Manual de Instrucciones BG28

Instruction manual
BG 28 H # 5336
Translation of the original instruction manual
V01_en_04.2021 5336_BG28H_en_0001209425_V01
Product information
Product information
This document has been compiled for the following product:
1 BG 28 H 7 BT 75 D
2 2021 8 75000 kg
3 5336 9 24 V
4 310 kW 10 330 kN
5 - 11 330 kN
6 350 bar 12 200 kN
13 80 kN
Expert inspection (repeat expert Certification

inspection once a year or more
frequently if necessary)
Date of publication of the Original instruction manual: 04.2021
BAUER Maschinen GmbH Head office

BAUER-Straße 1
Telephone: +49 8252 97-0
86529 Schrobenhausen
Telefax: +49 8252 97-1135
GERMANY
E-mail: [email protected]
Web: www.bauer.de
Postal address Technical Service
BAUER Maschinen GmbH Hotline: +800 1000 1200 (free of charge)
Postfach 12 60 Telephone: +49 8252 97-2888
86522 Schrobenhausen E-mail: [email protected]
GERMANY
BG 28 H # 5336 / V01_en_04.2021 3 - 390

BAUER Maschinen GmbH
Product information
Additional information regarding certification
This instruction manual, which is compiled by BAUER Maschinen GmbH, has been successfully
checked by an external certified expert for technical documentation in accordance with Machinery
Directive 2006/42/EC and other applicable directives and standards, as well as their requirements.
BAUER is therefore entitled to use the Docu-Check® test mark under certificate number
28109-12-16.
Completion of inspection: Nov. 23, 2017
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Table of contents
Table of contents
Product information 3
Preface 17
Declaration of Conformity 23
After Sales Service 25
Defects liability 27
Guarantee 31
1 Safety 33
1.1 Terminology 33
1.1.1 Hazard classification 33
1.2 First aid 34
1.2.1 Behavior upon finding a person 34
1.2.2 Immediate life-saving measures 34
1.3 Safety when handling the product 38
1.3.1 Safety principles 38
1.3.2 Safety information when handling the product 39
1.3.3 Personnel requirements 40
1.3.4 Responsibilities of the operator 42
1.3.5 Danger zone and safety distance 42
1.3.6 Safety when handling wire ropes 43
1.3.7 Information on stability 45
1.3.8 Operational safety 46
Safety when working in areas at risk of falling 49
Safety when working near over-ground or underground media supplies 50
Safety when working underground or in enclosed spaces 50
1.3.9 Safety during assembly/mounting and dismantling/removing 51
1.3.10 Safety when handling suspended loads and during transport 53
1.3.11 Safety during maintenance and environmental protection/disposal 54
Safety when handling pressurized components 56
Safety for welding, flame cutting and grinding operations 57
Safety when dealing with electrical energy 58
Safety when handling auxiliary materials and operating fluids 58
Safety in case of contamination risk 59
1.3.12 Specific safety information for large rotary drilling rigs 60
1.4 Labeling 65
1.4.1 Safety switch – Overview 65
1.4.2 Base machine signage plan 71
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Table of contents
1.5 Safety and protective equipment 75

1.5.1 EMERGENCY STOP 75
1.5.2 "Pilot Control" Safety Stick 77
1.5.3 Fire extinguishers 78
1.5.4 First aid box 79
1.5.5 Emergency Exit 79
1.5.6 Safety guardrails – Overview 80
1.5.7 Base machine limit switch 81
1.5.8 Signaling devices – Overview 82
1.5.9 Lighting devices – Overview 83
1.5.10 Camera equipment – Overview 84
1.6 Stability 85
1.6.1 Center of gravity factors 85
1.6.2 Additional specific guidelines for stability 90
1.6.3 Moving without process equipment 91
1.6.4 Danger zones 93
1.6.5 Permissible wind speeds 95
Maximum permissible wind speeds – unpredictable wind speeds 98
Maximum permissible wind speeds – predictable wind speeds 99
2 Product description 101

2.1 Intended use 101
2.1.1 Equipment-specific conditions 102
2.2 Improper use 102
2.3 Nameplates 103
2.3.1 Base machine 103
2.4 Equipment overview 104
2.4.2 Upper carriage 106
Sections 106
Cab 109
2.4.3 Undercarriage 110
2.4.4 Control unit/Software 111
B-Tronic 111
Assistance functions 111
Complementary software 114
2.5 Technical data 115
2.5.1 Equipment specifications 115
2.5.2 Permissible ambient temperatures 117
2.5.3 Noise emissions 118
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Table of contents
2.5.4 Exhaust gas emissions 118

2.5.5 Vibration acceleration 118
3 Operation 119
3.1 Operating modes 119
3.1.1 Derigging mode 119
3.1.2 Rigging mode 120
3.1.3 Operation 120
3.1.4 Winches Rigging mode 120
3.1.5 Transport mode 120
3.1.6 Operating mode 120
3.2 Operating elements/control elements 121
3.2.1 Overview of cab and control station 121
3.2.2 B-Tronic 122
3.2.3 Control pedals 123
3.2.4 Operator's seat 124
3.2.5 Control panel 1 125
3.2.9 B-Drive screen 137
3.2.10 Operating the B‑Drive 139
3.2.11 Control lever configuration Basic functions 140
3.2.12 Additional switches 141
Main fuse switches 141
Battery main switch 143
Diesel engine fuse switch 143
Diesel engine emergency control switch 144
3.3 Initial start-up 145
3.3.1 Wax removal 145
3.4 Start-up after prolonged shutdown or storage 146
Upper carriage and attachment 146
Hydraulic system 146
Diesel engine 147
Air conditioning system 147
Slewing ring 147
Undercarriage telescopic guide 147
Cylinders and piston rods 148
Hose assemblies 148
Electrical system/electrical cables 148
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Wire ropes 148

3.5 Daily start-up 148
3.5.1 Visual check before daily start-up 148
3.5.2 Starting the Equipment 149
Bringing the diesel engine and hydraulic system to the operating temperature 150
3.5.3 Jump starting the equipment 151
3.5.4 Safety checks before starting work - EMERGENCY-STOP 155
3.5.5 Safety checks before starting work - "Pilot control" safety lever 155
3.5.6 Safety tests before starting work - Base machine limit switches 156
3.5.7 Safety tests before starting work - Freewheel of the main winch 157
3.6 Shut-down 159
3.6.1 Brief interruption or end of work 159
3.6.2 Shutting down due to high wind speeds 159
3.6.3 Prolonged standstill or storage - Base machine 160
Upper carriage and attachment 160
Hydraulic system 160
Diesel tank 160
Diesel engine 161
Air conditioning system 161
Slewing ring 161
Undercarriage telescopic guide 161
Cylinders and piston rods 161
Hose assemblies 161
Electrical system/electrical cables 161
Wire ropes 162
3.6.4 Decommissioning 162
3.7 Basic functions - Base machine 162
3.7.1 Making the equipment operational 162
3.7.2 Driving and steering - Basics 163
3.7.3 Driving the base machine 165
3.7.4 Driving the base machine 165
3.8 Basic functions - Upper carriage 166
3.8.1 Diesel engine 166
3.8.2 Operating the swing brake 166
3.8.3 Turning the upper carriage 167
3.8.4 Check the control system of the load limit control 170
3.8.5 Operating the diesel engine emergency control 170
3.8.6 Exhaust gas post-treatment 171
Operating the SCR system 171
Operating regeneration of the exhaust system 174
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3.8.7 Operating the ECO mode 176

3.8.8 Operating the automatic diesel engine stop 177
3.8.9 Operating the engine diagnostics system 178
3.8.10 Refueling 179
3.8.11 Operating the camera attachment 182
3.8.12 Operating the "Climatronic" system 182
3.8.13 Operating the central lubrication system 182
3.8.14 Operating integrated service platform 183
Opening the integrated service platform 183
Closing the integrated service platform 185
3.9 Basic functions - Undercarriage 186
3.9.1 Operating the undercarriage 186
Extending/retracting the telescoping cylinders 186
3.10 Basic functions - Attachment 187
3.10.1 Aligning the mast automatically 187
3.10.2 Adjusting the operating radius 188
3.10.3 Adjusting the mast inclination 190
3.10.4 Operating the mast prop 193
3.10.5 Operating the rope winches 194
Operating the automatic rope tensioning facility 194
Free wheel operation 194
Operating back pull control 196
Winding/unwinding the rope of the main winch 197
Winding/unwinding the rope of the crowd winch 198
Winding/unwinding the rope of the auxiliary winch 198
3.10.6 Crowd operation 199
3.10.7 Operating the depth measurement function 201
Set main winch depth indicator to "0" 201
Set crowd winch depth indicator to "0" 201
4 Assembly/mounting 203
4.1 Assembly guidelines 204
4.1.1 Lubricant usage during installation 204
4.1.2 Hydraulic connection 205
Hydraulic screw couplings 206
4.2 Undercarriage 207
4.2.1 Extending the crawlers 207
4.3 Upper carriage 208
4.3.1 Mounting the platform handrails 208
4.3.2 Mounting climbing aid 209
4.3.3 Mounting the guard rail 210
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Table of contents
4.3.4 Mounting the exhaust pipe extension 211

4.3.5 Mounting the counterweights 212
Mounting the counterweights with a lifting device 213
Mounting the counterweights with the mast 217
4.4 Attachment 220
4.4.1 Mounting the mast sections 220
Mounting the prop pad 220
Pivoting the upper mast extension to the operating position 221
Tilt masthead into operating position 223
Mounting rope sheaves for the upper crowd rope 224
Mounting the sledge end stoppers 226
Rope anchorage for main rope/auxiliary rope 227
4.4.2 Preparing ropes for operation 228
4.4.3 Raising the mast 232
Raising the mast without process fitting 232
4.4.4 Mounting the rope swivel 234
5 Disassembly/removal 237
5.1 Guidelines for disassembly 237
5.1.1 Hydraulic connection 238
Hydraulic screw couplings 238
5.1.2 Use of preservatives 239
5.2 Attachment 240
5.2.1 Removing the rope swivel 240
5.2.2 Lowering the mast 240
Lowering the mast without process fitting 240
5.2.3 Preparing the ropes for transport 243
5.2.4 Removing the mast sections 246
Removing the sledge end stoppers 246
Removing rope sheaves for the upper crowd rope 247
Tilt masthead into transport position 248
Folding the upper mast extension to the transport position 249
Removing the prop pad 251
5.3.1 Removing the counterweights 252
Removing the counterweights with a lifting device 252
Removing the counterweights with the mast 254
5.3.2 Removing the exhaust pipe extension 256
5.3.3 Removing the guard rail 257
5.3.4 Removing the platform handrails 259
5.3.5 Removing climbing aid 259
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Table of contents

5.4.1 Retracting the crawlers 260
6 Transport 261
6.1 Transport guidelines 261
6.2 Transport measures 261
6.2.1 Transport mode 261
Before loading 262
After loading 262
6.3 Transport data 262
Base machine with upper mast extension 263
Counterweights 264
6.4 Symbols for transport - overview 264
6.5 Loading - Lifting 265
6.5.1 Lifting the base machine 265
Lifting counterweights 266
6.6 Loading – driving 267
6.6.1 Traveling for Loading 267
6.7 Loading - Tying down 268
6.7.1 Tying down the base machine 268
Tying down a counterweight 270
7 Maintenance/repair 271
7.1 Guidelines - Maintenance/repair 271
7.1.1 Expert inspection 271
7.1.2 Maintenance intervals 271
7.1.3 Hose assemblies 272
7.1.4 Connection elements 272
7.1.5 Welding work 272
7.1.6 Pressure containers 273
7.1.7 Cylinder 273
Cleaning piston rods 273
Leak testing 273
Replacing cylinders 274
Lubricating cylinder joints 274
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Table of contents
7.1.8 Bearings and bearing pins 274

Lubricating bearing connections and plug connections 274
7.1.9 Ball cock 275
7.1.10 Cleaning the equipment/rig 276
7.2 Maintenance plans 277
7.2.1 Entire equipment 278
7.2.2 Undercarriage 279
7.2.4 Attachment 288
Masthead 288
Mast 289
Rope winches 291
Ropes and rope accessories 294
Crowd sledge 296
7.3 Maintenance schedules 297
7.3.1 Lubrication plan - Base machine 297
7.4 Lubricants 299
7.4.1 Lubricants table 299
7.4.2 Lubricant selection lists 301
CLP HC gear oil 301
Hydraulic oil HVLP(D) 302
Motor oil API CJ-4 303
Greases 304
7.5 Entire equipment 305
7.5.1 Inspection of entire equipment 305
7.6.1 Screw connections 305
7.6.2 Plug connections 306
7.6.3 Crawler tracks 306
7.6.4 Crawler drive 306
Checking the oil level 307
Changing the oil 307
7.6.5 Telescopic guide 308
7.6.6 Steps/platforms/handrails 308
7.7.1 Diesel engine 308
Replacing the diesel engine filter elements 312
Checking, tensioning and replacing belt drives 312
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Table of contents
7.7.2 Cooling system of the diesel engine 312

Checking the cooler 313
Cleaning the cooler 313
Check the coolant level 314
Replacing the coolant 314
7.7.3 Pump distributor gear 318
Checking the breather filter 321
7.7.4 Hydraulic tank 321
Replenishing the oil 323
Depressurizing the hydraulic system 325
Taking an oil sample 328
Return oil filter 328
Vent filter 328
7.7.5 Oil cooler 328
Checking the oil cooler 329
Cleaning the oil cooler 329
7.7.6 Filter 330
Replacing the free-fall line filter 330
Replacing the return oil filter/leak oil filter 332
Replacing the hydraulic tank vent filter 333
Replacing the fuel tank vent filter 335
Replacing the air conditioning system air filter 336
Replacing the diesel engine air filter 336
Replacing the electrical box air filter 337
7.7.7 Pressure reservoir 337
Checking the charging pressure 338
7.7.8 SCR system 338
Checking the fluid level 338
Topping up the fluid 339
Emptying the tank 339
Replacing the filter element 340
7.7.9 Swing mechanism 341
Checking the swing brake 341
Lubricating the outer gear teeth on the slewing ring 341
Lubricating the rotary joint and rotor bearing 342
Tightening the connection elements on the slewing ring 342
Swing mechanism gear 343
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Table of contents
7.7.10 Counterweight 348

Checking the connection elements 348
7.7.11 Central lubrication system 348
7.7.12 Air-conditioning system 349
Compressor 349
Replacing the coolant 349
Cleaning the condenser 350
Replacing the air filters 351
7.7.13 Steps/platforms/handrails 353
7.7.14 Integrated service platform 353
Checking the tread rollers 353
Cleaning the tread rollers 353
7.7.15 First aid box 353
7.7.16 Fire extinguishers 354
7.8 Attachment 354
7.8.1 Masthead 354
7.8.2 Mast 354
Mast sections 354
Mast prop 355
Boom 355
Mast pivot 356
7.8.3 Rope winches 356
Main winch 357
Auxiliary winch 361
Pull-down winch 362
7.8.4 Wire ropes and rope accessories 363
Rope swivel 363
Pulleys 363
Rope hold-down rollers 364
Central rope guide 365
Wire ropes, rope fasteners, thimbles and sleeves 365
Changing ropes - General 366
Changing the main rope 366
Changing the auxiliary rope 368
Change crowd ropes 370
Changing the upper crowd rope 376
Changing the lower crowd rope 381
Tension crowd ropes 384
7.8.5 Crowd sledge 385
7.9 Process fitting 386
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Table of contents
8 Environmental protection/disposal 387

8.1 Storing and transporting equipment, units, consumables and operating materi- 387
als
8.2 Information on cleaning 388
8.3 Decommissioning 388
8.4 Disassembling the equipment 388
8.5 Waste disposal 388
8.5.1 Disposing of operating materials, lubricants and consumables 389
8.5.2 Disposing of metal components and synthetics 389
8.5.3 Disposing of electrical and electronic components 389
8.5.4 Hazardous waste 389
8.5.5 Recycling 390
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Table of contents
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Preface
Preface
BG 28 H # 5336 / V01_en_04.2021 17 - 390

Preface
18 - 390 BG 28 H # 5336 / V01_en_04.2021

Preface
BG 28 H # 5336 / V01_en_04.2021 19 - 390

Preface
This Instruction manual is intended for operating and maintenance personnel and is to be retained
for subsequent use.
Before using this equipment, please do the following:
Take the time to carefully read this document.
Always keep this manual with the equipment so you can refer to it at any time.
If the operator of the equipment/system changes (e.g. due to resale), all of the technical documen-
tation is to be handed over to the new operator.
Contact the BAUER customer service about the change in operator.
This Instruction manual provides a detailed description of the equipment, guidelines for transport
and start-up, as well as comprehensive instructions for operating the equipment, troubleshooting
tips and information regarding maintenance procedures.
Technical data, weights and dimensions apply to the date on which this Instruction manual was
published. We are constantly improving our products. As a result, the technical data, weights and
dimensions in this Instruction manual may differ slightly from those of the actual equipment deliv-
ered. However, these minor deviations are inconsequential and do not affect or invalidate the con-
tents of this Instruction manual.
Your equipment may have features that differ slightly from those described and illustrated in this In-
struction manual. This is because we customize equipment based on the needs and orders of indi-
vidual customers. These differences may not be used as a basis for claims of any kind.
The equipment may not be used for any other purposes than the applications listed in this Instruc-
tion manual. The manufacturer shall not assume any liability for improper or unauthorized use of
the equipment, operator errors or improper and/or inadequate maintenance.
The "Safety" section in this Instruction manual contains instructions and other information that re-
lates to safe use of the equipment. The instructions in this section must be followed at all times.
In addition, read and follow all the instructions in the included documents from component manu-
facturers.
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Preface
The Instruction manual has been written and published by
BAUER Maschinen GmbH • Postfach 12 60 • 86522 SCHROBENHAUSEN, GERMANY
Copyright 2021, BAUER Maschinen GmbH
The information contained in this Instruction manual and/or any of its parts, sections or sub-sec-
tions, is the intellectual property of BAUER Maschinen GmbH and is protected by domestic and in-
ternational copyright and other intellectual property laws.
The information in this manual is provided for operating, servicing, maintaining and troubleshooting
the equipment described in this document.
We strictly prohibit any duplication, reproduction, translation, microfilming, electronic or magnetic

storage or processing, copying or dissemination of these materials and/or the information con-
tained herein, or any part thereof, with the exception of internal use by BAUER Maschinen GmbH
or its authorized external suppliers, consultants or agents, without the prior written consent of
BAUER Maschinen GmbH.
All legal rights and remedies are hereby expressly reserved.
Violators will be prosecuted.
BAUER Maschinen GmbH assumes no liability for use of the information contained herein in a pro-
hibited fashion by any person or entity in any location.
BAUER Maschinen GmbH reserves the right to change, delete or otherwise modify any information
contained herein, or the equipment itself, at any time and for any reason, with or without prior no-
tice.
BG 28 H # 5336 / V01_en_04.2021 21 - 390

Preface
22 - 390 BG 28 H # 5336 / V01_en_04.2021

Declaration of Conformity
EU declaration of conformity under the terms of EU Machinery Directive 2006/42/EC
The declaration of conformity is distributed by the manufacturer. The original declaration of con-
formity should contain the following information:
We hereby declare that in the design and construction of the specialist foundation engineering
equipment/machine/system,
Type: BG 28 H
Serial number: 5336
Year of manufacture: 2021
Manufacturer: BAUER Maschinen GmbH
the EC Machinery Directive 2006/42, Directive 2000/14/EC, EMC Directive 2014/30/EU and the na-
tional standard(s) and technical specification have been applied.
Standards applied:
EN 16228 -1; EN 16228 -4
Please note that this declaration only applies to the maximum equipment weight specified in the
load capacity table.
Authorized representative for compiling technical BAUER Maschinen GmbH

documents: BAUER Straße 1
CE representative/Quality assurance: Manfred Neumann

BAUER Straße 1
BG 28 H # 5336 / V01_en_04.2021 23 - 390

24 - 390 BG 28 H # 5336 / V01_en_04.2021

After Sales Service
After Sales Service
Whenever you contact Customer Service, please provide the following information in order that we
can process your request more efficiently.
– Device description
– Device type
– Construction number
– Operating hours
– Description of damage
– Date (DD.MM.YYYY)
– Cause of damage (if known)
– Type of damage
– Extent of damage (which components might be defective/damaged?)
– Contact for queries
– Contact name
– Telephone/fax/e-mail
– Construction site description
– Construction site designation/name
– Full address
– Driving instructions for requested personnel (if necessary)
Customer Service contact information:

Abteilung Kundendienst
Postfach 12 60
86522 SCHROBENHAUSEN
GERMANY
Telephone +800 1000 1200 (free of charge) / +49 8252 97-2888
Fax +49 8252 97-2587
E-mail [email protected]
BG 28 H # 5336 / V01_en_04.2021 25 - 390

After Sales Service
Owner and equipment registration
We want be able to offer the owner optimum customer information service at all times.
We therefore ask you to register your equipment with BAUER.
All of the forms can be found online on your personal service platform.
CustomerCenter
Staff request
Please use the form provided to request staff.
CustomerCenter
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Defects liability
Defects liability
If any defects liability claims are made by the customer in accordance with the contractual provi-
sions, the following information is to be observed as a supplement to the contractual provisions.
Start and duration of the defects li- – The duration of the defects liability period is gener-
ability period: ally defined in the contractual provision.
Prerequisites of defects liability: – Inspection of the product immediately upon deliv-
ery; any defects are to be reported to BAUER im-
mediately using the "Defects Liability Claim" form.
– Proper operation, assembly and start-up of the

product by trained and qualified personnel in com-
pliance with the Instruction manual and the safety
provisions.
– During the defects liability period, only genuine

BAUER replacement parts and wear parts may be
used.
– During the defects liability period, the customer or

the owner of the product is obliged to have all main-
tenance and service work performed by BAUER or
an agent authorized by BAUER, or he is to carry out
the maintenance and service work herself in a regu-
lar and professional manner in accordance with the
service intervals in the Instruction manual and un-
der the supervision of BAUER or an agent autho-
rized by BAUER.
– All work (e.g. service, maintenance, repairs, etc.)

performed on the product must be recorded in the
maintenance and repair log provided with each
product.
– Defective or damaged components must not be dis-

mantled and/or repaired during the defects liability
period without the prior consent of BAUER.
– If a defect is detected, it is to be reported to BAUER

immediately in writing using the "Defects Liability
Claim" form to ensure proper processing and to pre-
vent consequential damage.
BG 28 H # 5336 / V01_en_04.2021 27 - 390

Defects liability
Exclusions from defects liability: – Damage resulting from operating errors, improper
use or assembly, or improper start-up, as well as
misuse of the product.
– Damage resulting from insufficient service and

maintenance procedures.
– Improperly performed repairs.
– Modifications or alterations to the product that have

not been authorized by BAUER.
– Deliberate damage.
– Wear parts. This does not apply if a wear part has a

defect and proof of this is provided (e.g. a material
or manufacturing defect).
Note: Drilling tools, Kelly bars, ropes, etc. are wear
parts, for example.
A) Liabilities and responsibilities of BAUER
– In the event of a defects liability claim, BAUER shall supply the (replacement) parts re-
quired for subsequent performance in accordance with CIF and CIP Incoterms®2010 in the
context of contractual obligations.
– If necessary for subsequent performance, BAUER shall also provide the required person-
nel.
The components removed as part of the subsequent performance shall become the property of
BAUER after they have been replaced. BAUER will then decide on a possible return delivery of the
removed components at the expense and risk of BAUER or any other further procedure. Returns
must always be conducted according to the specifications issued by BAUER.
– Returns/deadlines
For returns, the following deadlines apply from the date of receiving the new components at
the construction site in the destination country to the date of receiving the removed compo-
nents at BAUER headquarters, or any other destination designated by BAUER.
– Returns by air freight: 4 weeks
– Returns by sea freight: 4 months
If removed components requiring shipment by sea freight cannot be returned on time (e.g.
because of the situation at the construction site), BAUER's Customer Service department
must be informed of the delay in writing no later than six weeks before the above mentioned
deadline. BAUER can then extend the deadline for returns.
For returns by air freight, the deadline may generally not be extended.
If parts are not returned within the agreed period, any costs associated with subsequent per-
formance that are incurred by BAUER in the context of the respective defects liability claim
are to be borne by the customer.
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Defects liability
B) Liabilities and responsibilities of the customer
If the customer has informed BAUER of a defect, but it turns out there was no defect during the ex-
amination and rework carried out by BAUER, or that the prerequisites for BAUER's defects liability
are not met, then BAUER reserves the right to make a claim for any costs incurred.
Defects liability claim
Any defect identified at the product must be reported to BAUER without delay.
Use the intended form to ensure proper processing and to prevent consequential damage.
CustomerCenter
BG 28 H # 5336 / V01_en_04.2021 29 - 390

Defects liability
30 - 390 BG 28 H # 5336 / V01_en_04.2021

Guarantee
Guarantee
If a guarantee has been granted, it shall expire immediately if:
– The equipment is not operated properly and according to its intended use.
– The equipment has not been repaired or maintained in accordance with the prescribed
conditions. This also includes the fact that only approved operating fluid, auxiliary materi-
als, and original BAUER spare parts are used.
– The maintenance booklet and repairs booklet have not been properly updated.
BG 28 H # 5336 / V01_en_04.2021 31 - 390

Guarantee
32 - 390 BG 28 H # 5336 / V01_en_04.2021

1 Safety
1 Safety
SAFETY IS ALWAYS TOP PRIORITY!
Read the Instruction manual before operating the equipment.
Failure to observe operating instructions, safety regulations, and accident prevention regulations
can result in serious injury or death.
Most accidents result from failure to observe basic safety and accident prevention regulations when
starting, assembling, operating, or maintaining the equipment.
The separate Quick Reference Guide in/on the equipment serves as an overview aid for the oper-
ating processes described in the Instruction manual. It displays the operating and control elements
as well as the load capacity charts. However, it is not intended to replace the Instruction manual.
The Instruction manual may consist of multiple sections depending on whether the equipment has
been approved for one or more activities. This section of the Instruction manual is the main section.
Any other additional sections are listed at the end of this main section and marked "Supplement".
1.1 Terminology
A distinction is made between:
– Safety instructions = risk of personal injury
– Material and environmental damage
– "Tip" = additional and helpful information about using the equipment
– Link to the BAUER website
– Instructions (indicated by "∙").

All of the instructions for a procedure are always listed in chronological order.
– Lists (indicated by "−").
– Cross references, e.g. to other sections (indicated by "[➙]" and the page number).
– Interim results/final results (indicated by "✓").

These mark the completion of a procedure.
1.1.1 Hazard classification

Safety statements and warning statements for material/environmental damage are organized
based on the "SAFE" principle. This means they contain information on the type and source of the
hazard, the possible consequences and the prevention of the hazard "Δ". The following classifica-
tions apply to the safety instructions:
indicates a hazardous situation that will result in death or severe, permanent injuries.
indicates a hazardous situation that can result in death or severe, permanent injuries.
indicates a hazardous situation that can result in temporary, moderate or minor injuries.
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1.2 First aid

First aid must always be carried out in accordance with the respective country specific or regional
laws.
1.2.1 Behavior upon finding a person

Principles
• Stay calm.
• Secure the accident site.
• Pay attention to your own safety.
• Remove the person from the danger zone, if possible.
Emergency call
• Inform the emergency services, proceed as follows:
– Where is the emergency?
– What happened?
– How many people were injured?
– What type of injury is it?
– Wait for further questions.
1.2.2 Immediate life-saving measures
Flow chart for life-threatening situations
1. Safeguard/self-protection
• Recognize - What type of emergency is it?
• Reflect - What potential dangers pose a risk to the injured or the person helping?
• React - Secure the situation accordingly.
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2. Implement immediate life-saving measures
Person is unconscious Breathing NOT normal
Carry out chest

Check for
Check breathing compressions and
consciousness
resuscitation
Person is conscious Breathing normal
Help according to the

Recovery position
situation at hand
Make an emergency call
Monitor consciousness and breathing
Chest compressions
• The person’s back should be on a hard surface.
• Strip the injured person to the waist.
• Carry out chest compressions and rescue breaths in alternation.
• Remove pressure from sternum after every compression.
• Continue resuscitation until person starts to breathe or until the emergency services arrive.
Resuscitation
• Tilt the head back.
• Mouth to mouth (keeping the nose closed), or
• Mouth to nose (keeping the mouth closed).
• Blow air evenly into the mouth or nose.
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Recovery position
Do NOT do this if there are possible injuries to the spine!
– The person has lost consciousness.
• Place the person in the recovery position.
Bleeding
• Self-protection: Wear disposable gloves.
• Cover the wound aseptically with sterile material.
• Put the person into the shock position, if necessary.
• Apply a tourniquet, if necessary.
• In case of loss of body parts: give the detached body part packed aseptically in ice back to the
injured person to take with them.
Shock
• Keep the person calm.
• Protect them from heat loss.
• Put them in the shock position.
• Continually check for breathing and consciousness.
• Attention, care.
Bone fracture
• Stabilize the body part in the position it was found in.
• If injuries to the spine are suspected: Do NOT change the position of the injured person.
• Ice contusions and sprains to the joints.
• Exposed bone fractures: Carry out the procedure under ‘Bleeding’.
Burn injuries
• Extinguish the fire on the burning person.
• Immediately remove clothes affected by hot substances.
• Do NOT remove pieces of clothing which are stuck to the skin.
• Cool the affected areas by pouring water on them.
• Cover the burns aseptically.
• Protect the person against heat loss.
Chemical burn
The effect of the corrosive substances may appear later on. Therefore the appropriate first aid
measures must be carried out immediately if chemical burns are suspected.
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Eye
• Rinse out the eye thoroughly with water. Protect the eye which has not been damaged.
• Remove any remaining solid substances from the eye mechanically using appropriate means
(swabs).
• Apply sterilized bandage.
Skin
• Remove all contaminated clothes immediately.
• Rinse the skin with a lot of water.
• Cover the wound aseptically.
Swallowing
• Immediately rinse the mouth out thoroughly.
• Drink water in small gulps.
Corrosive gases - Respiratory organs
• Carry out the first aid measures laid down by the manufacturer.
Poisoning - general measures
• Securing/Self-protection: Remove the poisoned person from the danger zone while protecting
yourself (using suitable personal protective equipment).
• Do NOT induce vomiting.
• Keep the person comfortable and protect from heat loss.
• Determine the effects of the poison.
• Seek medical attention.
Poisoning - special procedures
Skin
• Remove all contaminated clothes immediately.
• Rinse the skin with a lot of water.
• Cover the wound aseptically.
Swallowing
• Immediately rinse the mouth out thoroughly.
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Corrosive gases - Respiratory organs
• Carry out special First Aid measures laid down by HSE Management.
Accidents caused by electrical energy
Every electrical accident is very likely to cause cardiac arrhythmia.
• Safeguard/self-protection: Switch off power through appropriate measures. For high voltage
only allow authorized skilled personnel to do this.
• Immediately make an emergency call.
• Carry out immediate first aid measures after authorized skilled personnel have intervened.
Accidents caused by hydraulic energy
• Safeguard/self-protection: Switch off hydraulic power supply using appropriate measures.
• Cover the injured parts of the body with sterile dressing material without applying pressure.
• Rinse eyes out with water.
1.3 Safety when handling the product

The chapter "Safety when handling the product" contains an overview and summary of all the
safety instructions that have to be observed in order to avoid/prevent risks associated with handling
the product in the individual life cycles.
The equipment-specific safety instructions, which have been compiled from the individual sections
of this Instruction manual, are presented at the end of this section as an ADDITIONAL SUPPLE-
MENT. The safety instructions listed in the individual sections of the Instruction manual must also
be followed. The safety instructions at the start of a section apply equally to the section and to its
sub-sections.
Safe operation of the product is only possible if all the listed safety instructions are followed. The
risk assessment available from BAUER provides further information on possible risks and how to
avoid them.
1.3.1 Safety principles

The equipment has been constructed in accordance with the state of the art, research and the rec-
ognized safety regulations and is consequently safe to operate.
The equipment may only be operated in a technically flawless condition, as well as in a safety-con-
scious and risk-conscious manner that complies with its intended use. Observe the Instruction
manual.
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The equipment may only be operated for the purposes and areas of application stipulated in the In-
struction manual. Any alternative or additional operation is considered contrary to the intended use
and is prohibited. Improper use of the equipment can lead to a risk of injury or death for the opera-
tor or third parties as well as damage to the equipment or other property. The manufacturer is not
responsible for damages caused in this manner. The risk is carried by the operator alone.
All accidents or near accidents that occur while operating the equipment, and which cause or al-
most cause injury to persons and/or damages in the work environment, must be reported to the
manufacturer.
All of the safety information that is specified in the Instruction manual and on the equipment itself
must be observed and adhered to. In addition, all of the applicable rules and regulations in the
country of use as well as other compulsory regulations on occupational health and safety, accident
prevention, and environmental protection must be complied with.
All work on the equipment must be carried out by qualified and suitably authorized technicians who
have received safety training. Access to the equipment is prohibited for unauthorized personnel.
1.3.2 Safety information when handling the product

The Instruction manual must always be kept within reach (in the tool compartment or the desig-
nated container) at the place where the equipment is operated. The same applies to additional writ-
ten instructions and safety regulations.
All of the safety instructions on the equipment must be clear and legible.
Before starting work, check to ensure the equipment is free from damage and is in proper working
order. If any hazards for personnel or changes to the operating behavior are detected, shut down
the equipment immediately. Report the incident to the supervisor or operator without delay.
All of the maintenance and inspection intervals specified in the Instruction manual must be fully ob-
served at all times. Only then is the safety of the equipment guaranteed in the long-term.
The interior of the equipment must be kept tidy and free from foreign objects. Any deposited tools,
devices or work equipment must be secured against falling, rolling, sliding or toppling over and they
must not hinder the safe operation of the equipment.
No changes may be made to the equipment and its accessories without the manufacturer's ap-
proval. This includes any activities that are not permitted or described in the Instruction manual and
in the additional documentation:
– Attachments or alterations to the equipment or to its accessories.
– The removal/dismantling of components.
– The installation and adjustment of safety equipment, protective equipment, and safety
valves.
– Welding of load-bearing parts.
– Making software changes to programmed control systems.
To ensure safe operation of the equipment, the equipment operator's workplace must be adapted
to his individual needs (for example, by adjusting the seat height and the mirror and by regulating
the temperature in the cab). Adequate lighting must be ensured for all work carried out on or with
the equipment.
Spare parts and wear parts, together with auxiliary materials and operating fluids, must satisfy the
technical requirements defined by the manufacturer.
It is generally prohibited to transport persons on the equipment or its attachments. Exceptional

cases relating to normal use of the equipment are defined in the Instruction manual.
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If it is necessary to use lifting equipment or aerial work platforms to work on the equipment (e.g. for
repairs), always implement the applicable safety measures.
Lifting work may only be performed with the equipment if it is explicitly permitted in the Instruction
manual as part of proper use of the equipment.
When a load is attached, the equipment may only be moved if the working platform required for
traveling is suitably level. The equipment operator must keep the load as close as possible to the
ground, to prevent it from swinging.
It is generally prohibited for persons to stand or work under suspended loads.
If any persons approach the equipment or enter the danger zone, the equipment should be shut
down immediately. The same applies in emergency situations.
When the equipment is operating, electronic components can emit electromagnetic radiation in the
low frequency range or the radio frequency range. This may impair the function of cardiac pace-
makers. Turn off all electronic components that are not required, in particular mobile radio units or
radiotelephones.
The equipment must not be towed.
The equipment may only be operated with fully-mounted counterweights (if counterweights are stip-
ulated for the equipment). The correct procedure for mounting the counterweights is described in
the Instruction manual and must be read.
The equipment must be inspected at regular intervals by a qualified person. The relevant inspec-
tion intervals are defined in the Instruction manual. Local conditions may result in an alteration of
the inspection intervals.
Qualified persons are persons who, as a result of their technical training and experience, have
above-average expertise in a particular field, so that they can evaluate the operational safety of the
equipment or its components according to the applicable standards and regulations and according
to the state of the art.
Only suitable tools may be used for performing the various tasks.
1.3.3 Personnel requirements

Anyone assigned the task of operating or servicing the equipment must first have read and under-
stood the entire Instruction manual. This also applies to persons who have previously worked with
or received training for such equipment.
The equipment may only be operated by skilled and authorized personnel who have received
safety training. Before starting any activities, personnel must be informed of the dangers associ-
ated with handling the equipment. The equipment can pose a serious danger of accidents and in-
jury if it is operated by personnel who are not suitably qualified. All personnel are only permitted to
perform tasks that correspond to their qualifications.
Refitting, assembly, dismantling, and repair work may only be performed by technically qualified
personnel who have received the appropriate safety training. Auxiliary personnel must be specially
instructed and assigned to specific tasks.
Personnel being trained, taught, or instructed, along with those working in the context of an appren-
ticeship, may only work on the equipment while under the constant supervision of a suitably experi-
enced trainer.
The equipment operator must fulfill the following minimum requirements:
– He may have to satisfy a minimum age stipulated in the country of use.
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– He must be trained to operate the equipment and demonstrate his qualification for the work
in accordance with the regulations in the country of use.
– He must perform the tasks he has been assigned reliably.
– He must have passed the legally prescribed health inspections.
Experience shows that persons who also possess the following qualifications are ideally suited to
the job of equipment operator:
– Persons who have successfully completed a German training course as a Certified Con-
struction Machine Operator for Earthworks and Foundation Works or an equivalent training
course in another country.
– Persons who have successfully participated in Bauer training courses.
– Persons who have at least one year of construction site experience.
– Persons who are conscious of risks and dangers, particularly in special foundation engi-
neering.
All persons who are assigned to work on or with the equipment must satisfy the following condi-
tions:
– No physical/mental limitations which temporarily or permanently restrict concentration and

judgment (e.g. due to fatigue, illness, or talking on mobile phones).
– Not under the influence of alcohol, drugs, or medication.
– Ensure long hair is tied back, do not wear any loose clothing or jewelry.
– If there is a legally prescribed minimum age, it must be satisfied.
Depending on the work being conducted and the existing work environment, personnel must wear
the following protective equipment:
– Safety vest
– Safety helmet
– Safety shoes
– Hearing protection
– Safety gloves
– Protective glasses
– Protective clothing (e.g. appropriate jacket, trousers, protective coat)
– Breathing equipment
Personnel must be in possession of the following knowledge in order to assure occupational safety:
– How to find and operate all of the equipment's safety and protective equipment.
– How the equipment's danger zones are demarcated, secured, and labeled.
– How to behave in case of an emergency.
– The location and use of fire extinguishers and first aid boxes.
– How to handle fuels, oils, and other operating fluids and auxiliary materials.
– Occupational safety and environmental protection procedures.

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In addition:
– No fire or naked light is permitted in the immediate vicinity of the equipment.
– No smoking, eating, or drinking is permitted in the immediate vicinity of the equipment.
1.3.4 Responsibilities of the operator

The operator may only put the equipment into operation if it is working properly and safe to oper-
ate. He/she must ensure compliance with the safety information set out in the Instruction manual,
as well as with the generally applicable safety and accident prevention regulations and with the en-
vironmental laws in the respective country of assignment. Additional regulations of this kind might
include, for example, first aid measures, fire reporting and fire fighting options, handling of danger-
ous materials, provision/wearing of personal protective equipment, or traffic regulations. The opera-
tor must ascertain the current version of these regulations for himself.
It is recommended to obtain written confirmation that personnel have taken note of the content of
the Instruction manual. It is also recommended to implement training courses which are offered by
the manufacturer or officially recognized in the country of use. Participation in such courses should
also be confirmed in writing.
If further instructions, in addition to the Instruction manual, are required to ensure accident-free op-
eration, the operator must put these in writing and make them known and accessible to personnel
(e.g. supervision and reporting requirements, observance of specific company requirements re-
garding the organization of work, operational procedures, or the personnel employed).
The operator is responsible for ensuring that all work on and with the equipment is performed ex-
clusively by appropriately qualified and authorized personnel who have received safety training. Ar-
eas of responsibility for personnel must be clearly defined and laid down in writing.
The operator must routinely monitor personnel to ensure they are working in a safety-conscious
manner, giving due consideration to attendant hazards, in compliance with the Instruction manual.
The operator must ensure that only those personnel to whom the task has been assigned are work-
ing with the equipment or in its danger zone. Unauthorized persons have no access to the equip-
ment. Responsibility for safe operation ultimately lies with the operator of the equipment or appro-
priately authorized personnel.
The operator is responsible for performing a suitable risk evaluation pursuant to the country-spe-
cific and/or local laws and regulations. This risk evaluation must take into consideration the working
conditions that prevail when the equipment is being operated. The necessary measures for acci-
dent-free operation must then be derived from this evaluation. This includes an analysis of the
weather conditions and the environmental conditions (e.g. temperature, air humidity and/or areas at
risk of contamination) to which the equipment and the personnel are exposed and a specification of
how long they should be deployed.
The operator must observe the inspection and maintenance intervals for the various equipment
components.
1.3.5 Danger zone and safety distance

The danger zone is the area around the equipment in which personnel could be injured by work-re-
lated movements of the equipment or its work fittings, attachments and accessories, or by falling
objects. The specific danger area and safety distance for the equipment are defined in the section
"Safety distance". Always observe and comply with the following safety instructions in reference to
the danger area and the safety distance:
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Risk of accident!
Standing or working in the danger zone while the equipment is being operated can result in acci-
dents and thereby in serious or fatal injuries, such as personnel getting hit or crushed.
Δ All personnel must be outside the danger zone when the equipment is being moved, positioned
or operated. Only when the equipment is at a complete standstill (i.e. no longer moving) is it
permitted to enter the danger zone.
Δ Before starting work with auxiliary personnel, definite signals should be agreed between the
equipment operator and the auxiliary personnel (e.g. in the form of hand signals). The agreed
signals should be put in writing and made known to all participants. If they do not impair con-
centration, radiotelephones may also be used for communication.
Δ Auxiliary personnel must wear highly-visibility clothing, e.g., safety vests. The equipment oper-
ator must maintain constant visual contact with the auxiliary personnel during the whole time.
Do not move the equipment unless there is direct visual contact. In cases of imminent danger,
use the horn as an acoustic warning device.
Δ Before putting the equipment into operation, always make sure that no hazards are caused by
starting the equipment. The equipment operator may only work with the equipment if it is en-
sured that, besides authorized auxiliary personnel, there are no other persons in the danger
zone.
Δ During all work on and with the equipment, please note that in certain situations it may be nec-
essary to enlarge the danger zone. For example, a minor adjustment of operating elements,
such as the control levers, mostly leads to a large movement of the corresponding equipment
components. Swinging movements of attached loads or equipment components can also ne-
cessitate an enlargement of the current safety distance.
Δ The equipment must have distinctly visible signs on two opposite sides, clearly indicating the
prohibition on entering the danger zone.
Δ If any persons are at risk, the equipment operator must give a warning. Warnings are generally
issued via acoustic signals (horn sound). If the horn is not a suitable warning sign, for example,
when hearing protection is worn, then other signals must be agreed. These must be incorpo-
rated in a written instruction, which must be observed by all persons.
Δ Warning devices integrated in the equipment to provide acoustic and optical warning signals
must be in proper working order. Always check for correct functionality before starting work.
Δ Observe the safety distance from stationary components, structures, scaffolding and other
equipment prescribed in the country of use. When determining the safety distance, take the
pivoting radius, fall radius and the outer contour of the equipment into account. If it is not possi-
ble to observe the safety distance, then close off the area between the stationary components
and the turning/pivoting radius.
1.3.6 Safety when handling wire ropes

Please follow all of the instructions in the Instruction manual and in the enclosed supplementary
document "Maintenance and care of wire ropes".
All of the specifications from ISO 4308-1 + 2 and ISO 4309, as well as all nationally and locally ap-
plicable regulations, must be observed.
Wire ropes are wear parts and must be inspected on a regular basis. In some circumstances, the
conditions of use or the environmental conditions can lead to a modification of inspection and main-
tenance intervals. Inspection and maintenance intervals must be adjusted accordingly.
To keep wear and tear to a minimum and to increase safety, always adhere to the following safety
instructions when handling wire ropes:
Risk of accident!
Wire rope changes not carried out by suitably authorized skilled personnel can cause damage to
the respective wire rope and rope breakages. This could result in severe or fatal injury.
Δ Only allow wire ropes to be changed by suitably authorized skilled personnel.
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Danger of getting crushed, shearing hazard and risk of getting pulled in!
If a wire rope is being moved by a rope drum or pulley, persons in the area of the rope drum/pulley
can be seriously or fatally crushed, entangled or pulled in.
Δ Do not reach between the wire rope and the rope drum/pulley.
Δ Do not touch moving wire ropes.
Δ When handling wire ropes, always wear the appropriate personal protective equipment.
Risk of accident!
If there is too little wire rope on a rope drum, the wire rope can become detached from the drum.
The wire rope may break if it is not sufficiently dimensioned or under too much tension. A wire rope
that is incorrectly wound onto or from a rope drum can also break. There is also a risk of a wire
rope breaking if it exhibits signs of wear and tear. If a wire rope breaks, persons may be hit by fall-
ing loads and thus seriously or fatally injured.
Δ It is fundamentally prohibited for persons to stand or work under suspended loads.
Δ The rope drum of a rope winch must always contain at least three windings of wire rope.
Δ Always wind and unwind wire ropes evenly and correctly onto and from the rope drum. Always
monitor the winding and unwinding process of a wire rope.
Δ Every wire rope used must possess an adequate minimum breaking force. In the case of rope
winches, this must be three times greater than the maximum tensile force of the rope drum.
Δ Never pull wire ropes diagonally.
Δ Check to ensure all wire ropes are in proper working order on a daily basis. A worn wire rope
must be replaced immediately with a new one. Immediate replacement is also necessary for
wire ropes that have been damaged by an electric shock (e.g. lightning strike). This type of
damage is not always externally apparent.
Δ If a rope swivel is prescribed for a wire rope, only use the rope with the corresponding rope
swivel. Only use rope swivels which are in proper working order. Replace defective or dam-
aged rope swivels immediately.
Δ Only use the wire ropes prescribed by BAUER.
Risk of accident!
Improper use of BAUER rope swivels may damage the rope swivel. If a wire rope breaks, persons
may be hit by falling loads and thus seriously or fatally injured.
Δ The use of rope swivels as a load suspension or lifting device is prohibited.
Δ Before start-up of the equipment/rig, ensure that the corresponding rope swivel for the respec-
tive wire rope is mounted correctly.
Δ Only use the rope swivel mounted on the equipment/rig for the use described in the instruction
manual.
Risk of injury by uncontrolled movement of the wire ropes!

If the wire ropes are not secured properly, the wire ropes could move in an uncontrolled way. Per-
sons could be struck as a result and suffer severe or fatal injuries.
Δ Secure wire ropes to prevent uncontrolled movement.
Δ Secure any loose wire ropes on the equipment by using the designated holding brackets as
specified in the Instruction manual.
Risk of accident!
A damaged wire rope can cause uncontrollable situations and result in severe or fatal injuries.
Δ Do not use a wire rope if the maximum number of wire breaks has been exceeded.
Risk of accident!
If the replacement state of wear of a wire rope is exceeded, uncontrollable situations can arise
leading to severe or fatal injuries.
Δ Do not exceed the replacement state of wear of wire ropes.
Δ Check the replacement state of wear of wire ropes according to currently applicable standards
and guidelines.
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1.3.7 Information on stability

The stability of the equipment is structurally guaranteed, provided the prescribed conditions are ob-
served.
The stability of the equipment cannot be guaranteed in cases of:
– Overloading of the equipment
– Sinking surface
– Abrupt acceleration or deceleration of components
– Working on a slope
– Extreme weather conditions
Before starting work, it must be checked whether the load-bearing capacity of the surface is ade-
quate for the loads being carried. A working platform with a suitable ground supporting layer must
be present. If the surface does not have adequate load-bearing capacity, it is necessary to take
suitable supporting and/or load-distributing measures, in order to secure the equipment against
sinking or sliding. If this is not possible, do not drive on the surface. The load-bearing capacity of
the ground is usually diminished close to the edge of excavations, shafts, pits, and slopes. The
equipment must be so far removed that there is no risk of falling.
The respective equipment specification, the configuration of the process equipment, and the re-
spective operating mode (rigging mode, operation, travel mode) affect the stability in different ways.
Therefore, the specific instructions and measures for stability are precisely defined in the respec-
tive sections of the Instruction manual.
If, in spite of all precautionary measures, the equipment tips over, the cab protects the equipment
operator (if trapped in the cab use the emergency hammer).
The following general safety instructions for stability must always be observed and followed:
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Equipment tipping hazard!

If there is insufficient stability, the equipment can tilt and fall over. Persons in the vicinity of the
equipment can be seriously or fatally injured as a result.
Δ Always ensure the stability of the equipment. If there are any doubts with regard to stability,
stop work immediately. If possible, move the equipment to a safe area (e.g. if surface is in dan-
ger of caving in) and shut down immediately.
Δ The limit values for loads, angles, and operating radii, which are prescribed for the different op-
erating modes, are valid for working platforms with a sufficiently stable surface. Never exceed
these limit values.
Δ The values prescribed for loads, angles, and operating radii are not valid in combination or
when the process equipment is changed.
Δ The individual value tables in the section entitled "Stability" with the prescribed values for oper-
ating the equipment must be kept at the place of deployment and within easy reach of the
equipment operator at all times.
Δ The stability values are only valid for the equipment specification and the process equipment
configuration specified in each case. Every change to the equipment specification or the
process equipment configuration demands a new stability calculation.
Δ Only move the equipment on level ground with a sufficiently stable surface. Create a suitable
unobstructed area for the travel path.
Δ Never leave the track of the prepared travel path when driving.
Δ When driving on slopes or inclines never exceed the maximum permissible tilt angle.
Δ When travel movements or rotary/swinging motions are executed by the equipment, keep the
equipment's overall center of gravity as low as possible. Lower the process equipment, mov-
able loads, and tools as far as possible.
Δ Driving the equipment crosswise or diagonally to slopes/inclines is prohibited.
Δ Avoid driving over curbs (e.g. when negotiating ramps). If this is not possible, adapt your driv-
ing style accordingly.
Δ Do not attach any additional loads or components to the equipment which are not permitted or
not expressly described in the Instruction manual.
Δ Avoid swinging of loads.
Δ Ensure an even distribution of the weight of the equipment when traveling on the surface (indi-
cated, in the case of equipment with crawler tracks, by an even penetration of the ground by
the crawler tracks).
Risk of accident!
If an item of process equipment is mounted on a base machine which modifies the original shape,
configuration and function of the equipment, the operator assumes full responsibility for the entire
device. If the process equipment is not properly installed, the equipment can be damaged and fall
over. Persons in the vicinity of the equipment could be hit and suffer severe or fatal injuries.
Δ Refer to and comply with all requirements of the Instruction manual for the corresponding
process equipment.
Δ Request valid stability for the additionally mounted process equipment from the manufacturer
of the base machine.
1.3.8 Operational safety

Risk of accident!
Missing or not-fully-functional safety and protective equipment can lead to improper operation of
the equipment and consequently to accidents. This could result in severe or fatal injury.
Δ All safety equipment and protective equipment (e.g. automatic brakes, warning devices, or
turn-off devices) should always be easily accessible and must be regularly checked in accor-
dance with the specifications in the Instruction manual for completeness, proper fastening and
location, as well as correct functionality.
Δ Only operate the equipment when all safety equipment and protective equipment are present
and fully functional. If any defects are detected, shut down the equipment immediately.
Δ Ensure defects are repaired by authorized, skilled personnel straight away.
Δ Any manipulation of the safety equipment and protective equipment is prohibited.
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Risk of accident!
If fault messages and/or warnings are not observed, it can result in unexpected, uncontrollable
movements. These movements could damage components or cause the equipment to tip over.
This could result in severe or fatal injury.
Δ Note the classification of fault messages and/or warnings and if necessary shut down the oper-
ation immediately.
Δ Have authorized specialists rectify the cause of fault messages and/or warning messages.
Risk of accident!
Defects, damages and/or faults affecting the equipment can lead to uncontrollable situations with
serious or fatal injuries to personnel.
Δ Before starting work or starting-up the equipment, check the equipment for external signs of
damage or defects. If there are any changes to the equipment, including its operational behav-
ior, either refrain from starting-up the equipment or shut it down immediately as the case may
be. The same applies if there are doubts as to the operational safety of the equipment, the
components, the process equipment, the tools or the auxiliary devices.
Δ Following an electric shock to the equipment, check that the equipment's electrical and elec-
tronic system is intact and in proper working order.
Δ Do not enter the equipment's danger zone during unclear operating situations or in the event of
any malfunctions.
Δ Have all defects and faults repaired without delay and exclusively by suitably authorized,
skilled personnel.
Δ Always secure the equipment against unintentional start-up.
Δ All operating and control elements in the cab or on the control stand must be fully functional.
Δ Pay attention to displays and fault messages during operation.
Δ Carrying out repairs or maintenance work during operation is prohibited.
Danger of getting crushed, danger of getting pulled in, danger of getting caught!
If the equipment is shut down under extraordinary circumstances (for example, a power failure,
malfunction or EMERGENCY STOP), it may conduct uncontrolled movements when it is started up
again. Anyone in the vicinity of the equipment could be hit and suffer severe or fatal injuries.
Δ No persons are allowed in the danger zone of the equipment when it is returned to operation.
Δ Determine the cause of the extraordinary shut-down and correct it accordingly before the
equipment is put into operation again.
Risk of accident!
Persons in the vicinity of the equipment could be hit by falling loads (e.g. in case of rope breakage)
and suffer severe or fatal injuries.

The equipment can tilt and fall over during storms with high wind speeds. Persons in the vicinity of
the equipment can be seriously or fatally injured as a result.
Δ Monitor the local weather, especially the wind conditions (dynamic pressure), in a suitable way
(anemometer, wind direction gage, weather service).
Δ Observe the maximum permissible wind speed for correct operation of the equipment.
Δ If the maximum permissible values are exceeded, shut down the equipment immediately and
secure it according to the specifications in the Instruction manual.
Δ Persons in the vicinity of the equipment must leave the danger zone immediately.
Risk of accident!
Lightning strikes can result in serious injury or death.
Δ If there is an imminent risk of a lightning strike, do not leave the cab, as it provides protection
against current transfer according to the Faraday cage principle.
Δ Following an electric shock to the equipment, check to ensure the equipment's electrical and
electronic system is intact and in proper working order.
BG 28 H # 5336 / V01_en_04.2021 47 - 390

1 Safety
Danger of accident, danger of equipment tipping over!

The equipment can tip over if it is driven in conditions which are not permitted. This could result in
severe or fatal injury.
Δ When driving the equipment, always make sure the composition of the ground is adequate to
ensure stability.
Δ Avoid driving in reverse over long distances.
Δ Before driving into an underpass or tunnel, always check the clearance dimensions of the
structural elements.
Δ Before driving onto an overpass, always check the clearance dimensions of the structural ele-
ments and their load bearing capacity.
Δ Do not execute any additional movements, such as rotating or pivoting movements, while driv-
ing.
Δ It is forbidden to drive the equipment without a banksman.
Danger of falling!
When driving or walking on slippery, uneven, or non-horizontal ground, there is a danger of slipping
which can lead to serious or fatal injuries to persons.
Δ Before driving, clean away snow, ice, and mud from the ground on which you have to drive
(e.g. ramps) and from the crawler tracks or wheels.
Δ To ascend or enter the equipment, only use the designated steps and platforms. It is forbidden
to climb on open maintenance flaps, for example.
Δ Steps, platforms, and traffic routes must always be safe to walk on (i.e. no snow, ice, dirt, oil).
Δ All necessary hand rails and hand grips must be completely mounted.
Risk of falling!
Incomplete and/or overloaded steps/platforms/handrails can cause people to fall and thereby suffer
serious or fatal injuries.
Δ Before using steps/platforms/handrails, check that they are complete and in proper working or-
der.
Δ Observe the maximum load of the steps/platforms/handrails being used.
Tipping hazard, danger of accident!

If the equipment is started up unintentionally or without authorization, the equipment can tip over or
its components can execute unexpected, uncontrolled movements. This could result in severe or
fatal injury.
Δ During interruptions to work and when work is finished, always secure the equipment against
unintentional/unauthorized start-up.
Δ Always follow the instructions for shutting down the equipment.
Risk of accident!
A lack of concentration while the equipment is in operation can lead to uncontrollable situations,
causing serious or fatal accidents.
Δ Before using mobile phones or radiotelephones, shut the equipment down and secure against
unintentional start-up.
Δ Only activate operating elements from the operating station.
Δ Only actuate control levers by hand and only press pedals with your feet.
Danger of accident, risk of falling!

Poor visibility during operation of the equipment can lead to serious accidents or collisions with ob-
jects. There is also a danger of stumbling over objects and/or falling from the equipment. This could
result in severe or fatal injury.
Δ The equipment operator must always ensure there is adequate and optimum lighting in the
danger zone and operating area.
Δ Check the lighting on and around the equipment to ensure it is functioning properly on a regu-
lar basis.
Δ If there is strong sunlight, use a suitable glare shield (e.g. special sun blind).
Δ Mirrors, cameras, screens and protective glazing must be kept clean at all times. The same ap-
plies to all operating and control elements.
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Risk of injury!
Incomplete or faulty protective glazing and safety guards on the cab or control station can lead to
serious or fatal injuries to persons in the case of falling objects or tipping of the equipment.
Δ Regularly check protective glazing and safety guards for completeness, damage (such as
cracks, breaks, or holes), and secure fastening.
Δ Always close the cab door during operation.
Risk of poisoning!
If the equipment is operated in excavation pits, depressions or densely covered areas, there is a
risk of exhaust gases accumulating. Personnel could suffer serious injuries or suffocate as a result.
Δ Ensure adequate ventilation of workplaces.
Δ Use suitable measuring instruments to detect a potential risk of poisoning at an early stage.
Risk of explosion!
Explosive gases can be generated and fuel can leak when refueling the equipment. Should these
gases or the fuel ignite, persons could be burned.
Δ Switch off the drive motor before fueling.
Δ Smoking and handling naked flames are prohibited while fueling and in the vicinity of the bat-
teries. Avoid spark formation.
Risk of chemical burns!

If the electrical equipment is not ready for operation after the ignition is switched on, the batteries
may be completely discharged. Completely discharged batteries can explode when jump starting.
Contact with the battery acid can cause chemical burns on body parts.
Δ Do not jump start equipment with a completely discharged battery.
Δ Have the electric equipment inspected by a qualified person.
Δ Wear appropriate personal protective equipment.
Δ Charge completely discharged batteries slowly and, if necessary, replace them with new ones.

If batteries are in operation, a highly flammable gas mixture can occur. Sparks. electrostatic dis-
charge or fire can ignite the gas mixture and the batteries can explode. This can result in persons
being seriously injured by burning or chemical burns.
Δ Do not use open flames or smoke in the immediate vicinity of batteries.
Δ Ensure that the correct polarity is used when connecting the jumper cable.
Δ The jumper cable for the minus connection (ground) should not be connected to the discharged
battery.
Danger of slipping!
Incorrect cleaning can result in personnel slipping and falling.
Δ Before starting-up the equipment, remove the protective wax from the entire equipment and its
accessories.
Δ Wear suitable personal protective equipment while cleaning.
Safety when working in areas at risk of falling

Risk of falling!
When creating pits, trenches, drill holes, or cut trenches, areas at risk of falling are created. Per-
sonnel may fall and suffer severe or fatal injuries as a result.
Δ In accordance with country-specific specifications, block or cover pits, trenches, drill holes or
cut trenches or put up protective nets around them.
Δ When working on pits, trenches, drill holes or cut trenches, wear personal protective equipment
against falls and secure it.
BG 28 H # 5336 / V01_en_04.2021 49 - 390

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Safety when working near over-ground or underground media supplies

The equipment may only be operated within the specifications and environmental conditions pre-
scribed in the Instruction manual. Exercise extreme caution when working near electricity lines.
The following general safety information for working near over-ground or underground media sup-
plies must be observed and adhered to:
Risk of electric shock!

If the equipment comes into contact with overhead or underground electricity lines, current will be
transferred to the equipment. Persons in the immediate vicinity will receive an electric shock as well
as burns, which can cause severe or fatal injuries.
Δ Before starting work, ask an authorized person about the prescribed safety distance. Always
observe the required safety distance. This also includes the avoidance of swinging loads and/
or components in the danger zone.
Δ Before starting work, inform the company responsible for the power supply.
Δ Consult the power supply company regarding the measures to be taken in the event of an
emergency.
Δ If a current transfer does occur, do not leave the cab. The equipment operator must instruct the
endangered persons accordingly (e.g. keep legs closed and remain still).
Δ The danger has passed only when the power supplier gives the all-clear.
Risk of electric shock, risk of explosion!

Underground lines (e.g. electricity, gas) may be inadvertently damaged during work. Current trans-
fers, explosions, and/or fire may occur and cause an electric shock and/or burns to persons in the
immediate vicinity.
Δ If underground lines are discovered in the working area, stop work immediately and report the
incident to the operator.
Δ In the case of equipment that causes tremors/vibrations, make additional allowance for this po-
tential source of risk and take separate precautionary measures in advance.
Δ Support or fix exposed lines to prevent them from shifting.
Δ Maintain an adequate safety distance to the source of the hazard.
Δ Do not drive over exposed lines.
Risk of accident!
In the case of equipment with ropes, there is a danger of rope breakage following a current trans-
fer. Persons may be hit by falling loads and suffer severe or fatal injuries.
Δ After a current transfer, the ropes must be replaced immediately.
Safety when working underground or in enclosed spaces

The equipment may only be operated within the specifications and environmental conditions pre-
scribed in the Instruction manual. Work carried out underground or in enclosed spaces demands
special protective measures.
The following general safety information about working underground or in enclosed spaces must al-
ways be observed and adhered to:
Risk of explosion, risk of suffocation!

When working underground or in enclosed spaces, explosive or poisonous gases can be gener-
ated. Persons could suffer serious or fatal injuries or suffocation.
Δ Workplaces and traffic routes must be adequately ventilated, so that no dangerous substances
or exhaust gases can reach the breathable air or the atmosphere.
Δ Always ensure that ventilation systems are in proper working order.
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1.3.9 Safety during assembly/mounting and dismantling/removing

Before starting the assembly or disassembly procedure, the equipment's danger zone/working area
must be made safe by closing off a sufficiently ample area. Work attachments, components and
tools that have been set down must not obstruct traffic routes and they must be secured by appro-
priate measures against shifting, rolling away and toppling over/falling.
Assembly work and disassembly work should always be performed on horizontal, level ground with
sufficient load-bearing capacity.
All necessary operating processes and functional relationships must have been mastered before
taking the first assembly or disassembly steps.
The following general safety information for assembly and disassembly must always be observed
and adhered to:

If the mounting sequence/removal sequence is not complied with, the equipment can tilt and fall
over. Persons in the vicinity of the equipment can be seriously or fatally injured as a result.
Δ Observe the mounting/removal sequence specified in the Instruction manual and the associ-
ated supplement.
Risk of accident!
Components may fall down or fall over as a result of the unexpected loosening or loss of form-fit,
force-fit and adhesively joined connections. Personnel could be hit as a result and suffer severe or
fatal injuries.
Δ When mounting components on the equipment, only secure them in place using the appropri-
ate connection elements.
Δ Only raise components which are being mounted or removed as far from the ground as abso-
lutely necessary.
Δ When mounting components on the equipment, check that all screw connections, plug connec-
tions, retaining elements and welding seams are in proper working order, as specified by the
Instruction manual, and replace with new ones if necessary.
Risk of accident!
The use of unsuitable lifting gear (e.g. lifting device, auxiliary crane) can lead to the lifting gear top-
pling over or to loads falling. Persons in the vicinity of the equipment could be hit and suffer severe
or fatal injuries.
Δ Only use suitable lifting gear with adequate load-bearing capacity.
Δ If there is an auxiliary winch attached to the equipment, it may only be used for assembly or
disassembly work if this is permitted by the Instruction manual.
Risk of falling!
If personnel are not properly secured when performing assembly or disassembly work on elevated
components, they could fall and suffer severe or fatal injuries.
Δ When working on elevated components, personnel must wear the fall protection equipment
specified in the Instruction manual and/or be secured accordingly.
Δ Before changing position, secure the safety harness twice. Only then can the suspension de-
vice be released and fixed again after the position change.
Δ When mounting the fall protection rails for the fall protection equipment, the transitions of the
rails must be aligned perfectly with one another.
Δ Only use transport cages that are suitable for transporting personnel.
Δ Use suitable aerial work platforms for working on elevated components.
Δ Do not use work platforms attached to the machine or process equipment as a hoist for per-
sonnel. When working on these platforms, first remove the key for the "Free-fall/freewheel"
function (if such a function is present) from the cab. The key is to remain with the fitter who is
working on the work platform.
Δ Never exceed the maximum permissible load for work platforms and aerial work platforms.
Δ When performing assembly or disassembly work, always position the equipment at an ade-
quate distance from ground holes, pits or shafts.
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1 Safety
Risk of falling!
der.
Δ Observe the maximum load of the steps/platforms/handrails being used.
Risk of injury!
Unsecured or loose objects left on or beside the equipment can fall or be flung outwards during op-
eration. Persons in the vicinity of the equipment could be hit and suffer severe or fatal injuries.
Δ During assembly or disassembly, any tools, devices, or work equipment which are left down
must be secured against falling, rolling, catapulting or toppling over.
Δ When assembly or disassembly is finished, all the tools, devices, and work equipment which
have been used must be removed from the equipment.
Danger of getting crushed, shearing hazard and impact hazard!

Crushing and cutting edges are produced when plug connections and screw connections are loos-
ened from components. Anyone that gets between these edges can be seriously or fatally injured.
Δ To prevent the sinking and/or toppling of components when they are being assembled or dis-
mantled, use the lifting gear to apply sufficient tensile stress to the lifting device attached to
these components.
Δ Always perform assembly/disassembly work outside the danger zone and with the support of
suitable personnel to assist in the work.
Risk of injury, risk of cutting!

Suddenly escaping media (e.g. operating fluids and consumables) can cut parts of the body.
Δ Depressurize media-carrying components that are under pressure before installation/removal.
Δ Depressurize media-carrying components that are under pressure before maintenance/repair.
Risk of accident!
If the hydraulic "leak oil/return" line is not mounted in the correct order, components of the hydraulic
system/hydraulic lines could be damaged and burst. Persons could be struck as a result and suffer
severe or fatal injuries.
Δ Mount the hydraulic "leak oil/return" line first when the hydraulic connections on the equipment/
rig have been established.
Δ Remove the hydraulic "leak oil/return" line last when the hydraulic connections on the equip-
ment/system have been disconnected.
Risk of accident!
If the hydraulic supply to detachable hydraulic cylinders has not been fully established, components
of the hydraulic system/hydraulic lines could be damaged and burst. Persons could be struck as a
result and suffer severe or fatal injuries.
Δ Ensure the hydraulic supply to detachable hydraulic cylinders is fully established.
Δ Check to ensure the hydraulic supply is complete prior to start-up.
Risk of injury!
If the hydraulic connections are not mounted properly, it can result in components of the hydraulic
system falling off. Personnel could be struck by these components and seriously or fatally injured
from escaping media.
Δ Before starting-up the equipment/system check to ensure the hydraulic connections are secure
and in proper working order.
Δ Ensure detachable hydraulic cylinders are fully connected.
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1 Safety
Danger of getting crushed, shearing hazard and impact hazard!

Components under bending stress can loosen unexpectedly when plug connections and screw
connections are loosened. Personnel could be hit as a result and suffer severe or fatal injuries.
Δ To prevent the sinking and/or toppling of components when they are being assembled or dis-
mantled, use the lifting gear to apply sufficient tensile stress to the lifting device attached to
these components.
Δ Always perform assembly/disassembly work outside the danger zone and with the support of
suitable personnel to assist in the work.
Risk of burning!
Contact with hot surfaces can cause the burning of body parts.
Δ Ensure that hot equipment components such as exhaust pipes, engines, transmission units,
hoses, lines (especially coolant lines) and pumps have cooled down before starting assembly/
disassembly and cleaning work.
Risk of injury!
Escaping compressed air or pressurized fluids (e.g. from high pressure cleaners) can cause injury
to body parts.
Δ When using compressed air, wear suitable personal protective equipment.
Δ When using a high pressure cleaner, wear suitable personal protective equipment. Observe the
specifications from the manufacturer of the high pressure cleaner.
1.3.10 Safety when handling suspended loads and during transport

Certain equipment or components may only be lifted using special lifting devices (e.g. cross-
beams). These special lifting devices, when required, are prescribed in the Instruction manual and
are generally included in the scope of delivery.
The commissioned haulage contractor is responsible for transporting the equipment and its acces-
sories.
The following general safety information for transport and for handling suspended loads must al-
BG 28 H # 5336 / V01_en_04.2021 53 - 390

1 Safety
Risk of accident!
Unsuitable lifting gear or improper loading/unloading procedures can result in the lifting gear, equip-
ment or the transport vehicle tipping over, or to loads falling. Persons in the vicinity of the equip-
ment could be hit and suffer severe or fatal injuries.
Δ Never conduct the entire lifting process or transport process without a person present to give
directions.
Δ All lifting devices used must be of a suitable and adequate size. Never exceed the permissible
load-bearing capacity of the lifting device.
Δ Only use approved and undamaged lifting devices.
Δ Only use lifting devices designated for the intended purpose. Observe the specifications of the
manufacturer of the lifting device.
Δ Only use the designated lifting points to attach the lifting device.
Δ Lifting points on the equipment are colored accordingly and labeled with the respective maxi-
mum permissible load.
Δ Only detach the lifting device from the component after securing the attached component or, al-
ternatively, before releasing the component, first attach the lifting device fully to the component.
Δ Always observe the specifications in the Instruction manual for lifting and rigging the equipment
and its components.
Δ If there is a load attached, take note of the altered weight distribution and the changed position
of the center of gravity.
Δ Attach loads in such a way that they cannot slide, tilt or fall down.
Δ Only lift loads vertically and only as high as necessary. Avoid swinging of the load.
Δ Only keep loads hanging freely for as long as necessary.
Δ Never pull loads diagonally.
Δ Always move loads carefully and never abruptly or too quickly.
Δ Transporting personnel with loads is prohibited.
Δ Always observe the transport instructions specified in the Instruction manual.
Δ When tying down, only use the designated tying points.
Δ Never use tying points or other fastening points as lifting points.
Δ Before transporting components they must be suitably secured against unintentional move-
ments.
Δ Only use suitable lifting devices for transport.
1.3.11 Safety during maintenance and environmental protection/disposal

For maintenance work, the equipment's danger zone must be made safe by closing off a suffi-
ciently ample area. Work attachments, components and tools that have been set down must not
obstruct traffic routes and they must be secured by appropriate measures against shifting, rolling
away and toppling over/falling.
Maintenance work should always be performed on horizontal and level ground with sufficient load-
bearing capacity.
Risk of accident!
Any missing safety and protective equipment, or equipment that is not fully functional, can result in
serious or fatal injuries to personnel during operation, such as crushing, burns, cuts and impact in-
juries.
Δ Only remove safety and protective equipment when the equipment is at a standstill and se-
cured against unauthorized start-up.
Δ Individual safety and protective equipment may only be removed for specific maintenance
tasks, rigging tasks, and repair tasks and only immediately before such tasks. Fully mount the
relevant safety and protective equipment immediately after every maintenance, rigging or re-
pair task.
Δ Whenever a piece of safety or protective equipment is mounted, check to ensure it is working
properly.
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1 Safety
Tipping hazard, danger of accident!

If the equipment is started up unintentionally or without authorization, the equipment can tip over or
its components can execute unexpected, uncontrolled movements. This could result in severe or
fatal injury.
Δ During interruptions to work and when work is finished, always secure the equipment against
unintentional/unauthorized start-up.
Δ Always follow the instructions for shutting down the equipment.
Risk of falling!
If personnel are not properly secured when performing maintenance work on elevated components,
they could fall and suffer severe or fatal injuries.
Δ When working on elevated components, personnel must wear the fall protection equipment
specified in the Instruction manual and/or be secured accordingly.
Δ Only use suitable aerial work platforms for transporting personnel.
Δ Work platforms fastened to the equipment or its fittings must not be used as personnel trans-
port baskets. When working on these platforms, first remove the key for the "Free-fall/free-
wheel" function (if such a function is present) from the cab. The key is to remain with the per-
son who is working on the work platform.
Δ Never exceed the maximum permissible load for work platforms, personnel transport baskets
or aerial work platforms.
Δ When performing maintenance work, always position the equipment at an adequate distance
from holes in the ground, pits or shafts.
Risk of injury!
Unsecured or loose objects left on or beside the equipment can fall or be flung outwards during op-
eration. Persons in the vicinity of the equipment could be hit and suffer severe or fatal injuries.
Δ During maintenance work, any tools, devices or work equipment that have been set down must
be secured against falling, rolling, being flung or toppling over.
Δ Remove all tools, devices and work equipment once the maintenance procedure is complete.
Risk of accident!
If maintenance work is not carried out properly and/or on schedule, it can lead to severe or fatal
personal injury during operation of the equipment.
Δ Always implement the maintenance tasks and adhere to the intervals prescribed in the Instruc-
tion manual.
Δ Before starting maintenance work, the components in question must be suitably cleaned.
Δ Clean reused components before installation and check their proper function. Only mount fully
functional components. Replace faulty or worn parts with new ones.
Risk of falling!
der.
Δ Do not exceed the maximum permissible load of the steps/platforms/railings being used.
Risk of accident!
Components may fall down or fall over as a result of the unexpected loosening or loss of form-fit,
force-fit and adhesively joined connections. Personnel could be hit as a result and suffer severe or
fatal injuries.
Δ Regularly check all screw connections, plug connections, retaining elements and welding
seams for signs of wear such as rust, cracks and deformation. Refer to the Instruction manual
for further information.
Δ Replace worn parts immediately.
Δ If the equipment has tipped over or a component has been subjected to an excessive load (e.g.
due to an operating error), replace the relevant connections of the component or replace the
entire component.
Δ Some connections are subject to regular replacement intervals. Always replace these in accor-
dance with the specifications in the Instruction manual.
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1 Safety
Shearing hazard, danger of getting crushed, risk of getting pulled in!

Rotating drive components can cause crushing, entanglement or shearing of body parts. This could
Δ All work, especially work in the interior of the equipment, should only be performed with the
diesel engine/electric motor switched off.
Risk of hearing damage!

Hearing damage can occur when the drive engine is running.
Δ Always keep the cabin door closed during operation.
Δ Persons in the immediate vicinity of the equipment must wear hearing protection.
Danger of getting crushed, shearing hazard!

Crushing and shearing of body parts can occur when opening or closing maintenance flaps on the
equipment.
Δ Only open maintenance flaps using the appropriate handles. Keep body parts outside the
swiveling range of the maintenance flaps.
Safety when handling pressurized components

Work on pressurized components (for example hydraulic and pneumatic equipment) may only be
performed by personnel with special skills and experience (for example in hydraulic and pneumatic
systems).
The following general safety information for handling pressurized components must always be ob-
served and adhered to:
Risk of injury!
When working on hydraulic and pneumatic components pressurized media can escape. This can
result in persons being seriously injured by burning, scalding or cutting.
Δ Regularly check all hydraulic and pneumatic components for tightness and exterior signs of
damage, such as leaks. Ensure that any damage and defects are repaired without delay.
Δ Before starting any repair work or assembly/disassembly work, discharge the pressure from the
hydraulic or pneumatic system.
Δ When handling pressure containers in particular, always observe the country-specific or local
laws, regulations, guidelines and standards.
Δ Only have the pressure containers inspected by trained persons and serviced by suitably au-
thorized personnel.
Δ Do not touch leaking media. Maintain a safe distance. Oil, for example, can reach tempera-
tures of up to 85°C (185°F).
Δ The method of storing hoses as well as the period of storage and period of use for hoses de-
pends on the operator's requirements. Refer to the Instruction manual for further information.
Δ Changes to the operating pressure of hydraulic or pneumatic systems can only be made with
the permission of the manufacturer.
Δ Only use hydraulic and pneumatic components which are approved or prescribed by the manu-
facturer. Observe the relevant replacement intervals.
Risk of injury, risk of cutting!

Suddenly escaping media (e.g. operating fluids and consumables) can cut parts of the body.
Δ Depressurize media-carrying components that are under pressure before installation/removal.
Δ Depressurize media-carrying components that are under pressure before maintenance/repair.
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1 Safety
Risk of injury!
Risk of accident!
Risk of accident!
Risk of poisoning!
Fine jets of hydraulic oil can escape under pressure due to wear, damage, aging, improper assem-
bly or improper checking of the hydraulic lines. Persons could be hit and hydraulic oil can penetrate
the skin (high pressure injection). This could result in severe or fatal injury.
Δ If such injuries occur, take appropriate countermeasures and seek medical advice without de-
lay.
Safety for welding, flame cutting and grinding operations

Welding, flame cutting and grinding operations may only be carried out by suitably authorized per-
sonnel who have received safety training.
The following general safety information for welding, flame cutting and grinding operations must al-
Risk of accident!
Statically loaded parts which are thermally processed loose their stability and can crack, break or
bend. This could result in severe or fatal injury.
Δ All statically loaded parts must be thermally processed only by the manufacturer or by suitably
authorized workshops.
Risk of explosion, risk of fire!

Welding, torch cutting, and grinding tasks on the equipment can cause fire or explosions. This
could result in severe or fatal injury.
Δ Before starting work, clean flammable or explosive substances from tools and the surrounding
area.
Δ Only perform such tasks in a suitable environment with adequate ventilation.
Δ Protect or shield all heat-sensitive components, such as hydraulic hoses, from the area being
thermally processed.
Δ Protect persons and the work environment from flying sparks.
Δ Before performing welding work on the equipment, protect sensitive electronic parts from cur-
rent transfers from the welding tool. Always attach the earth terminal of the welding tool as
close as possible to the weld point.
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1 Safety
Safety when dealing with electrical energy

All work on electrical systems or devices may only be performed by a qualified electrician pursuant
to the applicable rules of electrical engineering.
Electricians are persons who can assess the work assigned to them and recognize potential risks
based on their technical training or several years of work experience, skills and experience, and
knowledge of the applicable standards.
Work on electrical systems or devices may also be performed by electrically trained persons under
the direction and supervision of an electrician.
Electrically trained personnel are those who have been instructed and, if necessary, taught by an
electrician regarding the work they are assigned and the potential risks associated with inappropri-
ate behavior, and who have been instructed about the necessary protective equipment, personal
protective equipment, and safety measures.
The operator is responsible for selecting the relevant personnel. In the context of a risk assess-
ment, he must decide whether the person he assigns to the task fulfills the above mentioned re-
quirements.
The following general safety information for handling electrical energy must always be observed
and adhered to:

Inappropriate work with or on the equipment's electrical systems (particularly high-voltage compo-
nents) can lead to a current transfer and/or fire. Persons in the immediate vicinity can be seriously
or fatally injured by an electric shock and/or burns.
Δ Personnel must maintain an adequate safety distance from live components (particularly high-
voltage components).
Δ Before starting work on the equipment's electrical systems, particularly before working on any
high-voltage components that may be present, disconnect them from the voltage supply. Check
to ensure the voltage-free state of the equipment and ensure it is maintained for the required
duration by using appropriate measures.
Δ Due to electromagnetic fields, persons with cardiac pacemakers must not remain within the im-
mediate vicinity of high-voltage components.
Δ Do not introduce any sensitive electronic equipment into the immediate vicinity of high-voltage
components.
Δ Poisonous vapors or gases can be produced by voltage-conducting components. Ensure ade-
quate ventilation.
Δ Keep a fire extinguisher at hand in case an electrical fire occurs, for example due to spark for-
mation, short-circuit, over-voltage etc.
Δ Before starting up the equipment, ensure that all electrical connections and safety equipment
are properly installed, connected, and earthed.
Δ Only use insulated tools for the relevant tasks.
Δ Any identified defects, such as scorched, damaged, or loose cables and plugs must be re-
paired without delay.
Δ In case of malfunctions shut the equipment down immediately.
Δ Secure all of the equipment's electrical and electronic components against unauthorized ac-
cess. Access to these components is only permitted to authorized technicians.
Δ Do not repair or bypass fuses. Replacement fuses must be of the identical type and rating.
Safety when handling auxiliary materials and operating fluids

Only auxiliary materials and operating fluids which are approved by the manufacturer may be used.
The applicable safety regulations must be observed with regard to the precautionary measures ne-
cessitated by the use of auxiliary materials and operating fluids.
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1 Safety
The following general safety information for handling auxiliary materials and operating fluids must
always be observed and adhered to:
Risk of explosion, risk of fire, risk of suffocation!

Explosive and poisonous gases can be produced when handling auxiliary materials and operating
fluids. Persons could suffer serious or fatal injuries or suffocation.
Δ Ensure adequate ventilation of workplaces.
Δ Ensure that the extraction system is properly functioning at all times so that no dangerous sub-
stances can reach the breathable air or the atmosphere.
Δ Always ensure that ventilation systems are in proper working order.
Δ Dangerous auxiliary materials and operating fluids may only be present in a definite, limited
supply quantity.
Δ No fire, naked flame, and/or sparks are permitted in the immediate vicinity of auxiliary materials
and operating fluids.
Δ If the auxiliary materials or operating fluids come into contact with the skin or eyes, take appro-
priate countermeasures and seek medical advice without delay.
Risk of burning, risk of scalding!

Direct contact with hot auxiliary materials or operating fluids can lead to burning or scalding of body
parts.
Δ When handling auxiliary materials and operating fluids always wear the appropriate personal
protective equipment.
Risk of chemical burns, risk of poisoning, risk of eye damage, risk of skin damage!
Pressure containers, collection containers for fluids, and/or built-in parts (e.g. filters, batteries) can
contain dangerous residues, including acids, oils, oil-containing waste, chemical substances, and/
or gases.
Δ Avoid direct contact with such substances.
Δ Only transport and store such substances in suitable containers.
Δ Seal and label the containers appropriately.
Safety in case of contamination risk

When working in contaminated areas, the operator must first take the appropriate preventive and
precautionary measures.
The following general safety information for working in contaminated areas must always be ob-
served and adhered to:
Risk of injury!
When working in contaminated areas or on contaminated equipment components, serious or fatal
injuries can occur. Persons can be poisoned, infected or contaminated.
Δ Only perform work in contaminated areas if absolutely necessary.
Δ Shield the workplace from the contaminated environment.
Δ Before starting assembly and disassembly work or maintenance and repair work, find out to
what extent, and with what harmful substances, the equipment or components have been con-
taminated.
BG 28 H # 5336 / V01_en_04.2021 59 - 390

1 Safety
1.3.12 Specific safety information for large rotary drilling rigs

This section contains the equipment-specific safety information for large rotary drilling rigs, gath-
ered from individual sections of this instruction manual, and presented as a summary and SUP-
PLEMENT to the section "General Safety".

Crushing surfaces and cutting edges are produced, primarily during slewing and tilting of the tool,
raising and lowering of the crowd sledge, tilting the mast forwards and backwards, folding the mast-
head, retracting and extending the Mast prop, retracting and extending the clamping cylinder. Any-
one that gets caught between these edges can be seriously or fatally injured.
Δ Maintain an adequate safety distance.
Δ Do not insert any body parts between moving components.

Crushing surfaces and cutting edges are produced primarily when slewing and tilting the tool, rais-
ing and lowering the crowd sledge, raising or lowering the mast and folding the masthead. Anyone
that gets caught between these edges can be seriously or fatally injured.
Risk of accident!
Working without a rope swivel can lead to twisting of the stressed rope. A twisted rope can break
and/or cause spinning movements during unloading. Personnel could be hit as a result and suffer
Δ Always mount a suitable rope swivel between the main rope and the fittings.
Risk of getting pulled in!

There is a danger, when drilling or retracting the drilling tool from the borehole, that persons may
become entangled or caught by the drilling tool and thereby seriously or fatally injured.
Risk of injury!
When the drilling tool is withdrawn from the bore hole, soil, mud and stones can be flung outwards.
Personnel could be hit as a result and suffer severe or fatal injuries.
Δ Always withdraw the drilling tool carefully from the bore hole.

If the auger is not free of drill spoil when extracting the drilling tool from the bore hole, the additional
weight of the drill spoil on the auger can also impair the stability. The equipment can tip and fall
Δ Remove drill spoil from the auger with a suitable tool when removing from the bore hole (for ex-
ample auger cleaner).
Tipping hazard!
When a mast prop is used, a high concentration of the load occurs, which can result in the surface
caving in. The equipment can then sink on one side into the soil, tilt, and fall over. Persons in the
vicinity of the equipment can be seriously or fatally injured as a result.
Δ When using a mast prop, it is necessary to take additional propping measures and/or weight
distribution measures of an appropriate kind.
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1 Safety
Risk of accident!
Changing the operating position while the equipment is performing work can cause the equipment
to tip over or components to fall down. Personnel could be hit as a result and suffer severe or fatal
injuries.
Δ Never move the equipment from the operating position when the equipment and work attach-
ments are operational.
Δ Before starting work, align the Mast to the required inclination and do not alter this during oper-
ation. If the position of the Mast is changed by the impacting forces (for example in case of soft
ground), minimal adjustments can be made with caution.

An incorrect operating position of the sledge end stoppers can cause the equipment to tip over dur-
ing operation. This could result in severe or fatal injury.
Δ The prescribed operating position of the sledge end stoppers (maximum permitted stroke) can
be found in the load capacity chart.
Inappropriate work on or with the Kelly bar can lead to crushing, shearing, and/or entanglement of
body parts!
Δ Please consult the additional documentation "Kelly bar" and "Work procedure".
Δ During assembly, do not insert any body parts between the KDK/drill drive and Kelly bar.

Working on or with the equipment with the telescoping cylinders of the crawlers retracted can lead
to the equipment tipping over. This could result in severe or fatal injury.
Δ Extend the telescoping cylinders of the crawlers immediately after unloading the equipment
and before any further assembly work.
Risk of accident!
If not properly mounted, counterweights can fall or tip over. This could result in serious or fatal in-
juries to anyone in the danger zone.
Δ While the counterweights are being mounted, persons are not permitted in the danger zone,
and neither are they permitted on or under the counterweights.
Δ Do not insert any body parts between the equipment and the counterweights.
Δ The counterweights must always be lifted and mounted on the equipment individually and in
the correct order.
Δ Check to ensure the tension chain of the counterweights is in proper working order as specified
in the instruction manual.
Inappropriate work on the undercarriage can lead to crushing, shearing, and/or entanglement of
body parts.
Δ Only perform work on the undercarriage with the equipment at a standstill.
Δ Leave the danger zone before extending or retracting the telescoping cylinders.
Risk of accident!
If not properly removed, counterweights can fall or tip over. This could result in serious or fatal in-
Δ While the counterweights are being removed, persons are not permitted in the danger zone,
Δ Always remove counterweights and lift them from the equipment individually and in the pre-
scribed order.

Retracting the telescoping cylinders of the crawlers can cause the equipment to tip over and thus
lead to serious or fatal injuries to persons.
Δ Only retract the telescoping cylinders of the crawlers immediately before loading the equipment
and following dismantling work.
BG 28 H # 5336 / V01_en_04.2021 61 - 390
1 Safety

Failure to observe the correct removal sequence can cause the equipment to tip over. This could
Δ Before removing the counterweights first remove the work equipment and then the upper mast
section. Only then remove the counterweights in the prescribed order.
Δ Before further dismantling work, first remove the counterweights and then the lower mast sec-
tion.

When the emergency control system is switched on, the equipment is in emergency mode. In this
mode, the safety and protective equipment (such as the limit switches, overload shutdowns, moni-
toring functions, fault indicators) are deactivated. As a result, precise control of several of the
equipment's functions is not possible. The restricted control system can cause the equipment to tip
over. This could result in severe or fatal injury.
Δ Only use the emergency control system to move the equipment out of the danger area in case
of an emergency, damage or malfunction.
Δ Operate the equipment with extreme caution in the emergency mode.
Risk of injury!
If the drilling tool is not mounted properly on the fitting, it can fall down or tip over during operation.
Personnel could be hit as a result and suffer severe or fatal injuries.
Δ Always mount the drilling tool using the designated connecting elements.
Δ During the rigging process, never raise the drilling tool higher than necessary.
Risk of accident!
Rope damage can lead to rope breakage and thus to serious or fatal injuries to persons!
Δ A main rope which has been reeved via a rope traverse and not connected with a rope swivel
is subsequently only permitted for operation with a rope traverse.
Δ No other use of the rope, for example for Kelly operation, is permitted anymore.

Non-observance of the correct mounting order can cause the equipment to tip over. This could re-
sult in severe or fatal injury.
Δ The counterweights must be completely mounted before mounting the work equipment and up-
per mast section.
Δ If process equipment is attached, do not alter the counterweights and/or remove them from the
equipment.
Risk of accident!
Improperly mounted mud hoses can loosen during operation and come off or swing around. Per-
sons in the vicinity of the equipment could be hit and suffer severe or fatal injuries.
Δ Do not use any sharp-edged lifting devices.
Δ Always attach mud hoses to at least 2 points when lifting.
Δ Check mud hoses for damage prior to installation.
Δ Do not use any sharp-edged tools or fastening elements for the assembly/removal procedure.
Δ Install mud hoses so they are free of twists.
Δ Ensure the hose clips are mounted correctly (no bends, screw connections firmly secured).
Δ Note the specified lengths of the individual mud hoses when mounting.
Risk of accident!
Opening the hydraulic tube guide can lead to the tube guide on the mast suddenly falling down and
persons suffering severe or fatal injuries.
Δ Secure the hydraulic tube guide on the crowd sledge with the auxiliary rope to ensure against it
falling down.
Δ In drilling mode move the hydraulic tube guide simultaneously with the drilling tool. Always
maintain tension on the auxiliary rope.
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Risk of entanglement, danger of getting crushed, hitting hazard!

If hydraulic hoses and/or mud hoses are moving, persons can be hit by these hoses or components
and thus seriously or fatally injured.
Risk of accident!
If there are more than five counterweights on the upper carriage, it is possible they may topple and
fall. Personnel could be hit as a result and suffer severe or fatal injuries.
Δ After adding the fifth counterweight, attach the corresponding locking element to the counter-
weights.
Risk of accident!
If the Kelly bar is not properly unlocked, components of the Kelly bar can move in an uncontrolled
manner. If the Kelly bar is accidentally dropped, it can damage the main rope and other compo-
nents of the equipment/process equipment. If the main rope or other components of the equipment/
process equipment are damaged, this can lead to uncontrollable situations with serious or fatal in-
juries to persons.
Δ Check that the main rope and components of the equipment/process equipment are intact and
not damaged if the Kelly bar has been accidentally dropped.
Risk of getting pulled in!

Rotational movement of the tool can lead to persons being caught, trapped and becoming seriously
or fatally injured in the process.
Risk of entanglement, danger of getting crushed, hitting hazard!

Particularly when pivoting and tilting the tool, crushing zones and shearing edges can occur. Any-
Δ Do not stand in the danger zone of the tool.

If the mast is inclined too far to the rear, stability can be compromised for certain equipment config-
urations. The equipment can tip and fall over. Persons in the vicinity of the equipment can be seri-
ously or fatally injured as a result.
Δ Observe the maximum permissible mast inclination according to the corresponding table.
Risk of accident!
A lack of concentration when using the remote control can cause unexpected, uncontrollable move-
ments of the equipment or its components. Persons in the vicinity of the equipment could be hit and
suffer severe or fatal injuries.
Δ Make sure the selection of the user interface (display on the screen) is correct.
Δ Operate the operating elements of the remote control with extreme caution.

If the auger cleaner is mounted on equipment that is not designed for it, components could be dam-
aged and the equipment could tip over. This could result in severe or fatal injury.
Δ Only operate the auger cleaner on equipment approved by the manufacturer.
Δ Request valid stability for the additionally mounted components from the manufacturer of the
equipment.

If the Bauer Torque Multiplier is mounted on equipment that is not designed for it, components
could be damaged and the equipment could tip over. This could result in severe or fatal injury.
Δ Only operate the Bauer Torque Multiplier on equipment approved by the manufacturer.
Δ Request valid stability for the additionally mounted components from the manufacturer of the
equipment.
BG 28 H # 5336 / V01_en_04.2021 63 - 390

1 Safety
Risk of poisoning, risk of injury,

If the rotary drive is turned counterclockwise during drilling, the connection between the connecting
rod can loosen and pressurized media in the connecting rod can escape. Persons may be hit by
this media and thus seriously or fatally injured.
Δ Do not turn the rotary drive counterclockwise during drilling.
Δ If the rotary drive was turned counterclockwise during drilling, adjust the operation immediately
and check all connections of the connecting rod are in proper working order.
Danger of accident, risk of injury!

If hose assemblies are not installed properly, they can be damaged and tear. Persons in the vicinity
of the equipment could be hit and suffer severe or fatal injuries.
Δ Do not use sharp-edged lifting devices when installing the hose assemblies.
Δ Do not mix up the hose assemblies. Observe the markings on the hose assemblies.
Δ Install hoses in such a way that the hoses cannot be crushed, twisted or severed when the de-
vice/process equipment is moved.
Δ Check hose assemblies for leaks and proper working order before installation and before each
start-up.
Risk of accident!
If communication between the equipment operator and auxiliary personnel is not ensured, uncon-
trollable situations may occur during operation of the equipment. This could result in severe or fatal
injury.
Δ Before equipment start-up, the equipment operator must ensure that a permanent voice con-
nection (e.g. with a radio) to the auxiliary personnel is available.
Δ Stop operation immediately if the voice connection (e.g. with a radio) between the equipment
operator and auxiliary personnel is no longer present or is disturbed.

Crushing zones and shearing edges can be created, particularly when moving components of the
base machine. Anyone that gets caught between these edges can be seriously or fatally injured.
Risk of eye injury!

It is possible for suspension fluid to squirt out during operation and cause eye injuries.
Risk of injury!
Rotary motion of the tool can lead to drilling debris being flung out. This could result in personal in-
jury.
Δ Do not stand in the danger zone of the tool.
Risk of burning!
If regeneration of the diesel engine is activated, hot exhaust gases escape from the exhaust sys-
tem. Persons can be burnt by the hot exhaust gases.
Δ Do not remain in the immediate vicinity of the exhaust system.
Risk of accident!
Drilling debris can be flung outwards during the "Shake off drilling debris" process. This could result
in personal injury.
Δ Do not remain in the immediate work area of the drilling tool.
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1.4 Labeling
1.4.1 Safety switch – Overview
The following table provides a complete overview of all the possible safety signs that could be at-
tached to the equipment. The respective equipment-specific labeling plan indicates which of these
safety signs are attached to the equipment and their location(s).
Table: "Safety signs - Complete overview"

Safety Meaning Safety Meaning
sign/num- sign/num-
ber ber
Prohibition sign: Combination sign consisting of:
Entering hazard area prohibited!
Prohibition sign:
103 Drilling prohibited!
101, 102 Prohibition sign:

Welding prohibited!
Prohibition sign: Prohibition sign:
Entering area prohibited! Do not spray with water!
104 105
No access for persons with pace- Photography prohibited!
makers!
106 107
Prohibition sign: Combination sign consisting of:
Do not extinguish with water!
Prohibition sign:
Do not extinguish with water!
109
108 Prohibition sign:
No access for persons with pace-
makers!
Prohibition sign:
Naked flames prohibited! Smoking prohibited!
Fire prohibited!
Open sources of ignition and
smoking prohibited!
110 111
Prohibition sign:
Do not touch!
112
BG 28 H # 5336 / V01_en_04.2021 65 - 390

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sign/num- sign/num-
ber ber
Warning sign: Warning sign:
Crushing hazard! Danger of getting crushed be-
tween upper carriage and under-
carriage!
201 202
Warning of hand injury! Entanglement hazard!
203 204
Risk of injury from fan blade! Risk of injury from escaping
medium!
205 206
Risk of injury due to electrical volt- Risk of injury due to hot surfaces!
age!
207 208
Risk of falling! Risk of falling when walking
across open swing doors!
209 210
Warning sign: Combination sign consisting of:
Warning of suspended load!
212 Warning sign:
Entanglement hazard!
211
Warning sign:
Warning of hand injury!
Warning sign:
Risk of injury from ejected
medium!
Risk of injury from moving compo- Risk of injury from laser beam!
nents!
213 214
Risk of injury from class 2 laser Risk of injury from exploding pres-
beam! sure line!
215
216
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sign/num- sign/num-
ber ber
Risk of injury from explosive at- Warning of a hazard area!
mosphere! Risk of injury from tensioned
springs!
217
218
Warning sign:
Warning about a radio-controlled
product!
226
Mandatory sign: Mandatory sign:
Observe storage location of the in- Wear head and ear protection!
struction manual!
301 302
Observe the instruction manual! Wear a high-visibility vest!
303 304
Use a safety harness! Wear ear protection!
305 306
Wear head protection! Wear eye protection!
307 308
Wear safety gloves! Wear safety shoes!
309 310
Use slinging gear! Reference to battery disconnec-
tion switch!
311 312
Emergency sign: Emergency sign:
First aid kit! Eye wash station!
401 402
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sign/num- sign/num-
ber ber
Stretcher! Emergency telephone!
403 404
Escape route to the left! Escape route to the right!
405 406
Escape route to the left and down! Escape route to the right and
down!
407 408
Emergency sign:
Emergency exit!
409
Fire safety sign:
Storage location of the fire extin-
guisher!
501
Informational sign: Informational sign:
Top up fuel! Use low-sulfur fuel (diesel)!
601
or
601
Combination sign consisting of: Informational sign:
Top up hydraulic oil!
602 Warning sign:
Warning of a hazard area!
Mandatory sign: 603

Check type of fuel in the tank! or
Mandatory sign:
Observe maintenance instruc-
tions!
Informational sign: Combination sign consisting of:
Use BAUER Winch Fluid 86 hy-
draulic oil! 604 Warning sign:
Warning of a hazard area!
Mandatory sign:
Check type of oil in the tank!
603
Mandatory sign:
tions!
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sign/num- sign/num-
ber ber
Combination sign consisting of: Combination sign consisting of:
605 Warning sign: Warning sign:

Warning of a hazard area! 606 Risk of injury from ejected
medium!
Mandatory sign:
Remove the key! Mandatory sign:
Mandatory sign: tions!
tions!
Equipment lifting point! Component lifting point!
607 608
Tying point! 24 V operating voltage!
610
609
Warning sign: Informational sign:
High voltage hazard! EMERGENCY STOP position!
Always maintain a minimum dis-
tance from power lines!
611
612
Main direction of travel! Sound power level!
613
614
Painted white (no adhesive la- Combination sign consisting of:
615 bels)! 616
Prohibition sign:
Warning sign:
Risk of falling!
Mandatory sign:
Wear head and ear protection!
Mandatory sign:
Observe storage location of the in-
struction manual!
Emergency sign:
First aid kit!
BG 28 H # 5336 / V01_en_04.2021 69 - 390

1 Safety

sign/num- sign/num-
ber ber
Specified weight of counter- Warning mark for movable obsta-
weights! 621 cles!
617, 618,
619, 620
622 Vehicle makes wide turns! Keep out of the danger zone!
623
Informational sign: Warning sign:
Traveling speed of the equipment! Danger from falling counter-
625 weights!
624
Informational sign: Hazardous goods label:
BAUER Technical Service! Hazard class 3!
626
627
Mounting sequence/removal se- Directional arrow upwards!
quence!
636
639
Informational sign:
Use of the lifting points on the
654 cross beam!
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1.4.2 Base machine signage plan

View, cab inside
BG 28 H # 5336 / V01_en_04.2021 71 - 390

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View, cab outside
72 - 390 BG 28 H # 5336 / V01_en_04.2021

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View, cab outside
View of upper carriage from left
BG 28 H # 5336 / V01_en_04.2021 73 - 390

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View of upper carriage from right
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1.5 Safety and protective equipment

1.5.1 EMERGENCY STOP
Danger of getting crushed, danger of getting pulled in, danger of getting caught!
If the equipment is shut down under extraordinary circumstances (for example, a power failure,
malfunction or EMERGENCY STOP), it may conduct uncontrolled movements when it is started up
again. Anyone in the vicinity of the equipment could be hit and suffer severe or fatal injuries.
Δ No persons are allowed in the danger zone of the equipment when it is returned to operation.
Δ Determine the cause of the extraordinary shut-down and correct it accordingly before the
equipment is put into operation again.
Risk of causing damage to components!

Components on the equipment could be damaged by heavy loads.
Δ Only use the Emergency STOP function in an emergency.
The following figure shows the number and position of the Emergency STOP buttons on the equip-
ment.
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1 Safety
Initial position:
– In case of emergency
• Press the relevant EMERGENCY-STOP.
✓ All of the equipment's functions are shut down.
✓ Diesel engine shuts down.
Unlock the relevant EMERGENCY-STOP switch before restarting the diesel engine:
• Pull the relevant EMERGENCY-STOP switch.
✓ EMERGENCY-STOP is unlocked.
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1 Safety
1.5.2 "Pilot Control" Safety Stick

The "pilot control" safety stick switches the equipment's hydraulic pilot control on or off.
Risk of accident!
Danger of accident due to uncontrolled movements of the equipment.
Δ Before leaving the cab, switch off the equipment's hydraulic pilot control.
Initial situation:
– Equipment operator is in the cab.
"Pilot Control" Safety Position Process

Stick
• Move the "pilot control" safety stick forwards.
✓ Hydraulic pilot control is switched on.
✓ All hydraulic functions are operational.

• Move the "pilot control" safety stick backwards.
✓ Hydraulic pilot control is switched off.
✓ All hydraulic functions are deactivated.
• Before starting work again, switch on the hydraulic pi-

lot control.
After switching on the hydraulic pilot control, no rope winch is preselected.
BG 28 H # 5336 / V01_en_04.2021 77 - 390

1 Safety
1.5.3 Fire extinguishers

The following figure shows the number and position of the fire extinguishers on the equipment.
• Read the operating instructions on the fire extinguisher at regular intervals to ensure it can be
operated correctly in the event of a fire.
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1 Safety
1.5.4 First aid box

The figure shows the position of the
first aid box.
1.5.5 Emergency Exit

The following figure shows the position of the emergency hammer on the equipment.
Risk of injury!
Risk of injury due to broken glass.
Δ Protect body parts from broken glass when using the emergency hammer.
Prerequisite:
– It is not possible to leave the

cab.
• Strike the edge of the widow with

the emergency hammer.
• Leave the cab.
The following figure shows the position of the emergency cord system on the equipment.
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1 Safety
Prerequisite:
– It is not possible to leave the

cab.
• Pull on the red emergency cord

in the cab.
• Pull the piping out of the rubber

frame on the front windshield.
• Remove the windshield.
• Leave the cab.
The emergency cord system is optionally located outside of the front windshield.
1.5.6 Safety guardrails – Overview

The following overview shows the positions and the functions of the safety guardrails on the equip-
ment.
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1 Safety
1.5.7 Base machine limit switch

The following overview shows the positions and the functions of the limit switches on the equip-
ment.
When the limit switch is activated, the mast can be moved again in the following manner.
Changing the mast inclination
• Incline the mast in the opposite direction.
✓ Limit switch is re-enabled.

Designa- Function Figure
tion
HS 1 Stops the main rope winding
onto the main winch before the
load collides with the mast-
head.
HS 2 Stops the auxiliary rope wind-
ing onto the auxiliary winch be-
fore the load collides with the
masthead.
ES 15 Monitors the permissible
crowd range; if the permissible
range is exceeded, an error
message is displayed on the
B-Tronic screen.
B 004 Absolute encoder: Limits mast
inclination to the rear.
B 40 Limits the permissible mast in-
clination to the left and right.
B 39 Absolute encoder: Monitors
the operating radius of the
mast. When the limit switch is
activated, the rotary drive and
crowd are switched off.
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1 Safety
1.5.8 Signaling devices – Overview

The following figures show the number and positions of the signaling devices on the equipment.
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1.5.9 Lighting devices – Overview

The following figures show the number and positions of the lighting equipment on the equipment.
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1 Safety
1.5.10 Camera equipment – Overview

The following figures show the number and positions of the cameras on the equipment.
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1 Safety
1.6 Stability
Risk of accident!
Improper use can cause an accident. This could result in severe or fatal injury.
Δ Before performing any tasks or processes in accordance with this chapter, please read and ob-
serve the following safety sections in the chapter "Safety when handling the product”:
– Danger zone and safety distance [➙ 42]
– Information on stability [➙ 45]
Refer to the additional documentation "Working platforms for tracked plant" for further informa-
tion on proper preparatory measures for the working platform, the ground and the surface.
1.6.1 Center of gravity factors

The following overviews show influencing factors that alter the position of the center of gravity and
thus the stability of the equipment. When the position of the center of gravity changes, particularly
through a combination of several factors, the operating behavior of the equipment changes accord-
ingly.
Formula symbols used

Formula sym- Meaning Unit
bol
α Mast inclination forwards/backwards [°]
β Mast inclination left/right [°]
δ Rotation angle of upper carriage [°]
ε Maximum permissible working platform inclination [°]
Maximum permissible load [kN]
Maximum occurring soil compression [kPa]
Minimum operating radius [mm]
Maximum operating radius [mm]
X Distance, center of gravity in direction X [m]
Z Distance, center of gravity in direction Z [m]
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1 Safety
Working platform inclination (ε) = Deviation of the working platform in degrees [°]
Working platform inclination ε
– During operation: Horizontal working platform only.
– When moving: Maximum permissible working platform inclination in accordance with the
section "Moving".
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1 Safety
Mast inclination (α, β) = deviation from the vertical in degrees [°]

Direction of inclination: +α = forwards, -α = back- Direction of inclination: +β = right, -β = left
wards
– During operation: Maximum permissible Mast inclination in accordance with the section
"Operating loads/Load criteria".
– When moving: Maximum permissible Mastinclination in accordance with the section "Mov-
ing".
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1 Safety
Rotation angle (δ) = position of upper carriage to undercarriage in degrees (°)

Direction of rotation: +δ = clockwise, - δ = counterclockwise
– Rotation angle within a prescribed, re- – Rotation angle without prescribed re-
stricted range. strictions.
– During operation: Maximum permissible rotation angle in accordance with the section "Op-
erating loads/Load criteria".
– When moving: Maximum permissible rotation angle in accordance with the section "Mov-
ing".
Variable loads on the equipment, such as various process fittings and/or tools, optional
components, etc.
Tensile and pressing forces of the rope winches and the crowd system
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1 Safety
Operating radius ( , ) = distance from center of slewing ring to center of tool in [mm]
– = minimum operating radius – = maximum operating radius
BG 28 H # 5336 / V01_en_04.2021 89 - 390

1 Safety
1.6.2 Additional specific guidelines for stability

Stability has been calculated for the equipment BG 28 H # 5336 calculated. It is valid only for the
equipment specification defined in the technical data and for the activity approved in the intended
use.
Prerequisite for operation:
– Firm, horizontal and even working platform.
– The subsoil has sufficient load-bearing capacity.
– Crawlers are fully extended and locked in place.
– Upper carriage at standstill with crowd and load on main rope.
– With a load hanging from the auxiliary rope, only slew the upper carriage slowly and care-
fully.
– A load is not permitted on the auxiliary rope if the mast is inclined backwards.
– Loads must not be combined.
– A specified load may be lower than the possible pulling force of the rope winch.
– The corresponding value for the stroke limitation of the crowd sledge is entered on the
B‑Tronic screen. The value can be found in section "Maximum permissible operating loads/
load cases".
The loads specified in the stability tables are valid for the most unfavorable position of the compo-
nents.
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1 Safety
1.6.3 Moving without process equipment

When moving the equipment, particularly when traveling on slopes/inclines, components of the
equipment can collide with the ground and be damaged as a result.
Δ Always observe and comply with the prescribed conditions and the associated figures for mov-
ing the equipment.
The rotary drive can remain mounted when moving without process equipment, provided that it is
not raised by more than one meter from the lowest position.
Moving with a raised mast
The following conditions apply to the correct movement of this equipment without process equip-
ment:
– The mast is aligned as vertical to the horizontal working platform as possible.
– The upper carriage is positioned parallel to the undercarriage.
– No abrupt movements.
– Travel very carefully over edges at the transitions of ramps.
Permissible working platform inclination
Maximum permissible working platform inclination (ε) [°] 15
BG 28 H # 5336 / V01_en_04.2021 91 - 390

1 Safety
Moving with a lowered mast
The following conditions apply to the correct movement of this equipment without process equip-
ment:
– The mast is in the transport position.
– The upper mast extension is swung out.
– The masthead is in the operating position.
Permissible working platform inclination
Maximum permissible working platform inclination (ε) [°] 15
Traveling up or down Slopes
• Raise the mast slightly.
or
• Swing in the upper mast extension.
92 - 390 BG 28 H # 5336 / V01_en_04.2021

1 Safety
1.6.4 Danger zones

The equipment's danger zones are defined as follows (dimensions in [mm]).
During operation
BG 28 H # 5336 / V01_en_04.2021 93 - 390

1 Safety
In the rigging mode (assembly/disassembly) and during maintenance/repair
94 - 390 BG 28 H # 5336 / V01_en_04.2021

1 Safety
In the rigging mode (assembly/disassembly) and during maintenance/repair
When moving
1.6.5 Permissible wind speeds

The equipment can tilt and fall over during storms with high wind speeds. Persons in the vicinity of
the equipment can be seriously or fatally injured as a result.
Δ Monitor the local weather, especially the wind conditions (dynamic pressure), in a suitable way
(anemometer, wind direction gage, weather service).
Δ Observe the maximum permissible wind speed for correct operation of the equipment.
Δ If the maximum permissible values are exceeded, shut down the equipment immediately and
secure it according to the specifications in the instruction manual.
Risk of accident!
Lightning strikes can result in serious injury or death.
Δ Do not leave the cab if there is an imminent risk of a lightning strike.
Δ Following an electric shock to the equipment, check that the equipment's electrical and elec-
tronic system is intact and in proper working order.
BG 28 H # 5336 / V01_en_04.2021 95 - 390

1 Safety
Table of wind forces

Beau- Descrip- Wind speed Effect of the wind
fort tion
km/h m/s mph kn
0 Calm <1 < 0.2 < 0.5 <1 Smoke rises vertically;
sea like a mirror
1 Light air 1-5 0.3 - 1.5 0.6 - 3.3 1-3 Smoke moves, but flags
are motionless; small
ripples on the water
2 Light 6 - 11 1.6 - 3.3 3.5 - 7.4 4-6 Wind palpable on face,
breeze leaves move; small
waves on the water
3 Gentle 12 - 19 3.4 - 5.4 7.6 - 12.0 7 - 10 Leaves and thin
breeze branches move; flag is
stretched out
4 Moderate 20 - 28 5.5 - 7.9 12.3 - 17.7 11 - 16 Dust and loose paper
breeze are swept up; branches
move; small, but longer
waves
5 Fresh 29 - 38 8.0 - 10.7 17.9 - 23.9 17 - 21 Small trees start to
breeze sway; white crests on
the water
6 Strong 39 - 49 10.8 - 13.8 24.2 - 30.9 22 - 27 Strong branches sway;
breeze cables whistle; umbrel-
las are difficult to hold;
rough sea, with some
spray
7 Near gale 50 - 61 13.9 - 17.1 31.1 - 38.3 28 - 33 Entire trees moving; dif-
ficult to walk against the
wind; sea heaps up and
water foams
8 Gale 62 - 74 17.2 - 20.7 38.5 - 46.3 34 - 40 Branches break; signifi-
cant difficulty with walk-
ing outdoors; moder-
ately high waves; spray
blows off
9 Strong 75 - 88 20.8 - 24.4 46.5 - 54.6 41 - 47 Some structural dam-
gale age (roof tiles are
thrown down); high
waves
10 Storm 89 - 102 24.5 - 28.4 54.8 - 63.5 48 - 55 Trees are uprooted; sig-
nificant structural dam-
age; very high waves
11 Violent 103 - 117 28.5 - 32.6 63.8 - 72.9 56 - 63 Strong gusts; severe
storm storm damage; roofs
are taken off; extremely
high waves
96 - 390 BG 28 H # 5336 / V01_en_04.2021

1 Safety
Beau- Descrip- Wind speed Effect of the wind

fort tion
km/h m/s mph kn
12 Hurricane > 118 > 32.7 > 73.2 > 64 Very severe storm dam-
age and devastation;
sea completely white;
air filled with foam and
spray
BG 28 H # 5336 / V01_en_04.2021 97 - 390

1 Safety
Maximum permissible wind speeds – unpredictable wind speeds

Unpredictable wind speeds are wind speeds that occur abruptly and without warning.

Unpredictable wind speeds that exceed the "permissible wind speed for operation" can cause the
equipment to tilt and fall over. Persons in the vicinity of the equipment can be seriously or fatally in-
jured as a result.
Δ All persons must leave the danger zone without delay.
Wind speeds
[km/h] 0 - 47 >47 - 72 > 72

[mph] 0 - 29.2 >29.2 - 44.7 > 44.7
[m/s] 0 - 13 >13 - 20 > 20
1 Permissible wind speeds for rigging mode:

The equipment may be rigged or derigged in the event of wind speeds within range (1).
2 Permissible wind speeds for operation:
The equipment may be operated in the event of wind speeds within range (2).
3 Wind speed from which the equipment may no longer be operated:
The equipment may no longer be operated in the event of wind speeds within range (3).
All persons must leave the danger zone without delay.
98 - 390 BG 28 H # 5336 / V01_en_04.2021

1 Safety
Maximum permissible wind speeds – predictable wind speeds

Wind speeds
[km/h] 0 - 47 >47 - 72 >72 - 118 > 118

[mph] 0 - 29.2 >29.2 - 44.7 >44.7 - 73.3 > 73.3
[m/s] 0 - 13 >13 - 20 >20 - 32.7 > 32.7
1 Permissible wind speeds for rigging mode:

The equipment may be rigged or derigged in the event of wind speeds within range (1).
2 Permissible wind speeds for operation:
The equipment may be operated in the event of wind speeds within range (2).
3 Wind speed from which the equipment may no longer be operated:
At wind speeds within range (3), the equipment may no longer be operated and at wind
speeds within range (2), the equipment must be shut down. Further information can be
found in the section "Brief interruptions or end of work".
4 Wind speed from which the equipment must be derigged:
At wind speeds within range (4), the equipment must already be derigged. Rigging work
may only be carried out at wind speeds within range (1). Further information can be
found in the section "Shutting down due to high wind speeds".
BG 28 H # 5336 / V01_en_04.2021 99 - 390

1 Safety
100 - 390 BG 28 H # 5336 / V01_en_04.2021

2 Product description
2.1 Intended use
Intended, approved use means use in strict compliance with and strictly adhering to all instructions,
directives, precautionary measures and prohibitions set out in this instruction manual and all addi-
tional manuals and documents supplied.
The entire content of this instruction manual pertain and refer exclusively to the equipment, includ-
ing all original equipment and manufacturer-installed options, in the condition they were in on the
day of delivery to the initial purchaser.
Any modifications made to the equipment or its components or the manufacturer-installed options
after delivery can jeopardize the safety of the equipment, and renders this instruction manual void.
Use of this equipment after such modifications is unauthorized unless this use after modifi-
cation has prior written consent from BAUER Maschinen GmbH as indicated below.
The manufacturer cannot be held liable in any way for any incidents arising from or associated with
prohibited and unauthorized use of the equipment, unless such use after modification has been
consented to in writing by BAUER Maschinen GmbH.
Following modification of the equipment, original components or manufacturer-installed options,

the equipment may not be used in any way or at any location without written consent from
BAUER Maschinen GmbH or until such consent is granted. Please submit a change request to
BAUER Maschinen GmbH in order to obtain this authorization.
Authorization to use the equipment after modification to the equipment itself, its original compo-
nents or manufacturer-installed options may only be granted after a correct and complete change
request has been received and reviewed by BAUER Maschinen GmbH.
No other person, legal entity or organization, including but not restricted to any public authorities,
regardless of location, has the right to issue this authorization. Likewise, no agents, distributors, im-
porters, dealers or subsidiaries of BAUER Maschinen GmbH have the right to or are able to grant a
valid authorization. Valid authorization can only be granted by the head office of BAUER Maschinen
GmbH after submission of a correct and complete change request.
The equipment described in this instruction manual is intended for the country for which the initial
purchaser placed the order and must therefore only be used in that country. All contractual agree-
ments between the manufacturer and the initial purchaser regarding the requirements and restric-
tions involved in using and operating this equipment in a country other than the one for which the
equipment was ordered are binding for all individual and subsequent purchasers.
Any use of the equipment in a country other than the one for which it was ordered shall be consid-
ered unauthorized and strictly prohibited, unless prior written consent has been requested from and
granted by BAUER Maschinen GmbH.
The use of this equipment in the United States is authorized only if the equipment was initially or-
dered for use in and delivered to the United States, or if the use of this equipment in the United
States has been expressly permitted and authorized in writing by BAUER Maschinen GmbH.
Any use of this equipment other than as authorized and described in this instruction manual shall
be considered unauthorized and is hereby expressly prohibited.
The manufacturer shall not be held liable for any injuries or damages of any kind that occur directly
or indirectly in any way, shape or form in conjunction with, or as a result of, any unauthorized use
described herein or any use that is not expressly authorized in this instruction manual.
Change request
Authorization for modification of components, the process equipment, and the equipment itself
must be requested from the manufacturer.
Please use the form provided for this purpose.
BG 28 H # 5336 / V01_en_04.2021 101 - 390

CustomerCenter
2.1.1 Equipment-specific conditions

Risk of accident!
If an item of process equipment is mounted on a base machine which modifies the original shape,
configuration and function of the equipment, the operator assumes full responsibility for the entire
device. If the process equipment is not properly installed, the equipment can be damaged and fall
over. Persons in the vicinity of the equipment could be hit and suffer severe or fatal injuries.
Δ Refer to and comply with all requirements of the Instruction manual for the corresponding
process equipment.
Δ Request valid stability for the additionally mounted process equipment from the manufacturer
of the base machine.
This equipment is only approved for the following activities:
Authorized use / abbreviation

Operated in conjunction with specified process equipment. Each authorized use is described in
the intended use section of a designated, separate supplement.
2.2 Improper use

The equipment may only be used for the activities prescribed in the section "Intended use" and ac-
tivities that are approved by the manufacturer.
The following in particular are prohibited:
– Use of the equipment to transport personnel.
– Use of the equipment as a lifting platform for personnel.
– Use of the equipment as a transport vehicle and lifting vehicle/crane.
– Use of the equipment for leveling work.
– Use of the equipment for moving loads.
– Use of the equipment in potentially explosive areas.
102 - 390 BG 28 H # 5336 / V01_en_04.2021

2.3 Nameplates
2.3.1 Base machine
Designation Position
Large diameter rotary drilling rig
BG 28 H # 5336 / V01_en_04.2021 103 - 390

2.4 Equipment overview

2.4.1 Base machine
1 Backstay cylinders
2 Supporting boom
3 Boom
4 Boom cylinders
5 Upper carriage
6 Counterweight
7 Swing mechanism
8 Crawler drive
9 Undercarriage
10 Mast prop
11 Cab
12 Lower mast extension
13 Main winch
14 Auxiliary winch
15 Kinematic triangle
16 Mast pivot
17 Crowd winch
18 Upper crowd rope
19 Lower crowd rope
20 Crowd sledge
21 Mast (upper mast sec-
tion/lower mast section)
22 Crowd rope clamping
cylinder
23 Upper mast extension
24 Upper mast extension
tilting cylinder
25 Masthead tilting cylinder
26 Auxiliary rope
27 Main rope
28 Masthead
104 - 390 BG 28 H # 5336 / V01_en_04.2021

Components Function
Boom Movable connection piece between base machine and kine-
matic triangle.
Boom cylinder Enable adjustment of the operating radius.
Swing mechanism Enables continuous rotation of the upper carriage.
Crawler drive Moves the crawler track of the undercarriage.
Counterweight Ensures stability of the equipment.
Main winch with main rope Lifting equipment for working with the process equipment.
Auxiliary winch with auxiliary Lifting equipment for assembly work and auxiliary work.
rope
Cab The equipment operator controls the equipment from the cab.
Kinematic triangle Enables parallel adjustment of the mast.
Masthead tilting cylinder Tilts the masthead into operating position/transport position.
Upper mast extension tilting Tilts the upper mast extension to the operating position / trans-
cylinder port position.
Mast (upper mast section/lower Guides the crowd sledge and the attached components of the
mast section) process equipment.
Mast prop Supports the equipment when pulling the process equipment.
Mast pivot Connection point between mast and kinematic triangle. Enables
inclination of the mast.
Masthead Guides the main rope and the auxiliary rope.
Mast extension Lower mast extension:
Enables a lower position of the crowd sledge.
Upper mast extension:

Enables a higher position of the crowd sledge.
Backstay cylinder Support the mast. Enable adjustment of the mast inclination and
raising and lowering of the mast.
Upper carriage Carries the attachment with the process equipment as well as
all the components required for the equipment to function.
Crowd rope clamping cylinder Tensions or slackens the crowd ropes.
Supporting boom Enables parallel adjustment of the mast.
Undercarriage Carries the upper carriage and enables the equipment to be
driven.
Crowd sledge Is moved on the mast by the crowd ropes and carries the
process equipment.
Crowd ropes (upper, lower) Transmit crowd forces and crowd movements from the crowd
winch to the crowd sledge.
Crowd winch Generates the crowd forces and crowd movements.
BG 28 H # 5336 / V01_en_04.2021 105 - 390

2.4.2 Upper carriage

Sections
Sections Overview
In the cab:
– Operating and control elements
– Operator's seat
– Instruction manual
– Electrical fuses
– Components of the air conditioning system
– First aid box
– Switch, emergency control, diesel engine

In the upper carriage:
– Pump distributor gear
– Pump unit
– Hydraulic system test terminal block
– Pressure accumulator
– Line filter
– Components of the exhaust system
– 1 Fire extinguisher
– Water tank for the windshield washing system
On the upper carriage:

– Diesel engine
106 - 390 BG 28 H # 5336 / V01_en_04.2021

Sections Overview
– Diesel engine air filter
– Diesel engine charge air cooler
– Components of the air conditioning system
– Starter batteries
– Battery main switch
– Main fuse switches
– Fuse switch for the starter motor

– Hydraulic oil tank
– Sight glasses for hydraulic oil level
– Return flow filter for the hydraulic system
– Vent filter of the hydraulic oil tank

– Compressor (not present in this version)
– Mast pivot
– Swing mechanism gear
Under the upper carriage:
– Slewing ring
– Counterweights
BG 28 H # 5336 / V01_en_04.2021 107 - 390

Sections Overview
Front of upper carriage:
– Fitting plate with hydraulic oil couplings to supply

the process equipment
– Installation opening for electrical cables
– Hydraulic system components
– Swing brake
– Hydraulic oil cooler
– Tank for SCR system
– 1 Fire extinguisher
– Grease receptacle for the central lubrication sys-

tem
– Diesel engine water cooler
– Diesel cooler
– Fuel tank
– Fuel tank intake pump
– Fuel hose
– Fuel tank filler opening
– Fuel tank vent filter
– Electrical cabinet with fused switches
– Coolant filler opening
108 - 390 BG 28 H # 5336 / V01_en_04.2021

Cab
30 Cab door (hidden) 35 Electrical safety fuses

31 Storage compartments 36 Emergency control switch
32 Ventilation nozzles 37 Front windshield
33 Components of the air-conditioning system 38 Sun blind
(beneath operator's seat)
34 Cab door locking mechanism
BG 28 H # 5336 / V01_en_04.2021 109 - 390

2.4.3 Undercarriage
40 Crawlers 44 Crawler tracks

41 Middle bridge 45 Crawler drives
42 Slewing ring bearing 46 Telescoping cylinders
43 Front idlers 47 Lifting point
Components Function
Slewing ring bearing Connection between the undercarriage and the upper carriage.
Crawler drives Drive the crawlers.
Lifting point Intended for the recovery of the equipment.
Front idlers Directing the crawler tracks.
Middle bridge Carriers the crawlers and the upper carriage.
Crawler tracks Transmit the drive movement of the crawler drive.
Crawlers Enable driving of the equipment.
Telescoping cylinders Enable extension and retraction of the crawlers.
110 - 390 BG 28 H # 5336 / V01_en_04.2021

2.4.4 Control unit/Software

B-Tronic
The equipment has a large number of sensors that continuously record data at all of the relevant
points on the equipment. These machine parameters and production parameters are visualized on
the B-Tronic screen in displays that are tailored to the respective process. As a result, the equip-
ment operator is informed about the status of the equipment, and is provided with relevant informa-
tion regarding efficient use, at all times. Operating steps can be automated by configuring regula-
tion and control processes via the B-Tronic system, thereby increasing the performance of the
equipment and reducing wear.
Further information can be found in the enclosed additional documentation entitled "B-Tronic".
Assistance functions
The equipment offers a variety of fully automatic and semi-automatic assistance functions, which
can be used to relieve the strain on the operator, improve process reliability and increase the effi-
ciency of work activities by optimizing the respective performance parameters.
The following overview presents the individual assistance functions and also lists the documenta-
tion components that describe how to use the corresponding assistance function.
Depending on the class and configuration of the equipment used, not all of the assistance functions
that are listed here may be available.
Assistance function Instruction B-Tronic Process Separate

manual for instruction supplement documenta-
the manual tion
base ma-
chine
Kelly drilling assistant ●
The drilling assistant stores the deflection of the control lever and maintains the speed of the KDK
and the crowd at a constant level. The drilling parameters can be continuously adapted to the
ground conditions during the drilling process. This relieves the equipment operator, especially
when drilling holes in rock or hard ground over a long period of time.
Single Pass drilling assistant ● ●

The drilling assistant controls the crowd speed depending on the speed of the rotary drive. The
equipment operator can release the control lever when it has been set. The drilling assistant con-
tinues to drill automatically. This relieves the strain on the equipment operator. The drilling param-
eters can be adapted to the ground conditions. This ensures an optimum filling level of the tool
and a reduced load on the equipment.
Adaptive Kelly speed assistant ● ●

The adaptive Kelly speed assistant allows the Kelly bar to be lowered into, and lifted out of, the
borehole automatically. The drilling performance is increased and the level of wear reduced as a
result of an optimum winch speed.
Single Pass active mast prop ●
BG 28 H # 5336 / V01_en_04.2021 111 - 390


the manual tion
base ma-
chine
The equipment automatically executes the "Active support" function with the mast prop: The pres-
sure in the mast prop is controlled while the crowd and main winch pull. In doing so, the mast
prop can extend automatically to maintain the required pressure and contact with the ground. This
ensures stability and relieves the kinematics of the equipment.
Shake-out assistant ●
Drilling buckets, in particular, can be emptied quickly and efficiently with the shake-out assistant,
which rotates the rotary drive alternately. The parameters can be optimally adapted to both the
tool and ground conditions.
Automatic torque adjustment ●

The tool used can be entered on the B-Tronic screen in order to adapt the maximum released
torque to the tool. Tools that cannot withstand the full torque are protected from damage by the
torque limiting function. The full torque is available for casing processes.
B-APS ●
The GPS-based BAUER-Assistant Positioning System (B-APS) allows the equipment to be
moved to the precise position of a pile. Pile positions do not need to be marked manually; instead,
target coordinates and actual coordinates are documented. As a result, the speed and precision
of work can be increased.
Limitation of main winch rope ● ●

speed
The main winch can be reduced to preselectable speeds when pulling the tool out of the borehole.
This reduces the risk of negative pressure and hydraulic heave.
Slewing angle display ●

The slewing angle of the upper carriage is displayed on the B-Tronic screen. This supports the
equipment operator when slewing back towards the drill axis, especially in the case of uncased
deep boreholes.
Slewing angle limitation ● ●

When the slewing angle limiting function is used, the slewing range of the upper carriage is re-
stricted, meaning it can be adapted to conditions on the construction site.
Electronic mast reach limitation ●

The operating radius is electronically limited depending on the process equipment used. It is not
necessary to assemble mechanical components for limitation purposes. The limitation function
can be flexibly adapted to a wide range of process equipment.
Retract control ●
112 - 390 BG 28 H # 5336 / V01_en_04.2021


the manual tion
base ma-
chine
The retract control function controls the residual pulling force of the main winch when the free-
wheel function is activated. This allows the freewheel speed to be adjusted. As a result, controlled
drilling procedures are enabled with heavy process equipment in soft surfaces.
Kelly visualization system ●

The Kelly visualization system supports the equipment operator when retracting and extending
the Kelly bar by displaying permissible locking positions and warnings if a Kelly segment has not
been unlocked properly. This prevents damage to the Kelly bar and the equipment itself.
Automatic alignment of the mast ●

It is possible to define any 2 mast settings in which the mast can be automatically positioned. The
desired mast position is thereby reached in the shortest possible time without requiring any man-
ual adjustment.
Crowd pressure control ●

The crowd pressure control function monitors the pump pressure of the rotary drive. When the ro-
tary drive reaches a certain pressure, the crowd pressure is reduced. This allows the drilling tool
to cut itself free. The level of wear of the drilling tool is reduced and the drilling performance is in-
creased.
Slack rope prevention ●

The "Slack rope prevention" function ensures the main rope is tensioned when manually unwind-
ing the main winch. If the minimum load for the main rope set by the equipment operator is not
met, the main winch stops. This prevents the rope swivel from falling and causing damage to the
rope.
Single Pass rapid follow-up ●

When the Single Pass process is activated with an auger Kelly, the rotary drive can be moved to
the next locking area at increased speed. This reduces the time until the drilling process is contin-
ued.
Shock assistant ●
The drilling tool can be emptied quickly and efficiently with the shock assistant, which subjects the
rotary drive to a shocking rotary movement. The parameters can be optimally adapted to both the
tool and ground conditions.
Control lever assistance ●

The control lever configuration for the currently selected process can be displayed on the B-Tronic
screen. This provides a quick, dynamically adapted overview of the equipment functions that are
currently available.
Main rope overload protection ●
BG 28 H # 5336 / V01_en_04.2021 113 - 390


the manual tion
base ma-
chine
The main rope overload protection function stops the crowd if the pulling force of the main winch
is exceeded. This prevents damage to the main rope.
Crowd Plus ●
The Crowd Plus function supports the crowd system with the main winch when pulling casing
tubes. The pulling speed of the main winch and crowd are controlled in such a way that both rope
winches pull the casing tube out simultaneously.
Crowd stroke monitoring ●

The crowd stroke monitoring function monitors the position of the crowd sledge and stops it when
it reaches the maximum permissible height on the mast for operation.
Automatic swivel alignment ●

When the freewheel function is activated, the rope swivel of the main rope is set upright automati-
cally. This prevents damage to the rope.
Casing assistant ●
The casing assistant supports the screwing and pulling of casing tubes by subjecting the rotary
drive to an alternating rotary movement. The parameters can be adapted to specific conditions.
This relieves the equipment operator and optimizes the handling of casing tubes.
Single Pass pulling assistant ● ●

The pulling assistant controls the pulling speed depending on the concrete quantity and concrete
pressure. The equipment operator can release the control lever when the function is switched on.
This relieves the strain on the operator and ensures the optimum amount of concrete when pro-
ducing a homogeneous pile.
Complementary software
In addition to the actual control systems for the various equipment, the BAUER Customer Center
also provides advanced functionalities and software modules. These cover, in particular, external
monitoring of the equipment and a detailed evaluation of process data.
CustomerCenter
The functions of the individual modules are described in separate documentation.
114 - 390 BG 28 H # 5336 / V01_en_04.2021

Web-BGM
Web-BGM is a server application for equipment management. If an item of equipment is equipped

with a DTR module, information relating to this equipment can be displayed and analyzed in a
browser via Web-BGM.
The following displays are possible depending on the configuration:
– Equipment position
– Operating times
– Messages
– Production data
– Master data
– Service
– Live data
– B-Tronic online
– B‑Report
A comprehensive rights management function enables roles and teams to be defined with different
authorization levels.
B‑Report
The B-Report software is used for detailed evaluation of the process data that is recorded by the
equipment and it provides the following options:
– Detailed display of production data for evaluating productivity
– Daily reports
– Standardized reports that are used to document the progress of construction work and pro-
vide performance records and quality demonstration records
2.5 Technical data

2.5.1 Equipment specifications
The symbols used below mean:

"-" = not present
"●" = present
Complete equipment
Type BG 28 H
Serial number 5336
BG 28 H # 5336 / V01_en_04.2021 115 - 390

Type BG 28 H
Inclination values Mast [°] forwards 5
(during operation without process equipment)
backwards 15
left 8
right 8
Inclination values Mast [°] See Stability
(during operation with process equipment)
Operating radius [mm] See Stability
Ground clearance Mast [mm] See "Dimensions"
Upper carriage
Type BT 75 D
Serial number 5336
Counterweights [t] See Stability
Air conditioning system / Climatronic -/●
Central lubrication system ●
Compressor -
Generator -
Auxiliary heating system / cooling package -/-
Diesel engine
Type C9.3B
Serial number NGH01587
Output [kW] / at speed [rpm] 310 / 1850
Undercarriage
Type UW 80 DB
Serial number 10237626
Working width [mm] 4380
(extended state)
Width of floor plates [mm] 700
Middle bridge H version -
Spar in ●
spar
Spar next -
to spar
Telescopable ●
116 - 390 BG 28 H # 5336 / V01_en_04.2021

Attachment
Mast
Mastlength [mm] See "Dimensions"

Mast extension top / bottom ●/●
Mast prop ●
Rope winches
Type Main winch Auxiliary winch Pull-down winch
4.2701368570 4.22 1000328 4.26 1001908
Tensile force 1st layer [kN] 200 80 165
Rope speed [m/min]
Fast winding 79 55 29
Slow winding - - 7
Fast unwinding 79 55 29
Slow unwinding - - 7
(with a load of [t]) (2) (1) (-)
Wire ropes
Type Main rope Auxiliary rope Crowd rope
top/bottom
Finished length [m] 80 51 67.4 / 63.0
Diameter [mm] 28 20 24
2.5.2 Permissible ambient temperatures

If operated outside the specified temperature ranges, there is a risk of causing damage to the com-
ponents.
Δ For use at temperatures outside the specified ranges, the manufacturer must be consulted.

In the event of a brief interruption and/or prolonged periods where external temperatures reach
-10 °C (14 °F) or below, liquid media that is used for producing a product (such as water and slurry)
can freeze. The supply lines that are used to convey liquid media can become blocked and dam-
aged as a result.
Δ Stop operation during prolonged external temperatures of -10 °C (14 °F) or below, or imple-
ment suitable measures to prevent liquid media (such as water and slurry) from freezing.
Δ At external temperatures below 0 °C (32 °F), the flow of liquid media in supply lines should be
maintained (a stop of the flow should be avoided); if necessary, thoroughly clean and empty
supply lines so they are free of foreign particles.
Operating conditions Permissible temperature range
Normal operation with standard equipment -20 °C (-4 °F) to +40 °C (+104 °F)
Normal operation with cooling package to -25°C (-13°F)
BG 28 H # 5336 / V01_en_04.2021 117 - 390

Operating conditions Permissible temperature range

During storage -40 °C (-40 °F) to +40 °C (+104 °F)
2.5.3 Noise emissions

Acoustic emissions have been determined according to directive 2000/14/EC.
Sound power level outside LWA [dB(A)] 110
Sound pressure level in the cab LpA [dB(A)] 80
2.5.4 Exhaust gas emissions

The limit values for exhaust gas emissions comply with the directives 97/68/EC or regulations (EU)
2016/1628 stage V and the EPA/CARB TIER 4 Final.
If the diesel engine fulfills the applicable directives in the country where the equipment is used, the
operator is entitled to use this equipment.
If repairs or modifications of any kind are made to this diesel engine and original components are
not used, it is possible that the emission limit values which are applicable in the country of use are
not fulfilled.
In this case, the operator is obligated to contact Bauer to initiate service measures. Following an in-
spection and once the equipment complies with the emission limit values it can be operated again.
2.5.5 Vibration acceleration

The trigger values for whole-body vibrations (0.5 m/s2) are not exceeded.
The measurements correspond to directive ISO 2631-1.
Hand-arm vibration
The emissions for hand-arm vibration of 2.5 m/s2 are not exceeded at the operating elements/con-
trol elements for the equipment.
The measurements correspond to the guidelines DIN EN ISO 5349-1:2001 and DIN EN ISO
5349-2:2001.
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3 Operation
3 Operation
If the equipment comes into contact with overhead or underground electricity lines, current will be
transferred to the equipment. Persons in the immediate vicinity will receive an electric shock as well
as burns, which can cause severe or fatal injuries.
Δ Before starting work, ask an authorized person about the prescribed safety distance. Always
observe the required safety distance. This also includes the avoidance of swinging loads and/
or components in the danger zone.
Δ Before starting work, inform the company responsible for the power supply.
Δ Consult the power supply company regarding the measures to be taken in the event of an
emergency.
Δ If a current transfer does occur, do not leave the cab. The equipment operator must instruct the
endangered persons accordingly (e.g. keep legs closed and remain still).
Δ The danger has passed only when the power supplier gives the all-clear.
Risk of accident!
– Safety when handling wire ropes [➙ 43]
– Information on stability [➙ 45]
– Operational safety [➙ 46]

Risk of accident!
Changing the operating position while the equipment is performing work can cause the equipment
to tip over or components to fall down. Personnel could be hit as a result and suffer severe or fatal
injuries.
Δ Never move the equipment from the operating position when the equipment and work attach-
ments are operational.
Δ Before starting work, align the Mast to the required inclination and do not alter this during oper-
ation. If the position of the Mast is changed by the impacting forces (for example in case of soft
ground), minimal adjustments can be made with caution.
3.1 Operating modes

3.1.1 Derigging mode
Selection Process
button
• Press the button (3.19).
✓ LED of button (3.19) lights up green.
3.19 ✓ Derigging mode is selected.
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3 Operation
3.1.2 Rigging mode

Selection Process
button
3.18 ✓ Rigging mode is selected.
3.1.3 Operation
The operating mode which enables actual work with the equipment is referred to as operation.
Prerequisite:
– The equipment is ready for operation.
– The work application is selected.
– The process equipment is fully mounted.
3.1.4 Winches Rigging mode

Selection Process
button

3.17 ✓ Rigging mode of the winches is selected.
3.1.5 Transport mode

The equipment may only be loaded in the transport mode. In the transport mode, only the functions
necessary for loading and transporting the equipment are available.
Key Process
switch
• Turn the key-operated switch (3.8) to position "I".
✓ Transport mode is selected.
3.8
3.1.6 Operating mode
Exactly when each operating mode is to be used is explained in the respective sections.
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3 Operation
3.2 Operating elements/control elements

3.2.1 Overview of cab and control station
1 Control panel 1 6 B-Tronic screen

2 Control panel 2 7 B-Drive
3 Control panel 3 10 Control lever, right
4 Control panel 4 20 Control lever, left
5 Control pedals
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3 Operation
3.2.2 B-Tronic
Further information can be found in the enclosed additional documentation.
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3 Operation
3.2.3 Control pedals

=Kelly mode =SMW mode =VF mode =CSM mode
=BV mode =MIP mode =VD mode =BC mode (HDS)
=CFA mode =SCM mode =VCC mode =BC mode (HTS, HSS)
=CCFA mode =HPI mode =Piling (vibrator)
=FDP mode =HPD mode
5.1 Travel mode: Steer right

crawler
5.2 -
5.3 -
5.4 Travel mode: Steer left
crawler
Overview of drive levers:

5.5 Travel mode: Steer right
crawler
5.6 Travel mode: Steer left
crawler
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3 Operation
3.2.4 Operator's seat
1 Adjustable head restraint 6 Move seat cushion forwards/backwards

2 Adjust angle of armrests 7 Adjust height of the operator’s seat
3 Move operator's seat forwards or back- 8 Adjust lumbar supports
wards
4 Adjust angle of seat 9 Switch the seat cushion and backrest
heating on/off
5 Adjust vibration function of the seat 10 Adjust angle of the backrest
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3 Operation
3.2.5 Control panel 1
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3 Operation
=Kelly mode =SMW mode =RDV mode =CSM mode

=BV mode =MIP mode =VDD mode =BC mode (HDS)
=CCFA mode =HPI mode =Piling(vibrator)
=FDP mode =HPD mode
1.1 Monitor unit: 1.14 KDK 2nd gear: Gear stage 1 with reduced,
Left = Diesel engine operation indicators unadjustable torque
Right = Camera angles
1.2 Camera front right/rear right: Switch be- 1.15 KDK 3rd gear: Gear stage 1 with ad-
tween camera angles justable maximum torque
1.3 Call up equipment data 1.16 KDK 4th gear: Gear stage 2 with ad-
justable maximum torque
1.4 Lower rear-view camera/winch camera: 1.17 -
Switch between camera angles
1.5 Open/close service menu 1.18 -
1.6 Select screen display 1.19 Retract mast prop
1.6 Button (1.5) preselected: Select and oper- 1.20 Extend mast prop
ate menu navigation
1.7 Release: Adjust console 1.21 -
1.8 Indicator light: Swing brake activated 1.22 -
1.9 Indicator light: Main winch freewheel acti- 1.23 -
vated
1.10 Indicator light: Activate auxiliary winch 1.24 Increase operating radius
freewheel
1.11 Indicator light: Battery charge indicator 1.25 Operation: Extend left backstay cylinder
1.12 Indicator light: Diesel engine preheating 1.26 Operation: Extend right backstay cylinder
system
1.13 KDK 1st gear: Gear stage 1 with maxi-
mum, unadjustable torque
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3 Operation
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3 Operation

=FDP mode =HPD mode
1.27 - 1.40 -
1.28 - 1.41 -
1.29 - 1.42 Stop depth measurement
1.30 - 1.43 Tension crowd ropes
1.31 B‑Tronic display: Control lever configura- 1.44 Slacken crowd ropes
tion
1.32 Operation: Decrease operating radius 1.45 -
1.33 Operation: Retract left backstay cylinder 1.46 -
1.34 Operation: Retract right backstay cylinder 1.47 -
1.35 Preselection: Main winch 1.48 -
1.36 Preselection: Auxiliary winch 1.49 -
1.37 - 1.50 -
1.38 - 1.51 -
1.39 - 1.52 -
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3 Operation
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3 Operation

=FDP mode =HPD mode
2.1 - 2.19 -
2.2 - 2.20 -
2.3 - 2.21 -
2.4 - 2.22 -
2.5 - 2.23 -
2.6 - 2.24 -
2.7 - 2.25 -
2.8 - 2.26 -
2.9 - 2.27 -
2.10 - 2.28 -
2.11 - 2.29 -
2.12 - 2.30 -
2.13 - 2.31 -
2.14 - 2.32 -
2.15 - 2.33 -
2.16 - 2.34 -
2.17 - 2.35 -
2.18 - 2.36 -
2.37 Switch ignition on/off
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3 Operation

=FDP mode =HPD mode
3.1 Cigarette lighter/coupling 24 V 3.15 Folding the masthead to the transport po-
sition
3.2 Round spirit level 3.16 Folding the masthead to the operating po-
sition
3.3 USB connection 3.17 Rigging mode: Preselect rope winches
3.4 - 3.18 Preselection: Rigging mode
3.5 EMERGENCY STOP 3.19 Preselection: Derigging mode
3.6 Diesel engine: Speed control 3.20 Swing in mast extension
3.7 - 3.21 Swing out mast extension
3.8 Switch transport mode on/off 3.22 -
3.9 - 3.23 Rigging mode indicator light: Boom cylin-
der preselected
3.10 - 3.24 Rigging mode indicator light: Backstay
cylinders preselected
3.11 - 3.25 Undercarriage: Retract telescoping cylin-
ders
3.12 - 3.26 Undercarriage: Extending telescoping
cylinders
3.13 - 3.27 Front windshield: Switch wipers on/off
3.14 - 3.28 Front windshield: Adjust wiper interval
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3 Operation
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3 Operation

=FDP mode =HPD mode
3.29 Front windshield: Switch window wiper 3.43 -

system on/off
3.30 Activate horn 3.44 Switch beacon lights on/off
3.31 Roof: Switch wipers on/off 3.45 -
3.32 Roof: Adjusting wiper interval 3.46 Switch central lubrication system on/off
3.33 Roof: Switch window wiper system on/off 3.47 Buzzer: Suppress warning sound
3.34 Diesel engine: Activate/deactivate ECO 3.48 -
mode
3.35 Switch headlights on/off 3.49 -
3.36 Switch rear headlamps on/off 3.50 Deactivate automatic regeneration of the
exhaust system
3.37 Switch headlight on boom on/off 3.51 Activate manual regeneration of the ex-
haust system
3.38 Switch automatic diesel engine stop on/off 3.52 Indicator light illuminates: Switch off diesel
engine
3.39 Switch operator’s cab lighting device on/ 3.53 Indicator light: Diesel engine "Warning"
off
3.40 Switch engine compartment lighting de- 3.54 Switch diesel engine diagnostics on/off
vice on/off
3.41 Switch camera spotlight on/off 3.55 With diesel engine diagnostics switched
on: Scroll backwards through the stored
error messages in the B-Control
3.42 Central lubrication system: Activate inter- 3.56 With diesel engine diagnostics switched
mediate lubrication on: Scroll forwards through the stored er-
ror messages in the B-Control
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3 Operation
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3 Operation

=FDP mode =HPD mode
4.1 Switch "pilot control" safety stick on/off 4.3 Climatronic

4.2 - 4.4 B-Drive: Select and operate menu navi-
gation
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3 Operation
3.2.9 B-Drive screen
The day mode or night mode of the screen is linked to B-Tronic.
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3 Operation
=BV mode =BTM mode =HPD mode =CSM mode

=CSV mode =SCM mode =Piling (vibrator) =BC mode (HDS)
=TRD mode =SMW mode =VF mode =BC mode (HTS, HSS)
=FDP mode =CFA mode =VCC mode
=Kelly mode =FOW mode =VD mode
=MIP mode =Pre-drilling =SPP mode
Position Section Function

1 Values Display of set values
2 KDK-torque of preselected switching step
KDK-speed of preselected switching step
Slack rope prevention
Winch 1 retract control
Winch 2 retract control
Crowd pressure
Crowd speed
KDK-speed shake-out/shock assistant
Casing oscillator flow rate
Manual mode: Adjusting rotational speed of hose drums
3 Scale Display of value to be set / Exact display of the value set
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3 Operation
3.2.10 Operating the B‑Drive

Selecting and setting values
The B‑Drive can be used to set parameters for various equipment functions and store them perma-
nently. The parameters set for all of the available functions are displayed centrally on the B-Drive
screen (8) (see section "B-Drive screen").
• Select the desired function by turning the
multifunction knob (4.4).
✓ The corresponding symbol for the func-

tion is highlighted on the B-Drive screen
(8).
• Press the multifunctional knob (4.4).
✓ The scale is highlighted on the B-Drive

screen (8).
✓ The parameter can be adjusted for the

corresponding function.
• Set the desired value for the parameter by

turning the multifunction knob (4.4).
✓ The saved value is displayed next to the

symbol for the function on the B‑Drive
screen.
✓ The value is saved for the parameter.
The saved values are retained even after the equipment is restarted.
Adjusting the brightness of the screen

• Press the multifunction knob (4.4) and hold it
for approximately 2 seconds.
✓ The menu for adjusting the brightness

appears on the B-Drive screen.
• Set the desired brightness with the multi-

function knob (4.4).
✓ The menu closes.
✓ The brightness of the screen has been ad-

justed.
The brightness of the screen can be set independently for the day mode and night mode.
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3 Operation
3.2.11 Control lever configuration Basic functions
Basic functions
Control lever, left Control lever, right
(20) (10)
Button Process Button Process
20.1 - 10.1 Increase/decrease operating radius
20.2 Activate main winch freewheel 10.2 Activate high crowd speed
20.3 Preselection: Main winch 10.3 Align the mast automatically
20.4 Activate/deactivate swing brake 10.4 -
20.5 - 10.5 -
20.6 - 10.6 -
20.7 Retract/extend left backstay cylinder 10.7 Retract/extend right backstay cylin-
der
20.8 - 10.8 Activate horn
20.9 Preselection: Auxiliary winch 10.9 -
Basic functions
Control lever, left Process Control lever, right Process
(20) (10)
Turn the upper carriage
counterclockwise
Turn the upper carriage

clockwise
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3 Operation
Control lever, left Process Control lever, right Process

(20) (10)
+20.3 Unwind wire rope of Move the crowd sledge
main winch downwards
+20.3 Wind in wire rope of Move the crowd sledge up-

main winch wards
+20.9 Unwinding wire rope of

auxiliary winch
+20.9 Wind in wire rope of aux-

iliary winch
Extend left backstay Extend right backstay cylin-

cylinder der
Retract left backstay Retract right backstay cylin-

cylinder der
3.2.12 Additional switches

Main fuse switches
The individual main fuses electrically protect the corresponding components of the equipment from
overloading.
Main fuse for equipment
The following figure shows the position on the equipment of the components described here.
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3 Operation
1 Main fuse for equipment
Main fuse switches in the electric box
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3 Operation
2 Main fuse switch of the cab

3 Main fuse switch of the automobile portion
4 Main fuse switch of the BG portion
Battery main switch

The battery main switch establishes the power supply from the battery to the equipment or alterna-
tively disconnects the power supply.
(1) Battery main switch "0"
(2) Battery main switch "|"
Diesel engine fuse switch

The fuse protects the diesel engine starter from overloading.
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3 Operation
1 Fuse switch for the diesel engine starter
Diesel engine emergency control switch
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3 Operation
1 Switch for controlling the speed of the

diesel engine in emergency mode
3.3 Initial start-up

Typically, the equipment manufacturer performs initial start-up together with the future owner. The
work necessary to accomplish this is performed either as part of training activities held at the man-
ufacturer's premises or as part of a briefing on the construction site.
3.3.1 Wax removal

The equipment/rig is coated with a special protective wax, especially for longer transport distances.
This protects the equipment against the effects of the weather.
Danger of slipping!
Incorrect cleaning can result in personnel slipping and falling.
Δ Before starting-up the equipment, remove the protective wax from the entire equipment and its
accessories.
Δ Wear suitable personal protective equipment while cleaning.

Unsuitable cleaning agents can cause damage to seals and other sensitive components.
Δ Only use suitable cleaning agents.
• Clean the entire equipment and its accessories thoroughly with a hot water jet at 80°C to
100°C (176°F to 212°F) and completely remove the protective wax.
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3 Operation
3.4 Start-up after prolonged shutdown or storage

Incorrect start-up or removal of protective wax following long-term shut-down or storage can result
in damage to the equipment.
Δ In the event of a prolonged standstill (> 1 year), perform maintenance in accordance with the
maintenance plans (see section "Maintenance/repair").
Δ Take any national and regional regulations regarding equipment inspections into account.
Δ Perform the measures described below.
3.4.1 Base machine

Upper carriage and attachment
• Remove protective wax before starting the equipment (see "Removing protective wax").
Hydraulic system
Electrical connections are protected against splashing water. Water and aggressive cleaning
agents can penetrate the electrical connections and lead to malfunctions when cleaning with high
pressure cleaners.
Δ Do not clean electrical connections with a strong water jet.

Hydraulic connections may be open when the equipment is shut down. Water and aggressive
cleaning agents can penetrate the hydraulic system when cleaning with high pressure cleaners. In
addition, aggressive cleaning agents can damage the seals on the hydraulic connections.
Δ Seal open hydraulic connections before cleaning.
Δ Do not clean hydraulic connections with a strong water jet.

In general, hydraulic circulatory systems and components must be kept free of air pockets. After
longer periods of downtime, air bubbles may be found in the hydraulic system. This air mixes with
the oil when operated for the first time. Operating the equipment with this air-oil mixture can cause
damage to hydraulic components.
Δ Vent the hydraulic system after periods of downtime of more than four weeks.
Δ Then allow the equipment to rest.
• Remove any corrosion protection from the hydraulic system in a suitable manner.
• Clean equipment.
• Visually check the hydraulic system for leaks.
• After a prolonged period of downtime (more than 2 years), service the entire hydraulic system
in accordance with the maintenance table.
If you are using biodegradable oil, it must be subjected to an appropriate analysis prior to starting
the equipment after a prolonged period of inactivity. The oil sample must be taken from the hy-
draulic tank.
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3 Operation
Venting the hydraulic system
• Check the oil level (see section "Checking the oil level").
• Start the base machine diesel engine.
• Carefully operate the entire hydraulic system at a low engine speed for approx. 5 minutes. De-
activate ECO mode if necessary.
• Switch off the base machine diesel engine.
• Leave the equipment out of operation for at least 4 hours.
✓ Mixed air escapes from the hydraulic oil.
• Check the oil level.
✓ The hydraulic system has been vented.
Diesel engine
• Before starting up the diesel engine, remove the protective wax accordingly and perform main-
tenance in accordance with the manufacturer's specifications.
Air conditioning system

• Perform maintenance in accordance with the maintenance plan (see section "Maintenance and
repair").
• In case of a prolonged standstill (> 2 years) perform maintenance in accordance with the man-
ufacturer's specifications.
Further information can be found in the enclosed additional documentation or contact BAUER after
sales service.
Slewing ring
• Before starting up, clean the slewing ring and sprocket properly and remove the protective
wax.
Undercarriage telescopic guide

• Clean the telescopic guide properly and remove the protective wax prior to start-up.
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3 Operation
Cylinders and piston rods

• Check the surface of the cylinders and piston rods for corrosion before start-up and treat ac-
cordingly (see section "Maintenance/repair").
• Replace any heavily corroded/leaking cylinders and piston rods.
Hose assemblies
• Check hose assemblies for integrity and tightness prior to start-up. Replace any damaged and
leaking hoses.
• Observe the stipulated maximum period of use for hoses.
Electrical system/electrical cables

• Before start-up, check to ensure the electrical equipment and electrical cables are in proper
working order and replace if necessary.
• Connect the equipment's power supply (see section "Preparing for operation").
If the electrical power of the batteries is too low, jump start the equipment (see section "Jump start-
ing the equipment").
Wire ropes
• Check wire ropes for integrity and corrosion before start-up. Treat wire ropes in accordance
with the additional documentation "Maintenance and care of wire ropes".
3.5 Daily start-up

3.5.1 Visual check before daily start-up
Risk of causing damage to the equipment!
Any unresolved deficiencies can cause damage to the equipment.
Δ Visually check the equipment before each start-up procedure.
Δ Ensure defects are repaired by authorized, skilled personnel immediately.
• Check the entire equipment and accessories to ensure they are complete.
• Check the entire equipment and accessories to ensure the screw connections and plug con-
nections are secure and complete.
• Check all components, particularly load-bearing steel components and ropes, for integrity and
wear.
• Check all electrical, hydraulic and pneumatic components for integrity and correct connection.
• Check for accumulations of fluid or leaks.
• Ensure all operating fluids are at the required levels.
• Compare the hours on the operating hours meter with the specified maintenance intervals and
perform any pending maintenance tasks.
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3 Operation
• Check that lighting equipment is in proper working order.
• Check to ensure signaling devices are in proper working order.
• Check that camera equipment is in proper working order.
✓ A visual check has been carried out properly.
The use of a cooling package is intended for constant operating temperatures below -20 °C (-4 °F).
For operation with a cold package, please consult the section entitled "Cold package" and the as-
sociated additional documentation.
3.5.2 Starting the Equipment

• Perform the measures outlined in the chapter "Visual check before daily start-up".
• Set the battery main switch to position "I".
• Set the fuse switch of the main fuse "F1" to position "I".
✓ The power supply is established.
• Close all doors and maintenance flaps and mount the protective coverings.
• Risk of causing damage to the equipment! Uncontrolled movements of the equip-

ment can cause damage to components. Set all operating elements to position "0". Unlock the
Emergency STOP button. Switch off the hydraulic pilot control.
Starting the diesel engine
Prerequisite:
– The wireless remote control is deactivated
Ignition lock overview:

P Required for refueling the equipment
0 Ignition off
1 Ignition on (preheating if preheating system is present )
2 Starting the diesel engine
• Risk of causing damage to the diesel engine! A cold diesel engine can be dam-
aged when operated at full load. Cold diesel engines should first be brought up to the operating
temperature at idling speed.
• Switch on the ignition.
✓ The B-Control screen boots up.
✓ The B-Control screen has booted up.
• Start the diesel engine by turning the ignition key to position (2).
✓ Diesel engine is running.
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3 Operation
Switching on the central lubrication system
• Press button (3.46) .
✓ Central lubrication system is switched on.
Checking the temperature of the diesel engine coolant and the hydraulic oil
For further information, please refer to the enclosed additional documentation entitled "B-Control
screen".
• Read the coolant temperature (1) of the

diesel engine on the B-Control screen.
• Read the hydraulic oil temperature (2) on the

B-Control screen.
✓ The coolant temperature of the diesel

engine or the hydraulic oil temperature is
not 20 °C.
• Warm up the diesel engine and hydraulic

system (see section "Bringing the diesel en-
gine and hydraulic system to the operating
temperature").
✓ The coolant temperature of the diesel

engine and the hydraulic oil temperature
is at least 20 °C.
✓ The equipment is ready for operation.
Bringing the diesel engine and hydraulic system to the operating

temperature
Prerequisite:
– Diesel engine is running.
• Deactivate the ECO mode.
• Set the speed of the diesel engine between 1100 and 1200 rpm.
✓ The temperature of the coolant rises.
✓ The temperature of the coolant is +20°C [70°F].
• Switch on the hydraulic pilot control.
• If possible, raise the rotary drive slightly above the center of the mast.
• Activate the swing brake.
✓ Indicator light (1.8) illuminates.
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3 Operation
• Actuate the "Turn upper carriage" function and drive the upper carriage against the activated
swing brake for approximately one minute.
• Change the direction of rotation and drive the upper carriage against the activated swing brake
for approximately one minute.
• Let the rotary drive turn at low speed in first gear.
✓ The hydraulic oil circulates in the hydraulic system.
• Observe the hydraulic oil temperature and continue to drive the upper carriage against the acti-
vated swing brake alternately for one minute.
✓ The temperature of the hydraulic oil is +20°C [70°F].
• End the process of driving the upper carriage against the swing brake.
• Stop the rotary drive.
• Activate the ECO mode.
✓ The diesel engine and hydraulic system have been brought to the operating temperature.
If a continuous increase in temperature cannot be detected, contact the BAUER after sales service
department.
The electronic filter query is active for oil temperatures of 30 °C and above.
3.5.3 Jump starting the equipment

If the batteries are not sufficiently charged to start the diesel engine, it is possible to jump start the
equipment.

If the electrical equipment is not ready for operation after the ignition is switched on, the batteries
may be completely discharged. Completely discharged batteries can explode when jump starting.
Contact with the battery acid can cause chemical burns on body parts.
Δ Do not jump start equipment with a completely discharged battery.
Δ Have the electric equipment inspected by a qualified person.
Δ Charge completely discharged batteries slowly and, if necessary, replace them with new ones.

If batteries are in operation, a highly flammable gas mixture can occur. Sparks. electrostatic dis-
charge or fire can ignite the gas mixture and the batteries can explode. This can result in persons
being seriously injured by burning or chemical burns.
Δ Do not use open flames or smoke in the immediate vicinity of batteries.
Δ Ensure that the correct polarity is used when connecting the jumper cable.
Δ The jumper cable for the minus connection (ground) should not be connected to the discharged
battery.
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3 Operation
Risk of causing damage to the electrical/electronic control system!

When jump starting the equipment, voltage peaks can damage/destroy the electrical control sys-
tem.
Δ Never clamp the minus connection (chassis) of the jumper cable directly to the discharged bat-
tery.
Δ When jump starting the equipment, use an electrical voltage source that corresponds to the ve-
hicle power supply.
Information on the configuration of the fuses, the batteries and the main battery switch is provided
in the "Equipment Overview" section.
Jump start aid on the equipment batteries
Prerequisite:
– A suitable auxiliary machine with identical on-board voltage is available.
– Suitable jump leads are available.
• Set the main fuse switch on the equipment to position "0".
• Set the main battery switch on the equipment to position "0".
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3 Operation
• Remove or fold open any battery covers and battery terminal covers.
• Risk of injury! Incorrect connection of the jump leads can cause the discharged
batteries to explode. This sprays battery acid in all directions, which can cause acid burns to
body parts. Never connect the jumper leads directly to the terminals of the cable bridges (5) of
the two batteries.
• Use the jump lead (6) to connect the positive pole (1) of the charged battery to the positive
pole(2) of the discharged battery.
• Connect one end of the jump lead (7) to the negative pole of (3) the charged battery.
• For devices with a point for starting with the aid of an external power source (4), remove the
protective cap (8).
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3 Operation
• Connect the other end of the jump lead (7) with the point for starting with the aid of an external
power source (4), the engine block or with a connected, solid, and unpainted metal part of the
equipment.
✓ An electrical connection between the charged battery of the auxiliary machine and the dis-
charged batteries of the equipment is now established.
• Start the diesel engine of the auxiliary machine.
• Set the main battery switch on the equipment to position "I".
• Set the main battery switch on the equipment to position "I".
• Start the equipment diesel engine.
✓ Equipment diesel engine is started.
If the alternator or battery charging system is defective, the diesel engine will stop running when
the jump lead is disconnected.
• Immediately disconnect the jump lead (7) from the engine block/unpainted metal part (4) of the
equipment.
• Disconnect the jump lead (7) from the negative terminal (3) of the auxiliary machine.
• Disconnect the jumper lead (6) from the positive terminal (2) of the equipment.
• Disconnect the jump lead (6) from the positive terminal (1) of the auxiliary machine.
• Install all battery pole covers and battery covers.
✓ The equipment has been jump started correctly.
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3 Operation
3.5.4 Safety checks before starting work - EMERGENCY-STOP

Risk of causing damage to the exhaust aftertreatment system!
An Emergency STOP safety test during active regeneration can cause damage to the exhaust af-
tertreatment system.
Δ Only perform an Emergency STOP safety test when the regeneration of the exhaust system is
complete.
Further information can be found in the section "Regeneration of the exhaust system".
Information regarding configuration of the EMERGENCY-STOP equipment can be found in the sec-
tion "EMERGENCY-STOP".
Prerequisite:
• Actuate EMERGENCY-STOP.
✓ All operating and control elements are deactivated.
✓ The diesel engine is switched off.
• Unlock EMERGENCY-STOP.
✓ Safety test has been carried out properly.
3.5.5 Safety checks before starting work - "Pilot control" safety lever
For information on the arrangement of the "pilot control" safety stick on the equipment, please refer
to the section entitled "Pilot control safety stick".
Prerequisite:
• Switch off pilot control.
• Select the hydraulic function.
✓ Function does not respond.
✓ Hydraulic system is deactivated.
• Switch on pilot control.
• Select the hydraulic function.
✓ Function is executed.
✓ Hydraulic system is operational.
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3 Operation
3.5.6 Safety tests before starting work - Base machine limit switches
For information on the arrangement of limit switches on the base machine, please refer to the sec-
tion "Base machine limit switches".
The maximum permissible mast inclination for the respective process must be read from the stabil-
ity table.
Prerequisite:
Hoist limit switch HS 1
• Wind in the main rope with the main winch.
• Move the attached load (approx. 100 kg) slowly against the weight of the hoist limit switch.
✓ Winding in of the main rope stops.
Hoist limit switch HS 2
• Wind in the auxiliary rope with auxiliary winch.
• Move the attached load (approx. 100 kg) slowly against the weight of the hoist limit switch.
✓ Winding in of the auxiliary rope stops.
Limit switch ES 15
• Move the crowd sledge to the lower end of the mast.
• Slowly move the crowd sledge upwards until a message appears on the B-Tronic screen and
an acoustic signal sounds simultaneously.
✓ Monitoring of the permissible range for the crowd sledge is active.
Absolute encoder B 004
• Tilt mast backwards.
✓ Mast exceeds permitted value.
✓ Rotary drive is inoperable.
✓ Crowd is inoperable.
Limit switch B 39
• Increase operating radius
✓ Operating radius increases to the maximum value.
✓ Mast stops.
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3 Operation
Inclination sensor B 40 (operation)
Check mast inclination to the side.
• Tilt mast to the left.
✓ Mast tilts as far as the permitted value.
✓ Mast stops.
• Tilt mast to the right.
✓ Mast stops.
Inclination sensor B 40 (rigging mode)
Check mast inclination to the side.
• Tilt mast in rigging mode to the left.
✓ Mast stops.
• Tilt mast in rigging mode to the right.
✓ Mast stops.
3.5.7 Safety tests before starting work - Freewheel of the main winch
Swinging loads can cause damage to the mast and/or upper carriage.
Δ Do not turn the upper carriage during the inspection process.
Δ Do not adjust the mast during the inspection process.
The freewheel function of the rope winch must be tested by suspending a load of at least 500 kg.
The rope must be unwound at a controlled speed.
BG 28 H # 5336 / V01_en_04.2021 157 - 390

3 Operation
Checking the freewheel function

Key switch/foot Control lever, left Indicator Process
switch (20) light
- - • Turn key switch (3.4) to posi-
tion "1".
✓ The freewheel function is

switched on.
3.4
- - • Press and hold the foot switch
(5.2).
• Risk of accident!
Different winding speeds of
the ropes during the tests can
cause the attached loads to
swing, leading to serious in-
juries from crushing and colli-
sions. Please observe the
safety section of this instruc-
tion manual. In case of danger,
stop the freewheel inspection
by moving the left control lever
backwards.
- 20.2 • Briefly press the button (20.2)
on the left control lever.
✓ Freewheel is triggered.
1.9
✓ Indicator light of the button
(1.9) turns green.
✓ Weight is moved downwards

at a controlled speed.
- - • Release the foot switch (5.2).
✓ Freewheel is blocked.
• Turn key switch (3.4) to posi-

tion "0".

switched off.
3.4
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3 Operation
3.6 Shut-down
3.6.1 Brief interruption or end of work
• Only position the equipment on horizontal and level ground with sufficient load-bearing capac-
ity.
• Position the equipment so that it does not block traffic.
• Align the mast vertically.
• Position the upper carriage parallel to the undercarriage and in the main direction of travel.
• Lower process equipment and movable loads as far as possible.
• Set all operating elements to position "0".
• Switch off the hydraulic pilot control.
• Risk of causing damage to the diesel engine! A diesel engine running at full load
can be damaged if it is shut down suddenly. Before switching the diesel engine off, allow it to
run at idle speed for 5 minutes.
• Switch off the diesel engine by turning the ignition key to position "0".
• Remove the ignition key.
• Lock the cab, maintenance flaps and other doors when leaving the equipment.
✓ The equipment has been shut down.
For equipment with ACS quick-release coupling, the pressure release for the hydraulic line to the
crowd sledge must always be activated once the process equipment has been removed (see sec-
tion "Pressure relief on the crowd sledge").
3.6.2 Shutting down due to high wind speeds

The equipment must be derigged above a particular wind speed. Further information can be found
in the section "Permissible wind speeds".
• Position the equipment on horizontal and level ground with sufficient load-bearing capacity.
• Position the equipment in such a way that it does not cause an obstruction to traffic.
• Position the upper carriage parallel to the undercarriage and in the main direction of travel.
• Place the process equipment on the ground (see section "Disassembly/removal of process
equipment").
• Lower the Mast (see section "Lowering theMast").
• With a locking bar: Lock the upper carriage to the undercarriage.
• Set all operating elements to position "0".
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3 Operation
• Risk of damage to the diesel engine! A diesel engine running at full load can be
damaged if it is shut down suddenly. Before switching off the diesel engine, allow it to run at
idle speed for 5 minutes.
• Switch off the diesel engine by turning the ignition key to position "0".
• Set the battery main switch to position "0".
• Lock the cab, maintenance flaps and other doors when leaving the equipment.
✓ The equipment has been shut down.
3.6.3 Prolonged standstill or storage - Base machine

Prerequisite:
– The equipment has been shut down.
Risk of causing damage to components

Prolonged periods of standstill will result in damage to components if the necessary preservation
measures are not implemented.
Δ Perform the measures described below.
Upper carriage and attachment

• Before longer downtime periods, perform the appropriate conservation measures for the upper
carriage and the attachment (e.g. apply protective wax).
Hydraulic system
Risk of causing damage to the hydraulic system!
During longer downtime periods, it is possible for water to accumulate in the hydraulic tank, particu-
larly if biodegradable oil is used. When the equipment is started up, these could get into and dam-
age the hydraulic system.
Δ Check the hydraulic tank for water accumulations regularly and before start-up, and remove
any water accumulations found.
• Before longer downtime periods, fill the hydraulic system completely with oil.
If biodegradable oil is used, special measures must be undertaken. Always consult the manufac-
turer.
Diesel tank
• Fill the diesel tank completely with diesel to protect it from corrosion.
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3 Operation
Diesel engine
• Every 45 days, start the diesel engine and let it run at operating temperature for about 30 min-
utes.
Before longer downtime periods, apply appropriate conservation measures to the diesel engine.
Observe the additional documentation from the manufacturer.

• Switch on the air-conditioning system every 2 to 3 weeks and let it run for a short time.
Further information can be found in the enclosed additional documentation or contact BAUER after
sales service.
Slewing ring
• Check the material surface of the slewing ring and the sprocket for rust and dust.
• Clean and conserve the slewing ring and the sprocket in accordance with the section "Mainte-
nance/repair".
Undercarriage telescopic guide

• Check the material surface of the telescopic guide for rust and dust.
• Clean and conserve the telescopic guide in accordance with the section "Maintenance/repair".
Cylinders and piston rods

• Check the material surface of the cylinders and piston rods for rust and dust.
• Clean and conserve the cylinders and piston rods in accordance with the section "Mainte-
nance/repair".
Hose assemblies
• Store the hose assemblies in a cool, dry and dust-free location. Protect against direct sunlight
and UV radiation. Observe the minimum permissible bending radii.
• Hose assemblies must be inspected regularly by a qualified person. National standards and
guidelines in the country of assignment must be observed.
Electrical system/electrical cables

• Store the electrical cables and electronic components in a cool, dry and dust-free location. Pro-
tect against direct sunlight and UV radiation.

BG 28 H # 5336 / V01_en_04.2021 161 - 390
3 Operation
Wire ropes
Further information can be found in the enclosed additional documentation "Maintenance and care
of wire ropes"!
3.6.4 Decommissioning
• Shut down the equipment (see section "Brief interruptions or end of work").
• Perform other measures according to the section "Environmental protection/disposal [➙ 387]".
3.7 Basic functions - Base machine

3.7.1 Making the equipment operational
Symbol Process
• Set the battery main switch to position "I".
• Start the equipment.
• Switch on the hydraulic pilot control.
✓ Hydraulic functions are activated.
✓ The base machine is ready for operation.
If, after switching on the battery main switch, the base machine is not ready to operate, proceed as
follows:
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3 Operation
Symbol Function
• Check all of the Emergency STOP buttons; release the buttons if necessary.
• Check the starter speed and, if necessary, check the charge state of the batter-
ies. If necessary, charge the batteries, replace them with new ones or start the
equipment with the aid of an external power source (see section "Daily start-up,
jump starting the equipment").
• Check the fuel level. If necessary, replenish fuel.
• Check to ensure the main fuse switches are set to position "I". If necessary, set
the corresponding fused switch to position "I". If the fused switch cannot be
switched, there is a fault.
• Check the condition of the fuses present. Replace defective safety fuses with
new safety fuses.
3.7.2 Driving and steering - Basics

Risk of causing damage to the crawlers!
Incorrect operation of the crawlers reduces their service life.
Δ Main direction of travel always in the direction of the arrow on the crawlers (front idler at the
front, crawler drive at the rear).
Δ Do not travel long distances. To move the equipment over longer distances use a suitable
transporting vehicle.
1 Crawler drive
2 Arrow in main direction of
travel
3 Front idler
The following table describes how the base machine is driven and directed with the help of the
drive pedals.
Drive pedal Process

• Press both drive pedals forwards.
✓ Base machine drives forwards in the

main direction of travel.
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3 Operation
Drive pedal Process

• Press both drive pedals backwards.
✓ Base machine drives backwards in the

• Press left drive pedal forwards.
✓ Base machine turns clockwise around

the right crawler.
• Press right drive pedal forwards.
✓ Base machine turns counter-clockwise

around the left crawler.
• Press left drive pedal backwards.

around the right crawler.
• Press right drive pedal backwards.
✓ Base machine turns clockwise around

the left crawler.
• Simultaneously press the left drive pedal

forwards and the right drive pedal back-
wards.
✓ Base machine turns clockwise on the

spot.
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3 Operation
Drive pedal Process

• Simultaneously press the left drive pedal
backwards and the right drive pedal for-
wards.

on the spot.
Suitable levers can be attached to the drive pedals to enable more precise driving and steering pro-
cedures. The levers are operated in an analogous manner to the drive pedals.
3.7.3 Driving the base machine

Prerequisite:
– All the conditions specified in the "Stability" chapter are met.
• Prepare the equipment for operation.
• Swing the upper carriage parallel to the undercarriage and activate the swing brake.
• Adjust the minimum operating radius.
• Push both drive pedals (5.1) and (5.4) or

both levers (5.5) and (5.6) forwards.
✓ Base machine drives forwards in the main

direction of travel.

both levers (5.5) and (5.6) backwards.
✓ Base machine drives backwards in the main

3.7.4 Driving the base machine

Prerequisite:
– All the conditions specified in the "Stability" chapter are met.
• Prepare the equipment for operation.
• Swing the upper carriage parallel to the undercarriage and activate the swing brake.
• Adjust the minimum operating radius.
BG 28 H # 5336 / V01_en_04.2021 165 - 390

3 Operation

both levers (5.5) and (5.6) forwards.
✓ Base machine drives forwards in the main


both levers (5.5) and (5.6) backwards.
✓ Base machine drives backwards in the main

3.8 Basic functions - Upper carriage

3.8.1 Diesel engine
Diesel engine
The performance of the diesel engine is reduced if the temperature
– of the hydraulic oil
– of the cooling water
– of the charge air
is too high.
A corresponding message appears on the screen (for example: B-Tronic, monitor unit in the control
panel) when the performance of the diesel engine is reduced.
3.8.2 Operating the swing brake

The swing brake locks the upper carriage in place.

Activating the swing brake while the upper carriage is turning can cause damage to the swing
mechanism gear.
Δ Only activate the swing brake when the upper carriage has come to a stop.
The swing brake can lock the upper carriage in any position.
Activating the swing brake

Button Indicator Process
light
• Press button (20.4) forwards.
✓ Indicator light (1.8) illuminates.

1.8 ✓ Indicator light (20.4) turns red.
20.4 ✓ The swing brake is activated.
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3 Operation
Deactivating the swing brake

light
• Press button (20.4) backwards.
✓ Indicator light (1.8) does not illuminate.

1.8 ✓ Indicator light (20.4) turns green.
20.4 ✓ The swing brake is deactivated.
Releasing the swing brake in the rigging mode
It may be necessary to release the swing mechanism briefly during assembly and disassembly pro-
cedures.
Prerequisite:
– The rigging mode is activated.
– The equipment is positioned on a firm, level and horizontal working platform.
• Risk of accident! The upper carriage can rotate unhindered while the "Release
swing brake" function is activated due to the disengaged swing brake. This can damage the
equipment or cause it to fall over! This could result in severe or fatal injury! Only perform the
procedure briefly without a locking bar between the upper carriage and the undercarriage!

light
• Press button (20.4) briefly to the rear and hold.
✓ Indicator light (1.8) does not illuminate.

1.8 ✓ Indicator light (20.4) turns green.
20.4 ✓ The swing brake is deactivated.
✓ The swing mechanism is released.
3.8.3 Turning the upper carriage

Basic function
Prerequisite:
– Mast prop is retracted.
– Swing brake is deactivated.
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3 Operation
Control lever, left (20) Process

• Move the left control lever to the right.
✓ Upper carriage turns clockwise.
• Move the left control lever to the left.
✓ Upper carriage turns counterclockwise.
When the control lever is released, the upper carriage is slowly decelerated hydraulically.
A careful counter-movement results in faster braking.
Fine rotation of the upper carriage
To facilitate the process of attaching the casing drive adapter to the casing tube, for example, the
upper carriage can be finely rotated.
Δ Before rotating the upper carriage, release the swing brake and hold the operating button.
The upper carriage can only be finely rotated for a few degrees.
Δ Use the basic functions to rotate the upper carriage to the approximate position where fine ro-
tation is required.
Prerequisite:
– The upper carriage has been rotated to the approximate position where fine rotation is re-
quired by using the basic functions.
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3 Operation
Button Indicator Control lever, left (20) Process

light
• Press button (20.4) to the rear and
keep it depressed.
✓ Indicator light (1.8) does not il-

1.8 luminate.
20.4
✓ Indicator light (20.4) turns
green.
✓ Swing brake is deactivated.

• Move the left control lever to the
right.
✓ Upper carriage turns clock-

wise.
• Set the left control lever to the neu-

tral position.
✓ The upper carriage comes to a

standstill.
– The upper carriage no longer
rotates.
• Release button 20.4.

• Press button (20.4) to the rear and
keep it depressed.
✓ Indicator light (1.8) does not il-

1.8 luminate.
20.4
✓ Indicator light (20.4) turns
green.
✓ Swing brake is deactivated.

• Move the left control lever to the
left.
✓ Upper carriage turns counter-

clockwise.
• Set the left control lever to the neu-

tral position.
✓ The upper carriage comes to a

standstill.
– The upper carriage no longer
rotates.
• Release button 20.4.
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3 Operation
3.8.4 Check the control system of the load limit control
Further information can be found in the enclosed additional documentation "AT system".
3.8.5 Operating the diesel engine emergency control

When the emergency control system is switched on, the equipment is in emergency mode. In this
mode, the safety and protective equipment (such as the limit switches, overload shutdowns, moni-
toring functions, fault indicators) are deactivated. As a result, precise control of several of the
equipment's functions is not possible. The restricted control system can cause the equipment to tip
over. This could result in severe or fatal injury.
Δ Operate the equipment with extreme caution in the emergency mode.
Risk of causing damage to the equipment or the components!

In emergency mode, the equipment does not switch off automatically when operating fluids reach
critical levels, because there is no data exchange between the equipment and the control system.
Equipment or components can be badly damaged.
Δ Before operating the equipment in emergency mode, please contact the customer service de-
partment.
Δ Operate the equipment with particular care.
In the emergency mode there is no automatic shutdown of the equipment when operating fluids
reach critical values.
The "Emergency mode" menu on the B-Control screen does not impair equipment safety.
The menu enables a defective speed sensor or speed control to be electronically replaced until it
can be repaired. Moreover, the engine speed can be stabilized by reducing the pump performance.
Only activate emergency control after consultation with the after sales service, in order to ensure
any warranty claims remain valid.
The diesel engine has two different emergency control systems. These are selected for the error
that occurs.
Emergency control A
Prerequisite:
– Diesel engine running at reduced speed and the diesel engine speed cannot be increased.
Switch on emergency control A
Further information can be found in the enclosed additional documentation "AT system".
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3 Operation
Emergency control B
Prerequisite:
– The diesel engine does not start.
• Switch off the ignition.
• Remove cover (1).
• Set switch (2) to position "1".
✓ Acoustic signal is heard.
✓ A message appears on the screen of the

B-Tronic.
• Switch on the ignition and start the diesel en-

gine.
• Set the engine speed using the buttons (3.55)

and (3.56).
✓ Diesel engine emergency control is activated. 3.55 3.56
3.8.6 Exhaust gas post-treatment

Operating the SCR system
The injectors of the SCR system can be damaged if the exhaust gas temperatures are too high.
Δ Only switch off the diesel engine when the injectors of the SCR system have cooled sufficiently.
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3 Operation
The SCR system effectively reduces the emission of nitrogen oxide. Selective catalytic reduction
enables compliance with particularly low emission limit values. A corresponding fluid is required in
the tank of the SCR system for operation ("AdBlue" or "Diesel exhaust fluid").
Continued operation of the diesel engine
In order to protect the injectors of the SCR system from the high exhaust gas temperatures, the
diesel engine should not be shut down immediately under certain circumstances. A corresponding
indicator light will be visible to the equipment operator in this case.
To deactivate the "Do not switch off diesel engine" indica-
tor light, the following conditions must be fulfilled:
– "High exhaust gas temperatures" indicator light is

off.
– DPF outlet temperature is below 400 °C.
If the diesel engine is switched off while the "Do not switch off diesel engine" indicator light is illumi-
nated, it is recorded in the engine control unit. If subsequent damage occurs as a result, any de-
fects liability claims or warranty claims may be invalidated.
Indicator light Process

If the indicator light illuminates:
• Idle the diesel engine until the display goes out.
• Only then switch off the diesel engine.
Disconnecting the battery main switch
To empty the lines of the SCR system, the corresponding pump continues to run briefly after
switching off the equipment. The battery main switch must remain switched on during this time.
An indicator light indicates whether the pump of
the SCR system is running. The indicator light is
located near the battery main switch. A label
refers to this indicator light.
If the indicator light illuminates:
• Wait until the indicator light goes out.
• Only then switch off the battery main switch.
Displays on the screen
The status of the SCR system is permanently displayed on the operating screen.
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3 Operation
Indicator light Description

Low fill level in SCR system.
Engine warning
Engine failure
Exhaust system fault.
Low fill level in SCR system
The existing quantity in the tank of the SCR system is displayed next to the "Low fill level in SCR
system" symbol in percent. Additional indicator lights will also be shown depending on the fill level.
Indicator light Process
Level is sufficient.
Level below 19 %.
Level below 12.5 %.
"Exhaust system fault" indicator light flashes.
Level below 6 %.
Diesel engine power is limited to 50% of the maximum torque.
The speed of the diesel engine is reduced to a maximum of 1000 rpm.
The level in the tank of the SCR system is too low.
• Fill the tank of the SCR system with a suitable fluid.
Faults during operation
The SCR system has extensive diagnostics options.
A distinction is made between the following faults:
– Quality of the fluid in the SCR tank ("Q")
– Dosing system ("D")
– Manipulations of the system ("T")
– Exhaust gas return ("E")
A fault during operation will trigger a warning level that is issued for a fixed time period. When the
first warning level has expired, it is followed by a second and third. Each warning level is displayed
on the operating screen accordingly.
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3 Operation
When the last warning level has been issued, it is only possible to operate the equipment with re-
duced power:
– Diesel engine power is limited to 50% of the maximum torque.
– The speed of the diesel engine is reduced to a maximum of 1000 rpm.
A restart of the equipment enables short-term operation with normal power.
If the fault has been rectified, the equipment can be used in normal operation again.
Operating regeneration of the exhaust system

Risk of burning!
If regeneration is activated, hot exhaust gases escape from the exhaust system. Persons can be
burnt by the hot exhaust gases.
Δ It is forbidden to remain in the danger area during regeneration.
Risk of fire!
If regeneration is activated, hot exhaust gases escape from the exhaust system. The exhaust sys-
tem and its exhaust fumes can cause flammable materials to ignite.
Δ The danger zone must be kept clear at all times.

The exhaust system can be damaged by irregular regeneration.
Δ Only deactivate automatic regeneration in exceptional circumstances.
Δ Carry out manual regeneration as promptly as possible when the corresponding indicator light
is displayed on the operating screen.
Determining parameters for exhaust aftertreatment

• Press button (1.5) until the "Service" menu is
displayed.
• Turn knob (1.6) until "Exhaust gas post-treat-

ment" is highlighted.
• Press knob (1.6).
✓ The parameters for exhaust gas post-treat-

ment are displayed on the screen (1.1).
Displays on the screen

Symbol Description
Engine warning
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3 Operation
Symbol Description
Engine failure
Regeneration of the soot particle filter is required.
Regeneration is deactivated.
High exhaust gas temperatures that develop during an active regenera-

tion process.
Do not switch off the diesel engine.
Time until the next regeneration.
Loading conditions of the soot particle filter

Symbol Process
Soot particle filter load above 80 %. Regeneration required.
Soot particle filter load above 100 %. Engine performance is continuously

reduced. Regeneration is urgently required.
Soot particle filter load above 116 %. Regeneration is urgently required.
Power reduction of the diesel engine! After 5 minutes in this

state the diesel engine will run in idle mode.
Failure of the diesel engine! After 10 minutes in this condition

the diesel engine can only be recommissioned by customer service. Re-
generate the soot particle filter beforehand.
Soot particle filter load above 140 %. Diesel engine shuts down.
The particle filter must be changed.
Automatic regeneration
After the diesel engine is switched on, regeneration of the exhaust system is in automatic mode. A
regeneration of the exhaust system is performed automatically in the event of certain diesel engine
parameters.
– The speed of the diesel engine can change automatically during the regeneration process.
– Parameters for regeneration of the exhaust system can be found in the manufacturer's doc-
umentation.
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3 Operation
Deactivating automatic regeneration

light
• Press button (3.50) for 2 seconds.
✓ The "Regeneration" indicator light goes out.
✓ The "Regeneration deactivated" indicator light illuminates.
✓ Automatic regeneration is deactivated.
Automatic regeneration is reactivated when the diesel engine is restarted.
Manual regeneration
A manual regeneration process can be carried out by the operator when the corresponding indica-
tor light is displayed on the operating screen.
– Further parameters for regeneration of the exhaust system can be found in the manufac-
turer's documentation.
light
- Prerequisite:
The "Regeneration deactivated" indicator light illuminates or

The "Diesel particle filter load" indicator light illuminates.
• Press button (3.51) for 2 seconds.
✓ The indicator light illuminates and the manual regeneration

process is activated.
• Regeneration is performed.
✓ Indicator light goes out.
✓ Soot particle filter is regenerated.
3.8.7 Operating the ECO mode

Prerequisite:
Activate ECO mode

Button Process
• Press button (3.34).
✓ LED of button (3.34) lights up and ECO mode is activated.

3.34
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3 Operation
If the Eco-Mode is selected, the speed of the diesel engine is automatically controlled by the Eco-
Mode and the function of the knob (3.6) is deactivated.
Deactivate ECO mode

Button Process
✓ LED of button (3.34) goes out.

3.34
• Set the desired maximum speed of the diesel engine with the knob (3.6).
✓ ECO mode is deactivated.

3.6
The speed set at the knob (3.6) is applied.
3.8.8 Operating the automatic diesel engine stop

Prerequisite:
– Diesel engine is running.
Switching the automatic diesel engine stop on

Button Process
✓ LED of button (3.38) lights up.

3.38 ✓ The automatic diesel engine stop is switched on.
The diesel engine is only switched off after a set time if the conditions for the following parameters
are complied with:
– Speed
– Temperature cooling liquid
– Ambient air temperature
– The "Do not switch off diesel engine" indicator lamp does not light up (see chapter: "Re-
generation of the exhaust system").
– The control lever and foot pedals are not actuated.
Before switching off the diesel engine, a message is displayed on the B-Control screen. To prevent
the diesel engine from being shut down, do one of the following:
• Use the control lever or foot pedals to request power from the diesel engine.
• Switch off the automatic diesel engine stop.
BG 28 H # 5336 / V01_en_04.2021 177 - 390

3 Operation
✓ The diesel engine is switched off after the time has passed without any action.
• Use the ignition key to restart the diesel engine.
Switching off the automatic diesel engine stop

Button Process
✓ LED of button (3.38) goes out.

3.38 ✓ The automatic diesel engine stop is switched off.
3.8.9 Operating the engine diagnostics system

Risk of causing damage to diesel engine!
When the red indicator light (3.52) is flashing or illuminated, the diesel motor has a malfunction. If
continued in operation, the diesel engine can be damaged.
Δ Switch off the diesel engine immediately.
Δ Have faults repaired without delay.
The electronic diagnosis menu of the engine diagnostics system draws the operator's attention to
faults. Faults are indicated with the help of the indicator lights (3.52) and (3.53).
Indicator Process
light
Prerequisite:
– Indicator light (3.52) is flashing or illuminated.

3.52 • Switch off the diesel engine immediately.
• Use the blinking rhythm to ascertain the code number of the fault.
• Inform the customer service and commission them to repair the fault.
✓ The fault has been properly repaired.

Prerequisite:
– Indicator light (3.53) is flashing.

3.53 • Use the blinking rhythm to ascertain the code number of the fault.
Ascertain code number
The indicator lights (3.52) and (3.53) flash in a particular rhythm.
• Count the flashing light signals of the relevant control light.
☼ 1 Flashing signal
X short pause (1 second)
178 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
XXXXX long pause (5 seconds)
Example:
☼ X ☼☼☼ X ☼☼☼☼☼ XXXXX ☼ X ☼☼☼ X ☼☼☼☼☼ …

1 3 5 1 3 5 …
The code number is "135"
• Display further fault codes as follows:
Press but- Process

ton
✓ Buttons (3.55) and (3.56) are activated.

3.54
• Press buttons (3.55) or (3.56).
✓ Fault signals saved in the fault menu are indicated by flashing light signals.
3.55 • Use the rhythm of the flashing light signals to ascertain the code number of the
fault.

3.56
Customer service must be contacted to decode the code numbers and repair the faults.
3.8.10 Refueling
The diesel engine can be damaged, if you use fuel that does not meet the requirements.
Δ Only use fuel that has been approved by the diesel engine manufacturer.

Foreign objects or contamination in the fuel can damage the diesel engine or restrict its functional-
ity.
Δ Guard the openings against contamination.
Δ Prevent the entry of foreign objects and dirt into the fuel tank.

When the diesel engine is switched off, process equipment and movable loads can fall uncontrol-
lably and thereby damage the components of the equipment.
Δ Lower process equipment and movable loads as close to the ground as possible before switch-
ing off the diesel engine.
BG 28 H # 5336 / V01_en_04.2021 179 - 390

3 Operation
Prerequisite:
1 Filler opening of the diesel engine

2 Filling pump
3 Pump hose
The equipment can be refueled either using the internal refueling pump or via the filler openings us-
ing an external refueling pump.
180 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
Refueling with the internal refueling pump

• Open the filler opening (1).
• Clean the coarse filter (4) if necessary.
• Cover the filler opening (1) with the tank cap

(5).
• Attach the pump hose (9) with the quick-re-

lease coupling to the connection (8) of the
refueling pump (2).
• Insert the pump hose (9) into the fuel tank.
• Insert the ignition key into the ignition slot.
• Turn the ignition key to position "P".
• Press button (6).
✓ Refueling process starts.
When the diesel tank is full, the refueling process stops automatically.
• Finish the refueling process by pressing button (7).
✓ Diesel tank is full.
• Close the filler opening (1).
✓ Refueling process has been properly carried out.
Refueling via the filler openings
• Turn the ignition key to position "0".
• Open the filler opening (1).
• Clean the coarse filter (4) if necessary.
• Pour the fuel into the filler opening (1) with

the help of a suitable filling unit.
✓ Diesel tank is full.
• Close the filler opening (1).
✓ Refueling process has been properly carried out.
BG 28 H # 5336 / V01_en_04.2021 181 - 390

3 Operation
3.8.11 Operating the camera attachment
Further information can be found in the section "Camera equipment".
screen".
3.8.12 Operating the "Climatronic" system

Prerequisite:
3.8.13 Operating the central lubrication system

The central lubrication system lubricates the equipment's connected lubrication points at definite in-
tervals. The interval lubrication is only active when the central lubrication system is switched on.
Not all lubrication points are supplied by the central lubrication system. These lubrication points can
be inferred from the lubrication plan.
Switching on the central lubrication system

Button Process
✓ LED in the button (3.46) turns green.

3.46 ✓ The central lubrication system is switched on.
Switching off the central lubrication system

Button Process
✓ LED in the button (3.46) does not light up.

3.46 ✓ The central lubrication system is switched off.
182 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
Activating intermediate lubrication

Button Process
✓ Intermediate lubrication has been activated.

3.42
The intermediate lubrication function can be activated when needed.
Acknowledging fault messages
The "Acknowledge fault messages" function is available for equipment with timing control of the
central lubrication system.
Initial situation:
– A fault message is displayed.

Button Process
✓ The fault message is acknowledged.

3.42
Setting lubrication intervals
3.8.14 Operating integrated service platform

Opening the integrated service platform
Always pull out the service platform fully.
BG 28 H # 5336 / V01_en_04.2021 183 - 390

3 Operation
• Unlock the handle (1) via the locking ele-

ment (2).
• Fully depress the handle (1) and pull out the

service platform (3).
• Maneuver the handle (1) upwards and se-

cure it with locking element (2).
✓ The service platform (3) has been se-

cured from closing unintentionally.
• Fold out the walking platform (4).
• Risk of falling! If the handrails are

not closed, the operator may lose balance
while carrying out maintenance work and fall.
The handrails always close when the inte-
grated service platform is pulled out.
• Close the handrail (5) and engage it in

bracket (6).
✓ The service platform has been opened correctly.
184 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
Closing the integrated service platform

• Open the handrail (5) and engage it in
bracket (7).
• Close the opened maintenance flaps (8).
• Fold in the walking platform (4).
• Unlock the handle (1) via the locking ele-

ment (2) and depress it fully.
BG 28 H # 5336 / V01_en_04.2021 185 - 390

3 Operation
• Press and hold the handle (1) and push the

service platform (3) inwards.
• Lock the handle (1) via the locking element

(2).
✓ The service platform (3) has been secured

and closed correctly.
3.9 Basic functions - Undercarriage

3.9.1 Operating the undercarriage
Extending/retracting the telescoping cylinders
The telescoping cylinders move the crawlers into the operating position or transport position.
Extending telescoping cylinders: Operating position

Button Process
• Press and hold button (3.26) until the crawlers are fully extended.
✓ The telescoping cylinders of the undercarriage are in the operating position.

3.26
186 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
Retracting telescoping cylinders: Transport position

Button Process
• Press and hold button (3.25) until the crawlers are fully retracted.
✓ The telescoping cylinders of the undercarriage are in the transport position.

3.25
Extending/retracting the telescoping cylinders with radio remote control
3.10 Basic functions - Attachment

Tipping hazard!
Tipping hazard!
If the equipment is not correctly aligned when the boom is raised and lowered, it can tilt and fall
over. This could result in serious or fatal injuries to the equipment operator and persons in the vicin-
ity of the equipment.
Δ When raising or lowering the boom, make sure that the rope is in a vertical position. If this is
not the case, align the equipment accordingly.
Δ When the boom is raised or lowered, attached loads remain lying on the ground.
3.10.1 Aligning the mast automatically

When the function "Align mast automatically" is selected, there is no need to manually align the
mast during operation.
Risk of causing damage to components of the mast and the mast prop!
Components of the mast placed on the ground or an extended mast prop can be badly damaged
by the function "Align mast automatically".
Δ The mast components and the mast prop must not be in contact with the ground when the
function "Align mast automatically" is selected.
Prerequisite:
– Mast inclination deviates by more than 0.1° from the preset values
– Operation is selected.
BG 28 H # 5336 / V01_en_04.2021 187 - 390

3 Operation
Aligning the mast via the control lever

Button Process
10.3 • Press and hold button (10.3).
✓ Mast is aligned.
✓ The mast is aligned.
The process is terminated by releasing the button early.
3.10.2 Adjusting the operating radius

If the operating radius is adjusted, the Mast moves forwards and backwards on a parallel line. The
distance between the Mast and the upper carriage is increased and reduced.
To adjust the operating radius it is necessary to distinguish between rigging mode and operation. In
rigging mode the Mast is raised or lowered, while in operating mode the Mast is only tilted for-
wards, backwards, or sideways within the permissible range.
188 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
In rigging mode
Button Control lever, right Indica- Process
(10) tor
light
• Press button (3.18) or
button (3.19).
✓ Rigging mode is se-

3.18 lected.
✓ Button (3.23) is acti-

vated.
✓ The "Boom cylinder"

3.19 function is selected.
3.23
- - • Move the right control
lever (10) forwards.
✓ Both boom cylinders are

extended and the oper-
ating radius increases.
- - • Move the right control
lever (10) backwards.
✓ Both boom cylinders are

retracted and the oper-
ating radius is reduced.
✓ Button (3.23) is not illu-

minated.
3.23
✓ The "Boom cylinder"
function is not selected.
During operation
Button Process
• Press and hold button (1.24).
✓ LED of button (1.24) turns green.

1.24 ✓ Both boom cylinders are extended and the operating ra-
dius increases.

1.32 ✓ Both boom cylinders are retracted and the operating ra-
dius is reduced.
BG 28 H # 5336 / V01_en_04.2021 189 - 390

3 Operation
or
Control lever, right Process

(10)
• Hold button (10.1) to the right from the
equipment operator's point of view.
✓ Operating radius is increased.
10.1
• Hold button (10.1) to the left from the equip-
ment operator's point of view.
✓ Operating radius is reduced.
10.1
To enable parallel adjustment of the Mast, the inclination of the Mast must be aligned in parallel
(see section "Automatically aligning the Mast").
Depending on the configuration, the operating radius is electronically limited (electronic support
bracket). Observe the corresponding messages on the B-Tronic display.
3.10.3 Adjusting the mast inclination

In order to adjust the Mast inclination, it is necessary to distinguish between the rigging mode and
operation. In the rigging mode the Mast is raised or lowered, while in the operating mode the Mast
is only tilted forwards, backwards, or sideways within the permissible range.
In rigging mode
Prerequisite:
– Boom cylinders are fully extended.
– No process equipment is mounted on the mast.
190 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
Button Control lever, right Indicator Process

(10) and left (20) light
• Press button
(3.18).
-
✓ LED of button
3.18 3.24 (3.18) lights
up green.
✓ LED of indica-
tor light (3.24)
turns green.
• Move the right

control lever (10)
and left control
lever (20) back-
wards.
✓ The backstay
cylinders are re-
tracted and the
mast is raised.
• Press button
(3.19).
-
✓ LED of button
3.19 3.24 (3.19) lights
up green.
✓ LED of indica-
tor light (3.24)
turns green.
• Move the right

control lever (10)
and left control
lever (20) for-
wards.
✓ The backstay
cylinders are ex-
tended and the
mast is lowered.
In working mode
Button Process
✓ Left backstay cylinder is extended.

1.25
✓ Right backstay cylinder is extended.

1.26
BG 28 H # 5336 / V01_en_04.2021 191 - 390

3 Operation
Button Process
✓ Left backstay cylinder is retracted.

1.33
✓ Right backstay cylinder is retracted.

1.34
Button Button Process

• Press and hold buttons (1.25) and (1.26).
✓ The backstay cylinders are extended and the

mast tilts forwards.
1.25 1.26
• Press and hold buttons (1.33) and (1.34).
✓ The backstay cylinders are retracted and the

mast tilts backwards.
1.33 1.34
or
Button Process
• Press and hold button (20.7) forwards.
✓ Left backstay cylinder is extended.
20.7
• Press and hold button (10.7) forwards.
✓ Right backstay cylinder is extended.
10.7
• Press and hold button (20.7) backwards.
✓ Left backstay cylinder is retracted.
20.7
192 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
Button Process
• Press and hold button (10.7) backwards.
✓ Right backstay cylinder is retracted.
10.7
Button Button Process

• Press and hold button (20.7) and button
(10.7) forwards.
✓ The backstay cylinders are extended and the

mast tilts forwards.
20.7 10.7
• Press and hold button (20.7) and button
(10.7) backwards.
✓ The backstay cylinders are retracted and the

mast tilts backwards.
20.7 10.7
3.10.4 Operating the mast prop

Tipping hazard!
Danger of getting crushed!

When the mast prop is extended or retracted, persons in the danger zone can be seriously or fa-
tally injured.
Δ Persons must stay out of the area of the mast prop when the mast prop is extended or re-
tracted.
Always fully extend the mast prop, as high forces result from the pulling of the tool.
Prerequisite:
– LEDs of the buttons (1.19) and (1.20) light up green.
Extending mast prop

Button Process
✓ Mast prop is extended.

1.20 ✓ LED of the button (1.20) is not illuminated and the mast prop is fully extended.
BG 28 H # 5336 / V01_en_04.2021 193 - 390

3 Operation
Retract mast prop

Button Process

1.19 ✓ Mast prop is retracted.
3.10.5 Operating the rope winches

Operating the automatic rope tensioning facility
The "automatic rope tensioning facility" ensures a tensioned main rope during manual unwinding of
the main winch in the "Kelly" process.
If the minimum load for the main rope set by the equipment operator is not met, the main winch
stops. This prevents the rope swivel from falling and further unwinding of the main rope.
Adjusting the automatic rope tensioning facility
• Function: on the B‑Drive (see section "Operating the B-Drive").
• Set the desired residual tension force of the main winch.

Setting on the B‑Drive Residual tension force [t]
0% 0
100 % 2
Unwinding the main rope positively
Move the left control lever (20) forwards until the load touches down on the bottom of the bore hole.
If slack rope forms, "Main winch automatic rope tensioning facility" appears on the B-Tronic screen
and the main winch shuts down.
To continue operation the "freewheel" function can be activated. The formation of rope slack is pre-
vented by the retract control function (see section "Operating the retract control function").
Free wheel operation

When the freewheel mode is selected, the unwinding of the wire rope is automatically controlled by
the rope winch.
The equipment operator can operate the crowd without the rope winch having to be manually un-
wound at the same time.
194 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
For drilling methods with a main rope that is reeved or firmly connected to the crowd sledge, the
freewheel function is switched on automatically.
Prerequisite for freewheel operation
The weight on the rope winch must remain below a certain maximum value. The value depends on
the rope pulling force of the rope winch used.
– For 10 t winch to 20 t winch: Maximum 2.0 t
– For 25 t winch to 40 t winch: Maximum 5.0 t
As soon as the maximum value is exceeded a message appears on the screen. The wire rope
must now be unwound by manually operating the rope winch until the regular value is re-estab-
lished.
The freewheel function can be stopped at any time by moving the left control lever (20) backwards
or by actuating the right foot switch (5.2).
Activating the freewheel function - Version 1

Key switch Control lever, left (20) Indicator Process
light
- - • Turn the key switch (3.4) to
position "1".

switched on.
3.4
- 20.2 • Briefly press the button (20.2)
on the left control lever.
1.9
(1.9) turns green.

Activating the freewheel function - Version 2

Key switch/foot Control lever, left (20) Indicator Process
switch light
- - • Turn the key switch (3.4) to
position "1".

switched on.
3.4
BG 28 H # 5336 / V01_en_04.2021 195 - 390

3 Operation

switch light
- 20.2 • Press and hold button (20.2)
on the left control lever until
the correspond weight for the
freewheel function has been
1.9
reached.
• Release button (20.2).
• Move the control lever to the

neutral position.

(1.9) turns green.

Deactivating the freewheel function

switch light
20.2 - • Actuate foot switch (5.2) or
press button (20.2).
✓ Freewheel is blocked.
- - - • Turn the key switch (3.4) to

position "0".

switched off.
3.4
Operating back pull control

The retract control function enables controlled drilling in soft surfaces with heavy process equip-
ment.
Activating retract control
Prerequisite:
– Freewheel is activated (see section "Operating the freewheel").
• Function: Select on the B‑Drive (see section "Operating the B-Drive").
• Set the desired retract force of the main winch.
196 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
Setting on the B‑Drive Retract force [t] Freewheel speed

0% 0 maximum
100% maximum 0
Deactivating retract control

Key switch/foot Control lever, left Indicator Process
switch (20) light
- - • Release the foot switch (5.2).
✓ Retract control is deactivated.
When the "freewheel" function is re-activated, the previously set retract force is activated.
Winding/unwinding the rope of the main winch

Main winch selection
Selection Control lever, left (20) Process

button
+ 20.3 • Press button (1.35) or button (20.3).
1.35 ✓ The main winch is selected in normal operating

mode.
+ 20.3 • Press button (1.35) or button (20.3) again.
✓ LED of button (1.35) flashes once.
1.35 ✓ The main winch is selected with pulling speed limit 1.
✓ LED of button (1.35) flashes twice.
1.35 ✓ The main winch is selected with pulling speed limit 2.
1.35 • The main winch is selected in normal operating

mode.
BG 28 H # 5336 / V01_en_04.2021 197 - 390

3 Operation
Operating the main winch

Control lever, left (20) Process
- • Move the left control lever forwards.
✓ The wire rope of the main winch is unwound.
- • Move the left control lever backwards.
✓ The wire rope of the main winch is wound in.
or
Control lever, left Process
(20)
+ 20.3 • Press button (20.3).
• Move the left control lever forwards.
✓ The wire rope of the main winch is unwound.
+ 20.3 • Press button (20.3).
• Move the left control lever backwards.
✓ The wire rope of the main winch is wound in.
Winding/unwinding the rope of the crowd winch
Further information can be found in the section "Crowd operation".
Winding/unwinding the rope of the auxiliary winch

Selection Control lever, left Indicator Process
button (20) light
- - • Press button (1.36).
✓ The screen display of the auxiliary

winch is highlighted.
1.36
• Rope is unwound from the auxiliary

winch.
198 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
Selection Control lever, left Indicator Process

button (20) light
- - • Press button (1.36).
✓ The screen display of the auxiliary

winch is highlighted.
1.36
• Rope is wound onto the auxiliary winch.
or
(20)
+ 20.9 • Press button (20.9).
✓ The screen display of the auxiliary winch is highlighted.
✓ The rope is unwound from the auxiliary winch.

+ 20.9 • Press button (20.9).
✓ The screen display of the auxiliary winch is highlighted.
✓ The rope is wound onto the auxiliary winch.
3.10.6 Crowd operation
Moving the crowd sledge upwards/downwards

(10)
- • Move the right control lever forwards.
✓ Crowd sledge moves downwards. The crowd speed changes propor-

tionally with the deflection of the control lever.
- • Move the right control lever backwards.
✓ Crowd sledge moves upwards. The crowd speed changes propor-

tionally with the deflection of the control lever.
Activate high crowd speed

Components can be damaged if the high crowd speed is activated, particularly when the Kelly bar
is locked, while locking the Kelly bar, when retracting and extending the Kelly bar, and when
drilling.
Δ Only activate the high crowd speed during "idle stroke".
BG 28 H # 5336 / V01_en_04.2021 199 - 390

3 Operation

(10)
+ 10.2 • Press and hold button (10.2) on the right control lever. Simultane-
ously move the right control lever forwards.
✓ The crowd sledge moves quickly downwards.
+ 10.2 • Press and hold button (10.2) on the right control lever. Simultane-
ously move the right control lever backwards.
✓ The crowd sledge moves quickly upwards.
Deactivating crowd stroke monitoring
The crowd stroke monitoring monitors the position of the crowd sledge and stops the crowd sledge
when it reaches the maximum permissible height on the mast for operation. Depending on the situ-
ation, the crowd stroke monitoring may be temporarily deactivated in rigging mode and during
maintenance work/repair work. The crowd range permissible for operation may be exceeded under
certain circumstances. The manufacturer accepts no liability for activities outside the permissible
crowd range.

(10)
- • Move the right control lever backwards.
✓ Crowd sledge moves upwards and stops at the maximum per-

missible height for operation.
• Release the right control lever.
• Move the right control lever backwards.
✓ Query to exceed the permissible crowd range appears on the B-

Tronic screen.
• Acknowledge the query on the B-Tronic screen.
✓ Crowd stroke monitoring is deactivated.
If the B-Tronic query is acknowledged with “No”, a new query is possible after ten seconds.
The crowd stroke monitoring remains deactivated until the prohibited range is exceeded, the hy-
draulic pilot control of the equipment is switched off or the unit is switched off.
If the rotary drive is already in the prohibited range and the equipment is started or the hydraulic pi-
lot control is activated, the query of the B-Tronic is acknowledged again.
200 - 390 BG 28 H # 5336 / V01_en_04.2021

3 Operation
The deactivation of the crowd stroke monitoring is logged by the B-Tronic.
3.10.7 Operating the depth measurement function

Set main winch depth indicator to "0"
The depth indicator can be set to "0" at any time.
Setting on the B-Tronic screen
Alternatively: Adjustment via the control lever

(20)
+ 20.5 • Press button (20.5) on the left control lever.
✓ Depth indicator of the main winch is set to "0".
Set crowd winch depth indicator to "0"
The depth indicator can be set to "0" at any time.
Setting on the B-Tronic screen
BG 28 H # 5336 / V01_en_04.2021 201 - 390

3 Operation
202 - 390 BG 28 H # 5336 / V01_en_04.2021

4 Assembly/mounting
4 Assembly/mounting
Risk of accident!
– Safety during assembly/mounting and dismantling/removing [➙ 51]
– Safety when handling suspended loads and during transport [➙ 53]

ated supplement.


Working on or with the equipment with the telescoping cylinders of the crawlers retracted can lead
to the equipment tipping over. This could result in severe or fatal injury.
Δ Extend the telescoping cylinders of the crawlers immediately after unloading the equipment
and before any further assembly work.

If the connections of the hydraulic hoses are contaminated and they are not cleaned before being
mounted on the equipment/components, foreign particles may get into the hydraulic oil and dam-
Δ Protect the connections of the hydraulic hoses from damage and contamination.
Δ Clean the connections of the hydraulic hoses every time they are mounted or removed.
BG 28 H # 5336 / V01_en_04.2021 203 - 390

4 Assembly/mounting
4.1 Assembly guidelines

The following assembly guidelines serve as a summary overview for the steps outlined below:
• Always ensure any assembly/disassembly work is performed by suitably authorized personnel.
• Screw connections, plug connections and associated locking elements should always be man-
ufactured according to the applicable standards of good practice. Relevant technical informa-
tion can be found in the spare parts list.
• Secure the danger zone accordingly before starting any work.
• All work should always be performed on horizontal, level ground with sufficient load-bearing ca-
pacity.
• Assembly points must be easily accessible and clean.
• Check to ensure all components are complete and in proper working order before assembly,
particularly the following:
– Load-bearing steel components and their connection points
– Connecting elements such as screw connections, plug connections, locking elements and
welded joints
– Winch trestles
– Wire ropes
– Hose assemblies
– Piston rods and cylinder lugs along with their connections
• Before assembly work, make sure the protective wax has been completely removed from the
equipment and its accessories (see section "Wax removal").
Further information about determining a suitable lifting device can be found in the section "Trans-
port data".
• Only use suitable lifting devices with sufficient load-bearing capacity for assembly work.
• Only attach individual components to the designated attachment points.
• When working on the equipment, especially in elevated positions, first assemble any necessary
walkways such as platforms, steps, railings and fall protection equipment.
4.1.1 Lubricant usage during installation

Lubrication of components is essential for fault-free operation and durability of the equipment. If
components are lubricated properly, this can prevent direct metal contact, avoiding corrosion and
high levels of wear.
In order to select the correct lubricants, please refer to the section "Lubricant table".
204 - 390 BG 28 H # 5336 / V01_en_04.2021

4 Assembly/mounting
Lubricating statically supported components
Statically supported components are mounted components whose functional surfaces are not sub-
ject to friction or movement.
• Risk of causing damage to components! If any other lubricants are used other than
those prescribed by BAUER, this can result in damage to equipment components. Only use lu-
bricants that have been authorized or permitted by BAUER Maschinen GmbH.
• Lubricate statically supported components appropriately before every installation.
Example: Statically supported components

Plug connection on mast (1) Plug connection on boom (1)
Plug connection on the rope winch (1)
4.1.2 Hydraulic connection

Risk of accident!
BG 28 H # 5336 / V01_en_04.2021 205 - 390

4 Assembly/mounting
Risk of accident!
Risk of injury!
Risk of poisoning!
lay.
All of the components in the hydraulic system must be checked with the designated maximum op-
erating pressure, which can be achieved by taking all of the intended applications into account.
• Check all of the components in the hydraulic system for leaks.
• Check to ensure the hydraulic system is complete and in proper working order.
• Protect all of the hydraulic lines from damage during operation.
The hydraulic lines and the connection plate on the equipment/process equipment are provided
with corresponding symbols (for example, numbers and letters) or color-coded markings.
• Connect hydraulic connections with the same symbol or the same color-coded marking to one
another.
• Mount the hydraulic "leak oil/return" line first when the hydraulic connections on the equipment/
• Remove the hydraulic "leak oil/return" line last when the hydraulic connections on the equip-
Hydraulic screw couplings

Connecting the hydraulic screw couplings
Prerequisite:
– The hydraulic system has been depressurized.
• Remove the protective cover from both related couplings.
• Clean the related couplings.
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4 Assembly/mounting
• Visibly check that the seal is in proper working order and replace if necessary.
The figure shown may differ from the original.
• Risk of injury! When working on hydraulic and

pneumatic components pressurized media can escape.
This can result in persons being seriously injured by burn-
ing, scalding or cutting. Before starting any repair work or
assembly/disassembly work, depressurize the hydraulic or
pneumatic system. Check that the hydraulic connection is
secure and in proper working order.
• Connect the related couplings to each other with a suitable

tool as far as it will go (1).
• Check that the hydraulic coupling is secure and in proper

working order.
• If present, mount the corresponding locking elements.
• Connect the protective caps of both couplings with each

other and store safely.
✓ Hydraulic screw couplings are connected to each other.
4.2 Undercarriage
body parts.
4.2.1 Extending the crawlers
Plug connections and locking elements are located on the front and rear of the undercarriage.
Prerequisite:
– Crawlers are in the transport position.
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4 Assembly/mounting
• Remove the locking elements (1) and plug

connections (2) from the two crawlers.
• Completely extend the telescoping cylinders

of the crawler (see "Basic functions: Under-
carriage").
✓ The telescoping cylinders of the crawlers

are extended.
• Mount plug connections (2) on both crawlers

and secure with locking elements (1).
✓ Crawlers are fixed in the operating position.
4.3 Upper carriage

Risk of accident!
If not properly mounted, counterweights can fall or tip over. This could result in serious or fatal in-
Δ While the counterweights are being mounted, persons are not permitted in the danger zone,
Δ The counterweights must always be lifted and mounted on the equipment individually and in
the correct order.
Δ Check to ensure the tension chain of the counterweights is in proper working order as specified
in the instruction manual.

Non-observance of the correct mounting order can cause the equipment to tip over. This could re-
sult in severe or fatal injury.
Δ The counterweights must be completely mounted before mounting the work equipment and up-
per mast section.
Δ If process equipment is attached, do not alter the counterweights and/or remove them from the
equipment.
4.3.1 Mounting the platform handrails
Always completely pull out the walking platform.
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4 Assembly/mounting
Prerequisite:
– Suitable lifting devices are available.
• Pull out the walking platform (2) and (3) by

the handle until the lock engages.
• Insert the handrails (1) into the designated

holding brackets on platforms (2) and (3).
✓ The platform handrails have been properly

mounted on the upper carriage.
4.3.2 Mounting climbing aid

– The platform handrails have been
mounted.
• Turn the lever (2) until it latches into place at

its uppermost position.
• Pivot the climbing aid (1) counterclockwise by

90°.

its lowest position. Move the climbing aid (1)
slightly to and fro so that the locking element
of the lever (2) latches into the hole.
✓ The climbing aid has been properly mounted.
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4 Assembly/mounting
4.3.3 Mounting the guard rail

Folding the fall protection equipment into the operating position
• Fold the corresponding fall pro-
tection equipment into the oper-
ating position as shown.
• Pull the locking elements (2) be-

tween the parts of the corre-
sponding fall protection equip-
ment (1) in the direction of the
arrow and then release.
• Turn the locking elements (3)

between the parts of the corre-
sponding fall protection equip-
ment (1) in the direction of the
arrow.
• Unfold the other fall protection

units into the operating position
in the same manner as for the
first fall protection unit.
✓ The fall protection units are now

correctly unfolded into the oper-
ating position.
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4 Assembly/mounting
Mounting the safety chains

• Mount the hook connections (6) and (7) of the
safety chains (4) and (5) to the designated
connection points of the fall protection.
✓ The safety chains are mounted.
4.3.4 Mounting the exhaust pipe extension

Prerequisite:
– Exhaust pipe has cooled down.
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4 Assembly/mounting
• Risk of injury! Contact with hot

surfaces can cause the burning of body
parts. Ensure that the hot exhaust pipe has
cooled down before performing any installa-
tion/removal work.
• Remove the exhaust pipe extension (1) and

associated support element (4) from the
special holder (2).
• Open the exhaust pipe (3) cover.
• Lift the exhaust pipe extension (1) up to the

exhaust pipe.
• Attach the exhaust pipe extension (1) to the

exhaust pipe using the locking elements (5).
• Mount the support element (4).
✓ The exhaust pipe extension is correctly

mounted.
4.3.5 Mounting the counterweights

There are two different versions of the counterweights. A distinction is made between 4.9 t counter-
weights and 2.5 t counterweights. The quantity and version of the counterweights can be found in
the section "Stability". Mount the 4.9 t counterweights first.
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4 Assembly/mounting
4.9 t (Version 1) 2.5 t (Version 2)
The different versions of counterweights are mounted in the same way.
The quantity and design of the counterweights can differ depending on the process equipment
used. The quantity and version of the counterweights can be found in the section "Stability".
Prerequisite:
– Crawlers are extended.
– Mast is lowered.
Mounting the counterweights with a lifting device

Mounting Version 1 counterweights
• Mount a suitable lifting device at the lifting
points (3) of the counterweight (1).
• Danger of accident! Danger of getting crushed! Danger of falling! In order to mount

the counterweights, the auxiliary personnel must stand on the upper carriage. Sudden move-
ments with the counterweights, which are hanging by a lifting device from the auxiliary crane,
can cause severe or fatal injuries to persons. Avoid sudden movements with the counter-
weights. Do not turn the upper carriage.
• Lift the counterweight (1) onto the equipment
and place it on the frame (4) of the upper car-
riage.
The centering devices (5) on the frame (4) or the centering devices (6) on the counterweight (1)
must be inserted into the cavities on the underside of the counterweight.
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4 Assembly/mounting
• Remove the lifting device from the counterweight (1).
✓ The counterweight (1) is mounted on the upper carriage.
• Mount additional counterweights of Version 1 accordingly.
• Also mount the locking element when using more than four counterweights.
Mounting Version 2 counterweights

• Mount a suitable lifting device at the lifting
• Lift the counterweight (2) onto the equipment

and place it on the other counterweights.
• Danger of accident! Danger of getting crushed! Danger of falling! In order to mount

the counterweights, the auxiliary personnel must stand on the upper carriage. Sudden move-
ments with the counterweights, which are hanging by a lifting device from the auxiliary crane,
can cause severe or fatal injuries to persons. Avoid sudden movements with the counter-
weights. Do not turn the upper carriage.
The centering devices (6) on the counterweight (2) must be inserted into the cavities on the under-
side of the other corresponding counterweight.
• Remove the lifting device from the counterweight (2).
✓ The counterweight (2) is mounted on the upper carriage.
• Mount additional counterweights of Version 2 accordingly.
• Also mount the locking element when using more than four counterweights.
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4 Assembly/mounting
Mounting the locking element

Danger of accident! If there are more
than four counterweights on the upper carriage, it
is possible they may topple and fall. Persons
could be hit and receive serious or fatal injuries.
After adding the fourth counterweight, attach the
corresponding locking element to the counter-
weights.
• Mount suitable lifting devices to the lifting

points (16) of the locking element (15).
• Mount the locking element (15) on the fourth

counterweight.
✓ The locking element is mounted.
Mount additional counterweights in the same way

within the applicable stability limits.
Securing counterweights
• Mount the locking element (8).
• Insert the clamping chain (9) into the longitu-

dinal groove of the upper spring washer
(10).
• Guide the clamping chain (9) downwards

through the hole in the counterweights.
• Place the upper spring washer (10) into the

corresponding cavity of the uppermost coun-
terweight.
• Mount the plate (11) on the frame (4) of the

upper carriage using the screw connection
(12).
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4 Assembly/mounting
• Fit the lower end of the clamping chain (9) in

the longitudinal groove of the lower spring
washer (14).
• If more than two clamping chain (9) links

protrude over the spring washer (14), thread
a correspondingly deeper clamping chain (9)
link in the groove of the upper spring washer
(10). The last link of the clamping chain (9)
must be above the "X" mark.
• Fit the lower end of the clamping chain (9) in

the longitudinal groove of the lower spring
washer (14) again.
• Tension the clamping chain (9) by turning

the screws (13) evenly, whilst raising the
spring washer (14) into a horizontal position.
• Tighten one screw with a torque of 170 Nm

and secure the screw.
• Align the spring washer (14) so that it is hori-

zontal using the remaining screws (13) and
secure the screws (13).
• Turn the upper spring washer (10) by 90° if the tensioning length is insufficient.
• Fit the lower end of the clamping chain (9) in the longitudinal groove of the lower spring washer
(14) again.
• Tension the clamping chain (9) by turning the screws (13) evenly.
• Tighten one screw with a torque of 170 Nm and secure the screws (13).
• Fit the lower end of the clamping chain (9) in the longitudinal groove of the lower spring washer
(14) again.
• Tension the clamping chain (9) by turning the screws (13) evenly, whilst raising the spring
washer (14) into a horizontal position.
• Tighten one screw with a torque of 170 Nm and secure the screw.
• Align the spring washer (14) so that it is horizontal using the remaining screws (13) and secure
the screws (13).
✓ Clamping chain is mounted on the upper carriage.
✓ Counterweights are fully mounted and secured.
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4 Assembly/mounting
Mounting the counterweights with the mast
1 Place the counterweight on the upper X Distance between the undercarriage and
carriage with the boom cylinders. the lifting points on the counterweight
2 Lift the counterweight from the ground
with the backstay cylinders.
Prerequisite:
– A designated lifting device is provided.
– The rotary drive is mounted on the crowd sledge.
– The crowd sledge is positioned at the lower end of the mast.
– Counterweights should not be raised from a position lower than the working platform for the
equipment.
• Attach the designated lifting
device (2) to the corre-
sponding lifting points (1) of
the mast.
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4 Assembly/mounting
• Set the smallest operating radius.
• Attach the designated lifting device to the lifting points of the counterweight.
• Danger of accident! If the mast and counterweight are not correctly aligned with
one another, the counterweight can fall or start swinging uncontrollably when it is lifted. Per-
sons can be hit or trapped by the counterweight. The lifting points of the mast must be posi-
tioned vertically above the lifting points of the counterweight.
• Extend both backstay cylinders evenly to raise the counterweight.
• Retract the boom cylinders carefully to position the counterweight above the frame of the
equipment. The operating radius for each counterweight can be found in the "Table of required
operating radius".
• Retract both backstay cylinders carefully to deposit the counterweight on the frame of the
equipment.
• Mount additional counterweights according to the "Equipment specification" section.
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4 Assembly/mounting
• If the total weight of the counterweights does not exceed 14.7 t, secure the counterweights with
the clamping chain.
✓ Counterweights, no more than 14.7 t, are mounted correctly.
Mounting additional counterweights up to 24.5 t.
• Mount one more counterweight in the same way.

Danger of accident! If there are more
than four counterweights on the upper carriage, it
is possible they may topple and fall. Persons
could be hit and receive serious or fatal injuries.
After adding the fourth counterweight, attach the
corresponding locking element to the counter-
weights.
• Mount suitable lifting devices to the lifting

points (7) of the locking element (6).
• Mount additional counterweights in the same

way.
• The quantity of counterweights can be found

in the chapter "Stability".
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4 Assembly/mounting
• Mount additional counterweights according to the "Equipment specification" section.
• Secure the counterweights with the clamping chain.
✓ Counterweights are properly mounted and secured.
4.4 Attachment
4.4.1 Mounting the mast sections
Mounting the prop pad
The mast prop may only be operated when the prop pad is mounted.

tally injured.
tracted.
– The mast must be vertically aligned.
– Suitably instructed auxiliary personnel are

standing ready.
• Put the prop pad (1) down on the ground sur-

face under the mast.
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4 Assembly/mounting
• In Kelly mode, extend the mast prop (2) until

just over the prop pad (1).
• Hold the prop pad (1) to the mast prop (2)

and mount the plug connections (3).
• Secure the plug connections (3) using the

locking elements (4).
✓ Prop pad is mounted.
Pivoting the upper mast extension to the operating position

head, retracting and extending the mast prop, retracting and extending the clamping cylinder. Any-
Prerequisite:
– The equipment is in rigging mode.
– Mast (2) without process equipment is lowered.
– The main, auxiliary and crowd ropes are slackened.
– Masthead (4) is pivoted into the transport position.
– Upper mast extension (1) is folded into the transport position and secured.
• Remove the plug connection (3)

between the mast (2) and upper
mast extension (1).
Button Process
- • Risk of damaging the ropes! If the rope sheaves of the crowd ropes
are installed in the upper mast extension, ropes or components of the mast could
be damaged when folding. Slacken the crowd ropes sufficiently.
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4 Assembly/mounting
Button Process
✓ LED of button (3.21) flashes.

3.21 ✓ Mast tilting cylinder (5) extends.
✓ Upper mast extension (1) folds into the operating position.
✓ Release for folding the masthead (4).
• Mount the screw connections (6).
7 Locking element
8 Nut
9 Washer
10 Clamping sleeve
11 Bolt
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4 Assembly/mounting
• Mount the screw connections (12).
7 Locking element
8 Nut
9 Washer
10 Clamping sleeve
11 Bolt
✓ Upper mast extension is now pivoted into the operating position.
Tilt masthead into operating position

Risk of causing damage to components
If the masthead is used for single-strand pulling with a single-pass method (e.g. "CFA" mode), the
main rope, the masthead and the components of the mast could be damaged.
Δ For single-strand pulling with a single-pass method, screw the masthead to the mast.
Prerequisite:
– The mast is lowered.
– Upper mast extension is swung out.
– The masthead is folded into the transport position.
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4 Assembly/mounting
Button Process

3.16 ✓ Masthead tilting cylinder (2) extends.
✓ Masthead (3) folds into operating position.
✓ The masthead is in the operating position.
• In the event of single-strand pulling: Bolt the masthead (3) and mast (1) at the
front side (4).
✓ The masthead has been correctly folded into the operating position.
Mounting rope sheaves for the upper crowd rope

For various work applications (e.g. Kelly, CFA, FDP), the position of the rope sheaves for the upper
crowd rope needs to be adapted.
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4 Assembly/mounting
Mounting rope sheaves in the lower mast section
Prerequisite:
– Rope sheaves are removed from the upper mast section.
• Position the rope sheaves (6) in the lower mast section with a lifting device.
• Mount the rope sheaves (6) with plug connections (5).
• Secure the locking elements (4) with screw connections (3).
• Mount the holding bracket (2) with screw connections (1).
• If present, connect the hydraulic lines of the central lubrication system to the rope sheaves.
✓ Rope sheaves are properly mounted in the lower mast section.
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4 Assembly/mounting
Mounting rope sheaves in the upper mast section
Prerequisite:
– Rope sheaves are removed from the lower mast section.
• Position the rope sheaves (6) in the upper mast section with a lifting device.
• Mount the rope sheaves (6) with plug connections (5).
• Secure the locking elements (4) with screw connections (3).
• Mount the holding bracket (2) with screw connections (1).
• If present, connect the hydraulic lines of the central lubrication system to the rope sheaves.
✓ Rope sheaves are properly mounted in the upper mast section.
Mounting the sledge end stoppers

The sledge end stoppers on the mast limit the maximum stroke of the crowd sledge.
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4 Assembly/mounting
• Mount the sledge end stoppers (3) at positions (3) on the mast by using the plug connection (1)
and the corresponding locking element (2).
✓ The sledge end stoppers are installed.
Rope anchorage for main rope/auxiliary rope

The main rope and auxiliary rope are attached to the rope anchorage at the lower end of the mast
when they are not being used or during transport.

Winding or unwinding an attached main rope or auxiliary rope leads to movements at the holding
bracket of the rope anchorage. There is a risk of body parts getting crushed, leading to serious or
fatal injuries.
Δ Stay clear of the rope anchorage when an attached main rope or auxiliary rope is being wound
or unwound.
Risk of damage to components of the mast!

If an attached main rope or auxiliary rope is wound in too far, the rope anchorage and possibly the
mast can be damaged.
Δ Do not wind an attached main rope or auxiliary rope too far.
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4 Assembly/mounting
The maximum permissible angle of

the holding bracket (5) is determined
by the plug connection (4).
To change the angle:
• Remove the locking element (3).
• Hold the holding bracket (5)

steady and pull out the plug con-
nection (4).
• Insert the plug connection (4) in

the required opening of the
sledge (2).
• Secure the plug connection (4)

with the locking element (3).
✓ The permissible angle with the

holding bracket has been
changed (5).
• Use shackles to attach the main rope and auxiliary rope to the holding bracket (5) of the sledge
(1).
✓ The main rope and auxiliary rope must be attached to the rope anchorage as prescribed.
The screws (6) are used for fixing the sledge in one of the possible positions.
Wind in
When winding in an attached main rope or auxiliary rope, the rope fix point moves upwards on the
rail (1) to the stop. Do not wind the main rope or auxiliary rope any further.
Unwind
When unwinding an attached main rope or auxiliary rope, the rope fix point moves downwards on
the rail (1) to the stop. Do not unwind the main rope or auxiliary rope any further.
4.4.2 Preparing ropes for operation

Free hanging lifting gear can become caught when the crowd sledge is moved. This can result in
damage to the equipment components.
Δ Chains and other locking elements must be removed from the mast before any further assem-
bly work on the mast.
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4 Assembly/mounting
– Upper mast extension is

folded into the operating po-
sition. However for a better
overview, the upper mast ex-
tension is illustrated half-
folded below.
• Remove the locking elements

(2).
• Remove the folding end stopper

(1) from the mast extension.
• Remove the locking elements

(3).
• Remove all wire rope guides (4)

from the mast.
BG 28 H # 5336 / V01_en_04.2021 229 - 390

4 Assembly/mounting
– Upper mast extension is folded into the

operating position. However for a better
overview, the upper mast extension is il-
lustrated in the transport position below.
• Remove the lifting devices (13) from the

mast.

Tensioned ropes can damage the mast.
Δ The mast extension and masthead must always be pivoted into the operating position before
tensioning the ropes.
Tensioning the main rope in Rigging mode

Selection Process
button
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4 Assembly/mounting
Selection Control lever, left (20) Indicator Process

button light
+ 20.3 - • Press button (1.35).
✓ LED of button (1.35) illuminates.
1.35 ✓ Main winch is selected.
• Push the left control lever back, until the

main rope is tensioned.
✓ Main rope is tensioned.
Tensioning the auxiliary rope in Rigging mode

Selection Process
button

button light
+ 20.9 - • Press button (1.36).
1.36 ✓ Auxiliary winch is selected.

auxiliary rope is tensioned.
✓ Auxiliary rope is tensioned.
Tensioning the main rope during operation

button light
+ 20.3 - • Press button (1.35).

main rope is tensioned.
✓ Main rope is tensioned.
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4 Assembly/mounting
Tensioning the auxiliary rope during operation

button light
+ 20.9 - • Press button (1.36).

auxiliary rope is tensioned.
✓ Auxiliary rope is tensioned.
Tension crowd ropes

Button Process
✓ Crowd ropes are tensioned.
1.43
4.4.3 Raising the mast

Raising the mast without process fitting
Prerequisite:
– A maximum of 3 counterweights are mounted.
– The masthead is in the operating position.
• Risk of damage to components! Wire ropes and hoses can become damaged or
can damage other components if they are not correctly positioned when the mast is raised.
When raising the mast, make sure the wire ropes and hoses are correctly positioned.
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4 Assembly/mounting
• Extend the boom cylinders (1) until the mast is positioned at least 1 m above the mast bearing.
If the boom cylinders are extended to such an extent that the mast is positioned 2 m above the
mast bearing, it is possible to raise the mast in a single step with the backstay cylinders.
Mounting the elbow
Prerequisite:
– The concreting line is required for this drilling method.

• Mount a suitable lifting device
onto the elbow (5).
• Lift the elbow (5) to its mount-

ing position.
• Mount the plug connections (9)

and the corresponding locking
elements.
• Mount the clamping collar (10)

and corresponding locking ele-
ment.
• Mount the central lubrication

system (4).
• Mount the mud hose (8) with

the clamping collar (7) and cor-
responding locking element.
• Mount the holding rope onto the retaining eye (6) with shackles.
• Risk of accident! Loose process equipment can suddenly become detached when
raising the mast and fall or swing around in an uncontrolled manner. Fasten the loose end of
the mud hose to the mast using a suitable aid.
• Attach the mud hose (8) to the mast using a suitable aid.
BG 28 H # 5336 / V01_en_04.2021 233 - 390

4 Assembly/mounting
Adapt the central lubrication system on the oppo-

site side of the mast:
• Remove the coupling (13) of the central lubri-

cation system from the return (11).
• Attach the coupling (13) of the central lubrica-

tion system at the supply (12).
✓ The elbow is properly mounted.
• Tension the main rope and auxiliary rope.
• Risk of collision! Compo-

nents can collide if the lateral inclination
of the mast becomes too large when it
is being raised. The lateral inclination of
the mast must not exceed a value of
±2° when it is being raised.
• Extend the backstay cylinders (2)

evenly until the mast is standing verti-
cally.
✓ The mast without process equipment

has now been raised.
Subsequently mount counterweights and

process equipment in accordance with the
stability section.
4.4.4 Mounting the rope swivel

Risk of causing damage to the process equipment!
Working without a rope swivel will destroy the ropes. The process equipment can be damaged as a
result of this.
Δ Only use original rope swivels from the manufacturer.
Δ Do not use damaged and/or worn rope swivels.
Δ The rope swivel must be of sufficient size to withstand the maximum forces that occur.
Δ Ensure the rope swivel is installed in the correct position. Always align the lubrication point (4)
upwards to the rope thimble (1).
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4 Assembly/mounting
• Thread the rope thimble (1) into

the rope swivel (3) and secure
with the pin (2).
• Secure the pin (2) in place with

the designated locking elements
(5).
• Grease the rope swivel (3) via

the lubrication point (4).
• Check that the rope swivel (3)

rotates smoothly and easily. Re-
move any excess, overflowing
grease.
✓ Rope swivel (3) is mounted.
BG 28 H # 5336 / V01_en_04.2021 235 - 390

4 Assembly/mounting
236 - 390 BG 28 H # 5336 / V01_en_04.2021

5 Disassembly/removal
Risk of accident!
– Safety during assembly/mounting and dismantling/removing [➙ 51]

ated supplement.

Retracting the telescoping cylinders of the crawlers can cause the equipment to tip over and thus
lead to serious or fatal injuries to persons.
Δ Only retract the telescoping cylinders of the crawlers immediately before loading the equipment
and following dismantling work.


Failure to observe the correct removal sequence can cause the equipment to tip over. This could
Δ Before removing the counterweights first remove the work equipment and then the upper mast
section. Only then remove the counterweights in the prescribed order.
Δ Before further dismantling work, first remove the counterweights and then the lower mast sec-
tion.

5.1 Guidelines for disassembly
Individual components and their connection elements must be properly stored after disassembly.
The following disassembly guidelines serve as a summary overview for the steps outlined below:
BG 28 H # 5336 / V01_en_04.2021 237 - 390

• Always ensure any assembly/disassembly work is performed by suitably authorized personnel.
• Secure the danger zone accordingly before starting any work.
• All work should always be performed on horizontal, level ground with sufficient load-bearing ca-
pacity.
• Technical information on screw connections, plug connections and their associated locking ele-
ments can be found in the spare parts list.
Further information about determining a suitable lifting device can be found in the section "Trans-
port data".
• Only use suitable lifting devices with sufficient load-bearing capacity for assembly work.
• Only attach individual components to the designated attachment points.
5.1.1 Hydraulic connection

Risk of accident!
Risk of poisoning!
lay.
• Remove the hydraulic "leak oil/return" line last when the hydraulic connections on the equip-
Hydraulic screw couplings

Disconnecting the hydraulic screw couplings
Prerequisite:
– The hydraulic system has been depressurized.
• Risk of injury! When working on hydraulic and pneumatic components pressurized

media can escape. This can result in persons being seriously injured by burning, scalding or
cutting. Before starting any repair work or assembly/disassembly work, depressurize the hy-
draulic or pneumatic system.
• If present, remove the corresponding locking elements.
238 - 390 BG 28 H # 5336 / V01_en_04.2021

• Separate the connected couplings with a suitable tool.
• Mount the corresponding protective caps onto both couplings.
✓ The connection between the hydraulic screw couplings has been disconnected.
5.1.2 Use of preservatives
Preserving flange surfaces
Flange surfaces are sliding strips that must be protected from corrosion regularly.
Example: Flange surfaces

Masthead (1) Masthead connection points (1)
• Risk of damage to components! If any preservatives are used other than those pre-
scribed by BAUER, it can result in damage to equipment components. Only use preservatives
that have been authorized or approved by BAUER.
• Preserve all of the flange surfaces with the designated operating fluids.
Table: Preservatives
Component Quantity Quantity Designation Manufacturer Manufacturer's
[l] [gal] designation
Flange surfaces as re- as re- High-performance CHESTERTON 740 (E)
quired quired rust guard
BG 28 H # 5336 / V01_en_04.2021 239 - 390

5.2 Attachment
5.2.1 Removing the rope swivel
• Unwind the main rope and
place the rope swivel (3)
on the ground.
• Check to ensure the rope

swivel (3) is intact.
• Risk of caus-
ing damage to the man
rope and components! A
faulty rope swivel will
cause damage to the main
rope during subsequent
use. Replace a faulty rope
swivel with a new one.
• Remove the locking ele-

ments (5) and plug con-
nection (2).
• Remove the rope thimble

(1) from the rope swivel
(3).
• Clean the rope swivel (3),

the locking elements (5),
and the plug connections
(2) and protect them
against corrosion.
✓ Rope swivel (3) is re-

moved.
5.2.2 Lowering the mast

Tensioned ropes impose side loads on the mast, which can result in damage to the mast.
Δ The ropes must be slackened before lowering the mast.
Lowering the mast without process fitting

Prerequisite:
– Equipment is in the operating position.
– A maximum of 3 counterweights are mounted.
240 - 390 BG 28 H # 5336 / V01_en_04.2021

• Risk of collision! If the mast

inclines too far to the side when it is be-
ing lowered, components can collide.
The lateral inclination of the mast must
not exceed a value of ±2° when it is be-
ing lowered.
• Set the lateral inclination of the mast to

0°.
• Risk of causing damage to

components! Wire ropes and hoses can
become damaged or can damage other
components if they are not correctly po-
sitioned when the mast is lowered.
When lowering the mast, make sure the
wire ropes and hoses are correctly posi-
tioned.
• Retract the boom cylinders (1) until the

mast is located just above the working
platform.
• Retract the backstay cylinders (2) evenly until the mast is lying horizontally.
• Retract the boom cylinders (1) until the mast is positioned at least 1 m above the mast bearing.
• Slacken the main rope and auxiliary rope (3).
• Unwind the rope winches until the wire ropes are slack enough to allow the mast to be lowered
to the mast bearing.
Removing the elbow
Prerequisite:
– The console is mounted on the elbow of the concrete line.
BG 28 H # 5336 / V01_en_04.2021 241 - 390

Adapt the central lubrication system to the oppo-

site mast side of the elbow:
• Remove the coupling (13) of the central lubri-

cation system from the supply (12).
• Attach the coupling (13) of the central lubrica-

tion system at the return (11).
• Remove the central lubrication

system (4).
• Remove the holding rope from

the retaining eye (6).
• Attach suitable lifting device to

the mud hose (8).
• Keep the lifting device ten-

sioned.
• Remove the locking element

and clamping collar (7).
• Remove the mud hose (8).
• Mount a suitable lifting device onto the elbow (5).
• Keep the lifting device tensioned.
• Remove the locking element and clamping collar (10).
• Remove the locking elements and plug connections (9).
• Remove the elbow (5).
✓ The elbow has properly removed.
• Fully retract the boom cylinders (1) in order to lower the mast onto the mast bearing.
✓ Mast without process equipment is lowered.
242 - 390 BG 28 H # 5336 / V01_en_04.2021

5.2.3 Preparing the ropes for transport

If a wire rope is being moved by a rope drum or pulley, persons in the area of the rope drum/pulley
can be seriously or fatally crushed, entangled or pulled in.
Δ Do not reach between the wire rope and the rope drum/pulley.
Δ Do not touch moving wire ropes.
Δ When handling wire ropes, always wear the appropriate personal protective equipment.
Risk of injury by uncontrolled movement of the wire ropes!

If the wire ropes are not secured properly, the wire ropes could move in an uncontrolled way. Per-
sons could be struck as a result and suffer severe or fatal injuries.
Δ Secure wire ropes to prevent uncontrolled movement.
Δ Secure any loose wire ropes on the equipment by using the designated holding brackets as
specified in the Instruction manual.

Tensioned ropes impose side loads on the mast, which can result in damage to the mast.
Δ The ropes must be slackened before lowering the mast.
Slackening the main rope in Derigging mode

Selection Process
button

button light
+ 20.3 - • Press button (1.35).
• Push the left control lever forward, until

the main rope is slackened.
✓ Main rope is slackened.
Slackening the auxiliary rope in Derigging mode

Selection Process
button
BG 28 H # 5336 / V01_en_04.2021 243 - 390


button light
+ 20.9 - • Press button (1.36).

the auxiliary rope is slackened.
✓ Auxiliary rope is slackened.
Slackening the main rope in Operating mode

button light
+ 20.3 - • Press button (1.35).

the main rope is slackened.
✓ Main rope is slackened.
Slackening the auxiliary rope in Operating mode

button light
+ 20.9 - • Press button (1.36).

the auxiliary rope is slackened.
✓ Auxiliary rope is slackened.
Slacken crowd ropes

Button Process
✓ Crowd ropes are slackened.
1.44
244 - 390 BG 28 H # 5336 / V01_en_04.2021

• Hitting hazard, dan-

ger of getting crushed! Loose
ropes can lead to collision in-
juries and grazing of body parts.
Always fasten ropes securely
and adequately. Fasten loose
ropes to the equipment using the
holders or rope guides, which
are optionally available for this
purpose, as specified in the in-
struction manual.
• Mount the folding end stopper

(1) on the upper mast extension
using the corresponding plug
connections (2).
• Secure the plug connections (2)

using the appropriate locking el-
ements.
• Mount the wire rope guides (4)

on the mast using the corre-
sponding plug connections (3).
• Secure the plug connections (3)

using the appropriate locking el-
ements.
• Position main rope, auxiliary

rope and crowd rope behind the
wire rope guides (4) and position
the wire rope guide on the fold-
ing end stopper (1).
BG 28 H # 5336 / V01_en_04.2021 245 - 390

– The upper mast extension has not been

folded into the transport position. How-
ever for a better overview, the upper
mast section is illustrated already folded
below.
– The rope tensioning cylinder is fully ex-

tended.
– Wire ropes have been slackened.
• Hang the main rope (9), auxiliary rope (10),

and crowd rope (14) in the lifting devices
(13) to be attached.
• Attach the lifting devices (13) to the mast.
✓ The wire ropes are ready for transport.

Tensioned ropes can damage the mast.
Δ Ensure that all ropes are slackened before folding the mast extension and masthead into the
transport position.
5.2.4 Removing the mast sections

Removing the sledge end stoppers
246 - 390 BG 28 H # 5336 / V01_en_04.2021

• Remove locking element (2) with plug connection (1) and remove the sledge end stoppers.
✓ The sledge end stoppers have been removed.
Removing rope sheaves for the upper crowd rope

For various work applications (e.g. Kelly, CFA, FDP), the position of the rope sheaves for the upper
crowd rope needs to be adapted.
Removing rope sheaves from the lower mast section
Prerequisite:
– Rope sheaves are mounted in the lower mast section.
• If present, disconnect the hydraulic lines of the central lubrication system from the rope
sheaves.
• Remove the screw connections (1) with holding bracket (2).
• Remove the screw connections (3) and locking elements (4).
• Secure the rope sheaves (6) from falling with a lifting device.
• Remove plug connections (5) and remove the rope sheaves (6).
BG 28 H # 5336 / V01_en_04.2021 247 - 390

✓ Rope sheaves have been properly removed from the lower mast section.
Removing rope sheaves from the upper mast section
Prerequisite:
– Rope sheaves are mounted in the upper mast section.
• If present, disconnect the hydraulic lines of the central lubrication system from the rope
sheaves.
• Remove the screw connections (1) with holding bracket (2).
• Remove the screw connections (3) and locking elements (4).
• Secure the rope sheaves (6) from falling with a lifting device.
• Remove plug connections (5) and remove the rope sheaves (6).
✓ Rope sheaves have been properly removed from the upper mast section.
Tilt masthead into transport position

Prerequisite:
248 - 390 BG 28 H # 5336 / V01_en_04.2021

– The masthead has been folded into the operating position.
Button Process
• If present: Remove the screw connections (4) between the masthead (3) and the
mast (1).

3.15
✓ Masthead tilting cylinder (2) retracts.
✓ Masthead (3) folds into the transport position.
✓ The masthead is folded into the transport position.
Folding the upper mast extension to the transport position

Prerequisite:
– Mast (2) without process equipment is lowered.
– The main, auxiliary and crowd ropes are slackened.
– Masthead (4) is pivoted into the transport position.
BG 28 H # 5336 / V01_en_04.2021 249 - 390

– Upper mast extension (1) is folded into the operating position.
• Remove the screw connections (12).
• Remove the screw connections (6).
Button Process
- • Risk of damaging the ropes! If the rope sheaves of the crowd ropes
are installed in the upper mast extension, ropes or components of the mast could
be damaged when folding. Slacken the crowd ropes sufficiently.

3.20 ✓ Mast tilting cylinder (5) retracts.
✓ Upper mast extension (1) folds into the transport position.
250 - 390 BG 28 H # 5336 / V01_en_04.2021

• Mount the plug connection (3)

between the mast (2) and upper
mast extension (1).
• Secure the plug connection (3)

with the relevant locking ele-
ments.
✓ The upper mast extension has

been folded properly into the
transport position.
Removing the prop pad

The mast prop may only be operated when the prop pad is mounted.

tally injured.
tracted.
– The mast must be vertically aligned.
– Suitably instructed auxiliary personnel are

standing ready.
• In the Kelly mode, extend the mast prop (1)

until the prop pad (4) rests without pressure
on the surface.
• Remove the locking elements (3) and plug el-

ements (2).
• Retract the mast prop (1).
• Mount the plug elements (2) and locking ele-

ments (3) on the prop pad (4).
✓ Prop pad is removed.
BG 28 H # 5336 / V01_en_04.2021 251 - 390

5.3 Upper carriage

Risk of accident!
If not properly removed, counterweights can fall or tip over. This could result in serious or fatal in-
Δ While the counterweights are being removed, persons are not permitted in the danger zone,
Δ Always remove counterweights and lift them from the equipment individually and in the pre-
scribed order.
5.3.1 Removing the counterweights

There are two different versions of the counterweights. A distinction is made between 4.9 t counter-
weights and 2.5 t counterweights. The quantity and version of the counterweights can be found in
the section "Stability".
4.9 t (Version 1) 2.5 t (Version 2)
The different versions of counterweights are removed in the same way.
Prerequisite:
– Mast is lowered.
Removing the counterweights with a lifting device

Removing the clamping chain from the counterweights
• Loosen the bolted connections (13) and re-
move the spring washer (14).
• Danger of accident! Danger of

getting crushed! Danger of falling! In order to
remove the clamping chain, the auxiliary per-
sonnel must stand on the upper carriage.
Sudden movements of the upper carriage can
cause persons to fall, leading to severe or fa-
tal injuries. Avoid sudden movements with the
upper carriage.
252 - 390 BG 28 H # 5336 / V01_en_04.2021

• Remove the clamping chain (9) with the up-

per spring washer (10).
✓ The clamping chain (8) is removed.
Removing Version 2 counterweights

• Attach a suitable lifting device at the lifting
• Lift the counterweight (2) carefully from the

upper carriage and place it lying down on a
suitable depositing surface.
• Counterweight (2) is removed.
• Remove additional Version 2 counterweights

accordingly.
Removing Version 1 counterweights

• Attach a suitable lifting device at the lifting
• Lift the counterweight (1) carefully from the

• Counterweight (1) is removed.
• Remove additional Version 2 counterweights

accordingly.
Removing the locking element

• If the locking element (15) is mounted, attach
suitable lifting devices to the lifting points
(16).
• Lift the locking element (15) carefully from the

✓ The locking element is removed.
• Remove additional counterweights in the

same way.
✓ Counterweights are fully removed.
BG 28 H # 5336 / V01_en_04.2021 253 - 390

Removing the counterweights with the mast
1 Place the counterweight on the upper X Distance between the undercarriage and
carriage with the boom cylinders. the lifting points on the counterweight
2 Lift the counterweight from the ground
with the backstay cylinders.
– A designated lifting device is provided.
– The process equipment has been removed from the mast.
– The crowd sledge with rotary drive is positioned at the lower end of the mast.
– The clamping chain of the counterweights is removed.
– Counterweights must not be lowered to a position lower than the working platform for the
equipment.
• Attach the designated lifting
device (2) to the corre-
sponding lifting points (1) of
the mast.
254 - 390 BG 28 H # 5336 / V01_en_04.2021

• Set the operating radius in accordance with the "Table of required operating radius".
• Attach the designated lifting device to the lifting points of the counterweight.
• Danger of accident! If the mast and counterweight are not correctly aligned with
one another, the counterweight can slip or start swinging uncontrollably when it is lifted. Per-
sons can be hit or trapped by the counterweight. The lifting points of the mast must be posi-
tioned vertically above the lifting points of the counterweight. Set the operating radius in accor-
dance with the "Table of required operating radius".
• Evenly extend both backstay cylinders slightly to raise the counterweight.
• Fully extend the boom cylinders.
• Evenly retract the two backstay cylinders in order to lower the counterweight onto the ground.
After adding the fourth counterweight, the locking element (6) is mounted.
BG 28 H # 5336 / V01_en_04.2021 255 - 390

• Mount suitable lifting devices to the lifting points (7) of the locking element (6).
• Remove the locking element (6).
• Remove the remaining counterweights in the same way.
✓ Counterweights have been properly removed.
5.3.2 Removing the exhaust pipe extension

Prerequisite:
– Exhaust pipe has cooled down.
256 - 390 BG 28 H # 5336 / V01_en_04.2021

• Risk of injury! Contact with hot

surfaces can cause the burning of body
parts. Ensure that the hot exhaust pipe has
cooled down before performing any installa-
tion/removal work. Grasp the exhaust pipe
extension by the handle.
• Remove the support element (1).
• Have a second person hold the exhaust pipe

extension (3) securely by the handle (2).
• Release the fastening elements (4).
• Lift the exhaust pipe extension (3) off the

fastening point.
• Fit the exhaust pipe extension (3) and asso-

ciated support element (1) in the special
holder (6).
• Secure the exhaust pipe extension (3) with

the corresponding locking elements (5).
✓ The exhaust pipe extension is now correctly

removed.
5.3.3 Removing the guard rail

Removing the safety chains
• Loosen the hook connections (6) and (7) of
the safety chains (4) and (5).
• Stow the loose ends of the safety chains (4)

and (5) so that they do not obstruct any other
work or transport procedures.
✓ The safety chains are removed.
BG 28 H # 5336 / V01_en_04.2021 257 - 390

Folding the fall protection equipment into the transport position

• Turn the locking element (3) be-
tween the upper and lower parts
of the corresponding fall protec-
tion (1) in the direction of the ar-
row.
• Pull the locking element (2) be-

tween the upper and lower parts
of the corresponding fall protec-
tion (1) in the direction of the ar-
row.
• Fold the upper part of the corresponding fall

protection downwards, as shown in the fig-
ure.
• Turn the locking element (3) on the lower

part of the corresponding fall protection in
the direction of the arrow.
• Pull the locking element (2) on the lower part

of the corresponding fall protection in the di-
rection of the arrow.
258 - 390 BG 28 H # 5336 / V01_en_04.2021

• Fold the corresponding fall protection into

the transport position, as shown in the fig-
ure.
• Fold the other fall protection units into the

transport position in the same manner as for
the first fall protection unit.
✓ The fall protection units are now correctly

folded into the transport position.
5.3.4 Removing the platform handrails

Prerequisite:
– Suitable lifting devices are available.
• Remove the handrails (1) from the holding

brackets on platforms (2) and (3).
• Retract the walking platform (2) and (3) by

the handle until the lock engages.
✓ The platform handrails have been properly

removed from the upper carriage.
5.3.5 Removing climbing aid

its uppermost position.
• Pivot the climbing aid (1) clockwise by 90°.

its lowest position. Move the climbing aid (1)
slightly to and fro so that the locking element
of the lever (2) latches into the hole.
✓ The climbing aid has been properly removed.
BG 28 H # 5336 / V01_en_04.2021 259 - 390

5.4 Undercarriage
body parts.
5.4.1 Retracting the crawlers
Plug connections and locking elements are located on the front and rear of the undercarriage.
Prerequisite:
– Crawlers are in the operating position.

• Remove the locking elements (1) and plug
connections (2) from the two crawlers.
• Completely retract the telescoping cylinders

of the crawlers (see "Basic functions - Under-
carriage").
✓ The telescoping cylinders of the crawlers

are retracted.
• Mount plug connections (2) on both crawlers

and secure with locking elements (1).
✓ Crawlers are fixed in the transport position.
260 - 390 BG 28 H # 5336 / V01_en_04.2021

6 Transport
6 Transport
Risk of accident!
6.1 Transport guidelines

The haulage contractor must be informed of all necessary dimensions and weights as well as the
route.
The driver supplied by the haulage contractor must inspect and ensure the equipment and its ac-
cessories are properly secured before starting any journey.
Information regarding the necessary lashing forces should be available to ensure the equipment is
tied down properly.
• Only store accessories where they will not pose an obstacle, e.g. to public or construction site
traffic. Also secure accessories so that any unintentional or unauthorized factors do not create
a hazard.
• When loading/unloading make sure the transporting vehicle is positioned on horizontal and
level ground with sufficient load-bearing capacity.
• For equipment that is driven onto/off the transporting vehicle, be sure to level the loading sur-
face of the vehicle to achieve the flattest ramp angle possible.
• Align the loading surface of the transporting vehicle horizontally and remove any ice, snow and
mud. Use suitable non-slip mats.
• Make sure the dimensions of the loading surface on the transporting vehicle are sufficient. If
necessary, take appropriate measures such as constructing suitable extensions.
• Use suitable ramps for equipment that is driven onto/off the transporting vehicle. Observe the
maximum permissible load and maximum permissible gradient of the ramps. The ramps must
also be adjustable according to the track width.
• Extend the outriggers on the transporting vehicle (if available) when loading/unloading.
6.2 Transport measures

6.2.1 Transport mode
When the transport mode is selected the functions of the equipment are restricted. The following
functions are available:
– Control the crawlers
– Turn the upper carriage
– Increase/reduce operating radius *
BG 28 H # 5336 / V01_en_04.2021 261 - 390

6 Transport
– Retract/extend mast prop
* The boom cylinders can be extended no more than halfway.
6.2.2 Base machine

Before loading
The base machine must be put in the transport position before it is driven onto the transporting ve-
hicle or lifted with a suitable auxiliary crane.
The base machine is in the transport position when
– the upper carriage is positioned parallel to the undercarriage in the main direction of travel
and locked to it if the device has a locking bar component.
– all the process equipment, except the rotary drive, has been removed from the mast.
– the rotary drive is positioned at the lower end of the mast.
– the mast is resting on the mast bearing.
– the mast is lowered.
– the crawlers are fully retracted.
– the counterweights have been removed from the upper carriage (if applicable).
– sharp edges, pointed parts and cutting edges have been additionally covered and secured.
After loading
• Switch off the diesel engine.
• Close the cab and remove the key.
• Set the main fuse switch to position "0".
• Fold in, retract or remove projecting brackets, holding brackets, and steps.
• Lock and secure movable components.
• Secure and tie the equipment to the deck accordingly.
6.3 Transport data

6.3.1 Base machine
The following schematic figures are intended to provide a better overview and do not refer to a par-
ticular class of equipment.
262 - 390 BG 28 H # 5336 / V01_en_04.2021

6 Transport
Base machine with upper mast extension
Base machine with counterweights, without rotary drive

Dimensions
Dimensions Length 19427

[mm]:
Width 3000
Height 3500
Weight [t]: approx. 78 with counterweights

Counterweights [t]: 2 x 4.9 + 1 x 2.5
Centers of gravity
Dimensions 3061
[mm]:
1700
1600
Base machine without counterweights, without rotary drive

Dimensions
Dimensions Length 19427

[mm]:
Width 3000
Height 3500
Weight [t]: approx. 65.7
BG 28 H # 5336 / V01_en_04.2021 263 - 390

6 Transport
Centers of gravity
Dimensions 2461
[mm]:
1600
1700

Counterweights
Counterweights
Dimensions [mm]: Length 3000

Width 950
Height 450
Weight [t]: 2 × 4.9 + 1 × 2.5
6.4 Symbols for transport - overview

The attachment points on the equipment and its components or accessories are provided with cor-
responding color-coded symbols.
The position and type of the different symbols can be inferred from the labeling plan.
Example: Hook symbol to designate a lifting point
264 - 390 BG 28 H # 5336 / V01_en_04.2021

6 Transport
Example: Tying point with specified maximum permissible pulling force
Example: Component weight specification
6.5 Loading - Lifting

Incorrect attachment of the lifting device and lifting gear can result in damage to the equipment
and/or components.
Δ Only use suitable lifting devices with adequate load-bearing capacity.
Δ Only attach the lifting device to the lifting points provided for that purpose.
In the case of components without special devices for the lifting points, the individual lifting posi-
tions can be derived from the relevant documentation.
6.5.1 Lifting the base machine

The base machine may only be transported with an auxiliary crane if the rotary drive and counter-
weights have been removed.
1 Lifting points
BG 28 H # 5336 / V01_en_04.2021 265 - 390

6 Transport

Lifting counterweights
1 Lifting points
The attachment points of the individual counterweights are different. Observe any symbols present
at the attachment points!
266 - 390 BG 28 H # 5336 / V01_en_04.2021

6 Transport
6.6 Loading – driving

6.6.1 Traveling for Loading
When loading the equipment onto a transport vehicle, it can result in damage to the hose package.
Δ Lift the mast to the upper edge of the upper carriage. Make sure the hose package is posi-
tioned correctly.
Δ Keep the hose package sufficiently clear of the crawlers and the floor!
BG 28 H # 5336 / V01_en_04.2021 267 - 390

6 Transport
• 1. Set the battery main switch to position "I".
• 2. Unlock the Emergency STOP button.
• 3. Start the diesel engine.
• 4. Set the diesel engine to the appropriate speed.
• 5. Switch on the hydraulic pilot control.
• 6. Switch on the transport mode.
• 7. Raise the mast.
• 8. Drive the base machine forwards.
• 9. Drive the base machine backwards.
• 10. Lower the mast.
• 11. Switch off the transport mode.
• 12. Switch off the hydraulic pilot control.
• 13. Switch off the diesel engine.
• 14. Lock the Emergency STOP button.
• 15. Set the battery main switch to position "0".
✓ The loading procedure has been carried out accordingly.
6.7 Loading - Tying down

If the equipment and/or components are tied down incorrectly, they could be damaged during trans-
port.
Δ Cover and secure any sharp edges, projecting points and cutting edges.
Δ Use lifting devices which are adequately dimensioned.
Δ Only attach lifting devices to the designated tying points.
6.7.1 Tying down the base machine

• Attach a suitable lifting device to the specially provided tying points (1) on the base machine
and tie it down.
268 - 390 BG 28 H # 5336 / V01_en_04.2021

6 Transport
Rear tying points on the underside of the up-

per carriage
Rear tying points on the crawlers of the un-

dercarriage
Front tying points on the underside of the up-

per carriage
Front tying points on the crawlers of the un-

dercarriage
BG 28 H # 5336 / V01_en_04.2021 269 - 390

6 Transport
• Transport the individual counterweights lying down.
• Lay the counterweights on the depositing surface of the transporting vehicle and cover any
sharp edges.
• Attach suitable lifting devices to the counterweights and tie down accordingly.

Tying down a counterweight
• Transport the counterweight horizontally.
• Place the counterweight on the lay down area of the transport vehicle and cover any sharp
edges.
• Attach suitable slinging gear to the counterweight and tie it down accordingly.
270 - 390 BG 28 H # 5336 / V01_en_04.2021

7 Maintenance/repair
Risk of accident!
– Safety during maintenance and environmental protection/disposal [➙ 54]

7.1 Guidelines - Maintenance/repair

Maintenance/repair guidelines:
– All maintenance work must be performed in accordance with the maintenance plans and
associated sections of this Instruction manual. The appropriate additional documentation
provided by the manufacturer of supplied components must also be observed.
– The individual inspection points in the maintenance plans reflect the "target condition" of
each component. Have any defects remedied immediately.
– The maintenance work outlined by the manufacturer must be completely performed and
documented on a regular basis.
– Any maintenance work performed must be consistently registered in the maintenance and
repair logs and countersigned accordingly.
7.1.1 Expert inspection

The entire equipment must be inspected by an expert at regular intervals (in Germany, for example,
this is once per year). The inspection intervals must be performed in accordance with country-spe-
cific or regional laws, regulations, guidelines and standards.
The expert inspection may only be performed by a qualified person.
7.1.2 Maintenance intervals

Maintenance intervals are determined according to the operating hours/calendar periods. The first
interval reached always applies.
The maintenance intervals refer to the operating hours meter of the base machine.
The following maintenance intervals are specified:
BG 28 H # 5336 / V01_en_04.2021 271 - 390

– After 10 hours of operation or daily
– After 50 hours of operation or weekly
– After 250 hours of operation or monthly
– After 500 hours of operation or quarterly
– After 1000 hours of operation or annually
– After 2000 hours of operation or annually
– After 4000 hours of operation or every two years
– Special intervals
For normal operation the maintenance intervals are cumulative. This means that when mainte-
nance work is due for e.g. 1000 hours of operation, maintenance must also be performed every 10,
50, 250 and 500 hours of operation.
Under extreme environmental conditions, it may be necessary to perform maintenance at shorter

intervals. Such extreme environmental conditions include heavy dust build-up and extreme mois-
ture.
7.1.3 Hose assemblies

Hose assemblies must be inspected regularly by a qualified person.
National standards and guidelines in the country of assignment must be observed.
7.1.4 Connection elements

Screw connections and plug connections should always be manufactured according to the applica-
ble standards of good practice.
Tightening torques for bolts and screws can be found in generally accepted tables if no specific in-
dication is provided regarding the tightening torques in the Instruction manual or spare parts list.
For further information, please refer to the enclosed additional documentation entitled "Tightening
torque tables screw connections".
7.1.5 Welding work

General guidelines before starting any welding work:
• Shut down the equipment (see section "Brief interruptions or end of work").
• Disconnect the equipment from the power supply (actuate the battery main switch).
• Disconnect the cables from the positive and negative terminals of the batteries.
• Protect heat-sensitive and combustible components on the equipment and surrounding area
from heat radiation.
• Attach the grounding terminal of the welding tool to the weld point (always as close as possible
to the weld point).
272 - 390 BG 28 H # 5336 / V01_en_04.2021

7.1.6 Pressure containers

Pressure containers must be inspected, maintained, repaired, used and transported in accordance
with country-specific or regional laws, regulations, guidelines and standards (in Germany, for exam-
ple, according to DIN EN 13445 part 2).
Only have the pressure containers inspected by trained persons and serviced by appropriately au-
thorized skilled personnel.
7.1.7 Cylinder
Risk of causing damage to piston rods!
Corrosive environments can cause corrosive damage to extended piston rods.
Δ Move extended piston rods in and out multiple times according to environmental factors or treat
with hydraulic oil.
Δ Preserve extended piston rods with acid-free grease for prolonged periods of standstill.
• Check that the cylinders are in proper working order.
• Check to ensure connection elements are complete, secure and intact.
• Replace any defective connection elements.
• Check to ensure locking elements are complete, secure and intact.
• Replace any defective locking elements.
Cleaning piston rods

Risk of causing damage to piston rods!
Steam jet devices, tools with sharp edges, caustic fluids or cleaning agents can damage the piston
rods.
Δ Do not clean the piston rods with the above mentioned tools or cleaning agents.
• Check the cylinders before cleaning for any ejected media (e.g. hydraulic oil).
• Clean the cylinders.
• Clean piston rods.
• Repeatedly extend and retract the piston rods, then treat with hydraulic oil.
✓ The piston rods have been cleaned.
Leak testing
Prerequisite:
– The cylinders and piston rods have been cleaned.
• Check piston rods for integrity.
• Visually check the cylinders for leaks.
• Replace defective cylinders as described in the section "Replacing cylinders".
✓ The cylinders have been checked for leaks.
BG 28 H # 5336 / V01_en_04.2021 273 - 390

Replacing cylinders
Prerequisite:
– Components connected to the cylinder have been released and secured accordingly.
– The cylinders and their supply system have been depressurized.
– A suitable container for the waste oil is available.
• Disconnect the appropriate cylinder from the supply system.
• Close the supply ports to the cylinder.
• Remove the cylinder.
• Install the new cylinder.
• Connect the new cylinder to the supply system.
• If necessary, vent the supply system.
✓ The defective cylinder has been replaced.
Lubricating cylinder joints

• Clean cylinder joints.
• Clean lubrication points.
• Lubricate each cylinder joint at the corresponding lubrication points.
✓ The cylinder joints have been lubricated.
7.1.8 Bearings and bearing pins

Check the bearings and bearing pins according to the applicable standards of good practice.
Bearing and bearing pin tolerances can be found in generally accepted tables if no specific indica-
tion is provided regarding the tolerances in the Instruction manual or spare parts list.
The respective inspection intervals are defined in the maintenance plans in this Instruction manual.
Lubricating bearing connections and plug connections

• Clean bearing connections and plug connections.
• Clean lubrication points.
• Lubricate each bearing connection and plug connection at the corresponding lubrication points.
✓ The bearing connections and plug connections have been lubricated.
274 - 390 BG 28 H # 5336 / V01_en_04.2021

The respective lubrication intervals are defined in the maintenance plans in this Instruction manual.
7.1.9 Ball cock

Secure the ball cock from unintentional moving
So that the ball cock is not unintentionally moved to another position, it can be secured against un-
intentional moving.
• Remove the ball cock (2) together with the corresponding screw connection.
✓ The ball cock (2) has been removed.
• Position the flat washer (3) as shown in the figure.
• Mount the ball cock (2) together with the corresponding screw connection (1).
✓ Ball cock cannot be moved.
Setting the direction of movement of the ball cock.
• Remove the ball cock (2) together with the corresponding screw connection.
✓ The ball cock (2) has been removed.
• Position the flat washer (3) as shown in the figure.
BG 28 H # 5336 / V01_en_04.2021 275 - 390

A different direction of movement of the ball cock (2) can be achieved by altering the position of the
washer (3).
• Mount the ball cock (2) together with the corresponding screw connection (1).
• Ball cock can be moved in a certain direction.
Ball cock direction of flow
The direction of flow of the control unit must be taken into account when mounting the ball cock.
• Mount ball cock (2) so that the notches (marked green in
the figure) of the ball cock (2) and the square drive (4) lo-
cated above one another.
Ball cock is in the "open" position Ball cock is in the "closed" position
Notches on ball cock (2) and square drive (4) Notches on ball cock (2) and square drive (4)
are parallel to the hose assembly. are perpendicular to the hose assembly.
7.1.10 Cleaning the equipment/rig

If the equipment/rig is cleaned using a high pressure cleaner, the electrical equipment/rig compo-
nents may be damaged by water ingress.
Δ Do not clean electrical components (e.g. electrical box, measurement sensor, sensors) with a
high pressure cleaner.
All openings that need to be protected from the ingress of cleaning agent, water and steam due to
safety reasons and/or reasons of a functional nature must be covered accordingly before cleaning
the product with water, steam or other suitable cleaning agents. Electrical components such as
electrical boxes and electric motors are particularly sensitive.
276 - 390 BG 28 H # 5336 / V01_en_04.2021

After cleaning, all of the components on the product, in particular fuel lines and oil lines, must be
checked to ensure they are in proper working order. If any defects are detected, they must be recti-
fied immediately.
7.2 Maintenance plans
For a better overview, each maintenance task has been assigned a symbol in the individual mainte-
nance plans:
Symbol Description
All work involving oils (except for oil changes)
Changing the oil
Visual checks of all types
Cleaning
Lubrication
All "active" maintenance tasks such as replacement, adjustment, configuration and

repair
Maintenance tasks for supplier components are not always completely listed in this Instruction
manual. Please refer to the appropriate information in the respective maintenance plans.
An overview of the individual positions for the lubricating work listed in the maintenance plans can
be found in the relevant lubrication plan in this Instruction manual.
BG 28 H # 5336 / V01_en_04.2021 277 - 390

7.2.1 Entire equipment

○ Once after start-up
● Recurring
+ As needed
Symbol Maintenance inter- Activity

val
Entire equipment/rig
● Inspection of the equipment via a certified service partner
from the manufacturer after 20000 hours of operation or af-
ter 10 years.
Entire equipment
● Undercarriage, upper carriage, attachment:
Visually check to ensure load bearing steel parts are intact.
● Check to ensure that safety and protective equipment (e.g.

EMERGENCY-STOP, "pilot control" safety stick, limit
switches, etc.) is in proper working order.
● Check fire extinguishers, first aid boxes, warning signs and
fall protection equipment (safety harness, fall protection
rails, etc.) to ensure they are complete and in proper work-
ing order.
● Check to ensure that components for fluid and gaseous me-
dia are in proper working order.
● Check to ensure that operating and control elements are in

proper working order.
● Check to ensure the pressure containers are in proper work-

ing order.
278 - 390 BG 28 H # 5336 / V01_en_04.2021

7.2.2 Undercarriage
● Recurring
+ As needed

val
Screw connections
○ ● Floor plates:
Check that screw connections are complete and secure and
in proper working order.
● Crawler drive wheels, tread rollers, chain guides, crawler
drives, telescopic cylinders, track idlers, slewing ring:
Check to ensure the screw connections are complete and
secure and in proper working order.
Plug connections
● Check for proper working order.
Crawler
● If necessary, remove any foreign objects (such as stones).
● Check front idler units, tread rollers and track idlers for
leaks.
● Check floor plates, front idlers, tread rollers, track idlers and
slide rails for wear.
● Check the track tension for the prescribed nominal value.
Telescopic guide
● Clean spars and lubricate sliding surfaces.
○ ● Check spars for permissible play.
BG 28 H # 5336 / V01_en_04.2021 279 - 390

● Recurring
+ As needed

val
Crawler drive
Further information can be found in the enclosed additional
documentation!
● Check the oil level.
● Change the oil.
Steps/platforms
● Check to ensure everything is complete and in proper work-
ing order.
● Check to ensure the plug connections, screw connections

and locking elements are complete, secure and in proper
working order.
280 - 390 BG 28 H # 5336 / V01_en_04.2021


● Recurring
+ As needed

val
Diesel engine
documentation!
● Change the oil.
● Diesel engine oil filter: Replace filter elements with new

ones.
● Changing the V-belt
Cooling system of the diesel engine

documentation!
● Check level of coolant/antifreeze.
● Replace coolant with fresh coolant.
● Check the cooling system.
● Clean the cooling system.
Pump distributor gear

documentation!
○ ● Change the oil.
BG 28 H # 5336 / V01_en_04.2021 281 - 390

● Recurring
+ As needed

val
Hydraulic tank
○ ● Change the oil.
● Take an oil sample and check its purity (no solids, water or
other impurities).
● Have the hose lines checked for proper working order by a

qualified person.
SCR system
● SCR system filter: Replace the filter element with a new one
every 5000 hours.
Exhaust gas regeneration level IV

documentation!
● Replace diesel particle filter with a new one every 5000 en-
gine hours.
282 - 390 BG 28 H # 5336 / V01_en_04.2021

● Recurring
+ As needed
Symbol Maintenance in- Activity

terval
Filters
documentation!
○ ● Oil feed line filter: Replace the filter element with a new one.
○ ● Line filter for biodegradable oil: Replace the filter element

with a new one.
○ ● Control pressure line filter: Replace the filter element with a

new one.
○ ● Hydraulic oil return oil filter: Replace the filter element with a
new one.
● Hydraulic tank ventilation filter: Replace the filter element

with a new one.
● Fuel tank ventilation filter: Replace the filter element with a

new one.
● Diesel engine air filter: Check/clean the filter elements.
● Diesel engine air filter: Replace filter elements with new

ones.
Depth vibrator filter

○ ● Cooling oil line filter: Replace the filter element with a new
one.
● Return oil filter: Replace the filter element with a new one.
BG 28 H # 5336 / V01_en_04.2021 283 - 390

● Recurring
+ As needed

val
Pressure accumulator
documentation!
Oil cooler
● Clean.
Swing mechanism
documentation!
● Check to ensure the connection elements are complete and
● Check the swing brake.
● Check to ensure the screw connections on the slewing ring

are secure.
● Lubricate the outer gear teeth on the slewing ring.
● Lubricate rotary joint/rotor bearing.
● Swing mechanism gear: Check the oil level.
○ ● Swing mechanism gear: Change the oil.
● Swing brake: Check the oil level.
○ ● Swing brake: Change the oil.
284 - 390 BG 28 H # 5336 / V01_en_04.2021

○ Once after commissioning
● Recurring
+ As needed

val
Counterweights
○ ● Check to ensure the tension chain is adequately tensioned.

● Have the tension chain inspected by a qualified person.
Electrical equipment
documentation!
● Check the electrolyte level of the batteries.
● Check to ensure the cable connections of the batteries are

● Replace defective safety fuses with new safety fuses.
● Replace the air filters on the electrical box with new filters.
● Replace EMERGENCY-STOP relays with new ones every

ten years.
Central lubrication system

documentation!
● Check the grease level in the grease receptacle.
BG 28 H # 5336 / V01_en_04.2021 285 - 390

● Recurring
+ As needed

val
documentation!
● Check that all compressor fastening elements are intact,
complete and correctly seated.
● Check all compressor drive belts are intact, for wear and are
correctly seated.
● Start up the air conditioning system.
● Clean the condenser.
● Clean the air filter and, if necessary, replace it with a new

one.
286 - 390 BG 28 H # 5336 / V01_en_04.2021

● Recurring
+ As needed
Symbol Maintenance inter- Task

val
Steps, platforms, and handrails
● Check that the screw connections are complete and secure.
● Check the locking mechanisms for proper working order.
BG 28 H # 5336 / V01_en_04.2021 287 - 390

7.2.4 Attachment
Masthead
● Recurring
+ As needed
Symbol Maintenance inter- Task

val
○ Check plug connections, screw connections, and locking el-

ements are seated securely.
● Check that plug connections, screw connections, and lock-

ing elements are complete and in good working order.
● Replace screw connections every 10000 operating hours

with new ones.
288 - 390 BG 28 H # 5336 / V01_en_04.2021

Mast
● Recurring
+ As needed

val
Mast sections
+ Clean.
○ Check to ensure plug connections, screw connections and

locking elements are seated securely.
● Check to ensure plug-in connections, screw connections

and locking elements are complete and in proper working
order.
● Lubricate mast guidance rails.
● Replace screw connections every 5000 operating hours with

new ones.
Mast prop
+ Clean.

○ Check to ensure the connection elements are secure.
● Lubricate the swivel head and fastening point.
BG 28 H # 5336 / V01_en_04.2021 289 - 390

● Recurring
+ As needed

val
Mast pivot
+ Clean.
○ Check to ensure the screw connections are secure.
● ○ Check to ensure plug-in connections, screw connections

and locking elements are complete and in proper working
order.
● Lubricate the fastening points and guides.

with new ones.
290 - 390 BG 28 H # 5336 / V01_en_04.2021

Rope winches
● Recurring
+ As required

val
Main winch
documentation!
+ Clean.
● Change the oil.
● Lubricate counter bearings.
○ Check to ensure the screw connections are complete, se-

cure and in proper working order.
● Replace screw connections between mast and winch trestle

every 10000 operating hours.
BG 28 H # 5336 / V01_en_04.2021 291 - 390

● Recurring
+ As required

val
Auxiliary winch
documentation!
+ Clean.
● Change the oil.

● Replace screw connections between the mast and winch

trestle every 10000 operating hours.
292 - 390 BG 28 H # 5336 / V01_en_04.2021

● Recurring
+ As required

val
Crowd winch
documentation!
+ Clean.
● Change the oil.

● Replace screw connections between the mast and winch

trestle every 10000 operating hours.
BG 28 H # 5336 / V01_en_04.2021 293 - 390

Ropes and rope accessories

● Recurring
+ As needed

val
Rope swivel
+ Clean.
● Check for proper working order, integrity and low play.

working order.
● Lubricate swivel connection.
Pulleys
+ Clean.
● Check for proper working order, integrity and low play.
● Check for impermissible deviations in dimension and edge

formation.
● Lubricate (pulleys with floating bearing).
● Lubricate (pulleys with rolling bearing).

working order.
294 - 390 BG 28 H # 5336 / V01_en_04.2021

● Recurring
+ As needed

val
Rope hold-down rollers
+ Clean.
● Lubricate the bearing.
● Check to ensure the connection elements are complete, se-

Ropes, rope fasteners, thimbles and sleeves

documentation!
+ Clean.
+ Apply corrosion protection (depending on weather condi-

tions and ambient conditions).
+ Replace ropes with new ones.
BG 28 H # 5336 / V01_en_04.2021 295 - 390

Crowd sledge
● Recurring
+ As needed

val
Crowd sledge
● Clean.
● Check the sliding strips for wear and integrity.

with new ones.
296 - 390 BG 28 H # 5336 / V01_en_04.2021

7.3 Maintenance schedules
The following lubrication plan shows an overview of all relevant lubrication points on the equipment.
If there is a central lubrication system, some of these lubrication points will be automatically lubri-
cated. Components in this table marked with "*" must also be manually lubricated. If no central lu-
brication system is present, all lubrication points must be manually lubricated.
7.3.1 Lubrication plan - Base machine
BG 28 H # 5336 / V01_en_04.2021 297 - 390

● Recurring
+ As needed
Symbol Maintenance inter- Component

val
*) Must be lubricated by hand
**) Lubricated via the process equipment
● Mast guide rails (24) **
● Crowd sledge guides (23)
● Crowd rope sheaves: Pulley block (6)
● Central rope guide: Main rope sheave (4)
● Central rope guide: Auxiliary rope sheave (5)
● Central rope guide: Crowd rope sheaves (7)
● ○ Slewing ring (ball bearing race and rotor bearing) (12)
● Outer slewing ring gear teeth (14)
● Mast prop swivel head (15) *
● Rope swivel (26) *
● Masthead tilting cylinder joints (3) *
● Mast tilting cylinder joints (27) *
● Crowd rope clamping cylinder joints and guide (25) *
● Backstay cylinder joints (8)
● Boom joints (9)
● Boom cylinder joints (10)
● Supporting boom joints (11)
● Mast pivot joint (19)
● Mast pivot guide (20)
● Main winch counter bearing (17)
● Auxiliary winch counter bearing (18)
● Crowd winch counter bearing (21)
● Undercarriage spar sliding surfaces (13) *
● Masthead joints (29) *
● Main rope sheaves (1) *
● Auxiliary rope sheaves (2) *
● Crowd rope sheaves (16), (22), (28) *
298 - 390 BG 28 H # 5336 / V01_en_04.2021

7.4 Lubricants
Non-compliance with the following guidelines can cause damage to the components of the equip-
ment.
Δ Only use prescribed lubricants.
Δ Only use lubricants of the same lubrication type/specification and of the same viscosity class in
accordance with the “Initial lubricant fill” table and the specifications on the respective name-
plates.
Δ If another viscosity class is required, contact the customer service of BAUER Maschinen
GmbH.
Δ Do not mix synthetic and petroleum based lubricants.
Δ Do not mix zinc-free lubricants with lubricants that contain zinc.
Δ Only use fresh lubricants.
Incorrect use of lubricants can lead to loss of warranty if damage occurs.
7.4.1 Lubricants table

The following table shows the corresponding lubricants used for the initial filling procedure.
The specified quantities are guideline values. The specifications on the respective nameplates and
the level indicators of the individual components take priority. Alternative lubricants can be found in
the relevant "Lubricant selection lists" of this instruction manual.
Initial lubricant fill table

Component Quantity Quantity Lubricant Viscosity Manufac- Manufac-
[l] [gal] type/speci- class/de- turer turer desig-
fication scription nation
Main winch 11.00 2.91 Gear oil/ ISO VG 220 CASTROL Alphasyn
CLP HC EP 220
Auxiliary winch 3.30 0.87
Pull-down winch 9.50 2.51
Swing mechanism 2 x 7.00 2 x 1.85
gear
Pump distributor 8.50 2.25
gear
Crawler drive 2x 2 x 3.43
13.00
Total hydraulic sys- 1000.00 264.00 Hydraulic ISO VG 46 CASTROL Hyspin DHV
tem oil/ 46
HVLP (D)
In the hydraulic 630.00 166.43
tank
Diesel engine 30.00 7.92 Engine oil/ SAE CASTROL Vecton Long
API CJ-4 10W-40 Drain
10W-40 E6/
E9
BG 28 H # 5336 / V01_en_04.2021 299 - 390

Component Quantity Quantity Lubricant Viscosity Manufac- Manufac-

[l] [gal] type/speci- class/de- turer turer desig-
fication scription nation
Rolling bearings as as Multi-pur- Multi-pur- FUCHS Renolit MP
needed needed pose pose grease
grease/ based on
Floating bearings as as
KP2K-30 lithium soap
needed needed
NLGI class
Central lubrication as as 2
system needed needed
Statically supported as as Long-life Long-life FUCHS Lagermeis-

components needed needed grease/ grease ter WHS
KPF1-2K-20 based on 2002
NLGI class lithium soap
2
300 - 390 BG 28 H # 5336 / V01_en_04.2021

7.4.2 Lubricant selection lists

Only use lubricants of the same lubrication type/specification and of the same viscosity class in ac-
cordance with the “Initial lubricant fill” table and the specifications on the respective nameplates. If
another viscosity class is required, contact the customer service of BAUER Maschinen GmbH.
CLP HC gear oil

Specification CLP HC
Lubricant basis Synthetic (PAO)
Standard DIN 51517/3, ISO 12925/1
Special feature -
Viscosity grades
ISO-VG/DIN 51562 at +40°C in mm2/s
VG 100 VG 150 VG 220
Ambient temperature
ARAL ARAL Degol ARAL Degol ARAL Degol
PAS 100 PAS 150 PAS 220
AVIA AVIA Synthogear AVIA Synthogear AVIA Synthogear
EP 100 EP 150 EP 220
BP BP Enersyn BP Enersyn
EP-XF 150 EP-XF 220
CASTROL Alphasyn EP 150 Alphasyn EP 220
DEA Intor HCLP 150 Intor HCLP 220
ESSO Spartan Synthetic
EP 220
FUCHS Renolin Unisyn Renolin Unisyn Renolin Unisyn
CLP HC 100 CLP HC 150 CLP HC 220
KLÜBER Klübersynth Klübersynth
EG 4-150 EG 4-220
MOBIL Mobil SHC Mobil SHC
Gear Series 150 Gear Series 220
Mobil SHC 629 Mobil SHC 630
OPTIMOL Optigear Synth
A 220
SHELL SHELL Omala SHELL Omala
S4 GXV 150 S4 GXV 220
TEXACO/CHEVRON Pinnacle Pinnacle
EP 150 EP 220
TOTAL Carter SH 150 Carter SH 220
BG 28 H # 5336 / V01_en_04.2021 301 - 390

Hydraulic oil HVLP(D)

Specification HVLP(D)
Lubricant basis Petroleum
Standard DIN 51524/3 (HVLP); DIN EN ISO 6743/4 HV
Special feature Zinc-free
Viscosity grades
ISO-VG/DIN 51519 at +40°C in mm2/s
VG 32 VG 46 VG 68
Ambient temperature normal temperature high temperature
range e.g. Europe, range e.g. UAE, Africa
USA, China
ARAL Vitam HF 32 Vitam VF 46/ Vitam VF 68
Vitam HF 46
SHELL Tellus S3 V 32 Tellus S3 V 46 Tellus S3 V 68
BP Bartran HV 46 Bartran HV 68
CASTROL Hyspin DHV 46 Hyspin DHV 68
CASTROL Hyspin HVI 46 Hyspin HVI 68
STATOIL HydraWay HVXA 32 HydraWay HVXA 46 HydraWay HVXA 68
CONOCO ECOTERRA HVI 46
PANOLIN HLP UNI 46 HLP UNI 68
ADDINOL HVLPD 46
CHEVRON Clarity Synthetic Hy- Clarity Synthetic Hy- Clarity Synthetic Hy-
draulic Oils AW 32 draulic Oils AW 46 draulic Oils AW 68
MOBIL DTE 10 Excel 32 DTE 10 Excel 46 DTE 10 Excel 68
GULF Harmony ZF-HVI Plus Harmony ZF-HVI Plus
46 68
302 - 390 BG 28 H # 5336 / V01_en_04.2021

Motor oil API CJ-4

Specification API CJ-4
ACEA E 9
Lubricant basis -
Standard -
Special feature Low in phosphor, sulfur, and sulfate ashes
Viscosity classes
SAE/DIN 51511
SAE 5W-40 SAE 10W-40 SAE 15W-40
AGIP Sigma Truck E9
15W-40
ARAL Mega Turboral VR
10W-40
AVIA Multi LSP 15W-40
CASTROL Castrol Vecton
10W‑40 LS
CAT DEO-ULS 15W-40
CHEVRON Delo 400 LE 15W-40
TNK-BP Revolux D5 5W-40 Revolux D5 10W-40 Revolux D5 15W-40
FUCHS Titan Cargo 5W-40 Titan Cargo 15W-40
GULF Supreme Duty XLE
15W-40
STATOIL MaxWay E9 15W-40
MOBIL Delvac MX ESP
15W-40
SPC SDM 904 15W-40
Q8 T 760 15W-40
SHELL Rimula R4 L 15W-40
TEXACO Ursa Ultra 15W-40
IGOL TP 350 X 15W-40
TOTAL Rubia TIR 7900
15W-40
BG 28 H # 5336 / V01_en_04.2021 303 - 390

Greases
Specification/designation NLGI class 2/Multi-purpose grease EP
Lubricant basis -
Standard -
Special feature -
Specification
KP2K-30 KP2N-30 KPE2K-30
Ambient temperature
BAUER Long-life EP grease
ARAL Aralub HLP 2
SHELL Retinax EP 2
BP Energrease Biogrease EP 2
LS-EP 2
MOBIL Mobilux EP 2
ESSO Beacon EP 2
FINA Marson EPL 2A
ELF Epexa 2
FUCHS Renolit MP Lagermeister TS
AGIP GR MUEP 2
PANOLIN EP Grease 2
CASTROL Olit 2 EP
304 - 390 BG 28 H # 5336 / V01_en_04.2021

Lubricants for statically supported components
Specification/designation NLGI class 1-2; NLGI class 2/extended life

grease
Lubricant basis -
Standard DIN 51502
Special feature -
Specification
KPF1-2K-20 KPF2K-20
Ambient temperature
Fuchs Lubritech Lagermeister WHS
2002
Bechem Bechem LFB 2000
Specification/designation NLGI class 1-2/extended life grease

Lubricant basis -
Standard DIN 51502
Special feature Sea water resistant
Specification
KP1-2E-25
Ambient temperature
Bechem Bechem High-Lub SW
2
7.5 Entire equipment

7.5.1 Inspection of entire equipment
Good care, using original BAUER parts and adhering to regular service intervals guarantees a long
service life for your BAUER equipment.
However, the most diverse operating conditions in various regions of the world can produce very
different levels of wear and tear. To keep your BAUER equipment in good condition for safe opera-
tion, we recommend that the equipment is thoroughly inspected by one of our certified service part-
ners.
7.6 Undercarriage
7.6.1 Screw connections
• Clean both crawlers thoroughly.
• Check that the screw connections of the following components on both crawlers are complete
and secure and in proper working order:
BG 28 H # 5336 / V01_en_04.2021 305 - 390

1 Carrier rollers
2 Floor plates
3 Crawler drive wheels
4 Track guides
5 Tread roller
6 Crawler drive
• Tighten loose screw connections accordingly.
• Replace any faulty and missing screw connections with new ones.
✓ Screw connections are properly checked.
7.6.2 Plug connections
7.6.3 Crawler tracks
7.6.4 Crawler drive
306 - 390 BG 28 H # 5336 / V01_en_04.2021

Checking the oil level

• Position the equipment such that the screw
plug of the discharge hole (2) is at the deep-
est point.
• Remove the screw plug from the filler hole

(1).
The oil level is below the lower edge of the open-

ing (1):
• Replenish the oil as described in "Changing

the oil".
• Oil level is correct if it reaches the lower

edge of the filler hole (1).
• Clean the screw plug of filler hole (1) and the sealing surfaces.
• Check seals for wear and make sure they are intact.
• Replace damaged or worn seals with new ones.
• Mount the screw plug in the filler hole (1).
✓ Oil level has been properly checked.
Changing the oil

• Position the equipment such that the screw
plug of the discharge hole (2) is at the deep-
est point.

(1).
• Place a suitable container for catching the

old oil beneath the screw plug of the dis-
charge hole (2).
• Remove the screw plug from the discharge

hole (2).
✓ Waste oil flows into the prepared con-

tainer.
• Clean the screw plug of the discharge hole (2) and sealing surfaces.
• Check seal for wear and make sure it is intact.
• Install the screw plug in the discharge hole (2).
• Pour the new oil into the filler hole (1) with the help of a suitable filling unit.
• Check the oil level as described in "Checking the oil level".
• Clean the screw plug of the filler hole (1) and the sealing surfaces.
BG 28 H # 5336 / V01_en_04.2021 307 - 390

• Check seals for wear and make sure they are intact.
• Mount the screw plug in the filler hole (1).
• Dispose of the old oil in an environmentally friendly manner.
✓ The oil change has been properly carried out.
7.6.5 Telescopic guide
7.6.6 Steps/platforms/handrails
• Visually check to ensure the components are complete, secure and intact (e.g. damage,
cracks, wear, corrosion, deformation).
• Replace damaged, loose, or missing components with new ones.
• Check the integrity of the paintwork and repaint if necessary.
• Tighten screw connections as needed.
• Check locking elements for completeness, firm seating and integrity.
• Replace damaged, loose, or missing connection elements and locking elements with new
ones.
• Check to ensure the locking mechanisms are in proper working order.
• Clean the platforms and handrails.
✓ Inspection of the steps, platforms and handrails has been properly performed.
7.7 Upper carriage

7.7.1 Diesel engine
308 - 390 BG 28 H # 5336 / V01_en_04.2021

Prerequisite:
– The equipment is positioned horizontally.
– The diesel engine has been at a standstill for at least 5 minutes.
The dipstick (1) is located behind the integrated service platform on the left-hand side of the upper
carriage in the main direction of travel.
• Remove the dipstick (1).
• Clean the dipstick (1) with a clean, lint-free

cloth.
• Mount the dipstick (1) and remove it again.
• Read the oil level from the dipstick (1).
• Risk of causing damage to com-

ponents! If the oil level is above the green-
marked range "X", there is too much oil and/
or accumulations of fluid in the diesel en-
gine. Components could be damaged during
further operation. Adjust the level accord-
ingly or have the fault analyzed and re-
paired.
If the oil level is below the green zone desig-

nated with an "X":
• Top up the oil as described in the section

"Changing the oil".
✓ The oil level is OK when it is within the green

zone designated with an "X".
• Check the seal for wear and make sure it is intact.
• If the seal is damaged or worn, replace it with a new one.
BG 28 H # 5336 / V01_en_04.2021 309 - 390

• Insert the dipstick (1).
Changing the oil
The corresponding oil filters are to be replaced at every oil change in accordance with the enclosed
additional documentation.
Prerequisite:
– The diesel engine is switched off.
– Oil is at operating temperature.
– A suitable container for the waste oil is

available.
– A suitable draining device (4) for draining

the waste oil is available.
– Equipment is positioned horizontally.
The filler hole (2) is located behind the integrated service platform on the left-hand side of the up-
per carriage in the main direction of travel.
310 - 390 BG 28 H # 5336 / V01_en_04.2021

• Open the cap (2).

waste oil beneath the discharge opening (3).
• Remove the protective cap from the dis-

charge opening (3).
• Mount the draining device (4) on the dis-

charge opening (3).
✓ Waste oil flows into the prepared container.
The discharge opening opens automatically when the draining device is mounted.
• Remove the draining device (4) from the discharge opening (3).
• Clean the protective cap and the sealing surfaces.
• Mount the protective cap on the discharge opening (3).
• Fill the specified quantity of fresh oil into the filler hole (2) with the help of a suitable filling unit.
• Check the oil level as described in the section "Checking the oil level".
• Clean the cap (2) and the sealing surfaces.
BG 28 H # 5336 / V01_en_04.2021 311 - 390

• Close the cap (2).
• Start the diesel engine and allow it to run at idle speed for 2 minutes.
• Switch off the diesel engine and wait for 10 minutes.
Replacing the diesel engine filter elements
Fuel pre-filter, fuel main filter, filter element in the diesel engine water separator
Oil filters of the diesel engine
The corresponding oil filters are to be replaced at every oil change in accordance with the enclosed
Checking, tensioning and replacing belt drives
7.7.2 Cooling system of the diesel engine

Risk of polluting the environment!
Leaking coolant pollutes the ground and the groundwater.
Δ Dispose of the coolant in compliance with the legal regulations!
The following figures show the position of the charge air cooler (left figure) and the coolant cooler
(right figure) on the equipment.
312 - 390 BG 28 H # 5336 / V01_en_04.2021

1 Charge air cooler 2 Cooler

3 Sight glass
4 Coolant container
Checking the cooler

• Visually inspect the relevant coolers on both sides to ensure they are clean and intact (e.g.
damage, leaks, wear, corrosion).
• Replace damaged or missing components with new ones.
• Check connection elements for completeness, firm seating and integrity.
• Replace damaged, loose or missing connection elements and locking elements with new ones.
✓ The cooler has been properly checked.
Cleaning the cooler

Risk of causing damage to the cooling systems!
The use of sharp-edged tools, corrosive fluids, or scouring agents for cleaning can damage the
cooling systems.
Δ Do not clean the cooling systems using sharp-edged tools, corrosive fluids, or scouring agents.
Risk of causing damage to the cooling systems!

Excessive air pressure can damage the fins of the cooling systems.
Δ The maximum permissible air pressure is 3.5 bar.
Δ Direct the air jet along the fins.
Risk of causing damage to the cooling system!

When cleaning with a hot water jet, excessively high water pressure can damage the core of the
cooling system.
Δ Reduce the water pressure on the hot water jet appropriately and work a suitable distance
away from the cooling system.
Δ Direct the water jet along the cores.
• If necessary, clean the cooling systems with compressed air from the exhaust side.
BG 28 H # 5336 / V01_en_04.2021 313 - 390

• In case of heavy contamination (oily or greasy deposits), clean the cooling systems with a
steam cleaner.
• In case of obstinate contamination, wash the cooling systems.
Check the coolant level
Prerequisite:
Checking the coolant level at the coolant container

• Open the corresponding integrated service
platform and maintenance flap.
• Check the coolant level via the sight glass

(1).
✓ Coolant level is not visible on the sight

glass.
• Top up the coolant level as described in the

section "Replacing the coolant".
✓ Coolant level is visible on the sight glass.
✓ The coolant level has been checked properly.
Checking the coolant level in the cab
The coolant level is checked electronically. If the coolant level is not OK, an appropriate warning
message appears on the monitor unit.
• If the coolant level is not OK, replenish the coolant as described in the section "Replacing the
coolant".
Replacing the coolant

Leaking coolant pollutes the ground and the groundwater.
Δ Dispose of the coolant in compliance with the legal regulations!
Applicable for cooling system - diesel engine.
314 - 390 BG 28 H # 5336 / V01_en_04.2021

Prerequisite:
– Cooling system - diesel motor is cooled

down.
– A suitable container for the waste coolant

is prepared and ready for use.
– Suitable draining device (4) for draining

the old coolant is available.
• Risk of scalding by the coolant! If the cap is removed from the water cooler, hot
coolant can escape. Only remove the cap from the water cooler when the coolant has cooled
down. Carefully remove the cap from the water cooler to allow any overpressure in the cooling
system to escape.
BG 28 H # 5336 / V01_en_04.2021 315 - 390

• Open the cap (1).
316 - 390 BG 28 H # 5336 / V01_en_04.2021

• Place a suitable container for collecting the

old coolant underneath the discharge open-
ing (2).
• Remove the cap from the discharge opening

(2).
• Mount the draining device (4) on the dis-

charge opening (2).
✓ The waste coolant drains into the prepared

container.
• Flush the cooling system in accordance with the enclosed additional documentation.
• Remove the discharge device (4) from the discharge opening (2).
• Mount the cap on the discharge opening (2).
• Risk of damage to components! If different types of coolant are mixed, the proper-
ties of the coolant can change and impair the functionality of the cooling circuit. Only use pre-
scribed coolants.
• Risk of damage to components! If the coolant concentrate needs to be diluted with

water, it must be noted that the quality of the water will affect the service life and performance
of the engine coolant. Use distilled water or fully desalinated water. If only untreated water is
available, it must meet certain minimum requirements. Only use untreated water after consult-
ing the manufacturer's after sales service department.
• Risk of damage to components! If the coolant is poured in too quickly, air pockets
can form. Pour in the coolant slowly (19 l/min).
• Pour the fresh coolant into the filler opening (1) with the help of a suitable filling unit in accor-
dance with the enclosed additional documentation.
• Check the coolant level as described in the section "Checking the coolant level".
• Clean the cap (1) and the sealing surfaces.
• If the seal is damaged or worn, replace it with a new seal.
• Close the cap (1).
BG 28 H # 5336 / V01_en_04.2021 317 - 390

✓ The coolant has been properly replaced.
7.7.3 Pump distributor gear
The pump distributor gear is located at the rear of the base machine (1).
Prerequisite:
– The pump distributor gear has been in operation for at least 30 minutes.
The pump distributor gear must have been in operation for at least 30 minutes before checking the
oil level, otherwise oil is still trapped for component lubrication.

cloth.
• Insert the dipstick (2) into the filler hole and

leave the screw fitting on the housing (3).
• Remove the dipstick (2) from the filler hole.
318 - 390 BG 28 H # 5336 / V01_en_04.2021


ponents! If the oil level is above the green-
marked range "X", there is too much oil and/
or accumulations of fluid in the pump distrib-
utor gear. Components could be damaged
during further operation. Analyze and correct
any faults and then change the oil if neces-
sary.
✓ If the oil level is below the green zone desig-

nated with an "X":

"Changing the oil".
✓ The oil level is OK when it is within the

green zone designated with an "X".
• Replace the dipstick.
✓ The oil level has been checked.
Changing the oil
Prerequisite:
– Suitable draining device for draining the waste oil is available.

• Remove the dipstick from the filler hole (2).
BG 28 H # 5336 / V01_en_04.2021 319 - 390


waste oil beneath the discharge opening (3).
• Remove the protective cap from the dis-

charge opening (3).
• Mount the draining device on the discharge opening (3).
• Remove the draining device from the discharge opening (3).
• Clean the protective cap and the sealing surfaces.
• Mount the protective cap on the discharge opening (3).
• Pour fresh oil into the filler hole (2) with the help of a suitable filling unit.
• Clean the dipstick and sealing surfaces.
• Mount the dipstick onto the filler hole (2).
• Operate the equipment for 30 minutes.
• Shut down the equipment.
• After 5 minutes, check the oil level again as described in the section "Checking the oil level".
320 - 390 BG 28 H # 5336 / V01_en_04.2021

Checking the breather filter

• Check the breather filter (1) for cleanliness
and clean it if necessary.
• If there are any oil deposits on the riser pipe

(2), replace the breather filter (1).
7.7.4 Hydraulic tank

Foreign particles in the hydraulic system have a negative impact on system safety.
Δ When working on the hydraulics, make sure that no foreign particles find entry into the hy-
draulic system.
Δ Only refill the hydraulic system via the filler hole.
When the equipment is at a standstill, hydraulic oil can flow from the higher components of the
process equipment and back into the hydraulic tank. This results in an increased oil level in the hy-
draulic tank. The correct oil level can only be determined when the operating temperature has been
reached.
BG 28 H # 5336 / V01_en_04.2021 321 - 390

If the oil level falls close to the specified minimum level, a corresponding warning message will ap-
pear on the B-Control unit.
If the oil level falls below the prescribed minimum level, the equipment will shut down automatically.
Further information can be found in the "B-Control" operating instructions.
• Read the oil temperature on the B‑Control

screen on control panel 1.
✓ The hydraulic oil must have reached an

operating temperature (1) of 20 °C.
• Position the base machine horizontally.
✓ The equipment has been at a standstill

for at least 5 minutes.
• Check the oil level on the B-Control unit on

control panel 1.
✓ The oil level indicator (2) is highlighted in

green.
✓ The oil level is in the prescribed range.
– The oil level indicator (2) is NOT high-

lighted in green.
• Replenish with oil as described in the sec-

tion "Replenishing the oil".
screen"!
322 - 390 BG 28 H # 5336 / V01_en_04.2021

• Alternatively, read the oil level via the

sight glass on the hydraulic tank.
3 Maximum permissible oil level in
transport position.
4 Maximum permissible oil level in op-
erating position.
5 Minimum permissible oil level for op-
erating or transport position. Replen-
ish hydraulic oil immediately.
Risk of causing damage to components of the hydraulic system!

If there is too much oil/liquid accumulation in the hydraulic tank, components could be damaged by
continued operation.
Δ Take an oil sample, analyze and correct any faults.
Replenishing the oil

Foreign particles in the hydraulic system have a negative impact on the safety of the system. If hy-
draulic oil is filled through the opening of the breather filter, for example, it would enter the hydraulic
tank without being filtered. Unfiltered hydraulic oil can result in damage to the components of the
hydraulic system.
Δ Fill the oil through the designated filler hole. The oil flows into the tank through the return oil fil-
ter and has the required level of purity.
Δ When working on the hydraulics, make sure no foreign particles enter the hydraulic system.
Risk of soil contamination!

When lowering the mast, for example, hydraulic oil flows from the backstay cylinders and back into
the hydraulic tank. If the hydraulic tank is overfilled, oil can escape through the vent. This oil can
enter the subsoil through the ground.
Δ Do not fill the hydraulic tank beyond the prescribed range.
Only replenish the hydraulic oil through the designated filler hole on the hydraulic tank. The filler
hole is situated in the middle of the upper carriage, above the hydraulic tank and below a screw
plug. The screw plug is accessible from the roof of the base machine.
• Position the base machine horizontally.
• Shut down the equipment and wait for 5 minutes.
BG 28 H # 5336 / V01_en_04.2021 323 - 390

• Open the maintenance flap (1).

(2).
• Refill the tank with hydraulic oil via the filler

hole (2).
Checking the oil level on the B-Control unit
For further information, please refer to the enclosed additional documentation entitled "B-Control".
Equipment is in the operating position:
• Refill with oil until the fill level indicator (4) is

between 80% and max. 85%.
Equipment is in the transport position:
When the equipment is in the transport position,

the filler hole is not accessible due to the mast/
hose bundle positioned above it. When the mast
is raised, the level in the hydraulic tank changes;
as a result, the correct hydraulic oil level cannot
be determined.
• To replenish the oil, set the equipment to the

operating position.
Alternatively, read the oil level via the sight glass on the hydraulic tank
324 - 390 BG 28 H # 5336 / V01_en_04.2021

Equipment is in the operating position:
• Refill with oil until the oil level reaches the

range (6).
Equipment is in the transport position:
• Refill with oil until the oil level reaches the

range (5).
• Clean the screw plug.
• Mount the screw plug for the filler hole (2).
• Close the maintenance flap (1).
✓ The oil has been refilled.
Depressurizing the hydraulic system

Risk of soil contamination!
Residual pressure may be present in the hydraulic system. When connecting the measuring line,
oil can escape suddenly under high pressure and spray out of the collecting container. Oil can en-
ter the subsoil through the ground.
Δ Place a suitable container and cloths to catch the oil accordingly.
Δ Hold the loose end of the measuring line firmly when connecting to the test strip and let the oil
spray into a cloth.

If a pressure gauge with too small a measuring range is connected to the test terminal block, the
pressure gauge can be damaged.
Δ Only connect a pressure gauge with a suitable measuring range to the terminal of the test ter-
minal block.
Further information on the measuring ranges can be found in the enclosed additional documenta-
tion "Hydraulics plan".
Prerequisite:

✓ The pressure in the hydraulic system is released.
BG 28 H # 5336 / V01_en_04.2021 325 - 390

This figure shows the position of the test strip (1)

on the equipment.
• Select the required connection on the test

strip (2) according to the additional docu-
mentation "Hydraulic plan".
• Connect the pressure gauge (measuring

range 600 bar) (4) to the corresponding con-
nection on the test strip (2) by using the
measuring line (3).
✓ The pressure gauge displays the pres-

sure.
• Remove the measuring line from the con-

nection on the test strip.
• Connect the measuring line without the pres-

sure gauge to the connection on the test
strip and allow the oil to drain into the con-
tainer.
✓ The oil has been drained.
✓ The hydraulic circuit has been depres-

surized.
• Remove the measuring line from the test

strip.
• Mount the corresponding protective caps

onto the test strip (2).
• Depressurize other hydraulic circuits if nec-

essary.
✓ The hydraulic system has been depressur-

ized.
326 - 390 BG 28 H # 5336 / V01_en_04.2021

Changing the oil

Prerequisite:
– Maximum hydraulic oil temperature: 40 °C.

• Close the shut-off valve (4) of the hydraulic
tank.
• Place a suitable container for catching

the waste oil beneath the discharge
opening (1).
• Remove the screw plug from the dis-

charge opening (1).
• Attach the supplied drainage hose (2) to

the discharge opening (1).
• Tighten the union nut on the drainage

hose until the valve opens.
✓ Waste oil is drained.

• Remove the drainage hose (2) from the
discharge opening (1).
• Mount the screw plug on the discharge

opening (1).
• Replenish with fresh hydraulic oil until

the maximum level is reached (see sec-
tion "Replenishing the oil").
✓ Oil has been filled to the maximum

level.
• Replace all of the filters in the hydraulic system with new ones (see section "Replacing filter el-
ements").
• Open the shut-off valve (4) of the hydraulic
tank.
BG 28 H # 5336 / V01_en_04.2021 327 - 390

• Start up the equipment and operate the entire hydraulic system at a low engine speed for ap-
prox. 5 minutes.
• Check the oil level again and top up the oil if necessary until the maximum level is reached.
✓ The oil has been changed.
Taking an oil sample

Prerequisite:
– An oil sample is required according to the maintenance plan.
For more detailed information, contact the BAUER after sales service.
• Have a chemical analysis of the oil carried out.
✓ The chemical analysis decides whether the hydraulic oil can continue to be used.
If the oil analysis exhibits a water content that is constantly too high or a purity level that is too low,
a fine mesh oil filter, for example, can be retrofitted. For more detailed information, contact the
BAUER after sales service.
• Risk of causing damage to components! If the base machine is operated with hy-
draulic oil, which according to the chemical analysis may no longer be used, components can
be damaged by further use. Change the hydraulic oil!
• Change the oil if it may no longer be used.
Return oil filter

Replace the filter elements of the return oil filter (see section "Replacing the return oil filter/leak oil
filter").
Vent filter
Replace the filter element of the vent filter from the hydraulic tank as described in the chapter "Re-
placing filter elements."
7.7.5 Oil cooler
328 - 390 BG 28 H # 5336 / V01_en_04.2021

Checking the oil cooler
Before the cooler is checked, the grid that is located above the cooler must be removed.
• Visually inspect the cooler (1) to ensure it is

clean and intact (e.g. damage, leaks, wear,
corrosion).
• Replace damaged or missing components

with new ones.
• Check the integrity of the paintwork and re-

paint, if necessary.
• Check to ensure locking elements are complete, secure and intact.
ones.
✓ The cooler has been properly checked.
Cleaning the oil cooler

The use of sharp tools, corrosive fluids or scouring agents for cleaning can damage the cooling
systems.
Δ Do not clean the cooling systems with the above mentioned tools or cleaning agents.
Risk of causing damage to cooler!

Excessive air pressure can damage the fins of the cooler.
BG 28 H # 5336 / V01_en_04.2021 329 - 390


When cleaning with a hot water jet, excessively high water pressure can damage the core of the
cooling system.
Δ Reduce the water pressure on the hot water jet appropriately and work a suitable distance
away from the cooling system.
Δ Direct the water jet along the cores.
Before the cooler is cleaned, the grid that is located above the cooler must be removed.
• If necessary, clean the cooler (1) with com-

pressed air from the exhaust side.
• In case of heavy contamination (oily or

greasy deposits), clean the cooler with a
steam cleaner.

• In case of obstinate contamination, use suitable cleaning agents.
✓ The cooler has been properly cleaned.
7.7.6 Filter
Replacing the free-fall line filter
The following figure shows the position of the line filters (1) on the equipment.
330 - 390 BG 28 H # 5336 / V01_en_04.2021

2 Oil feed line filter

3 Line filter rotary drive coupling pressure
4 Control pressure line filter
Prerequisite:
– The hydraulic connection to the process equipment may be separated.

• Place a suitable container to catch any drip-
ping oil.
• Remove the filter bowl (7).
• Remove the filter element (6).
• Dispose of the filter element (6) in an envi-

ronmentally friendly manner.
• Clean the filter head (5).
• Clean the filter bowl (7).
• Check the seals for wear and make sure

they are intact.
• Replace damaged or worn seals with new

ones.
• Coat the seals with fresh oil.
• Insert a new filter element (6) into the filter

head (5).
• Tighten the filter bowl (7) as far as you can

onto the filter head (5) by hand.
• Turn the filter bowl (7) back by 1/4 rotation.
✓ The filter element of the line filter has been

replaced with a new one.
BG 28 H # 5336 / V01_en_04.2021 331 - 390

Replacing the return oil filter/leak oil filter

Foreign particles in the hydraulic system have a negative impact on system safety.
Δ When working on the hydraulics, make sure no foreign particles enter the hydraulic system
The following figure shows the position of the return oil filter/leak oil filter (9) on the equipment.
1 Maintenance flap/cover
2 Return oil filter

3 Leak oil filter
Prerequisite:
– The hydraulic connection to the process equipment may be separated.
• Open the maintenance flap/cover (1).
332 - 390 BG 28 H # 5336 / V01_en_04.2021

• Loosen the ventilation screw (5).
✓ The vacuum in the filter chamber is dis-

sipated.
• Remove 4 screw connections (4).
• Remove the filter cover (6).
• Remove the filter element (7) by simultane-

ously turning clockwise and pulling.

• Clean the filter cover (6).

they are intact.

ones.
• Coat new seals with fresh oil.

bowl (8).
• Mount the filter cover (6) carefully by using

the 4 designated screw connections (4).
• Tighten the ventilation screw (5).
• Replace the filter elements of the other re-

turn oil filters/leak oil filters in the same way.
✓ The filter elements of the return oil filters/

leak oil filters have been replaced.
• Establish the hydraulic connection to the process equipment if necessary.
Replacing the hydraulic tank vent filter
The following figure shows the position of the hydraulic tank vent filter (9) on the equipment.
BG 28 H # 5336 / V01_en_04.2021 333 - 390

1 Maintenance flap
2 Hydraulic tank vent filter
Prerequisite:
• Remove the maintenance flap (1).
• Risk of causing damage to the hydraulic system! Foreign particles in the hydraulic
system have a negative impact on system safety. When working on the hydraulics, make sure
no foreign particles enter the hydraulic system.
• Remove the cover (3).

• Clean the cover (3).

bowl (5).
• Mount the cover (3).
✓ The filter element has been replaced with a

new one.
334 - 390 BG 28 H # 5336 / V01_en_04.2021

• Fit the maintenance flap (1).
Replacing the fuel tank vent filter
1 Diesel tank vent filter
• Open the fuel tank maintenance flap/drawer.
• Risk of causing damage! Foreign particles in the fuel tank have a negative impact
on system safety. When working on the open fuel tank, make sure that no foreign particles en-
ter the tank.
BG 28 H # 5336 / V01_en_04.2021 335 - 390


• Clean the cover (3).

bowl (5).
✓ The filter element has been replaced with a

new one.
• Close the fuel tank maintenance flap/drawer.
Replacing the air conditioning system air filter

Air conditioning system air filter
Change the filter insert of the air conditioning system air filter as described in chapter "Air condition-
ing system".
Replacing the diesel engine air filter

Diesel engine air filter
336 - 390 BG 28 H # 5336 / V01_en_04.2021

1 Diesel engine air filter
• Remove the cover (2) from the filter housing

(4).
• Remove the filter elements (5).
• Clean the filter elements (5). If necessary,

dispose of them in an environmentally
friendly manner.
• Clean the filter housing (4) and the cover (2).

they are intact.

ones.
• Mount the cleaned or new filter elements (5)

in the filter housing (4).
• Attach the cover (2) to the filter housing (4)

using the corresponding locking elements
(3).
✓ Filter elements of the diesel engine air filter

have been cleaned or replaced with new
ones.
Replacing the electrical box air filter

Electrical box air filters
Replace the filter elements of the electrical box air filters as described in the chapter "Electrical sys-
tem".
7.7.7 Pressure reservoir
BG 28 H # 5336 / V01_en_04.2021 337 - 390

Checking the charging pressure
1 Pressure accumulator
7.7.8 SCR system
The SCR system is located in the upper carriage next to the fuel tank.
Checking the fluid level
If the fill level of the SCR system falls below the prescribed minimum level, the power and speed of
the diesel engine will be reduced automatically.
The fill level (1) of the SCR system is perma-

nently displayed on the operating screen.
The indicator light (2) illuminates depending on

the level.
If the level falls below the prescribed minimum,

the power of the equipment will be reduced.
• Fill the tank of the SCR system with a suit-

able fluid in sufficient time.
✓ Indicator light (2) goes out.
✓ The fill level of the SCR system is OK.
338 - 390 BG 28 H # 5336 / V01_en_04.2021

Topping up the fluid

Danger of corrosion!
The fluid of the SCR system is highly corrosive. If metallic components come in contact with it, rust
quickly forms on the affected areas.
Δ Avoid contact of components with the fluid of the SCR system.
Prerequisite:
– The base machine is positioned horizontally.

The LED (4) will illuminate when the level of the
tank used by the SCR system is low.
After switching on the ignition, the pointer of the

level indicator (3) initially moves to both end-
points of the scale.
• Shut down the base machine.
• Switch on the ignition.
• Open the service platform and maintenance

flaps.
• Remove the screw plug (1).
• Fill the tank (2) of the SCR system with a

suitable fluid.
✓ The level indicator (3) indicates the cur-

rent fill level.
• Mount the screw plug (1).
✓ The fluid has been topped up properly.
Emptying the tank

Danger of corrosion!
The fluid of the SCR system is highly corrosive. If metallic components come in contact with it, rust
quickly forms on the affected areas.
Δ Avoid contact of components with the fluid of the SCR system.
Prerequisite:
– Base machine is positioned level.
BG 28 H # 5336 / V01_en_04.2021 339 - 390

• Shut down the base machine.
• After switching off the ignition, wait briefly

until the lines of the SCR system have been
emptied by the pump.
• Open the service platform and maintenance

flap.
• Ensure a suitable collecting container is

available to drain the fluid.
• Place a suitable hose between the discharge

opening (4) and the collecting container.
• Drain the fluid into the collecting container.
• Mount the screw plugs (4).
• Mount the screw plugs (1).
✓ The fluid has been drained properly.
Replacing the filter element
The filter element of the SCR system is possible, for example, after removing the cover behind it.
340 - 390 BG 28 H # 5336 / V01_en_04.2021

• Remove the screw plug (2) of the filter ele-

ment on the SCR tank (1).
• Replace the old filter element with a new

one.
• Mount the screw plug (2) of the filter ele-

ment.
✓ The filter element of the SCR system has

been replaced.
7.7.9 Swing mechanism

Checking the swing brake
✓ The upper carriage cannot be rotated.
• Deactivate the swing brake.
✓ The upper carriage can be rotated.
✓ Swing brake has been properly checked.
Lubricating the outer gear teeth on the slewing ring
The rotary joints and bearing of the slewing ring are lubricated by the central lubrication system.
• Lubricate the outer gear teeth on the slewing

ring (1).
BG 28 H # 5336 / V01_en_04.2021 341 - 390

• Turn the upper carriage several times in both

directions.
✓ The lubricant is evenly distributed.
✓ The outer gear teeth on the slewing ring are

properly lubricated.
Lubricating the rotary joint and rotor bearing
The rotary joints and bearing of the slewing ring are lubricated by the central lubrication system.
Tightening the connection elements on the slewing ring

• Switch off the diesel engine.
• Tighten the connection elements (1) cross-

wise using a torque wrench.
✓ The connection elements are tight.
The initial tensioning of the tightened screws is influenced by the tightening of other screws. For
this reason, after the initial tightening of all screw connections, tighten the screw connections a sec-
ond time with the same bolt torque value.
342 - 390 BG 28 H # 5336 / V01_en_04.2021

Swing mechanism gear

Risk of causing damage to the gears!
Foreign objects or contamination in the gear oil can damage the gears or restrict their functioning.
Δ Guard the opening against contamination.
Δ Prevent the entry of foreign objects and dirt into the gear oil.
Checking the oil level of swing mechanism gear 1
Prerequisite:
– The swing mechanism gear has been at standstill for at least 5 minutes.
The sight glass of the swing mechanism gear (1) can be accessed at the lower rear area of the up-
per carriage.
BG 28 H # 5336 / V01_en_04.2021 343 - 390

• The oil level must be in the marked range (2).

ponents! If the oil level is below the marked
range, there is too little oil in the gears. Com-
ponents could be damaged during further op-
eration. Adjust the level accordingly or ana-
lyze and repair the fault.
• If the oil level is below the marked range, replenish the oil accordingly.

If the oil level is above the marked range, there is too much oil and/or an accumulation of fluid in
the gears. Components could be damaged during further operation. Adjust the level accordingly or
have the fault analyzed and repaired.
• If the oil level is above the marked range, drain the oil accordingly.
✓ If the oil level is within the marked range, the right amount of oil is in the gears.
Checking the oil level of swing mechanism gear 2
Prerequisite:
The dipstick of the swing mechanism gear (2) can be accessed at the side of the upper carriage.
344 - 390 BG 28 H # 5336 / V01_en_04.2021

• Pull out the dipstick (2) and clean it with a

clean, lint-free cloth.
• Insert the dipstick (2) and pull it out again to

measure the oil level.
• The oil level on the dipstick (2) must be be-

tween the "MIN" and "MAX" markings.

ponents! If the oil level is below the "MIN"
marking, there is too little oil in the gears.
Components could be damaged during fur-
ther operation. Adjust the level accordingly or
analyze and repair the fault.
• If the oil level is below the "MIN" marking, re-

plenish the oil accordingly.
Risk of causing damage to components! If the oil level is above the "MAX" marking,
there is too much oil and/or accumulations of fluid in the gears. Components could be damaged
during further operation. Adjust the level accordingly or analyze and repair the fault.
• If the oil level is above the "MAX" marking, drain the oil accordingly.
✓ If the oil level is between the MIN and MAX marks, the right amount of oil is in the gears.
Topping up the oil in swing mechanism gear 1
Prerequisite:
The seal of the swing mechanism gear (3) can be accessed right area of the upper carriage.
BG 28 H # 5336 / V01_en_04.2021 345 - 390

• Unscrew the seal (3).

ponents! If the oil level is above the marked
range, there is too much oil and/or an accu-
mulation of fluid in the gears. Components
could be damaged during further operation.
Adjust the level accordingly or analyze and
repair the fault.
• Fill the required amount of oil into the open-

ing.
• The oil level on the sight glass (1) must be in

the marked range (2).
• Screw the cap (3) back in place.
✓ Oil level is OK.
Topping up the oil in swing mechanism gear 2
Prerequisite:
– Too little oil in the swing mechanism gear.
The dipstick of the swing mechanism gear (2) can be accessed at the side of the upper carriage.
346 - 390 BG 28 H # 5336 / V01_en_04.2021

• Pull out the dipstick (2).

ponents! If the oil level is above the "MAX"
marking, there is too much oil and/or accumu-
lations of fluid in the gears. Components
could be damaged during further operation.
Adjust the level accordingly or analyze and
repair the fault.
• Fill the required amount of oil into the open-

ing.
• The oil level on the dipstick (2) must be be-

tween the "MIN" and "MAX" markings.
✓ Oil level is OK.
Changing the oil
Prerequisite:
– A suitable container for waste oil is ready.

Leaking oil pollutes the ground and the groundwater.
Δ Dispose of the oil in compliance with the legal regulations!
• The discharge openings (2) of the swing

mechanism gear are located on the bottom of
the upper carriage.
BG 28 H # 5336 / V01_en_04.2021 347 - 390


waste oil beneath the discharge outlets (2).
• Remove the screw plugs from the discharge

outlets (2).

tainer.
• Dispose of the waste oil in an environmentally

friendly manner.
• Mount the screw plug on the discharge openings (2).
• Fill in new oil as described in Chapter "Changing the oil".
7.7.10 Counterweight
Checking the connection elements
• Check to ensure connection elements, tension chains and clamping plates are complete, se-
cure and intact.
• Replace damaged, loose or missing connection elements, tension chains and clamping plates
with new ones.
✓ Connection elements have been properly checked.
7.7.11 Central lubrication system
Inject the lubricating grease preferably with a pneumatic grease gun.
• Use a grease gun to fill the grease receptacle via the relevant lubrication point.
348 - 390 BG 28 H # 5336 / V01_en_04.2021

✓ Fill the grease receptacle with lubricating grease up to a maximum of 2 cm below the upper
edge.
7.7.12 Air-conditioning system
• Shut the equipment down and wait for 10 minutes.
Compressor
• Remove the cover of the compressor (1).
• Check that the compressor (1) fasteners are

intact, complete and correctly seated.
• Check that the compressor (1) drive belts (2)

are intact, complete and correctly seated.
• Install the compressor (1) cover.
✓ The compressor has been properly checked.
Replacing the coolant

Risk of causing damage to the components of the equipment!
Improper maintenance work performed on the refrigeration circuit of the air-conditioning system
can cause damage to the air-conditioning system.
Δ Maintenance work may only be performed on the refrigeration circuit of the air-conditioning
system by authorized personnel.
The coolant is to be replaced by authorized skilled personnel.
BG 28 H # 5336 / V01_en_04.2021 349 - 390

1 Position of the condenser, compressor

and dryer
2 Position of other air-conditioning system
components
Cleaning the condenser

Risk of causing damage to the condenser!
The use of sharp-edged tools, corrosive fluids or scouring agents when cleaning can damage the
condenser.
Δ Do not clean the condenser with the mentioned tools or cleaning agents.

Excessive air pressure can damage the fins of the condenser.

When cleaning with a hot water jet, excessively high water pressure can damage the fins of the
condenser.
Δ Reduce the water pressure on the hot water jet accordingly and operate it at a suitable dis-
tance from the condenser.
Δ Direct the water jet along the fins.
350 - 390 BG 28 H # 5336 / V01_en_04.2021

• Gain access to the condenser (1).
• If necessary, clean the condenser (1) with

compressed air from the exhaust side.
• In case of heavy contamination (oily or

greasy deposits), clean the condenser with a
steam cleaner.

• In case of obstinate contamination, use suitable cleaning agents.
✓ The condenser has been cleaned properly.
Replacing the air filters
BG 28 H # 5336 / V01_en_04.2021 351 - 390

• Move the operator's seat to its foremost posi-

tion.
• Remove the filter element (3) from the guide

rail.
• Check the filter element (3) for dirt.
• Clean filter element (3) and, if necessary, re-

place it with a new one.
Mount the filter element (3) in such a way that the arrow printed on the filter element points in the
• Mount the new filter element.
• Mount the maintenance flap (2) using the designated screw connections.
• Mount the maintenance flap (1) using the designated screw connections.
✓ The filter element of the air filter has been cleaned or replaced with a new one.
352 - 390 BG 28 H # 5336 / V01_en_04.2021

7.7.13 Steps/platforms/handrails
cracks, wear, corrosion, deformation).
ones.
• Check to ensure the locking mechanisms are in proper working order.
• Clean the platforms and handrails.
✓ Inspection of the steps, platforms and handrails has been properly performed.
7.7.14 Integrated service platform

Checking the tread rollers
cracks, wear, corrosion, bending).
Tread rollers have been properly checked.
Cleaning the tread rollers
Do not lubricate or oil the tread rollers.
• Remove contamination on the tread rollers.
✓ Tread rollers have been properly cleaned.
7.7.15 First aid box
Information regarding the position of the first aid box can be found in the section "Safety and pro-
tective equipment".
• Check to ensure the contents of the first aid box are complete and in proper working order.
• Promptly replace accessories which are missing or damaged and/or have passed the expiry
date.
✓ The first aid box has been properly checked.
BG 28 H # 5336 / V01_en_04.2021 353 - 390

7.7.16 Fire extinguishers
Information on the individual positions of the fire extinguishers on the equipment can be found in
"Safety and protective equipment".
• Check all fire extinguishers for integrity and proper working order.
• Have all fire extinguishers checked in accordance with the national or regional regulations (in
Germany DIN 14406 Part 4).
• Promptly replace fire extinguishers which are missing or damaged and/or have passed the ex-
piry date.
✓ All fire extinguishers have been properly checked.
7.8 Attachment
7.8.1 Masthead
• Check to ensure plug connections, screw connections and locking elements are seated se-
curely.
• Tighten any loose screw connections.
• Replace any missing plug connections, screw connections, and locking elements with new
ones.
• Replace any faulty plug connections, screw connections, and locking elements with new ones.
• Visually check steel components for completeness and integrity (damage, cracks, wear, corro-
sion).
• Replace faulty steel components with new ones.
• Replace any missing steel components.
• Check paintwork for damage and repaint if necessary.
• Replace screw connections in accordance with the specifications in the maintenance plan.
✓ Masthead has been properly checked.
7.8.2 Mast
Mast sections
curely.
ones.
sion).
354 - 390 BG 28 H # 5336 / V01_en_04.2021

• Lubricate mast guide rails pursuant to the specifications in the maintenance plan.
✓ Mast sections have been properly checked.
Mast prop
curely.
ones.
sion).
• Lubricate the swivel head pursuant to the specifications in the maintenance plan.
✓ Mast prop has been properly checked.
Boom
curely.
ones.
sion).
BG 28 H # 5336 / V01_en_04.2021 355 - 390
• Lubricate the fastening points and the guides.
✓ Boom has been properly checked.
Mast pivot
curely.
ones.
sion).
• Lubricate the mast pivot pursuant to the specifications in the maintenance plan.
✓ Mast pivot has been properly checked.
7.8.3 Rope winches

General components
1 Rope drum
2 Winch trestle
3 Counter bearing (lubrication
point)
4 Winch trestle screw connections
Not all rope winches have a counter bearing.
356 - 390 BG 28 H # 5336 / V01_en_04.2021

Main winch
General information
sion).
• Check to ensure the rope drum is in proper working order.
• Replace faulty parts with new ones.
• Check to ensure the screw connections are secure.
• Replace missing screw connections with new ones.
• Lubricate the counter bearing pursuant to the specifications in the maintenance plan.
• Check the plug connections and locking elements between the winch trestle and the upper car-
riage for completeness and proper working order.
• Replace missing plug connections with new ones.
• Replace faulty plug connections with new ones.
General information
sion).
• Replace screw connections between the winch trestle and the mast with new ones in accor-
dance with the maintenance plan.
Checking the oil level (dipstick)
Prerequisite:
– Filler tube/discharge tube (2) for the oil is vertically aligned.
BG 28 H # 5336 / V01_en_04.2021 357 - 390


cloth.
• Mount the dipstick (1) and remove it again.

ponents! If the oil level is above the green
zone (designated with an "X"), there is too
much oil and/or accumulation of fluid in the
gears. Components could be damaged dur-
ing further operation. Adjust the level accord-
paired.

nated with an "X":

"Changing the oil".

• Check the dipstick seal (1) for integrity and wear.
• Insert the dipstick (1).
Checking the oil level (circular sight glass)
The oil level can be checked at any hoist position.
• Read the oil level from the sight glass (3).
• Risk of causing damage to compo-

nents! If the oil level is above the horizontal
center of the winch, there is too much oil and/or
accumulation of fluid in the gears. Components
could be damaged during further operation. Ad-
just the level accordingly or have the fault ana-
lyzed and repaired.
Oil level is 20 mm below the horizontal center of the

winch:

"Changing the oil".
✓ The oil level is OK if it is 0 mm - 20 mm below

the horizontal center of the winch (area "X"
highlighted in green).
358 - 390 BG 28 H # 5336 / V01_en_04.2021

Checking the oil level (rod sight glass)
Prerequisite:
– Rope winch and sight glass (1) are vertically aligned.
• Read the oil level from the sight glass (1).

ponents! If the oil level is above the green
zone (designated with an "X"), there is too
much oil and/or accumulation of fluid in the
gears. Components could be damaged dur-
ing further operation. Adjust the level accord-
paired.

nated with an "X":

"Changing the oil".

Changing the oil (dipstick)
Prerequisite:
– Filler tube/discharge tube (2) for the oil is vertically aligned.

waste oil beneath the screw plug (3).
• Remove the screw plug (3) from the filler tube/

discharge tube (2).
At low ambient temperatures, flush with heated oil.
• Clean the sealing surfaces.
BG 28 H # 5336 / V01_en_04.2021 359 - 390

• Check the seals for wear and make sure they are intact.
• Mount the screw plug (3) on the filler tube/discharge tube (2).
• Pour the fresh oil into the filler tube/discharge tube (2) with the help of a suitable filling unit.
• Mount the dipstick (1) on the filler tube/discharge tube (2).
Changing the oil (circular sight glass)
Prerequisite:
– Screw plugs (4) and (5) are vertically aligned with one another.
• Remove the screw plug (4) from the filler hole.

• Remove the screw plug (5) from the discharge

opening.
If the ambient temperature is low, flush with some preheated oil.
• Mount the screw plug (5) on the discharge opening.
• Pour the new oil into the filler hole with the help of a suitable filling unit.
• Mount the screw plug (4) on the filler hole.
360 - 390 BG 28 H # 5336 / V01_en_04.2021

Changing the oil (rod sight glass)
Prerequisite:
– Screw plugs (4) and (5) are vertically aligned with one another.
• Remove the screw plug (4) from the filler

hole.

• Remove the screw plug (5) from the dis-

charge opening.

tainer.
If the ambient temperature is low, flush with some preheated oil.
• Mount the screw plug (5) on the discharge opening.
• Pour the new oil into the filler hole with the help of a suitable filling unit.
• Mount the screw plug (4) on the filler hole.
Auxiliary winch
General information
sion).
BG 28 H # 5336 / V01_en_04.2021 361 - 390

• Check the oil level as described in "Main winch".
Changing the oil
• Change the oil as described in "Main winch".
Pull-down winch
General information
sion).
• Check the oil level as described in "Main winch".
Changing the oil
• Change the oil as described in "Main winch".
362 - 390 BG 28 H # 5336 / V01_en_04.2021

7.8.4 Wire ropes and rope accessories
of wire ropes"!
Rope swivel
Lubricating the rope swivel
• Lubricate the rope swivel at the lubrication
point (3)
✓ The rope swivel has been properly lubri-

cated when grease escapes from the rope
swivel.
Checking the connection elements
• Check the plug connections (1) and the as-

sociated locking elements (2) above and
below.
• Tighten loose locking elements.
• Replace worn or faulty plug connections

with new ones.
✓ Connection elements have been properly

checked.
Pulleys
Risk of causing damage to the rope!
Sluggish or seized pulleys result in excessive wear of the rope.
Δ Lubricate the pulleys.
Δ Repair sluggish or seized pulleys or replace them with new ones.
BG 28 H # 5336 / V01_en_04.2021 363 - 390

Checking and lubricating pulleys

• Check the pulleys (2) for proper working or-
der, integrity, and low play, and replace them
with new ones if necessary.
• Check for impermissible deviations in dimen-

sion and edge formation.
• Check to ensure plug connections (1) and

(4), screw connections and locking elements
are complete and in proper working order.
• Check to ensure the screw connections are

complete, secure and in proper working or-
der.
• Risk of causing damage to the

bearing seals of the rolling bearings! Incor-
rect lubrication of pulleys with rolling bear-
ings will result in damage to the bearing
seal. Rotate the pulleys during the lubrica-
tion process. Inject the grease slowly and
carefully.
• Lubricate the lubrication points if these have

not been lubricated by the central lubrication
system.
Cable rollers are lubricated automatically if there is a central lubrication system. If there is no cen-
tral lubrication system, the cable rollers must be lubricated pursuant to the specifications in the
maintenance plan.
Rope hold-down rollers

• Check to ensure the rope hold-down rollers
(1) are complete, secure and intact (e.g.
damage, cracks, wear, corrosion, scoring).
• Replace damaged, worn or missing rope

hold-down rollers with new ones.
• Check that the rope hold-down rollers are positioned parallel to the rope drum.
• Clean rope hold-down rollers and their components.
• Replace damaged, loose, or missing connection elements with new ones.
• Check that the protecting bars are complete, securely fitted, and intact.
• Replace damaged or missing protecting bars with new ones.
364 - 390 BG 28 H # 5336 / V01_en_04.2021

• Check to ensure tension springs are complete, secure and intact.
• Replace damaged or missing tension springs with new ones.
• Re-tension the tension springs.
• Check to ensure axles, sleeves and distance bushings are complete, secure and intact.
• Replace faulty or missing axles, sleeves and distance bushings with new ones.
• Lubricate the bearings.
✓ Rope hold-down rollers have been properly checked.
Central rope guide

• Lubricate bearing (2) if this has not been lu-
bricated by the central lubrication system.
• Check that all relevant plug connections (1),

bolted connections (4) and locking elements
(3) are complete and in proper working or-
der.
• Replace loose or faulty plug connections (1),

bolted connections (4) and locking elements
(3) with new ones.
✓ Central rope guide has been properly

checked.
Wire ropes, rope fasteners, thimbles and sleeves

• Check the position of the wire ropes in the respective fasteners.
• Check cast rope ends for wire breakage and corrosion, directly at the point where the wire rope
exits the fork sleeve.
• Check compressed rope ends for wire breakage next to the sleeve, cracks in the sleeve and
signs of slippage on the wire rope.
• Replace faulty or corroded wire ropes, rope fasteners, thimbles, and sleeves with new ones.
✓ Wire ropes, rope fasteners, thimbles and sleeves have been properly checked.
BG 28 H # 5336 / V01_en_04.2021 365 - 390

Changing ropes - General

Ropes may only be changed by suitably authorized personnel. The manufacturer assumes no re-
sponsibility for damages which result from non-compliance with these instructions. In this context,
the separate additional documentation "Maintenance and care of wire ropes" and the general
safety section entitled "Safety when handling ropes" must also be observed.
Changing the main rope

Risk of causing damage to the new wire rope!
If the components of the rope guide are faulty, worn or damaged, they can cause damage to the
newly mounted wire rope.
Δ Before mounting the new wire ropes, check that the components of the rope guide are in
Δ Replace damaged rope guide components with new ones.
Prerequisite:
– Rigging mode and rope winch are selected.
of wire ropes"!
Removing the main rope

• Fully unwind the old rope from the rope drum.
• Release the screw connections of the clamp-

ing rail (2) at the rope anchorage on the rope
winch.
• Remove the wedge (1).
✓ Main rope has been properly removed.
Depending on the design of the equipment, there may be a depth measurement on the rope winch.
After the rope has been removed, the rope winch must not be moved or turned. If the rope winch is
turned, the depth measurement must be reset. Further information can be found in the enclosed
366 - 390 BG 28 H # 5336 / V01_en_04.2021

Mounting the main rope
• Unwind the new rope (6) from the reel.
• Guide the pointed end of the new rope through the contactor weight (8).
• Lay the rope over the rope sheaves (4) and (7) or pull it through.
• Guide the rope over the central rope guide (3).
• Mount the plug connections (5).

• Thread the rope end into the clamping rail
(19) of the rope winch.

rope winch and the wire rope! A protruding
wire rope can get caught in the winch trestle
during winding/unwinding and thereby dam-
age the rope winch and the wire rope. Do
not allow the rope end to protrude above the
edge of the rope drum.
• Mount the wedge (21).

• Danger of accident! Incorrect tightening of the screw connections can result in the
wire rope becoming detached from its fix point on the rope winch and thereby cause serious
accidents. This could result in serious or fatal injuries to persons in the immediate vicinity.
Tighten the screw connections properly.
• Mount the screw connections (20) on the clamping rail (19).
• Wind the rope slowly and carefully onto the main winch.
✓ Main rope has been properly changed.
BG 28 H # 5336 / V01_en_04.2021 367 - 390

Changing the auxiliary rope

Prerequisite:
– Rigging mode and rope winch are selected.
of wire ropes"!
Removing the auxiliary rope

• Fully unwind the old rope from the rope drum.
• Release the screw connections of the clamp-

ing rail (2) at the rope anchorage on the rope
winch.
• Remove the wedge (1).
✓ Auxiliary rope has been properly re-

moved.
Depending on the design of the equipment, there may be a depth measurement on the rope winch.
After the rope has been removed, the rope winch must not be moved or turned. If the rope winch is
turned, the depth measurement must be reset. Further information can be found in the enclosed
368 - 390 BG 28 H # 5336 / V01_en_04.2021

Mounting the auxiliary rope
• Unwind the new rope (6) from the reel.
• Guide the pointed end of the new rope through the contactor weight (5).
• Lay the rope over the rope sheaves (7) and (8) or pull it through.
• Guide the rope over the central rope guide (3).
• Mount the plug connections (4).

• Thread the rope end into the clamping rail
(19) of the rope winch.

rope winch and the wire rope! A protruding
wire rope can get caught in the winch trestle
during winding/unwinding and thereby dam-
age the rope winch and the wire rope. Do
not allow the rope end to protrude above the
edge of the rope drum.

• Danger of accident! Incorrect tightening of the screw connections can result in the
• Mount the screw connections (20) on the clamping rail (19).
• Wind the rope slowly and carefully onto the auxiliary winch.
✓ Auxiliary rope has been properly changed.
BG 28 H # 5336 / V01_en_04.2021 369 - 390

Change crowd ropes

of wire ropes"!
Removing crowd ropes
Prerequisite:
– The mast is aligned horizontally.
– Rope winch rigging mode is pre-selected.
– The crowd sledge is approximately 1000 mm above the lower end of the mast.
• Fully extend the clamping cylinder (8).
• Remove the locking elements of rope sheaves (4), (5), (6) and (7).
• Remove the plug connection (11) of the rope end connection (10) and corresponding locking
element.
• Take the rope end connection (10) from the rope end connection adapter (9).
370 - 390 BG 28 H # 5336 / V01_en_04.2021

• Remove the rope sheave guard (15).
• Remove the rope clip (18).
• Loosen the jaw (17).
• Pull the lower crowd rope (2) out of the jaws (17).
• Wind the lower crowd rope (2) onto the crowd winch (1). Unwind the upper crowd rope (3) com-
pletely while doing this.
• Remove the screw connection (22) and clamping wedge (24).
• Remove the upper crowd rope (3) from the clamping bar (23) and the drill hole.
• Remove the upper crowd rope (3) out of the rope sheaves (4), (7), (14), and (6).
• Remove the lower crowd rope out of the rope sheaves (13), (16) and (5).
• Unwind the lower crowd rope (2) from the rope drum of the crowd winch (1) completely.
• Remove the screw connection (20) and wedge (21).
• Remove the lower crowd rope (2) from the clamping rail (19) and the drill hole.
✓ The crowd ropes have been correctly removed.
BG 28 H # 5336 / V01_en_04.2021 371 - 390

Configuration Safety windings, Free rope

upper crowd rope grooves between
the wire ropes
Without mast extension 6.5 2.5
With lower mast extension 4.0 2.5
With 2 m upper mast extension 6.5 0.5
With 2 m upper and lower mast extension 4.0 0.5
With 3 m upper mast extension and 2 m lower mast ex- 3.0 0.5
tension
With all mast configurations, 4.2 safety turns of the lower crowd rope will be wound onto the rope
drum.
Mounting crowd ropes
• Guide the lower crowd rope (2) over the rope drum of the crowd winch (1).
372 - 390 BG 28 H # 5336 / V01_en_04.2021

• Guide the lower crowd rope (2) through the drill hole on the left side of the rope drum in the
main direction of travel into the clamping rail (19).
• Risk of causing damage to the rope winch and the wire rope! A protruding wire
rope can get caught in the winch trestle during winding/unwinding and thereby damage the
rope winch and the wire rope. Do not allow the rope end to protrude above the edge of the
rope drum.
• Risk of accident! Incorrect tightening of the screw connections can result in the
• Install screw connection (20) of the clamping rail (19).
• Wind in the lower crowd rope (2) until the rope drum is full except for the free rope grooves
(see table) and the clamping rail (23) on the right side viewed in the main direction of travel is
accessible from below.
• Position the reel of the upper crowd rope (3) above the crowd sledge at the end of the mast.
• Guide the pointed end of the upper crowd rope (3) over the rope sheaves (6).
BG 28 H # 5336 / V01_en_04.2021 373 - 390

• Guide the upper crowd rope (3) through the crowd sledge over the rope sheave (14) of the pul-
ley block.
• Guide the upper crowd rope (3) over the rope sheave (7).
• Guide the upper crowd rope over the rope sheave (4) to the crowd winch (1).
• Guide the upper crowd rope (3) through the drill hole on the right side of the rope drum in the
rope drum.
• Slowly wind in the upper crowd rope (3) until the rope drum is full with the safety layers (see ta-
ble) and an additional layer. At the same time unwind the lower crowd rope (2) and follow it
with your hands.
• Guide the pointed end of the lower crowd rope (2) over the rope sheave (5) through the mast to
the lower end of the mast.
• Guide the lower crowd rope (2) inside the lower mast section through the relevant openings.
• Guide the crowd rope (2) over the rope sheave (16).
• Push the lower crowd rope (2) on the right-hand side viewed in the main direction of travel into
the crowd sledge and around the rope sheave (13) of the pulley block.
374 - 390 BG 28 H # 5336 / V01_en_04.2021

• Insert the rope end connection (10) flush in the rope end connection adapter (9).
• Danger of accident! Incorrect mounting of the plug connection can lead to the rope
end connection coming out of the rope end connection adapter. Components of the equipment
may move uncontrollably. Persons in the vicinity of the equipment can be seriously or fatally in-
jured as a result. Do not guide the plug connection (11) through the connection point (12) of the
rope end connection (10). Mount the plug connection as shown in the illustration.
• Secure the rope end connection (10) with the plug connection (11) and corresponding locking
element.
• Thread the lower crowd rope (2) into the jaws (17) and manually pretension it.
• Tighten the screw connection of the jaws (17) crosswise. Repeat this process until all the screw
connections are mounted with the prescribed bolt torque value.
• Mount the rope clip (18) at a distance of about 20 mm from the jaws (17).
• Mount the locking elements of rope sheaves (4), (5), (6) and (7) and rope sheave guard (15).
• Slightly tension the wire ropes (2) and (3) by retracting the clamping cylinder (8).
• Test the complete upper and lower rope guide of the crowd system.
• Raise the mast (see section "Raising the mast").
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• Move the crowd sledge against the lower sledge end stoppers and clamp it with the clamping
cylinder (8).
• Move the crowd sledge upwards. In doing so, stop every 2 m and re-tension using the clamp-
ing cylinder (8).
• Position the crowd sledge at the lower end of the mast.
• Trim the protruding end of the lower crowd rope (2) at the clamping jaws (17) of the lower mast
section to 200 mm in accordance with the additional documentation "Maintenance and care of
wire ropes".
✓ The crowd ropes have been properly mounted.
✓ The crowd ropes have been changed correctly.
Changing the upper crowd rope

of wire ropes"!
Removing the upper crowd rope
Prerequisite:
– Mast is aligned horizontally.
– Rope winch rigging mode is selected.
– The crowd sledge is approximately 1000 mm above the lower end of the mast.
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• Extend the clamping cylinder (8).
• Remove the locking elements of rope sheaves (4), (6) and (7).
• Remove the plug connection (11) of the rope end connection (10) and corresponding locking
element.
• Take the rope end connection (10) from the rope end connection adapter (9).
• Remove the rope sheave guard (15).
• Wind the lower crowd rope (2) onto the crowd winch (1). Unwind the upper crowd rope (3) com-
pletely while doing this.
• Remove the upper crowd rope (3) from the clamping bar (23) and the drill hole.
• Remove the upper crowd rope (3) out of the rope sheaves (4), (7), (14), and (6).
BG 28 H # 5336 / V01_en_04.2021 377 - 390

Mounting the upper crowd rope

Configuration Safety windings, Free rope
upper crowd rope grooves between
the wire ropes
Without mast extension 6.5 2.5
With lower mast extension 4.0 2.5
With 2 m upper and lower mast extension 4.0 0.5
With 3 m upper mast extension and 2 m lower mast ex- 3.0 0.5
tension
• Wind in/unwind the lower crowd rope (2) until the rope drum is full except for the free rope
grooves (see table) and the clamping rail (23) on the right side viewed in the main direction of
travel is accessible from below.
• Position the bobbin of the upper crowd rope (3) above the crowd sledge at the end of the mast.
• Guide the pointed end of the upper crowd rope (3) over the rope sheaves (6).
• Guide the upper crowd rope (3) through the crowd sledge over the rope sheave (14) of the pul-
ley block.
• Guide the upper crowd rope (3) over the rope sheave (7).
• Guide the upper crowd rope over the rope sheave (4) to the crowd winch (1).
378 - 390 BG 28 H # 5336 / V01_en_04.2021

• Guide the upper crowd rope (3) through the drill hole on the right side of the rope drum in the
rope drum.
• Slowly wind in the upper crowd rope (3) until the rope drum is full with the safety layers (see ta-
ble) and an additional layer. At the same time unwind the lower crowd rope (2) and follow it
with your hands.
• Push the lower crowd rope (2) on the right-hand side viewed in the main direction of travel into
the crowd sledge and around the rope sheave (13) of the pulley block.
BG 28 H # 5336 / V01_en_04.2021 379 - 390

• Insert the rope end connection (10) flush in the rope end connection adapter (9).
• Danger of accident! Incorrect mounting of the plug connection can lead to the rope
end connection coming out of the rope end connection adapter. Components of the equipment
may move uncontrollably. Persons in the vicinity of the equipment can be seriously or fatally in-
jured as a result. Do not guide the plug connection (11) through the connection point (12) of the
rope end connection (10). Mount the plug connection as shown in the illustration.
• Secure the rope end connection (10) with the plug connection (11) and corresponding locking
element.
• Mount the locking elements of rope sheaves (4), (6), and (7) and rope sheave guard (15).
• Check the entire upper and lower rope guidance of the crowd system.
380 - 390 BG 28 H # 5336 / V01_en_04.2021

cylinder (8).
ing cylinder (8).
✓ The upper crowd rope has been properly changed.
Changing the lower crowd rope

of wire ropes"!
Removing the lower crowd rope
Prerequisite:
– Mast is aligned horizontally.
– Rope winch rigging mode is selected.
– The crowd sledge is at the upper end of the mast.
• Remove the locking element of the rope sheave (5) and the rope sheave guard (15).
• Remove the lower crowd rope (2) from the rope sheaves (13).
BG 28 H # 5336 / V01_en_04.2021 381 - 390

• Remove the lower crowd rope from the rope sheaves (15) and (5) and from the mast.
Before pulling the lower crowd rope out of the rope drum, the safety windings of the lower crowd
rope on the rope winch should first be counted.
• Completely unwind the lower crowd rope (2) from the rope drum of the crowd winch (1).
• Remove the lower crowd rope (2) from the clamping bar (19) and the drill hole.
Mounting the lower crowd rope
• Push the lower crowd rope (2) on the left side viewed in the main direction of travel into the
crowd sledge and around the rope sheave (13) of the pulley block.
The necessary safety windings of the lower crowd rope must be wound manually around the rope
drum of the crowd winch.
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• Guide the lower crowd rope (2) over the rope drum of the crowd winch (1).
• Guide the lower crowd rope (2) through the drill hole on the left side of the rope drum in the
rope drum.
BG 28 H # 5336 / V01_en_04.2021 383 - 390

• Mount the locking elements of the rope sheave (5) and the rope sheave guard (15).
• Check the entire upper and lower rope guide of the crowd system.
cylinder (8).
ing cylinder (8).
• Trim the protruding end of the lower crowd rope (2) at the jaws (17) of the lower mast section
up to 200 mm in accordance with the additional documentation "Maintenance and care of wire
ropes".
✓ The lower crowd rope has been properly changed.
Tension crowd ropes

Uncontrolled movements of the crowd sledge while the mast is lowered can cause damage to the
components of the mast, the crowd sledge, and the hydraulics.
Δ Only move the crowd sledge with the assistance of a person giving directions.

384 - 390 BG 28 H # 5336 / V01_en_04.2021

The crowd ropes can be re-tensioned at the following position:
– Clamping block (2) on the lower crowd rope.
The wire ropes must have a sufficient length for the transport position. Only slightly re-tension the
ropes therefore.
Prerequisite:
• Extend the clamping cylinder for the crowd ropes in order to slacken the crowd ropes.
• Re-tension the crowd ropes carefully.
• Retract the clamping cylinder for the crowd ropes in order to tension the crowd ropes.
• Move the crowd sledge upwards and downwards several times.
✓ Crowd ropes are tensioned properly.
7.8.5 Crowd sledge

Checking the sliding strips
• Check the sliding strips (1) for wear and replace if the remaining thickness is 15 mm.
• Remove screw connection (2) and fastening element (3).
• Remove slide rails (1) and replace them with new ones.
BG 28 H # 5336 / V01_en_04.2021 385 - 390

• Mount fastening element (3) and screw connection (2).
✓ The sliding strips have been properly checked.
7.9 Process fitting

Risk of crushing, cutting, collision!
Crushing surfaces, cutting edges, and abutting edges can occur during work on the grabber's rope
holder. If persons get between these edges, they can receive serious or fatal injuries.
Δ Before starting work on the rope holder, always shut the equipment down and secure against
unintentional and unauthorized start-up.
Tipping hazard!
If the grabber is shut down and not adequately secured, it can topple over. This could result in seri-
ous or fatal injuries to persons in the vicinity of the equipment.
Δ Secure the grabber against falling over using a suitable lifting device.
Δ For maintenance and repair work, always leave the grabber horizontally on the ground.
Tipping hazard!
If the cutter is shut down and not adequately secured, it can topple over. Persons in the vicinity of
the equipment could be hit and receive serious or fatal injuries.
Δ Secure the cutter against falling with suitable lifting devices.
Δ For maintenance and repair work, always leave the cutter horizontally on the ground.
386 - 390 BG 28 H # 5336 / V01_en_04.2021

8 Environmental protection/disposal
Any work on and with the product must be conducted in compliance with the legal obligations per-
taining to waste disposal and proper recycling/disposal. Any additional documentation must be ob-
served for specific types of work.
In nature conservation areas, more comprehensive measures than those described here may be in
effect.
8.1 Storing and transporting equipment, units, consumables and operating

materials
The following components must be emptied, cleaned, sealed and reliably protected from leaks prior
to transport and storage:
– Capped lines
– Hoses and hose connections
– Engine compartment
– Fuel tank
– Oil tanks
Suitable and sufficiently large containers must be placed in order to catch oil and fuel. When dis-
connecting hydraulic connections, changing oil and performing repairs, make sure no oil seeps into
the soil through the ground. Filling/emptying e.g. oil tanks/hydraulic lines must be constantly moni-
tored.
Remove any grease and oil residues from components prior to storage (steam cleaner). Oily waste
water is to be purified using a suitable system.
Consumables and operating materials such as greases and oils, fuels, coolants and cleaning
agents must be kept in suitable and properly labeled containers.
Appropriate storage conditions must be reasonably provided when storing hydraulic lines and
hoses. Eventual aging and the associated change in material properties and binding properties
must be kept to a minimum. Maximum storage periods should not exceed two years for hydraulic
lines and hoses. Hydraulic lines and hoses that have been kept in storage for longer periods must
be inspected for visible damage and deficiencies prior to use. Inspection may only be carried out by
persons who possess the necessary expertise for inspecting hydraulic lines and hoses from their
professional training, professional experience and recent occupational responsibilities.
All components, particularly hoses, lines and fasteners must be regularly inspected for leaks/visible
damage for the duration of storage. Any damage must be remedied by suitably authorized person-
nel.
Equipment components and containers with capacities exceeding 20 l (5.3 gal) may only be stored
on reinforced surfaces (concrete or pavement). If storage on unreinforced ground is necessary, no
oil or fuel may leak out onto the ground.
BG 28 H # 5336 / V01_en_04.2021 387 - 390

8.2 Information on cleaning

All openings that need to be protected from the ingress of cleaning agent, water and steam due to
safety reasons and/or reasons of a functional nature must be covered accordingly before cleaning
the product with water, steam or other suitable cleaning agents. Electrical components such as
electrical boxes and electric motors are particularly sensitive.
Cleaning may only be done in special areas with suitable equipment where no liquid contaminants
can seep through the soil into the groundwater.
After cleaning, all of the components on the product, in particular fuel lines and oil lines, must be
checked to ensure they are in proper working order. If any defects are detected, they must be recti-
fied immediately.
8.3 Decommissioning
See section "Decommissioning" for individual steps on shutting down the equipment.
• Disconnect the equipment from the power supply.
• Remove any operating materials, lubricants and consumables.
✓ The equipment is shut down.
8.4 Disassembling the equipment

Prerequisites:
– Equipment has been completely shut down and cleaned.
• Disassemble the equipment accordingly and place individual components on suitable surfaces
using an appropriate lifting device.
• Disassemble any steel constructions that cannot be disassembled without destruction into
transportable parts by flame cutting or another appropriate process.
• Disassemble the components and sort separately by material.
✓ The equipment has been completely disassembled.
8.5 Waste disposal

Local applicable laws and regulations must be observed when disposing of components of the
product. Make sure that materials and assemblies can also be easily recycled, disassembled and
separated and take environmental hazards and health risks into consideration when recycling and
disposing.
388 - 390 BG 28 H # 5336 / V01_en_04.2021

8.5.1 Disposing of operating materials, lubricants and consumables

Operating materials, lubricants and consumables may only be stored separately in suitable contain-
ers that are appropriately labeled. Used operating materials, lubricants and consumables must be
treated as hazardous waste. The disposal of this kind of waste must be performed by special com-
panies according to applicable legal regulations.
In order to ensure environmentally friendly recycling practices, petroleum-based oil should not be
mixed with the following substances:
– Fuels (e.g. gasoline, diesel, heating oil)
– Antifreeze
– Brake fluid
– Vegetable oils
– Glycol-based oils
– Cleaners, chemicals, emulsions
– Halogen products, CHC, PCB
Ester-based synthetic hydraulic oils (biodegradable oil) can generally be disposed of along with
waste mineral oil after consulting the disposal company.
The containers used for storing waste oil must be protected against the penetration of rainwater.
Never dispose of waste oil in the surrounding environment (ground, water, drains). The same ap-
plies e.g. for antifreeze, brake fluid, cleaners, fuels, chemicals, emulsions and halogen products.
These products must be transferred to an appropriate disposal company.
8.5.2 Disposing of metal components and synthetics

Metals and synthetics of various kinds must be sorted and transferred to the corresponding recy-
cling/disposal facilities.
8.5.3 Disposing of electrical and electronic components

Electrical and electronic components of various kinds must be sorted and transferred to the corre-
sponding recycling/disposal facilities.
8.5.4 Hazardous waste

Hazardous waste poses an increased risk to humans and the environment and is subject to special
legal regulations. Hazardous waste in particular includes:
– All used operating materials, lubricants and consumables.
– All acid-containing components (e.g. batteries).
– All containers and their feeds and drains.
– Oil filters.
– Lines and hoses used to transport operating materials, lubricants and consumables.
BG 28 H # 5336 / V01_en_04.2021 389 - 390

– Pressure containers for storing gases.
– All contaminated components and materials.
8.5.5 Recycling
Individual product components can be accepted for recycling and used for new applications.
390 - 390 BG 28 H # 5336 / V01_en_04.2021


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Instruction manual

Translation of the original instruction manual

Expert inspection (repeat expert Certification

Date of publication of the Original instruction manual: 04.2021

BAUER Maschinen GmbH Head office

BG 28 H # 5336 / V01_en_04.2021 3 - 390

Additional information regarding certification

Completion of inspection: Nov. 23, 2017

4 - 390 BG 28 H # 5336 / V01_en_04.2021

After Sales Service 25

BG 28 H # 5336 / V01_en_04.2021 5 - 390

1.5 Safety and protective equipment 75

2 Product description 101

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2.5.4 Exhaust gas emissions 118

BG 28 H # 5336 / V01_en_04.2021 7 - 390

Wire ropes 148

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3.8.7 Operating the ECO mode 176

4.3.4 Mounting the exhaust pipe extension 211

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5.4 Undercarriage 260

BG 28 H # 5336 / V01_en_04.2021 11 - 390

7.1.8 Bearings and bearing pins 274

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7.7.2 Cooling system of the diesel engine 312

BG 28 H # 5336 / V01_en_04.2021 13 - 390

7.7.10 Counterweight 348

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8 Environmental protection/disposal 387

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BG 28 H # 5336 / V01_en_04.2021 17 - 390

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BG 28 H # 5336 / V01_en_04.2021 19 - 390

Before using this equipment, please do the following:

Take the time to carefully read this document.

Contact the BAUER customer service about the change in operator.

20 - 390 BG 28 H # 5336 / V01_en_04.2021

The Instruction manual has been written and published by

BAUER Maschinen GmbH • Postfach 12 60 • 86522 SCHROBENHAUSEN, GERMANY

Copyright 2021, BAUER Maschinen GmbH

We strictly prohibit any duplication, reproduction, translation, microfilming, electronic or magnetic

All legal rights and remedies are hereby expressly reserved.

Violators will be prosecuted.

BG 28 H # 5336 / V01_en_04.2021 21 - 390

22 - 390 BG 28 H # 5336 / V01_en_04.2021

Authorized representative for compiling technical BAUER Maschinen GmbH

CE representative/Quality assurance: Manfred Neumann

BG 28 H # 5336 / V01_en_04.2021 23 - 390

24 - 390 BG 28 H # 5336 / V01_en_04.2021

After Sales Service

– Cause of damage (if known)

– Extent of damage (which components might be defective/damaged?)

– Contact for queries

– Construction site description

– Construction site designation/name

– Driving instructions for requested personnel (if necessary)

Customer Service contact information:

BAUER Maschinen GmbH