.10 AUGER CLEANER CONTROL (OPTIONAL)

The auger cleaner is mounted with a sledge on the
mast and suspended to the auxiliary rope.

The reamer (1) will be folded out during
the drilling. During drilling, the auger 1
cleaner serves as guidance only and
1-2 m
should be positioned approx. 1 – 2 m
above the ground (2).
CAUTION BJ332520.wmf
Auger cleaning is possible only when
the auger has been stopped from ro-
tating.
Auger cleaning:
● When the final depth has been achieved, lift the
4
auger cleaner by the auxiliary rope, to a position 1
where the reamer (1) can be folded into the flight of
the auger.
Be careful no to fold reamer into auger B000856.wmf
until the reamer is located below the 3

lifting eyes (4).
CAUTION
BM779502.wmf
● Fold in the reamer in manual way.
● Pull the auger and the cleaner up by approx. 2 - 3 m.

● Start auger cleaning by pressing the button (3).
Now the cleaner will rotate clockwise, screwing itself
downwards to clean the auger.
● Press the button (3) again to Stop rotation before the
auger cleaner reaches the lower end stoppers on the
mast.
● Repeat the procedure until the complete auger has
been withdrawn.
B000859.wmf
BG 24 H / 2008 5 - 41
OPERATION
5.11 CENTRAL LUBRICATION CONTROL

The central lubrication greases automatically at preset intervals all the spots linked up to
the central lubrication system. Both the length of the lubrications and the length of the
pauses are pre-adjustable.
In addition, a green push-button enables release of lubrication at any time.
The lubrication interval will be interrupted and saved when ignition is turned off, and will
be resumed when ignition is turned on again.
Not all the places to be lubricated are covered by the central lubrication
system. Please, find in the Lubrication Plan the places requiring sepa-
NOTE rate lubrication.
During the automatic lubrication, it is recommended to run the crowd

sledge up and down the mast 2 - 3 times in order to distribute the
grease from the runners to the rails.
NOTE Additional lubrication with a grease gun is possible through a free nipple
found on the distributor block on the crowd sledge.
Flashing codes of the green push-button:
1.5 sec.
1
1 System on
2 Lubrication on 2 0.5 sec. / 0.5 sec.
3 Low lubricant level 1 sec. 1 sec.

2 sec. 2 sec.
4 High lubricant pressure 3
5 Lubricator control failure 4 2 sec. 4 sec. 2 sec. 4 sec.
5 Dauerlicht / Permanently
B0000705.wmf
Red warning light:
Indicates a failure in the automatic lubrication of the runners of the crowd sledge. The
failure must be repaired without delay, to avoid extensive damage.
To avoid failures in the central lubrication system, switch OFF central

lubrication system during rigging procedure of the rig (switch in the
NOTE cab).
A manufacturer's documentation on the Central Lubrication System is

supplied in the Appendices of this manual.
NOTE
BG 24 H / 2008 5 - 42
OPERATION
5.12 EMERGENCY CONTROL
The emergency control enables the major functions of the equipment still be controlled
in case the normal control system is failing.
WARNING!
Rig damage and tipping hazard!

The emergency control does not allow fine operation of the individual
functions.
The emergency control must be used in an emergency only, to move
the equipment out of a hazardous situation when the normal control is
failing.
The emergency control may be controlled from the operator’s cab only.
How to use:
● Shut down the equipment and stop the

engine.
● In the control cabinet, unplug processors
B1.2 and B1.3 (pull safety lever down
(1) and remove plug (2)).
● Turn the key-operated switch (3) into 2. 2.
"On" position. B 1.2 B 1.3
● Start up the equipment. Now the essen-

tial functions may be controlled by the 1. 1.
control levers.
● When the emergency operation is com-
pleted, shut down the equipment and
stop the engine. 3
● Repair the defect.
● Turn the key-operated switch into "Off"
position.
● Plug in the processors again.
● Start up the equipment. B0000764.wmf
BG 24 H / 2008 5 - 43
OPERATION
5.12.1 Emergency Control of Engine Speed
If the speed of the engine will not adjust by the control from the cab:
● Check the load limit regulation for proper working order (see instruction manual of
base machine). If it is in order, proceed as follows:
● Adjust the speed of the engine by the

rotary switch (2) located in the engine
compartment.
BV993500.jpg
BG 24 H / 2008 5 - 44
OPERATION
5.13 COMPRESSOR OPERATION (OPTIONAL)
A manufacturer's documentation on the Compressor is supplied in the

Appendices of this manual.
NOTE
● Turn the compressor On by button

on control panel.
● Adjust the pressure by regulator (2).
1 Compressed air filter with condensate

bowl
2 Compressed air regulator
3 Oil-fog lubricator with oil bowl
BV877426.jpg
BG 24 H / 2008 5 - 45
START-UP / SHUT-DOWN
6 START-UP / SHUT-DOWN
6.1 START-UP
6.1.1 Initial Start-Up
The initial start-up of the equipment concerns both the manufacturer and the future
user, the customer. In general, the job required here will be carried out jointly in a train-
ing held at the manufacturer’s or in a briefing on the construction site.
Even before the first rigging operations are begun, the operator of the equipment must
be familiar with all the control elements and their capabilities.
6.1.2 Visual Inspection before Starting
A visual inspection and thorough check is required before putting the equipment into
operation:
● Inspect the entire equipment for loose connections and missing pins or bolts.
● Check all components for wear.
● Look for leaks and fluid spills.
● Check all contained oils and fluids have the proper level.
BG 24 H / 2008 6-1
6.1.3 Daily Start-Up
6.1.3.1 Starting the Equipment
Risk of damaging the equipment!

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

● Set all controls to "0" position.
● Pull the Emergency STOP button.
● Start the engine by turning the ignition key.
Risk of damaging the engine!

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

When starting with the aid of an external power source, first switch off
CAUTION main fuse F1 (BAUER part)!
● Move the safety stick of the pilot control to "On" position.
BG 24 H / 2008 6-2
6.1.3.2 Selecting the Work Application
When the computer has started, a menu comes on display offering the operator to se-
lect the kind of application in which to work.
With equipment designed for one work application only, the Operating
Screen of the respective application will appear right away when the
NOTE computer has started up.
Colours used in the display mean: green  selected

white  available
grey  not available
The operator has 10 seconds now to select a new application:
● Touch the name of the desired application
Name Application
Kelly Drilling with kelly equipment
CFA Drilling with continuous-flight-auger equipment
FOW Drilling with front-of-wall equipment
TRD Drilling with twin-rotary-drives equipment
MIP Drilling with mixed-in-place (triple auger) equipment
Drilling with continuous-flight-auger equipment
CFA with main winch
sustained by main winch pull
FDP Drilling with Full Displacement System equipment
HPI Drilling with high-pressure-injection equipment
Soil Mixing Drilling with soil mixing equipment
● Touch "End".
The Operating Screen of the new application comes on display.
If no new selection is made within 10 seconds, the Operating Screen

of the already selected application comes automatically.
NOTE
BG 24 H / 2008 6-3
6.1.4 Safety Tests before Starting to Work
WARNING!
Serious accident hazard!
Faulty safety devices are dangerous.
All equipped safety devices must be tested prior to starting to work, and
any faults found must be repaired by skilled personnel.
The equipment may be put to work only when all safety devices are in
proper working order.
Initial situation:
– Diesel engine is running
6.1.4.1 Checking the Emergency STOP
● Press the Emergency STOP button.
All control elements must be out of function and the diesel engine come to a stop.
6.1.4.2 Checking the Pilot Control Safety Stick
● Move the safety stick of the pilot control to "Off" position.
All hydraulic functions must be blocked. The diesel engine remains on.
BG 24 H / 2008 6-4
6.1.4.3 Checking the End Limiters
Initial situation: Drilling mode selected
– Hoist limiters (HS 1 and HS 2)
● Select main winch.

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

 Selection of rigging modes must not be enabled.
● Extend boom cylinders completely.
 Selection of rigging modes must be enabled.
– Mast sideward angle end limiters (ES 2 and ES 4)
WARNING!
Danger of being crushed!
Do not actuate end limiters with your bare hands!
Only actuate them by touching with an object (piece of wood e.g.)
held in your hand.
● Hold left end limiter depressed and extend right backstay cylinder.
 Right backstay cylinder must not extend.
● Hold right end limiter depressed and extend left backstay cylinder.
 Left backstay cylinder must not extend.
– Mast backward angle end limiter (ES 1)
● Retract backstay cylinders.

 Retraction of the cylinders must come to a stop when the mast has obtained the
max. permissible angle to the rear.
BG 24 H / 2008 6-5
6.2 SHUT-DOWN
6.2.1 Daily Shut-Down
● Park the machine on firm level ground.

● Set the mast upright.
● Lower attached work equipment, tools and suspended load as close to the ground as
possible.
● Adjust the uppercarriage in line with the crawlers.
● Set all control elements to "0" position.
● Move the safety stick of the pilot control to "Off" position.
● Stop the engine.
Risk of damaging the engine!

If the engine has been operating with a high load, let it run idle for about
5 minutes before stopping, to allow the temperature of coolant and oil
CAUTION drop and stabilize.
● Before leaving, remove the ignition key and lock the cab.
● Set the battery main switch to "Off" position.
6.2.2 Shut-Down for a longer Period
Fuel tank
● Before longer periods of standstill fill up fuel tank completely with fuel because of cor-
rosion protection.
BG 24 H / 2008 6-6
RIGGING / DE-RIGGING
7 RIGGING / DE-RIGGING
7.1 GUIDELINES FOR RIGGING AND DE-RIGGING
● Have assembly job carried out by skilled personnel only.
Severe accident hazard!

The operator must be familiar with all the control elements and their
capabilities before he starts rigging operations.
CAUTION
WARNING!
Danger of falling down!

Personnel carrying out assembly on the mast or on the uppercarriage
must wear the prescribed fall protection equipment.
● Provide an unobstructed and level area for the assembly.

● Before assembling, check all parts for possible damage resulting from the transport.
● Before start of assembly, inspect the equipment for a film of protecting wax. All such
wax must be removed (see sect. Wax Removal).
● For lifting and loading, use only the lifting slings forming part of the basic outfit.
● Attach lifting slings only to provided lifting eyes.
Rig tipping hazard!

During rigging operations, the uppercarriage must be in line with the
CAUTION undercarriage.
● Select Rigging mode:
To rig up: Press button
To de-rig: Press button
BG 24 H / 2008 7-1
● Procure rigging advice:
For safe raising and lowering of the mast, a dialog program showing all the steps to be
carried out has been installed.
Risk of damaging or tipping the rig!

The prescribed steps must be strictly adhered to.
CAUTION
For more information, please refer to special manual for "Monitor Unit"
or "B-Tronic" found in the Appendices of this manual.
NOTE
7.2 WAX REMOVAL
● Prior to putting into service, remove all protecting wax with a hot water jet, at a tem-
perature of 90 – 95° C (approx. 200° F).
Alternatively, the equipment can be washed down with a cold water de-
tergent.
NOTE The treatment must be repeated until all the equipment is totally free of
wax.

Detergents used must not be harmful to seals etc.
CAUTION Check detergents for their areas of application prior to use.
BG 24 H / 2008 7-2
7.3 EXTENDING THE CRAWLERS
Tipping hazard!
The crawlers must be extended as soon as the machine has been
CAUTION unloaded and before rigging operations are begun.
Do not extend the right and the left crawler at the same time.
1 1
● Remove all four pins (1) and stow
them in a clean container so they
do not have to be cleaned before
the next use.
● If a pin will not move, the operator
may have to align the crawlers so
the pin can be pulled out com-
pletely by hand.
● By the control buttons in the cab,

retract one crawler after the other.
● Immediately reinstall the four pins

(1) and secure them. 1 1
● If a pin will not move, the operator
may have to align the crawlers so
the pin can be pushed in com-
pletely by hand.
BOHSL041.wmf
BG 24 H / 2008 7-3
7.4 MOUNTING THE COUNTERWEIGHT
Rig tipping hazard!

Prior to further rigging operations, the machine must be fitted with the
proper counterweights.
CAUTION
WARNING!
Serious injury hazard!
There must be no people on or under the counterweights while they are
being mounted.
Persons working on the uppercarriage must wear a fall protection belt
secured to the uppercarriage (red painted loop).

Counterweights consisting of several parts are to be transported in up-
right position.
CAUTION
The counterweights can be mounted and dismounted by auxiliary crane.
To mount counterweight(s):
1. Counterweight
BU759413.jpg
● Lift counterweight by an auxiliary crane steadly they can be mounted

● Install pins (3) in bores and secure.
BG 24 H / 2008 7-4
2. Counterweight
BU759413.jpg
● Lift counterweight by an auxiliary crane steadly they can be mounted

● With the hexbolt (4) screw counterweights tight to base machine.
BG 24 H / 2008 7-5
7.5 ASSEMBLY OF MAST

7.5.1 Mounting the Masthead
● Raise the masthead by pressing button .

1
BJ095518.wmf
WARNING!
Rig tipping hazard!
In Kelly mode:
Install crowd sledge upper end stoppers in accordance with the load
capacity chart, in provided holes in mast, and secure with cotter pins.
BG 24 H / 2008 7-6
7.5.1.1 Folding Out the Upper Mast Extension
Initial state:
– Mast lowered onto supports
– Rope tensioning cylinder completely
extended
– Main and auxiliary rope sufficiently
slackened
● Remove locking pin (4).

● By pressing the "Mast extension raising"
button, unfold the mast extension.
BU726428.wmf
Risk of damaging ropes and

mast components!
To unfold the mast extension,
the operator needs assistance
CAUTION from a person watching the
ropes and hydraulic hoses!
DANGER!
Severe injury hazard from
mast unfolding operation!
The danger zone must be free
BU726421.wmf
of people.
● Mount connecting bolts (1).
Before raising the mast, pay attention to the position of the ropes.
NOTE
BG 24 H / 2008 7-7
7.5.2 Raising the Mast – without Rotary Drive and Kelly
BK000503.wmf
● Extend boom cylinders (1) half way.
1 5
BK000502.wmf
● Extend backstay cylinders (2) com-

pletely.
BK000501.wmf
● Mount supporting clamps on boom

cylinders.
It is not allowed to operate

the rig without supporting
clamps mounted on the
boom cylinders! Support-
CAUTION ing clamps prevent inad-
missible working radius.
3
BG 24 H / 2008 7-8
7.5.3 Mounting Supporting Clamps

● Mount halves of supporting clamps (2)
to piston rods of boom cylinders. 2 2
● Bolt together the clamp halves.
B0000670.wmf
BG 24 H / 2008 7-9
7.6 ASSEMBLY OF WORK ATTACHMENTS

7.6.1 Assembly of Kelly Equipment
7.6.1.1 Mounting the Rope Swivel

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

Mount the swivel in the right way.
CAUTION The lube nipple must be up.
● After mounting, grease the swivel and test it rotates freely.
1
1 Main rope
2 Pin 6
3 Lube nipple
4 Hex head bolt 5
5 Lock washer 2
6 Washer
4
B0000572.wmf
BG 24 H / 2008 7 - 10
7.6.1.2 Mounting Extension Frame to Crowd Sledge (optional)
On BG 24:
● Set mast to upright.
● Move crowd sledge to lowermost point.
● Attach lifting slings to the proper lifting eyes
(1 or 2) for the type of rig in question (see figs.). 3
1
● Suspend the slings to the rig's main rope (or, if
not equipped, to the hoist rope of an assist
crane) and lift until the extension frame may be
pinned to the crowd sledge.
3
● Thread the extension frame onto the crowd
sledge, mount with pins (3), and secure the pins.
● Remove the lifting slings.
2
BU000513.wmf
On BG 28:
2 3
BV000508.wmf
BG 24 H / 2008 7 - 11
7.6.1.3 Mounting the Rotary Drive

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

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

● Stop engine.
● Connect hydraulic lines.
B0000700.wmf

Connect the leak oil line first.
CAUTION
3/A1, 5/A2 Pressure

4/B1, 6/B2 Return flow
1/T Leak oil
9/SP-L Flush oil Ansicht A:
12/P Control oil Ansicht A View A:
View A
T A1 A2
P
SP-L B1 B2
Hydraulic lines and connections wear

matching identifications.
NOTE
BJ705507.wmf
● Connect electric lines.
BG 24 H / 2008 7 - 12
7.6.1.4 Mounting the Kelly
To mount the kelly, the mast must be in upright position and be fitted
with the rotary drive.
NOTE
● Lay the kelly bar down lengthwise to front of the machine, in the centerline of the ma-
chine.
Suspension eye on kelly must face the machine.
NOTE
● Mount rope swivel to eye on kelly, in accor- 1

dance with fig. below.
1 Main rope
2 Rope swivel 2
3 Pin 8
4 Kelly 7 3
5 Lock washer
6 Hex head bolt 6
7 Washer 5
8 Lube nipple
4
B0000621.wmf
● Move rotary drive to lowermost position.

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

Keep the main rope vertical at all times.
CAUTION
BG 24 H / 2008 7 - 13
● Lift kelly until its square stub is approx. 20 cm above the rotary drive.

Avoid collision with the rotary drive!
CAUTION
● Set mast to upright again.
● Allow the kelly to stop swinging and then insert it into the rotary drive.
Slight rotation with the rotary drive can be helpful when inserting the
kelly.
NOTE
● Insert the kelly through the rotary drive.
● Mount drilling tool to kelly with two pins.

At all times, use TWO pins to mount the drilling tool, and do not forget
CAUTION to secure the pins.
BG 24 H / 2008 7 - 14
7.6.1.5 Mounting Kelly Guidance (optional)
Initial situation:
2 3
– The kelly is removed.

– Arms (2) for holding the guidance (1)
are mounted with pins (3).
1
B0000708.wmf
– End cover (8) is removed from the kelly. 8

7
5
B0000711.wmf
Mounting the kelly guidance:

6
● Mount to the kelly bar (5) an extension

(4) for the rope swivel. 4
● Mount the kelly guidance (2) with bolts
(7) to the kelly bar.
● Mount the rope swivel (6) to the swivel 2
extension (4); see also next page. 7
5
B0000707.wmf
BG 24 H / 2008 7 - 15
1 Main rope
2 Mounting pin
3 Lube nipple
4 Swivel extension
5 Hex socket tie bolt 3
6 Lock washer
7 Washer
7
6
2
5
4
B0000710.wmf
● Mount main rope to swivel.

● Lift the kelly into the rotary drive.
● Mount drilling tool to kelly and drill down.
DANGER!
Serious injury hazard by revolving kelly guidance!
Danger of causing damage to components!
Drill with care and without people in the danger zone.
● Run the rotary drive down to the lowest point.
3 2 8
● Remove the pins (3).

● Swivel the arms (2) towards the mast (8)
by 180°.
● Reinstall the pins (3) and secure them.
3 2
B0000709.wmf
BG 24 H / 2008 7 - 16
7.6.2 Assembly of CFA / FDP equipment
To mount the CFA equipment, an elevating platform providing safe work

conditions for the personnel is required.
NOTE
7.6.2.1 Mounting a Wedge (only with CFA-V) (optional)
In prevention of a collision with the masthead in applications using an

extended concreting kelly (V), a wedge has to be installed in the con-
NOTE nection of the upper end of the mast and the masthead.
● Unscrew bolts (2) from masthead.

● By lifting equipment (or by the tilting cylinder on rigs of version H), tilt the masthead.
● By lifting equipment, lift the CFA wedge (1) in place on upper mast end (3) and screw
down.
● Tilt back masthead and screw down to wedge.
WARNING!
Squashing hazard!
The danger zone must be free of people during the tilting of the mast-
head.
2 1 3 B0000815.wmf
BG 24 H / 2008 7 - 17
7.6.2.2 Retrieving the Main Rope
In all CFA applications (except for the "CFA with Main Winch" mode),
the rig's main rope will be at rest wherefore it must be retrieved from the
masthead.
NOTE When drilling with CFA, the Drilling mode function of the main winch is
deactivated. The main winch can be used only in the Rigging mode.
● Remove rope swivel from main rope.

● Retrieve main rope from masthead and rewind to first rope guide sheave.
Risk of damaging the main rope and mast components!

With the rope end rewound to the first rope guide sheave, the resting
CAUTION main rope must be slack.
7.6.2.3 Mounting Concreting Kelly (optional)
1 Concreting kelly
2 Cardan joint
3 Eye
4 Pin
5 Retaining ring
2
4
5
● By main rope, insert concreting kelly
(1) from below into rotary drive.
● Mount concreting kelly (3) to cardan

joint with the two free pins (4). 1
● Screw down retaining rings (5) tightly. 3
BM639417.wmf
BG 24 H / 2008 7 - 18
7.6.2.4 Mounting Concreting Kelly CFA-V (optional)
● Attach lifting slings to eyes (7) on con-

creting kelly.
● By lifting equipment, lift concreting kelly
in place above rotary drive.
● Lower concreting kelly through rotary 6
drive until groove (1) is in reach below
the drive. 2
● Place double ring flange (four ring 3
halves) staggered by 90° into groove (1)
and bolt together.
7 7
4
6
BM514434.wmf
● Elevate rotary drive to upper end of con-

creting kelly (see far right).
● Engage torque support and concreting
head with pins (2).
● Connect electric cable to concrete pres-
sure gauge (3). The cable comes stowed
in the torque support. 1
● Remove lifting slings.
● Lower the rotary drive and lock it to the
concreting kelly.
BM473516.wmf
BG 24 H / 2008 7 - 19
7.6.2.5 Mounting Concreting Head CFA (optional)
1 Concreting head
2 Concreting kelly
1
● Clean flange faces.
● Install O-ring. 2
● Place concreting head on concreting kelly.
● Install bolts and lock washers and screw tight.
BM639519.wmf
7.6.2.6 Mounting Concreting Head CFA-V (optional)
1 Concreting head 1
2 Extended concreting kelly
● Clean flange faces.

● Install O-ring.
● Connect both parts with provided bolts
and lock washers.
BM086521.wmf
BG 24 H / 2008 7 - 20
7.6.2.7 Mounting Torque Support (optional)
Risk of damaging the concreting head and drive components!

The concreting head must be prevented from rotating with the drive.
Depending on the manufacturer's specifications, either a torque support
CAUTION or a concrete conduit with a holding bracket must be installed to arrest
the concreting head!
● Mount torque support (4) with pins (3) to

concreting head. 3 4
B0000821.wmf
7.6.2.8 Mounting Torque Support (optional)
● Lower the rotary drive to the lowest point.

● By lifting equipment, lift torque support (1)
from above into rotary drive.
● Install pins (2) and secure.
2
B0000814.wmf
BG 24 H / 2008 7 - 21
7.6.2.9 Mounting Holding Bracket for Concrete Hose (optional)
Risk of damaging the concreting head and drive components!

The concreting head must be prevented from rotating with the drive. De-
pending on the manufacturer's specifications, either a torque support or a
CAUTION concrete conduit with a holding bracket must be installed to arrest the
concreting head!
1 Flange on rotary drive

2 Holding bracket for concrete hose
● Remove cover plate from flange on ro-

tary drive.
● Bolt down holding bracket for concrete
hose.
● Mount concrete conduit.
2 1
B0000817.wmf
7.6.2.10 Connecting Concrete Pressure Gauge (optional)
● Connect cable from concrete pressure

gauge to electric junction box on rotary 2
drive. 1 3
1
1 Connection to concrete pressure gauge
of CFA
2 Connection to crowd sledge 2
3 Connection to concrete pressure gauge
of CFA-V* 3
B0000835.wmf
* V = an extended concreting kelly
BG 24 H / 2008 7 - 22
7.6.2.11 Mounting CFA Auger
To suspend CFA auger
● Adjust uppercarriage in line with crawlers.

● Place the auger to front of the machine,
in the machine's direction of travel.
● Attach lifting slings from the auger (2)
to the cardan joint (1), if the concreting
kelly is CFA-V*,
or to the lifting eyes on the concreting kelly
itself, if it is CFA).
1
(* V = an extended concreting kelly)
2
BM086515.wmf
WARNING!
Use genuine lifting slings, of sufficient capacity, from the
BAUER Maschinen GmbH only.
BG 24 H / 2008 7 - 23
To raise CFA auger
BE021516.wmf
● Slowly and uniformly elevate the rotary drive and at the same time carefully travel up
towards the auger.
WARNING!
Rig tipping hazard!
The crawlers must keep in line with the auger.
Carry out movements with care.
BG 24 H / 2008 7 - 24
To mount CFA auger to concreting kelly
3
3
2
2
2
5
5 2
1 1
7 4
6 6
BM086524.wmf
Version 1 Version 2
 600 mm  750/880 mm
● Set the mast to upright.

● Slightly lift the auger off the ground and then put it down again.
● Adjust the rotary drive into a central position above the auger.
● Clean the male fitting (1) of the auger and check the O-rings (2) are properly in place.
● Lower the rotary drive and let the female fitting (3) of the concreting kelly settle on the
male fitting of the auger, down to stop.
● Push chains (4) or wedges (7) into the opening (5) on the female.
● Install the cover plate (6) such that the locating block on the plate separates the
chains or wedges from one another.
● Screw the cover down.
● Remove lifting slings from the cardan joint and the auger.
BG 24 H / 2008 7 - 25
7.6.2.12 Mounting the Tubes and the Full Displacement Head (FDP)
The tubes will be lifted one by one into the tube guide and will be fixed there to mount
the complete string.
3
3
2
2
2
5
5 2
1 1
7 4
6 6
BM086524.wmf
Version 1 Version 2
 600 mm  750/880 mm
● Set the mast to upright.

● Align the rotary drive in central position above the tube.
● Clean the male fitting (1) of the drill string and check the O-rings (2) are properly in
place.
● Lower the rotary drive and let the female fitting (3) of the concreting kelly settle on the
male fitting of the tube, down to stop.
● Push chain (4) or wedge (7) into opening (5) on the female.
● Install the cover plate (6) such that the locating block on the plate separates the
chains or wedges from one another.
● Screw the cover down.
● Mount full displacement head to the last mounted tube.
BG 24 H / 2008 7 - 26
7.6.2.13 Mounting Auger Guidance (optional)
Risk of damaging drill auger, rotary drive and mast components by au-
ger swinging when drilling is started!
At all times, use an auger guide or an auger cleaner when drilling with
CAUTION CFA.
● By lifting equipment, lift auger guide (1)

in place at lower mast end.
● Install pins (2 + 3) and secure.
1 2 3
B0000832.wmf
BG 24 H / 2008 7 - 27
7.6.2.14 Mounting CFA Auger Cleaner (optional)
● Lower drill string into initial bore.

● Remove pilot bit from auger.
● Remove lower sledge stoppers from
mast.
● By lifting equipment, lift and thread au-
ger cleaner from below onto slide rails
on mast and pull upward.
● Reinstall sledge stoppers on mast.
● By auxiliary rope, pull auger cleaner up.
● Reinstall pilot bit on auger.
BM086516.wmf
● Stop engine and make hydraulic connection.

The bulkhead to which the hydraulic hoses of the auger cleaner will be mounted is
found on the right side on the lower mast section.
View from below:
1 Kelly auger cleaner / lower pipe conduit

2 Kelly auger cleaner / lower pipe conduit
3 CFA auger cleaner, leakoil
4 CFA auger cleaner
5 CFA auger cleaner
BV10904011.wmf
BG 24 H / 2008 7 - 28
7.6.2.15 Mounting the FDP Tube Guide (optional)
● Dismount lower crowd sledge stoppers

(3) from mast.
● Lubricate the rollers (4) of the tube
guide.
● Fix lifting slings at the lifting point (2) on
the tube guide and lift it into the guide
rails of the mast.
● Remount sledge stoppers (3) to the
mast.
● Remove pin (1) and open the guide to
mount the tubes and the full displace-
ment head. BK480462.jpg
● Stop engine and make hydraulic connection.

The bulkhead to which the hydraulic hoses of the auger cleaner will be mounted is
found on the right side on the lower mast section.
View from below:
1 Kelly auger cleaner / FDS tube guide

2 Kelly auger cleaner / FDS tube guide
3 CFA auger cleaner, leakoil
4 CFA auger cleaner
5 CFA auger cleaner
BV10904011.wmf
BG 24 H / 2008 7 - 29
7.6.2.16 Installing Main Rope for "CFA with Main Winch" Mode
Starting position:
– Mast lying on the ground.
To install:
● Pass main rope around guide sheave on
crossbeam (3). Install rope guard pin!
Crossbeam with rope guide

sheave (3) not yet mounted
NOTE with pins (4) to rotary drive. 2 3 4
BM779505.wmf
● Remove pin from bore (1) on masthead.

● Anchor main rope end thimble with pin in
bore (2) on masthead.
● Unwind rope from the main winch and
raise the mast to upright while pulling the
crossbeam towards the base machine to
avoid a collision.
BM779419.jpg
BG 24 H / 2008 7 - 30
7.6.2.17 Mounting Crossbeam to Rotary Drive for "CFA with Main Winch" Mode
Starting position:
– Mast raised to upright.
– Main rope (1) installed on sheave (3) on crossbeam and 1
anchored to bore (2) on masthead before mast is raised.
To mount:
● Mount crossbeam to rotary drive with pins (4) and secure. 2
● Tension the main rope.
3
For ease of presentation, the fig. shows the 4
rotary drive on the upper mast end. The
NOTE mounting itself, however, will take place with
the rotary drive positioned at the lower mast
end.
BM639521.wmf
BG 24 H / 2008 7 - 31
7.7 DISASSEMBLY OF WORK ATTACHMENTS

7.7.1 Disassembly of Kelly Equipment
7.7.1.1 Removing the Kelly
● Set mast to upright position.

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

● Stop engine. Ansicht A:
View A:
Ansicht A
● Disconnect electric lines. View A
● Disconnect hydraulic lines.
T A1 A2
P
SP-L B1 B2
Disconnect the leak oil line (T) last.
CAUTION
● Attach lifting slings to lifting eyes (5). BJ705507.wmf
● Suspend the slings to the rig's main rope (3)

(or to the hoist rope of an assist crane, if not
equipped), and slightly pre-stress the rope. 1 1 2 2
● Remove pin retainers and pull the pins out
(1 and 2).
3
On rotary drive fitted with an auxiliary
lifting lug, the rig's auxiliary rope (4)
NOTE may be used additionally to help align 4
the rotary drive. 5 5
● Lift off and put the rotary drive down on ground.
B0000700.wmf
BG 24 H / 2008 7 - 32
7.7.2 Disassembly of CFA Equipment (optional)
To remove the CFA equipment, an elevating platform providing safe

work conditions for the personnel is required.
NOTE
7.7.2.1 Removing CFA Auger Cleaner
● Lower drill string into initial bore.

● Remove pilot bit from auger.
● Stop engine and uncouple hydraulic
hoses.
● By lifting equipment, lift auger cleaner.
● Remove lower sledge stoppers from
mast.
● Lower auger cleaner and unthread from
slide rails on mast.
● Reinstall sledge stoppers on mast.
● Reinstall pilot bit on auger.
BM086516.wmf
7.7.2.2 Removing the Auger Guidance
● Sling auger guide (1) to lifting equip-

ment.
● Remove pins (2 + 3).
● Lift off auger guide.
1 2 3
B0000832.wmf
BG 24 H / 2008 7 - 33
7.7.2.3 Removing CFA Auger
To suspend CFA auger

● Adjust upper carriage in line with crawlers.
● Lower the rotary drive until the auger stands
on the ground.
● Attach lifting slings from the auger (2)
to the cardan joint (1), if the concreting kelly is
CFA-V*, (or to the lifting eyes on the concret-
ing kelly itself, if it is CFA).
● Remove chains or wedges from the coupling.
1
(* V = an extended concreting kelly) 2
B0000822.wmf
WARNING!
Use genuine lifting slings, of sufficient capacity, from the
BAUER Maschinen GmbH only.
To lower CFA auger
B0000823.wmf
● Slowly and uniformly lower the rotary drive and at the same time carefully travel in
reverse away from the auger.
WARNING!
Rig tipping hazard!
The crawlers must keep in line with the auger.
Carry out movements with care.
BG 24 H / 2008 7 - 34
7.7.2.4 Removing Torque Support
● Lower rotary drive to lowest point.

● By lifting equipment, secure the torque
support (1).
● Remove pins (2).
● By lifting equipment, lift off the torque
support.
2
B0000814.wmf
7.7.2.5 Removing Concreting Head CFA-V
1 Concreting head 1
2 Extended concreting kelly
● Unscrew bolts and remove concreting

head.
BM086521.wmf
BG 24 H / 2008 7 - 35
7.7.2.6 Removing the Concreting Head
1 Concreting head
2 Concreting kelly
1
2
● Uncouple the concrete conduit.
● Remove concrete hose holding bracket.
● Remove torque support.
● Unplug cable from concrete pressure
gauge.
● Remove the concreting head.
BM639519.wmf
7.7.2.7 Removing Concreting Kelly CFA-V
● Attach lifting slings to eyes on concreting kelly.

● Elevate rotary drive to upper end of concreting kelly (see far right).
● Unplug electric cable from concrete pressure gauge.
● Remove pins to disengage concreting head from torque support.
● Unscrew ring and split ring flange from groove.
● By lifting equipment, lift concreting kelly out of rotary drive.
BG 24 H / 2008 7 - 36
7.7.2.8 Removing Concreting Kelly
1 Concreting kelly
2 Cardan joint
3 Eye
4 Pin
5 Retaining ring
2
● By main rope, secure concreting kelly 4
(1). 5
● Unscrew pin retaining rings (5).
● Remove the two pins (4) from cardan
joint.
● By main rope, lower kelly to ground, and 1
lay it down.
3
B0000824.wmf
BG 24 H / 2008 7 - 37
7.7.2.9 Removing the Wedge (only with CFA-V)
● Unscrew bolts (2) from masthead and wedge.

● By lifting equipment (or by the tilting cylinder on rigs of version H), tilt the masthead.
● By lifting equipment, secure the CFA wedge and unscrew bolts from wedge and up-
per mast end (3).
● Remove the wedge.
● Tilt back masthead and screw down to upper mast end.
WARNING!
Squashing hazard!
The danger zone must be free of people during the tilting of the mast-
head.
2 1 3 B0000815.wmf
BG 24 H / 2008 7 - 38
7.8 DISSASSEMBLY OF THE MAST

7.8.1 Removing the Supporting Clamps
● Remove the clamp halves (2) from the 2 2

boom cylinders.
B0000672.wmf
BG 24 H / 2008 7 - 39
7.8.2 Lowering the Mast - without Rotary Drive and Kelly
● Remove supporting clamps from

boom cylinder (3).
BK000500.wmf
● Retract boom cylinders until the mast

has been lowered to slightly above the 4
ground.
● Retract backstay cylinders (2) com- 2

pletely.
BK000501.wmf
● Release main and auxiliary rope (5)

tension. Spool out sufficient length of
rope, until the ropes are slack enough
to allow the mast to be laid down on 1 5
the uppercarriage.
BK000502.wmf
● Lay the mast down:

Retract boom cylinders completely.
When laying down the mast in the
support on the uppercarriage pay at- BK000503.wmf
tention to correct position of ropes and
hoses.
BG 24 H / 2008 7 - 40
7.8.3 Lowering the Masthead
Risk of damaging the ropes!

Before lowering the masthead, unspool sufficient length of rope.
CAUTION
● Lower the masthead by pressing button .
BJ095523.wmf
BG 24 H / 2008 7 - 41
7.8.4 Folding in the Upper Mast Extension
Initial state:
– Mast lowered onto supports
– Drilling equipment removed
– Masthead tilted down
● Extend the rope tensioning cylinder

completely.
● Slacken main and auxiliary rope suffi-
ciently.
● Ensure ropes are in place behind the
pipe (6).
● Remove connecting bolts (1).
● By pressing the "Mast extension lower-
ing" button, fold in the mast extension
until stop plate (3) contacts mast. BU726429.wmf
Risk of damaging ropes and

mast components!
To fold the mast extension,
the operator needs assistance
CAUTION from a person watching the
ropes and hydraulic hoses.
DANGER!
Severe injury hazard from
mast folding operation!
The danger zone must be free
BU726421.wmf
of people.
BG 24 H / 2008 7 - 42
7.9 REMOVING THE COUNTERWEIGHT
WARNING!
There must be no people on or under the counterweights while they are
being mounted.
Persons working on the uppercarriage must wear a fall protection belt
secured to the uppercarriage (red painted loop).

Counterweights consisting of several parts are to be transported in up-
right position.
CAUTION
To remove counterweight(s):
1. Counterweight
BU759413.jpg
● Attach lifting slings to red lifting eyes on mast and counterweight.

● Remove the hexbolt.
● Remove the secure and pins.
● Secure the counterweights with an auxiliary crane (see fig.)
● Dismount the screw (4).
BG 24 H / 2008 7 - 43
2. Counterweight
BU759413.jpg
● Attach lifting slings to red lifting eyes on mast and counterweight.

● Remove the hexbolt.
● Remove the secure and pins.
● Secure the counterweights with an auxiliary crane (see fig.)
● Remove the pin (3).
BG 24 H / 2008 7 - 44
7.10 RETRACTING THE CRAWLERS
DANGER
Severe squashing hazard!
The operator in the cab must be assisted by a person giving hand sig-
nals. The danger zone must be cleared before crawlers are retracted.
Do not retract the right and the left crawler at the same time.
1 1
● Remove all four pins (1) and stow
them in a clean container so they do
not have to be cleaned before the
next use.
● If a pin will not move out, the opera-
tor may have to align the crawlers so
the pin can be pulled out completely
by hand.
● By the control buttons in the cab,

retract one crawler after the other.
● Immediately reinstall the four pins (1) 1 1

and secure them.
● If a pin will not move in, the operator
may have to align the crawlers so the
pin can be pushed in completely by
hand. BOHSL042.wmf
BG 24 H / 2008 7 - 45
TRANSPORT
8 TRANSPORT
8.1 SAFETY GUIDELINES FOR TRANSPORT
● Only use hoisting equipment and lifting slings that have sufficient capacity.
WARNING!
Danger of serious accidents!
Attach lifting slings only to the provided and identified lifting points.
Lifting points on the machine are painted GREEN and have a hook
symbol. In addition, numbers tell the weight picked up at the respective
points.
Lifting points on individual components are painted RED.
The hoist rope must be vertical at all times, to prevent swinging.

If the load begins to swing, land it immediately and readjust until the
CAUTION rope is vertical again.
● Arrest and secure movable parts of the equipment.
● Put accessories to be stored safely away so they will not be an obstacle to traffic on
a road or on a construction site and that they will not be interfered with by accident or
abuse.
● Additionally cover up and secure sharp edges, projecting points and cutting blades.
● The driver of the transporting vehicle is responsible for checking each time before he
starts to drive that all the equipment, the machine and accessories are restrained
from movement and properly tied down to the deck of the vehicle.
● The haulier in charge is responsible for the transport of the equipment, the machine
and accessories.
● The haulier should be informed of the transport dimensions and weights and the
route.
● A road permit must be asked for.
BG 24 H / 2008 8-1
TRANSPORT
8.2 MEASURES TO TAKE FOR TRANSPORT
MACHINE
Before loading
The machine must be put into the following shape before it may be driven onto a low-
loader or be lifted by a crane.
– all attachments have been removed from the mast.

– the mast is lowered,
– the uppercarriage is in line with the crawlers and locked to the undercarriage,
– the crawlers are retracted,
– the beam extensions (if so equipped) have been removed,
– the counterweights have been removed (as necessary).
After loading
● Put the safety stick of the pilot control to "Off" position.

● Stop the engine and remove the ignition key.
● Lock the cab and remove the key.
● Put the battery main switch to "Off" position.
● Tie the machine safely down to the deck of the transporting vehicle.
EQUIPMENT
● The rotary drive must be in upright position during the transport.
BG 24 H / 2008 8-2
TRANSPORT
8.3 DRIVING ON / OFF A LOWLOADER
Aufrüsten Abrüsten
6.
7.
9. 9.
5. 10. 10.
5 6
4
7
2
8
1
9
0
10
11.
8.
2. 4.
0 0 0 0 0 0 00
3.
8
1.
11 8
11
9 1m
10
? ? 10 A
?
B0000780.wmf
1 Set battery switch to "ON" 7 Select boom cylinders operation

2 Release "Emergency STOP" button 8 Slightly raise mast by right control lever
3 Start engine 9 Travel forward by pushing both levers forward
4 Adjust engine speed 10 Travel reverse by pulling both levers back
5 Move pilot safety stick to "ON" 11 Lower mast by right control lever
6 Select rigging mode
BG 24 H / 2008 8-3
TRANSPORT
8.4 LIFTING POINTS
BJ535513.wmf
BG 24 H / 2008 8-4
TRANSPORT
8.5 TYING DOWN
WARNING!
Tie-downs must be attached to the provided intended points only.
The chains used for tie-downs must have sufficient capacity.
Tying points
– On blue undercarriages the points provided for tying down are painted YELLOW.
– On yellow undercarriages the points provided for tying down are painted BLUE.
– In addition, tying points wear a hook symbol and tell the max. tension to be applied.
To tie down
● Tie the equipment down to the transporting vehicle in the professional manner and in
compliance with national directives.
Principally, the haulier in charge is responsible for tying down correctly.
Example of tying points
CI439400.jpg
BG 24 H / 2008 8-5
TRANSPORT
8.6 TRANSPORT DATA
Dimensions in [mm]
19203
3600
3462
1200
1180
6300 5503
700
3000 - 4400
BU1550503.wmf
Weights
Unit Weight in [tonnes]

Machine
Machine with counterweights and without 70
rotary drive
Machine without counterweights and without 60
rotary drive
Counterweights 6.0 + 2.0 + 2.0
Equipment
Rotary drive 5.10
Kelly bar BK 25/394/3/33 5.90
Drilling tool 1.90
BG 24 H / 2008 8-6
MAINTENANCE
9 MAINTENANCE
9.1 SAFETY GUIDELINES FOR MAINTENANCE
● Have maintenance carried out by the after sales service only or by skilled personnel
authorized by the after sales service.
● Replace with genuine spare parts from the BAUER company only.
● Observe the "Safety Information" book supplied with the equipment.
● Carry out maintenance at the prescribed intervals.
● Also observe the other manufacturers‘ service instructions for components of the
equipment.
BG 24 H / 2008 9-1
MAINTENANCE
9.2 MAINTENANCE INTERVALS
The maintenance for this equipment is organized into the following intervals:
– Every 10 hours of operation or daily

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

Maintenance carried out on the equipment shall be entered into the sup-
plied "Maintenance and Repair Log". This is to be done by the person who
CAUTION carried out the job and be signed by himself and a foreman.
In case of a warranty claim, BAUER shall have the right to consult the log.
BG 24 H / 2008 9-2
MAINTENANCE
9.3 MAINTENANCE PLAN

9.3.1 Entire Equipment
Table Entire equipment maintenance

Item Prescribed intervals
10 hrs 50 hrs 250 hrs 500 hrs 1000 hrs 2000 hrs 3000 hrs Note
Service daily weekly monthly monthly yearly yearly 2 years
Entire equipment
Visually check for:
- Missing or damaged parts X
- Missing or loose pinned / bolted / X
screwed connections
- Missing or damaged safety X
equipment such as
fire extinguishers,
medical box,
warning signs
- Leaks X
Check the functioning of:
- Controls and indicators X
- Safety devices like the X
emergency Stop,
pilot control safety stick,
end limiters,
hoist limiters
- Free-fall (optional) X
Thorough inspection by an expert X
* only during the first run-in
BG 24 H / 2008 9-3
MAINTENANCE
9.3.2 Components
Table Components maintenance

10 hrs/ 50 hrs/ 250 hrs/ 500 hrs/ 1000 hrs/ 2000 hrs/ 3000 hrs/ Note
Service daily weekly monthly 3 months yearly yearly 2 years
Masthead
- Check head-to-mast mounting X*
pins and bolts are firm; re-tension
the bolts
- Replace the head-to-mast 10000 hrs
mounting bolts with new ones
(if equipped)
Mast
Mast
- Grease the slide rails X
- Check mast assembly pins and X*
bolts are firm; re-tension the bolts
- Replace the mast assembly bolts 5000 hrs
with new ones (if equipped)
Mast prop (optional)
- Check hinge pin and pin retainer X
are firm
- Grease piston lug X
Mast ladder (optional)
- Check mounting bolts are firm X
- Check transits between ladder X
sections are flush
- Check fall protection equipment X
for proper functioning
Mast pivot
- Grease the pivot assembly X
- Grease the pivot pin X
- Check the mounting bolts are X*
firm; re-tension them
- Replace the mounting bolts with 10000 hrs
new ones
BG 24 H / 2008 9-4
MAINTENANCE
Table Components maintenance continued

Winches
- Check oil level in
main winch X
auxiliary winch X
crowd winch X
- Change oil in
main winch X* X
auxiliary winch X* X
crowd winch X* X
- Grease counter bearings of
main winch X
auxiliary winch X
crowd winch X
- Check mounting bolts of winch X*
trestles are firm; re-tension them
- Replace mounting bolts of winch 10000 hrs
trestles
Cylinders
- Clean piston rods X
- Check cylinders are tight X
- Grease joints X
Bearings and bearing pins
- Grease all bearings and bearing X
pins fitted with lube nipples
BG 24 H / 2008 9-5
MAINTENANCE
Table Components maintenance continued

Wire rope and accessories

Rope, sockets and end fittings
- Check for wear and damage X
Rope swivel
- Grease X
- Check mounting pins are firm X
- Check swivel is free to rotate X
Rope hold-down rollers
- Check roller is parallel to winch X
drum
Rope guide sheaves
- Check for wear and damage and X
excessive play
- Check sheaves are free to rotate X
- Check sheave centre pins are firm X
- Check for burrs and edges on the X
sheaves and that grooves still
comply with the nominal diameter
- Put grease in lube nipples where
fitted:
- Sheaves with friction bearings X
- Sheaves with roller bearings X
Rope roller brackets
- Check mounting bolts of roller X*
brackets are firm; re-tension them
- Replace mounting bolts of roller 10000 hrs
brackets
BG 24 H / 2008 9-6
MAINTENANCE
9.3.3 Work Equipment
Table Work equipment maintenance

Rotary drive
Rotary drive
- Clean X
- Check for leaks X
- Check magnetic sticks for metal X
particles
- Check oil level in
main gear X
planetary gears X
- Change oil in
main gear X* X
planetary gears X* X
- Take oil sample and check it X
- Check mounting bolts of the X* X
hollow shaft are firm
- Check response pressure X Nominal value:
35-40 bar
- Lubricate rotary shaft seal X
Kelly driver/Guide flange/Shock absorber
- Check for damage on springs, X
buffer ring and absorbers
- Check mounting bolts are firm X
- Check wear on driver strips X
Cardan joint
- Check rubber buffers for damage X
- Check suspension pins are X
properly in place and firm
Crowd sledge
- Check wear on sliding strips X
Kelly bar
- Check for wear and damage X* X
Drilling tool
- Clean it and check for wear and X
damage
CFA/FOW/TRD/FDP-Equipment
- Lubricate concreting head X
Lubricate auger cleaner: X
-guide rollers,
-reamer,
-bearing
BG 24 H / 2008 9-7
MAINTENANCE
9.3.4 Uppercarriage
Table Uppercarriage maintenance

Engine Observe separate manual for the engine!!
Cooling system Observe separate manual for the engine!!
Pump distributor gearbox

- Check oil level X
- Change oil X* X
Hydraulic system
Hydraulic tank
- Check oil level X
- Change oil X* X
- Take oil sample and check it X
Hose assemblies
- Have them checked for damage X
by a skilled person
Filter replacement
- Pilot-oil filter element X* X
- Return-flow filter element X* X
- Leak-oil filter element X* X Or on con-
- Rotary drive filter element X* X tamination
- Filler filter element X indication
Pressure accumulators
- Check pre-tension pressure X* X
Oil cooler
- Clean X
- Check for damage X
Swing mechanism
- Grease external gear teeth on X
swing ring
- Grease ball bearing race and X* X
rotor bearing
- Retension mounting bolts X* X
BG 24 H / 2008 9-8
MAINTENANCE
Table Uppercarriage maintenance continued

Service daily weekly 3 months monthly yearly yearly 2 years
Counterweights
- Check they are properly in place X
and firm and all the fixating ele-
ments are applied
Electric system
Batteries
- Check electrolyte level X
- Check cable connections X
Fuses
- Check the fuses X
Filter
- Change breather filter(s) on X
switch cabinet
9.3.5 Undercarriage
Table Undercarriage maintenance

Service daily weekly. monthly monthly yearly yearly 2 years
Crawler track assemblies

Visual inspection
- Check for missing or damaged X
parts
- Visually check mounting bolts of X
crawler drive wheels, tread rollers
and gear cases; tighten up as re-
quired
Crawler drives
- Check oil level X
- Change oil X* X
Crawler tracks
- Check track tension X
- Check mounting bolts of track X
pads are firm
Telescoping surfaces
- Clean and grease X
Crossbeam
- Checking and adjusting the cross- X
beam play
BG 24 H / 2008 9-9
MAINTENANCE
9.3.6 Optional Equipment

Service daily weekly. monthly monthly yearly yearly 2 years
Air conditioning
- Put air conditioner into operation X 2 – 3 weeks
- Clean air filter (optional) X
- Clean condenser X
Compressor Observe separate manual for the compressor!!
- Clean cooling ribs X
- Clean suction air filter X
- Replace suction air filter X
- Check oil level X
- Change oil X* X
Compressed air filter
- Drain condensate X after every
use
- Clean the bowl and filter insert X
Oil-fog lubricator
- Check oil level before every
use,
Do not use
synthetic oil
- Clean the bowl X
BG 24 H / 2008 9 - 10
MAINTENANCE
9.4 LUBRICATION PLAN

16 1000h
10h 21
11 250h
1000h 13
5 50h
50h 26 5 50h
10h 31 13 1000h
40 250h
50h 30
50h 15
50h 8
250h 14
50h 6
1000h 13
250h 14
3 10h 9 250h 3 50h

B0000890.wmf
Every 10 Hours of operation: Every 250 Hours of operation:

3 External gear ring 11 Crowd rope tensioning cylinder joints
21 Rope swivel* and masthead tilting cylinder
optional: Kelly Guidance* 14 Mast supporting cylinder joint
40 Backstay cylinder, boom cylinder, kine-
matic triangle, boom, supporting boom
joints
Every 50 Hours of operation: Every 1000 Hours of operation:
3 Swing gear bearing 13 Rope sheaves crowd
5 Rope sheaves 16 Rope sheaves masthead*
6 Main winch bearing 50 Rope sheaves
8 Auxiliary winch bearing
9 Telescopic guide*
15 Mast pivot*
26 Slide rails, pulley block crowd sledge
30 Crowd winch bearing *) Lubricate lubrication points manually
31 Rotary shaft seal*
BG 24 H / 2008 9 - 11
MAINTENANCE
9.5 MAINTENANCE DURING LONGER PERIODS OF STANDSTILL
Engine
● Every 2 to 3 weeks, start the diesel engine and let it run in the medium r.p.m. range
for about 1 hour.
Risk of engine damage!

If engine starting will not be possible during the standstill, preservation
measures must be taken. To do so, please refer to the manufacturer’s
CAUTION
manual of the diesel engine.
Air conditioning
● Every 2 to 3 weeks, turn the air conditioning on (if equipped) for a short while.
Slewing ring
● Preserve gear teeth.

● From time to time during the standstill, remove dust and inspect the surface of teeth
and drive pinion for beginning corrosion; clean and grease as required.
Telescoping guides on undercarriage (only with extendible crawlers)
● Preserve the telescoping surfaces with grease.
BG 24 H / 2008 9 - 12
MAINTENANCE
9.6 HYDRAULIC SYSTEM

9.6.1 Hose Assemblies
Inspection
● Hose assemblies must be inspected at least once a year by a competent person. A
hose assembly on which one or several of the following criteria are found must be re-
placed with a new one:
– Damage in the outer layer down to the core of the hose (e.g. abrasions, cuts or fis-
sures).
– The outer layer of the hose is brittle (cracks in the tubing).
– The hose does no longer comply with its natural shape, both with and without pres-
sure and while it is bent (e.g. layers separating, bubbles forming).
– Leaks.
– Damage or deformation of hose end fittings (tightness impaired); minor damage to
the surface does not require replacement.
– Hose slips out of end fitting.
– Corrosion on the end fitting, impairing the function and stability.
– The hose is not assembled in compliance with instructions.
– The storage and service life is exceeded.
Storage and service life

● Hoses and hose assemblies are to be stored in a cool and dry place free of dust.
Direct exposure to sunshine or UV-rays should be avoided.
Storage and service life

Hose Hose assembly
Storage time 2 years 2 years
Service life
6 years
(including storage time)
Re-use
Generally, hoses that have been in service as part of a hose assembly ought not to be
re-used in a new hose assembly, since they do no longer meet the requirements.
BG 24 H / 2008 9 - 13
MAINTENANCE
9.6.2 Hydraulic Cylinders
● Every 10 operating hours or daily, and every time before starting up again after a
longer period of rest, clean all cylinders and check them for tightness.
Risk of damaging the piston rod!

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

Immediately repair or replace cylinders that are not tight.
CAUTION
● Every 50 operating hours or once a week, grease the cylinder lugs (holes for pins).
On cylinders that are kept extended during rest:
● Once or twice a week, rub down piston rods with a hydraulic oil, or retract and
extend the rods repeatedly.
● Before a longer standstill, preserve piston rods with an acid free grease.
BG 24 H / 2008 9 - 14
MAINTENANCE
9.6.3 Filter Replacement
Replacing the Line Filters
The elements of the line filters must be replaced after the first 250 operating hours or
one month. Subsequent replacements of the line filter elements are due every
2000 operating hours or whenever contamination is indicated (optional; by a warning
lamp or by a text message).
WARNING!
Before beginning to replace a filter element, remove the pressure from
the hydraulic system and allow it to cool down.
While the hydraulic oil is still cold, it can happen that the contamination
indication comes on for a little while.
NOTE
"A"
Line filters:
1 2
1 Rotary drive 3
2 not used
3 not used "A"
BJ535505.wmf
● Place a suitable container underneath

the filter housing and unscrew the bot-
tom (3).
● Remove filter element (2) from top (1) 1
of housing, and put it to hazardous
waste. 2
● Clean top and bottom of housing.
● Install new filter element in top of hous-
ing. 3
● Reinstall bottom on top and screw tight.
B0000623.wmf
BG 24 H / 2008 9 - 15
MAINTENANCE
9.7 WINCHES
9.7.1 Checking the Oil Level
The oil level must be checked every 50 operating hours or once a week, and whenever
the equipment is started up again after a longer standstill.
Danger of oil spray!

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

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

the winch in any position. 2
● If the oil level has reached the lower limit

("min." = 20 mm below the winch centre line),
add oil through one of the screw plugs (2), max.
20 mm
then recheck the oil level. Be sure to avoid the min.
oil level exceeding the upper limit ("max." =
winch centre line).
● Clean sealing surfaces, check seal for wear
and damage, replace it as required. 1
● Reinstall the screw plug and screw it down B0000846.wmf
tight.
BG 24 H / 2008 9 - 16
MAINTENANCE
9.7.2 Changing Gear Oil
The oil must be changed after the first 250 operating hours or one month. Subsequent
oil changes are due every 1000 operating hours or once a year.
Danger of oil spray!

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

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

2
winch in almost any position.
● Unscrew and remove any of the screw plugs (2).

● Unscrew and remove any of the screw plugs (1)
max.
and allow the gear oil to drain. 20 mm
min.
● At low outdoor temperatures, flush the empty gear-
box with a warmed-up part of the new oil.
● Clean sealing surfaces, check seal for wear and
damage, replace it as required. 1
● Reinstall the screw plug (1). B0000846.wmf
● Refill with new oil.

● Check the oil level.
● Reinstall the screw plug (2) and screw it down tight.
BG 24 H / 2008 9 - 17
MAINTENANCE
9.8 WIRE ROPE ACCESSORIES

9.8.1 Rope Swivel
Every 10 operating hours or daily:
● Apply grease to nipple (2) until grease exits from the

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

Immediately inspect the swivel for damage after an accidental drop of
CAUTION the kelly bar.
BG 24 H / 2008 9 - 18
MAINTENANCE
9.8.2 Rope Hold-Down Rollers
Every 50 operating hours or weekly:
● Check rope hold-down rollers for wear and

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

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

If a defect is found on a rope fitting, cut off the rope end and re-fit it.
CAUTION
BG 24 H / 2008 9 - 19
MAINTENANCE
9.8.4 Rope Sheaves
Danger of rope breaking!

Sluggish or seized rope sheaves subject the rope to excessive wear and
abrasion and make the load distribute unevenly on the rope structure.
CAUTION Repair or replace as necessary sluggish or seized rope sheaves if greas-
ing will not do.
9.8.4.1 Greasing Rope Sheaves
Rope Sheave Type Prescribed interval Maintenance instructions

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

bearings
Risk of damaging the
bearing sealing!
1000 Operating hours/ Grease during rotating
yearly rope sheave.
CAUTION Fill in grease slowly to
prevent squeeze out
bearing sealing.
BM659822.jpg
Rope sheaves greased

by the central lubrication
system
automatical
BM659823.jpg
BG 24 H / 2008 9 - 20
MAINTENANCE
9.8.4.2 Checking Rope Sheaves
Service Prescribed interval Maintenance instructions
Check the rope sheaves 250 Operating hours/

are free to rotate. monthly
Check sheave centre

pins have the proper 250 Operating hours/
bearing play and are monthly
properly in place.
Check for burrs and

edges on the sheaves
Re-machine the groove, or replace
and that grooves in 1000 Operating hours/
the sheave with a new one, if the
sheaves still comply yearly
groove does no longer comply.
with the diameter of
the rope used.
BG 24 H / 2008 9 - 21
MAINTENANCE
9.9 ROTARY DRIVE

9.9.1 Routine Inspection
● Clean the rotary drive with a water jet.

● Inspect all components for wear and
damage.
On rotary drives with shock absorbers
1
check especially:
2
– Buffer ring (1) 3
– Spring-loaded ring (2) 4
– Compression springs (3)
– Shock absorbers (4)
● Check the rotary drive for leaks.
B0000577.wmf

At once, replace damaged components with new ones.
CAUTION
BG 24 H / 2008 9 - 22
MAINTENANCE
9.9.2 Checking the Oil Level
9.9.2.1 Main Gear
The oil level in the main gear must be checked every 10 hours of operation or daily.
● Set the rotary drive to upright position.

● While the drive is out of motion, check the oil level.
The oil must reach half way up the glass (see fig.).

At all times, watch for proper oil level.
CAUTION
B0000624.wmf

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

A too high oil level in the main gear is an indication of a defect in the
CAUTION planetary gears. Shut down the rotary drive and repair.
BG 24 H / 2008 9 - 23
MAINTENANCE
9.9.3 Changing the Oil
The oil must be changed after the first 250 operating hours and subsequently every
1000 operating hours or once a year.
To carry out an oil change, the oil had better be as warm as possible
from operating.
NOTE
To drain the Main gear:

Ansicht "A"
● Shut down the rotary drive. View "A"
● Place the rotary drive such that the 2 2

drain valve (1) is in the lowermost po-
sition.
● Unscrew filler screws (2). Ansicht "A"
View "A"
Ansicht "B"
● Have an oil collecting container View "B"
ready.
● Screw a drain hose to the drain valve 1
(1). The valve opens by itself and the
oil flows off. Ansicht "B"
View "B"
B0000578.wmf
To drain the Planetary gears:
● Shut down the rotary drive.

● Set rotary drive to upright position.
● Have an oil collecting container
ready.
● Screw a drain hose to the drain 1
valves (1). The valves open by
themselves and the oil flows off.
K0000507.wmf
Danger of scalding!
Hot gear oil can cause severe injury!
CAUTION
BG 24 H / 2008 9 - 24
MAINTENANCE
● Inspect magnets on magnetic sticks for gear abrasives, and clean the screws (see
also sect. "Oil Sampling").
Check the mounting bolts of the hollow shaft (see sect. "Hollow Shaft
Mounting Bolts").
NOTE
● If the outside temperature is low at the time of the oil change, warm up (to approx.
50°C / 122°F) a part of the new oil and rinse the gear housing with this oil before re-
filling.
Benzol (benzene) or flushing oils too may be used here for rinsing.
NOTE
Risk of damaging the gears!

Do NOT use petrol (gasoline), petroleum or diesel oil for rinsing here.
Allow the rinsing fluid to drain off completely.
CAUTION
To replace the line filter:
Line filter:
1 Rotary drive
1
KX000502.wmf
● Place a suitable container underneath the filter

housing and unscrew the bottom (3).
● Remove filter element (2) from top (1) of hous-
1
ing, and put it to hazardous waste.
2
● Clean top and bottom of housing.
● Install new filter element in top of housing.
● Reinstall bottom on top and screw tight. 3
B0000623.wmf
BG 24 H / 2008 9 - 25
MAINTENANCE
Cleaning the Oil Precleaner:
2 Pump suction strainer
2
KX000516.wmf KAP841410.wmf
To clean the strainer, the main gear must be empty of oil, or an oil col-
lecting container must be held ready.
NOTE
● Disconnect the hydraulic hose used (2) and unscrew the strainer.
● Clean and reinstall the strainer.
● Reinstall the hydraulic hose.
To refill the Main and Planetary gears:
● Remove the drain hose and close the drain valves.

● Refill the Main gear with the quantity of oil specified for the Main gear.
● Reinstall the filler screws.
● Start the engine and run the rotary drive at medium r.p.m. for approx. 2 minutes, to fill
up the planetary gears.
Risk of damaging the gears!

The rotary drive must not be operated at maximum capacity until the
planetary gears have been filled with oil.
CAUTION
● Shut down the rotary drive.
● Refill the Main gear with the quantity of oil specified for the Planetary gears.
● Reinstall the filler screws and tighten them.
● Let the rotary drive rotate for a short while and then put it out of motion again.
● Let the oil settle.
● Check for proper oil level at the Main gear; top up with more oil as necessary.
BG 24 H / 2008 9 - 26
MAINTENANCE
9.9.4 Oil Sampling
Every 250 operating hours or monthly, take an oil sample from the main and planetary
gears and inspect it:
● Inspect the oil for dark or black colouring.

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

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

The maximum permissible amount of foreign particles in the total oil fill of one gear-
box must not exceed 0.15 %. Particles found in the oil must not exceed 5 m in size
(as measured in compliance with DIN 51592); if they do – no matter the amount – the
rotary drive will have to be removed and taken apart.
BG 24 H / 2008 9 - 27
MAINTENANCE
9.9.5 Hollow Shaft Mounting Bolts
The mounting bolts of the hollow shaft must be checked every time the oil of the rotary
drive is changed.
● Unscrew and remove access plugs (1).
● Visually, check the mounting bolts (2) are properly

in place and firm. 1 1 1
Risk of damaging the drive!

Do not re-tension these bolts unless
necessary, or the Loctite seal of the
bolts will break making the bolts loosen
CAUTION
during operation. Check visually only.
Do not put fingers into the bores.
1
2
Turning around the rotary drive enables
checking all the bolts.
NOTE Ansicht von unten:
View from below:
1
● Unscrew mounting bolts found to be loose, clean
them and apply Loctite to threads, reinstall and ten-
sion the bolts with the specified torque. 1 1
1
BHVSF177.wmf
Bolt torque value

Ma[Nm]
Hollow shaft mounting (2)
Hex head bolts see Spare Parts List
BG 24 H / 2008 9 - 28
MAINTENANCE
9.9.6 Kelly Driver and Guide Flange
9.9.6.1 Checking the Mounting Bolts
● Visually, check mounting bolts of kelly driver and

guide flange (1 and 2) are properly in place and
firm.
Risk of damaging the drive!

Do not re-tension these bolts unless
necessary, or the Loctite seal of the bolts
CAUTION will break making the bolts loosen during
operation. Check visually only.
1
2
● Unscrew mounting bolts found to be loose, clean
them and apply Loctite to threads, reinstall and ten-
B0000579.wmf
sion the bolts with the specified torque (see below).
Bolt torque value

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

Hex head bolts see Spare Parts List
Set screws with nut see Spare Parts List
Replacing the Kelly Driver and / or Guide Flange:

● Clean contacting surfaces of the hollow shaft and the kelly driver / guide flange free
of grease. Apply Loctite 0586 Type AVX on the cleaned surfaces.
● Apply Loctite to threads of the mounting bolts, and screw the bolts down with the
specified torque in a diagonal manner.
BG 24 H / 2008 9 - 29
MAINTENANCE
9.9.6.2 Checking Driver Strips for Wear
● Check kelly driver strips (5) for wear.
● If the wear (x) is in excess of 8 mm, turn the strip around by 180° and reinstall it, or
replace it right away with a new one.
Replace also bushings (4) and bolts (3) if they are worn down.
When fitting a new driver strip, the play (y) should not exceed 0.5 mm.
NOTE
Bolt torque value

Ma [Nm]
Kelly driver strips mounting
Hex socket head bolts see Spare Parts List
Hex socket head bolts with nuts see Spare Parts List
A - A:
A A
B B
1
B - B:
2
3
4
5
6
x y
B0000580.wmf
BG 24 H / 2008 9 - 30
MAINTENANCE
9.9.7 Cardan Joint (optional)

● Check suspension pins (see arrow) are properly in place and firm, with the holes for
the pins completely assembled.
● Check rubber buffers for damage.
K0000501.wmf
9.9.8 Sledge Sliding Strips

 Check the wear on the strips (1) in the runners (4) of the crowd sledge.
 Where the remaining thickness (X) is found to be less than 16 mm, replace with a
new strip (see below).
Ansicht "A"
View A
Schnitt B-B
Section B-B
1
A B B
4
B0000582.wmf
To replace:
● Unscrew bolts (2) and remove the tension plate (3).
● Pull out the strip (1) and install a new strip.
● Reinstall the tension plate and screw tight.
BG 24 H / 2008 9 - 31
MAINTENANCE
9.9.9 Greasing the Shaft Seal Ring
● Clean the rotary drive.

● Apply grease to nipples (1 or
2) and rotate the drive in
between, from time to time.
3 3
● Repeat the procedure until
grease exits steadily along the 1
whole circumference (arrow). 2
4 4
K0000515.wmf

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

Brownish coloured gear oil or a heavily contaminated filter (3 or 4) can
be an indicator of solid matters brought-in from the outside.
CAUTION Shut down the rotary drive and contact the After Sales Service.
BG 24 H / 2008 9 - 32
MAINTENANCE
9.10 CRAWLER TRACK ASSEMBLIES

9.10.1 Routine Inspection
● With the uppercarriage positioned crosswise, thoroughly clean crawlers free of mud
and dirt.
● Walk-around inspect for wear, damage and loss of oil, especially on following com-
ponents:
– Track pads (1)

– Track links (2)
– Carrier rollers (3)
– Front idlers (4)
– Track guides (5)
– Tread rollers (6)
– Crawler drive wheels (7)
– Gear cases (8)
1 2 3 4
8 7 6 5
B0000676.wmf
On machine with crawlers extended, the crawler telescoping surfaces

should be kept corrosion protected with grease.
NOTE
BG 24 H / 2008 9 - 33
MAINTENANCE
9.10.2 Crawler Tracks
9.10.2.1 To Check the Track Tension
Check track tension every 10 operating hours or daily.

1 - 1,5 m
2-3 cm
● Thoroughly clean each crawler, track
and rollers.
● Travel forward a bit with the machine 1 - 1,5 m

and then park it. 2-3 cm
● Using a straight rod, measure the sag

of 1 - 1.5 m length of track in midway
(see fig.): The distance from the rod to
the track should be approx. 2 - 3 cm. 1 - 1,5 m
Otherwise, the track tension must be 2-3 cm
readjusted.
B0000680.wmf
9.10.2.2 Adjusting Crawler Track Tension
To tighten the track
● Remove cover plate (5) and clean the grease nipple (2).
2
5
1 3 4
B0000725.wmf
● Put a high-pressure grease gun to the grease nipple.

● Work the grease gun until the proper track tension is obtained. Check the track ten-
sion again after a short travel forward and backward, and top up with more grease as
necessary.
● Reinstall the cover plate.
BG 24 H / 2008 9 - 34
MAINTENANCE
To loosen the track
2
5
1 3 4
B0000725.wmf
● Remove cover plate.

● Unscrew the safety valve (1) by approx. 3 revolutions (SW 41) until excessive grease
escapes at the spot identified with (4).
WARNING!
Injury hazard by pressurized grease!

Unscrew the safety valve with great care only.
● Retighten the safety valve when the proper track tension is obtained.
● Check the track tension again after a short travel forward and backward.
● Clean the nipple and surrounding free of grease.
● Reinstall the cover plate.
WARNING!
Injury hazard by loaded spring!

If a track tensioner is defective, replace it completely with a new one.
Do not attempt to repair it, for safety reasons.
BG 24 H / 2008 9 - 35
MAINTENANCE
9.10.3 Checking Mounting Bolts
● Check visually mounting bolts are tight.

● Retension bolts that are loose.
5 8 2 1
4 3 6
BK587502.wmf
BK587440.jpg BM564683.jpg
Bolt torque value Prescribed intervals in

Bolted connection
Ma [Nm] operating hours
Track pad (1) 675 ± 35 50

Carrier roller (2) 560 250
Track guide (3) 560 250
Tread roller (4) 560 250
Crossbeam (5) -- --
Drive wheel (6) 460 250
Gear case (7) 960 250
Telescopic cylinder mounting 560 250
Swing ring (8) 960 After the first 250
and then every 2000
BG 24 H / 2008 9 - 36
MAINTENANCE
9.10.4 Crawler Drive Gears
9.10.4.1 Checking the Oil Level
Check the oil level every 250 operating hours or monthly.
● Move machine until oil drain plug (2) on

crawler drive wheel is in lowermost posi-
tion.
● Unscrew inspection / filler screw (1) to-
gether with seal (if equipped).
● The oil must reach the lower edge of the
filler opening; top up with oil as neces- 1
sary.
● Clean inspection / filler screw and sealing
surfaces on housing, and replace with
new seals as necessary.
3
● Reinstall the inspection / filler screw with
new seal and tighten. 2
B0000514.wmf
9.10.4.2 Changing the Oil
The oil must be changed after the first 250 operating hours or 1 month. Subsequent oil
changes are due every 1000 operating hours or once a year at least.
● Move machine until oil drain plug (2) on

crawler drive wheel is in lowermost posi-
tion.
● Unscrew inspection / filler screw (1) to-
gether with seal (if equipped).
● Place an oil collecting container under-
neath the drain.
● Unscrew the drain plug (2) and let the oil 1
out.
● Clean screw and plug and sealing sur-
faces on housing.
● Reinstall drain plug with new seal and 3
screw tight. 2
● Refill with new oil to proper level. B0000514.wmf
● Reinstall inspection / filler screw with new
seal and screw tight.
BG 24 H / 2008 9 - 37
MAINTENANCE
9.10.5 Adjusting Crawler Crossbeam Play
● Every 1000 operating hours, check the play at the crawler crossbeams; readjust as
necessary.
For the appropriate adjustment of play, please consult the After Sales Service in
Schrobenhausen.
BG 24 H / 2008 9 - 38
MAINTENANCE
9.11 BOLTED CONNECTIONS
● After the first 250 operating hours, re-tension all the bolted connections described in
the following.
Generally, apply the prescribed torque on these bolts to tension them

("torque pretension method").
NOTE
Bolted connections of Mast sections
● Every 5000 hours of ordinary operation, replace all elements used in the bolted con-
nections.
WARNING!
Replace the elements of bolted connections which have been opened-
up more than 25 times or which are corroded, fissured, deformed or
have damaged threads.
Bolted connections of Mast pivot, Winch trestles, Roller brackets and Masthead
● Every 10000 hours of ordinary operation, replace all elements used in the bolted
connections.
WARNING!
Replace the elements of bolted connections every time components are
mounted or reassembled anew and whenever the connections have
been excessively stressed from rig tipping or improper handling.
BG 24 H / 2008 9 - 39
MAINTENANCE
9.12 CENTRAL LUBRICATION SYSTEM
● Every 50 operating hours or weekly, top up the grease jar with a standard grease, of
NGLI-Cl. 2 grade, using a grease gun (preferably a pneumatic one).
The jar has a capacity of 2 kg.
For further information, please refer to the manufacturer's documentation supplied with
the equipment.
● Greases containing solid particles like graphite or copper pastes

must not be used.
NOTE ● To avoid dirt intruding into the grease and causing clogging, the
grease must be pressed through the lube nozzle into the jar
(without unscrewing the cap).
● The grease must not be topped up to more than 2 cm below the up-
per edge, or the ventilation system will get smudged.
BG 24 H / 2008 9 - 40
LUBRICANTS / TABLES
10 LUBRICANTS / TABLES
10.1 LUBRICANTS
10.1.1 General
● Observe instructions given in the supplied "Safety Information" book on this subject.
● Use only oils and greases prescribed or suitable for the application in question.
● Before changing to another kind of lubricant, check it is compatible with the previous
one used.
● The lubricants used must be fresh.
Risk of damage to the equipment and loss of the equipment warranty!

A damage resulting from non-observance of lubricant instructions in this
CAUTION manual will not be covered by the equipment warranty.
The lubricants listed in the lubricant tables of this manual are suitable
for ambient temperatures from -20°C to 40°C (-4°F to 104°F).
Information on applications below -20°C and above 40°C can be or-
NOTE dered from the BAUER Service Centre.
BG 24 H / 2008 10 - 1
LUBRICANTS / TABLES
10.1.2 Lubricant Table
The following table lists the lubricants with which the equipment is filled when leaving
the factory.
The quantities given in the table serve as a guide only. Decisive are
the specifications found on the nameplates of the respective parts and
NOTE the actual fill level found when checking.
Alternative lubricants are listed on following pages.
Table Initial lubricant fill

Specifica- Qty.
Application Viscosity grade Producer Name of product
tion [litres]
Gear oils, CLP

petroleum
Gear oils, API

petroleum
Gear oils, ATF *) At 40°C:

petroleum 38mm2/s
At 100°C:
7.1 mm2/s
Rotary drive ARAL ARAL ATF 22 60
planetary gears
Rotary drive ARAL ARAL ATF 22 2 x 7.5
main gear
Gear oils, CLP PG

synthetic
Gear oils, CLP HC

synthetic
Main winch ARAL DEGOL PAS 220 15.0
Auxiliary winch ARAL DEGOL PAS 220 3.0
Crowd winch ARAL DEGOL PAS 220 8.0
Pump distributor ARAL DEGOL PAS 220 8.5
Crawler drive gears ARAL DEGOL PAS 220 2 x 13
*) 40°C = 104°F; 100°C = 212°F
BG 24 H / 2008 10 - 2
LUBRICANTS / TABLES
Specifica- Qty.
Application Viscosity grade Producer Name of product
tion [litres]
Hydraulic oil, HVLPD

petroleum
Hydraulic systems ISO VG 46 ARAL ARAL Vitam VF 46 535
Hydraulic oil, HEES

fixed (biodegradeable)
Engine oil, API CI -4
Engine SAE 15W-40 ARAL ARAL Plus Turboral 33

SAE 15W-40
Engine oil, API CF

synthetic
Grease, KP2N-20 Multi-purpose

petroleum NLGI- grease on lithium
Grade2 soap base
Roller bearings / ARAL Aralub HLP 2
friction bearings
Central lubrication ARAL Aralub HLP 2
system
BG 24 H / 2008 10 - 3
LUBRICANTS / TABLES
10.1.3 Lubricant Guide
10.1.3.1 List of Approved Gear Oils, Petroleum – CLP
Table Gear oils, petroleum – CLP

Specification
Application DIN 51517 /
DIN 51502
Petroleum gear oils CLP
Viscosity grade
ISO-VG / DIN 51519 at 40°C (104°F) in mm2/s
Producer
VG 100 VG 150 VG 220
Product
ARAL ARAL ARAL

ARAL
Degol BG 100 Degol BG 150 Degol BG 220
SHELL SHELL Omala 100 SHELL Omala 150 SHELL Omala 220
BP Energol BP Energol BP Energol
BP
GR-XP 100 GR-XP 150 GR-XP 220
MOBIL Mobilgear 627 Mobilgear 629 Mobilgear 630
AVIA Avilub RSX 100 Avilub RSX 150 Avilub RSX 220
CASTROL Alpha SP 100 Alpha SP 150 Alpha SP 220
NL Gear NL Gear NL Gear
CHEVRON
Compound 100 Compound 150 Compound 220
ESSO Spartan EP 100 Spartan EP 150 Spartan EP 220
FINA Giran 150 Giran 220
EP Lubricant EP Lubricant
GULF
HD 150 HD 220
TEXACO Meropa 150 Meropa 220
TOTAL Carter EP 150 Carter EP 220
KLÜBER Unimoly Oil 100 Unimoly Oil 150 Unimoly Oil 220
ELF Reductelf SP 100 Reductelf SP 150 Reductelf SP 220
Renep
FUCHS
Compound 106
AGIP Blasia 100 Blasia 150 Blasia 220
DEA Falcon 100 Falcon 150 Falcon 220
PANOLIN Mecano ISO 220
BG 24 H / 2008 10 - 4
LUBRICANTS / TABLES
10.1.3.2 List of Approved Gear Oils, Petroleum – API
Table Gear oils, petroleum – API
Specification
Application
DIN 51502
API GL-5 /
Petroleum gear oils
MIL-L-2105 B
Viscosity grade
SAE / DIN 51511
Producer
SAE 90 SAE 85W-90
Product
Gear oil HYP

ARAL Gear oil HYP 90
SAE 85W-90
SHELL Shell Spirax MB 90
Energear
BP Energear Hypo 90
Hypo 85W-90
Mobilube
MOBIL Mobilube HD-A 90
HD 85W-90
AVIA
AVIA
HYPOID 90 EP
CASTROL Castrol EPX 90
RPM Universal
CHEVRON Gear Lubricants
SAE 80W-90
ESSO GEAR OIL ESSO GEAR OIL
ESSO
GX-D 90 GX-D 85W-90
FINA PONTONIC
FINA
MP 85W-90
Gulf Multi-Purpose
GULF Gear Lubricant
SAE 90
TEXACO
TOTAL
KLÜBER
TRANSELF
ELF
TYP B SAE 90
Fuchs Titan Gear Fuchs Titan Gear
FUCHS
Hypoid 90 8090 MC
AGIP Agip Rotra MP
Daegear EP-B
DEA
SAE 85W90
Panolin Super Duty Panolin Super Duty
PANOLIN
SAE 90 SAE 80W-90
BG 24 H / 2008 10 - 5
LUBRICANTS / TABLES
10.1.3.3 List of Approved Gear Oils, petroleum – ATF
Table Gear oils, petroleum – ATF
Specification
Application
DIN 51502
Petroleum gear oils Dexron II D
Viscosity grade
Producer *) At 40°C:
38 mm2/s
At 100°C:
Product 7.1 mm2/s
ARAL ATF 22
SHELL Donax TA
BP Autran DX II
MOBIL ATF 220
AVIA Aviafluid ATF 86
CASTROL
CHEVRON
ESSO
FINA Finamatic II D
GULF
TEXACO Texamatic
TOTAL Totalfluid ATX
KLÜBER
ELF
FUCHS
AGIP
DEA
PANOLIN
*) 40°C = 104°F
100°C = 212°F
BG 24 H / 2008 10 - 6
LUBRICANTS / TABLES
10.1.3.4 List of Approved Gear Oils, Synthetic – CLP PG
Table Gear oils, synthetic – CLP PG

Specification
DIN 51502
Synthetic gear oils CLP PG
Viscosity grade
Producer
VG 100 VG 150 VG 220
Product
ARAL Degol ARAL Degol

ARAL
GS 150 GS 220
SHELL SHELL Tivela WA SHELL Tivela WB
BP Enersym BP Enersym
BP
SG-XP 150 SG-XP 220
MOBIL Mobil Glygoyle 22 Mobil Glygoyle 30
AVIA Avilub VSG 150 Avilub VSG 220
CASTROL
CHEVRON
Circulation oil
ESSO
S 220
FINA
GULF
TEXACO
TOTAL
Klübersynth Klübersynth
KLÜBER
GH 4-150 GH 4-220
ELF Syntherma P 270
FUCHS Renodiol PGP 220
AGIP
DEA
PANOLIN
BG 24 H / 2008 10 - 7
LUBRICANTS / TABLES
10.1.3.5 List of Approved Hydraulic Oils, Petroleum – HVLPD
Table Hydraulic oils, petroleum – HVLPD

Specification
DIN 51502
Petroleum
HVLPD
hydraulic oils
Viscosity grade
Producer
VG 46 VG 68
Product
ARAL ARAL Vitam VF 46

SHELL
SHELL
Hydrol HV 46
BP BP Bartram HV 46
MOBIL Mobil DTE 15 M
AVIA Avia Fluid HVD 46
CASTROL
CHEVRON
ESSO
Fina Hydraulic oil
FINA
D 3017
GULF
TEXACO
TOTAL
KLÜBER
ELF Elf Hydrelf DS 46
FUCHS
AGIP Agip Arnica 46
Dea Actis
DEA
HVLPD 46
PANOLIN
BG 24 H / 2008 10 - 8
LUBRICANTS / TABLES
10.1.3.6 List of Approved Gear Oils, Synthetic – CLP HC
Table Gear oils, synthetic – CLP HC
Specification
Application
DIN 51517
Synthetic gear oils CLP HC
Viscosity grade
Producer
VG 100 VG 150 VG 220
Product
ARAL Degol ARAL Degol ARAL Degol

ARAL
PAS 100 PAS 150 PAS 220
AVIA Synthogear AVIA Synthogear AVIA Synthogear
AVIA
EP 100 EP 150 EP 220
BP Enersyn BP Enersyn
BP
EP-XF 150 EP-XF 220
CASTROL Tribol 1710 / 100 Tribol 1710 / 150 Tribol 1710 / 220
DEA Intor HCLP 150 Intor HCLP 220
Spartan Synthetic
ESSO
EP 220
Renolin Unisyn Renolin Unisyn Renolin Unisyn
FUCHS
CLP 100 CLP 150 CLP 220
Klübersynth Klübersynth
KLÜBER
EG 4-150 EG 4-220
Mobilgear Mobilgear
MOBIL
SHC XMP 150 SHC XMP 220
Optigear Synth
OPTIMOL
A 220
SHELL OMALA SHELL Omala
SHELL
HD 150 HD 220
Pinnacle Pinnacle
TEXACO
EP 150 EP 220
TOTAL Carter EP/HAT 150 Carter EP/HAT 220
TRIBOL Tribol 1710 / 100 Tribol 1710 / 150 Tribol 1710 / 220
BG 24 H / 2008 10 - 9
LUBRICANTS / TABLES
10.1.3.7 List of Approved engine oils – API CI-4
Table Engine oils – API CI-4
Specification
Application
DIN 51502
Engine oils API CI-4
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40 SAE 10W-40 SAE 15W-40
Product
AGIP
Aral Plus Turboral
ARAL
SAE 15W-40
Avia Multi HDC Plus
AVIA
SAE 15W-40
BP
CASTROL
Chevron Delo 400
CHEVRON
Multigrade SAE 15W-40
DEA
ELF
ESSO
Fina Universal Plus XL
FINA
SAE 15W-40
Titan Truck Plus
FUCHS
SAE 15W-40
Gulf Super Duty Select
GULF
SAE 15W-40
KLÜBER
MOBIL Mobil Delvac MX 15W-40
PANOLIN
Q8 Q8 T 750 SAE 15W-40
Shell Rimula Super
SHELL
15W-40
TEXACO
TOTAL
BG 24 H / 2008 10 - 10
LUBRICANTS / TABLES
10.1.3.8 List of Approved Engine Oils, Petroleum – API CF-4
Table Engine oils, petroleum – API CF-4
Specification
Application
DIN 51502
API CF-4 /
Petroleum engine oils
MIL-L-2104 C/D
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40 SAE 10W-40 SAE 15W-40
Product
Aral Multi Turboral
ARAL
SAE 15W-40
Rimual TX
SHELL
SAE 15W-40
BP Vanellus Multigrad
Mobil Super M
MOBIL
15W-40
AVIA MULTI HDC
AVIA
15W-40
Castrol RX Super
CASTROL
Plus 15W-40
Chevron RPM
Heavy Duty
CHEVRON
Motor oil
SAE 15W-40
ESSO Essolube XT 401
Fina Kappa Supra
FINA
SAE 15W-40
GULF
TEXACO
TOTAL
KLÜBER
ELF
ELF PERFORMANCE
XR 15W-40
Titan Universal
FUCHS
HD 1540
AGIP Agip Sigma Turbo
Super DX
DEA
SAE 15W-40
PANOLIN
PANOLIN UNIVERSAL
SAE 15W-40
BG 24 H / 2008 10 - 11
LUBRICANTS / TABLES
10.1.3.9 List of Approved Greases, Petroleum – KP2N
Table Greases, petroleum – KP2N
Specification
Application
DIN 51502
Petroleum greases KP2N-20
Name
Producer Multi-purpose
grease on lithium
Product soap base
ARAL Aralub HLP 2

SHELL Retinax EP 2
Energrease
BP
LS-EP 2
MOBIL Mobilux EP 2
AVIA
CASTROL
CHEVRON
ESSO Beacon EP 2
FINA Marson EPL 2A
GULF
TEXACO
TOTAL
KLÜBER
ELF Epexa 2
FUCHS Renolit MP
AGIP Agip GR MUEP 2
DEA Glissando EP 2
PANOLIN EP Grease 2
BG 24 H / 2008 10 - 12
LUBRICANTS / TABLES
10.1.3.10 List of Approved Engine Oils, Synthetic – API CF
Table Engine oils, synthetic – API CF
Specification
Application
DIN 51502
API CF /
Synthetic engine oils
MIL-L-2104 C/D
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40 SAE 10W-40 SAE 15W-40
Product
Aral Extra Turboral
ARAL
SAE 10W-40
Myrina
SHELL
TX SAE 10W-40
BP Vanellus HAT
MOBIL Mobil Delvac 1310
AVIA TURBO
AVIA SYNTH HAT-E
10W-40
Castrol RX Super
CASTROL
15W-40
Chevron RPM
Heavy Duty
CHEVRON
Motor oil
SAE 10W-40
ESSO Essolube XTS 301
FINA Fina Kappa FE
GULF
TEXACO
TOTAL
KLÜBER
ELF ECOMAX
ELF
FE PLUS 10W-40
Titan Unic 1040
FUCHS
MC
Agip Sigma
AGIP
Super TFE
Premium XL
DEA
SAE 10W-40
PANOLIN
UNIVERSAL SFE
PANOLIN
LC
SAE 10W-40
BG 24 H / 2008 10 - 13
LUBRICANTS / TABLES
10.1.3.11 List of Approved Hydraulic Oils, Fixed – HEES - unsaturated Ester
Table Hydraulic oils, fixed – HEES - unsaturated Ester
Application Specification
Fixed hydraulic oils

HEES
(biodegradeable)
Viscosity grade
Producer
VG 46 VG 68
Product
ARAL Aral Vitam EHF 46

SHELL
SHELL NATURELLE
HF-E 46
BP
Mobil
MOBIL
EAL Syndraulik 46
AVIA
CASTROL
CHEVRON
Univis
ESSO
HEES 46
FINA BIOHYDRAN
FINA
TMP 46
GULF
TEXACO
TOTAL
TOTAL
Biohydran TMP 46
KLÜBER
ELF
FUCHS Plantohyd S 46
AGIP Agip ARNICA S46
DEA
PANOLIN

Oils from different producers must not be mixed with one another.
CAUTION
BG 24 H / 2008 10 - 14
LUBRICANTS / TABLES
10.1.3.12 List of Approved Hydraulic Oils, Fixed – HEES - saturated Ester
Table Hydraulic oils, fixed – HEES - saturated Ester
Application Specification
Fixed hydraulic oils

HEES
(biodegradeable)
Viscosity grade
Producer
VG 46 VG 68
Product
ARAL
SHELL
BP Biohyd SE-S 46
MOBIL
Avia
AVIA
Syntofluid N 46
CASTROL
CHEVRON
ESSO
FINA
GULF
TEXACO
TOTAL
TOTAL
Biohydran SE 46
KLÜBER
ELF
FUCHS Plantosyn 46 HVI
AGIP
DEA Econa E 46
PANOLIN HLP Synth 46

Oils from different producers must not be mixed with one another.
CAUTION
BG 24 H / 2008 10 - 15
LUBRICANTS / TABLES
10.2 BOLT TORQUE VALUES
Bolt torque values given in the following tables are valid only for slightly
oiled bolted connections and where the Spare Parts List does not pre-
CAUTION scribe other torque values.
Bolts with coarse-pitch metric thread

Strength class as per DIN/ISO 898
8.8 10.9 12.9
Coarse-pitch metric thread Bolt torque values MA [Nm]
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M8 23 34 40
M 10 46 68 79
M 12 79 117 135
M 14 125 185 215
M 16 195 280 330
M 18 280 390 460
M 20 390 560 650
M 22 530 750 880
M 24 670 960 1120
M 27 1000 1400 1650
M 30 1350 1900 2250
M 33 1850 2600 3000
M 36 2350 3300 3900
Bolts with fine-pitch metric thread

Strength class as per DIN/ISO 898
8.8 10.9 12.9
Fine-pitch metric thread Bolt torque values MA [Nm]
M 8x1 24.5 36 43
M 10x1 52 76 89
M 10x1,25 49 72 84
M 12x1,25 87 125 150
M 12x1,5 83 122 145
M 14x1,5 135 200 235
M 16x1,5 205 300 360
M 18x1,5 310 440 520
M 20x1,5 430 620 720
M 22x1,5 580 820 960
M 24x2 730 1040 1220
M 27x2 1070 1500 1800
M 30x2 1490 2120 2480
M 33x2 2000 2800 3300
M 36x3 2500 3500 4100
BG 24 H / 2008 10 - 16
LUBRICANTS / TABLES
10.3 CONVERSION TABLE
Measures for Power

N dyn kp Mp p
1 105 0.102 1.0210-4 102
10-5 1 1.0210-4 1.0210-9 1.0210-2
9.81 9.81105 1 10-3 103
9.81103 9.81108 103 1 106
9.8110-3 981 10-3 10-6 1
Measures for Energy and Operating Efficiency

J erg kpm kWh kcal ev
1 107 0.102 2.7810-7 2.3910-4 6.241018
10-7 1 1.0210-8 2.7810-14 2.3910-11 6.241011
9.81 9.8110-7 1 2.7210-6 2.3410-3 6.121019
3.60106 3.601013 3.67105 1 860 2.251025
4187 4.191010 427 1.1610-3 1 2.611022
1.610-19 1.610-12 1.6310-20 4.4510-26 3.8310-23 1
Measures for Output

W kW kpm/s PS kcal/s kcal/h
1 10-3 0.102 1.3610-3 2.3910-4 0.86
103 1 102 1.36 0.239 860
981 9.8110-3 1 1.3310-2 2.3410-3 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
Measures for Pressure

at atm bar N/m² Torr Psi
1 0.968 0.981 98100 736 14.22
1.033 1 1.0133 101330 760 14.69
1.02 0.987 1 105 750 14.5
1.0210-5 9.8710-6 10-5 1 7510-4 14.510-5
1.3610-3 1.3210-3 1.3310-3 133 1 19.2810-3
0.070 0.0680 0.0689 0.145 51.72 1
Measures for Length

in ft yd mm m km
1 0.08333 0.02778 25.4 0.0254 -
12 1 0.3333 304.8 0.3048 -
36 3 1 914.4 0.9144 -
0.03937 328110-6 109410-6 1 0.001 10-6
39.37 3.81 1.094 1000 1 0.001
39370 3281 1094 106 1000 1
BG 24 H / 2008 10 - 17

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Instruction Manual

Keep this manual also for future use!

BAUER Maschinen GmbH

Before putting the equipment in operation, please:

Carefully read through the whole Instruction Manual and

This manual was edited and published by

ABOUT THE MANUAL............................................................................................................................. VIII

AFTER SALES SERVICE........................................................................................................................... XI

WARRANTY TERMS................................................................................................................................. XII

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

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

This manual is made for

This manual was published in

The chapters of this manual

"Danger!" is used to identify an immediate hazard that can result in

"Warning!" is used to identify a potential hazard that can result in

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

"Note" is used to highlight an operation, assembly or maintenance

Nameplates on the equipment

Assembly Location Nameplate

How to reach the Service Centre

Phone +49 8252 97-2586

For possible check-backs

– Name of person to contact, phone / fax:

 Warranty Period: The warranty period is either

 Warranty – Improper use or operation (misuse) of the equipment.

– Redeliveries via air freight: 4 weeks

B) Liabilities and Responsibilities of the Client

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

From (Customer, Agent):

Total number of pages of claim:

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

3. Delivery of new parts and repair

Date Name of claimant Signature Company

4. For internal use only (to be filled in by BAUER)

Return of damaged parts by:

(Signed by authorized BAUER employee)

Personalanforderung / Staff request

Von Firma / Company:

Besteller / Ordered by: Tel.:

Bestell-Nr. / Order no.: e-mail:

Standort des Geräts / Location of machine:

Ansprechpartner Baustelle / Baustellentelefon /

Zielflughafen / Airport of destination:

Datum des gewünschten Einsatzes / Date of requested assignment:

Gewünschtes Personal / Requested staff: Mechaniker Elektriker Einweiser

Voraussichtliche Dauer / Estimated duration:

Besonderheiten / Special requirements:

Ersatzteile / Spare parts:

Kommunikation auf der Baustelle /Communication on jobsite:

deutsch/German englisch/English Landessprache/Language of country

Datum / Date: Unterschrift / Signature:

1.1 EQUIPMENT APPLICATIONS

Area of application In short Allowed

1.2.1.1 Components Overview

1.2.1.2 Components Description

Table Basic rig components description

1.2.2 CFA Equipment (optional)

1.2.2.1 Components Overview

1 Concreting kelly extension 2

1.2.2.2 Components Description

Table CFA equipment components description