0583 Grab System en 0000661694 PDF

Instruction Manual
GRAB SYSTEM
G0040500.wmf
Keep for future use!
BAUER Maschinen GmbH

P.O. Box No. 12 60 D-86522 Schrobenhausen, Germany
Telephone +49 8252 97-0 Fax +49 8252 97-1359
PREFACE
If you are not familiar with the language used in this operating manual you
must not operate the equipment. If you cannot read this operating manual or
US understand its contents, you must contact the customer service department of
BAUER Maschinen GmbH and order a manual in a language you understand.
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GB 34 / 2010 I
Sollten Sie die in dieser Betriebsanleitung verwendete Sprache nicht
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GB 34 / 2010 II
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vous ne devez pas mettre en service l'appareil/l'installation. Dans ce cas,
veuillez contacter le service aprs -vente de BAUER Maschinen GmbH et
commandez u manuel d'utilisation rdig dans une langue comprhensibles
FR pour vous.
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IT ordinare le istruzioni d'uso in una lingua a scelta.
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GB 34 / 2010 III
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GB 34 / 2010 IV
Jeli nie rozumiej Pastwo jzyka, w ktrym napisana zostaa instrukcja
obsugi, to nie mog Pastwo uruchamia urzdzenia/instalacji. W takim
przypadku naley skontaktowa si z serwisem firmy BAUER Maschinen
PL GmbH i zamwi instrukcj w jzyku przez Pastwa rozumianym.
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PT idioma que entenda.
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GB 34 / 2010 V
Ak by ste nerozumeli jazyku, v ktorom je napsan tento nvod na obsluhu,
nesmiete prstroj / zariadenie uvdza do prevdzky. V takomto prpade
kontaktujte, prosm, zkazncku slubu firmy BAUER Maschinen GmbH a
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sizden geri alnmayacaktr. Bu gibi bir durumda, BAUER Maschienen GmbH
ile temasa gein ve sizin anlayabileceiniz dilde bir kullanm klavuzu sipari
TR edin.
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GB 34 / 2010 VI
This Instruction Manual is written for use by operating and maintenance personnel.
Before the first use of this equipment PLEASE
First, take your time and read the "Instruction Manual" and the
enclosed booklet entitled "Safety Information".
These two documents shall always be kept at the equipment to be accessible for review
at any time.
The "Instruction Manual" gives you a detailed description of the equipment, guidelines
for transport and initial start-up as well as comprehensive instructions for the operation
of the equipment, trouble shooting tips and information related to maintenance.
Technical data, weights and measurements are accurate as of the day this Instruction
Manual is printed. Due to the continuous technical advancements made, there may be
minor deviations between the technical data, weights and measurements contained in
the Instruction Manual and the equipment as actually built and delivered. These minor
deviations are, however, inconsequential and do not change in any material way nor do
they invalidate the contents of this Instruction Manual.
The equipment as delivered to you may have options that might not be pictured in the
photographs or described in the text contained in this Instruction Manual exactly as they
appear on your equipment. This is due to the individualization of the equipment based
on the wishes and orders of the individual customers and no claims of any kind shall be
based on such deviations.
The equipment shall only be used for the authorized purposes listed in the Instruction
Manual. The manufacturer shall have no liability whatsoever for the improper or
unauthorized use of the equipment, operator errors or mistakes or improper respectively
insufficient maintenance.
The enclosed booklet entitled "Safety Information" contains the directions and related
information for the safe use of the equipment. The "Safety Information" must be
followed at all times.
Also, pay attention to and follow all the instructions contained in the attached
documents (Appendix ___) of the component manufacturers.
GB 34 / 2010 VII
The "Instruction Manual" was written and published by
BAUER Maschinen GmbH Postfach 12 60 D-86522 Schrobenhausen, Germany
Copyright 2010, BAUER Maschinen GmbH
The information contained in this manual and/or any of its parts, sub-parts or chapters,
is the intellectual property of BAUER Maschinen GmbH and is protected by domestic
and international copyright and other intellectual property laws.
The information contained herein is provided for the operation, service, maintenance
and troubleshooting of the equipment described herein.
Any duplication, reproduction, translation, micro filming, storage in electronic or

magnetic form, processing as electronically or magnetically stored media, copying or
dissemination of these materials and/or the information contained herein, or any part
thereof, except for the internal use of BAUER Maschinen GmbH or its authorized
external suppliers, consultants or agents, without the prior written consent of BAUER
Maschinen GmbH, is hereby strictly prohibited.
All rights and remedies are hereby expressly reserved.
Violators will be prosecuted.
BAUER Maschinen GmbH shall have no liability whatsoever arising from or connected
in any way to the so prohibited use of the information contained herein by any person or
entity, wherever located.
BAUER Maschinen GmbH reserves the right to change, delete or otherwise alter or
modify any information contained herein, or the equipment itself, at any time and for any
reason, with or without notice.
GB 34 / 2010 VIII
TABLE OF CONTENTS
PREFACE ............................................................................................................................................... I
TABLE OF CONTENTS......................................................................................................................... IX
ABOUT THE MANUAL ........................................................................................................................ XIII
NAMEPLATES ..................................................................................................................................... XV
AFTER SALES SERVICE.................................................................................................................... XVI
WARRANTY TERMS.......................................................................................................................... XVII

WARRANTY CLAIM............................................................................................................................. XIX
PERSONALANFORDERUNG / STAFF REQUEST............................................................................... XX
REGISTRIERUNG BETREIBER UND GERT/ OWNER AND EQUIPMENT REGISTRATION ............ XXI
1 DESCRIPTION ..................................................................................................................1 - 1
1.1 INTENDED AND AUTHORIZED USE ................................................................................1 - 1
1.1.1 nderungsantrag / Change request....................................................................................1 - 3
1.2 COMPONENTS .................................................................................................................1 - 4
1.2.1 Basic Rig / Grab Equipment ...............................................................................................1 - 4
1.2.1.1 Components Overview.......................................................................................................1 - 4
1.2.1.2 Components Description ....................................................................................................1 - 5
2 SAFETY ............................................................................................................................2 - 1
2.1 GENERAL SAFETY REQUIREMENTS ..............................................................................2 - 1
2.2 EQUIPMENT SAFETY.......................................................................................................2 - 1
2.3 MAJOR HAZARDS ............................................................................................................2 - 1
2.4 SAFETY DEVICES ............................................................................................................2 - 2
2.4.1 Emergency Stop ................................................................................................................2 - 2
2.4.2 Pilot Control Safety Stick....................................................................................................2 - 2
2.4.3 Fire Extinguisher ................................................................................................................2 - 2
2.4.4 Medical Box .......................................................................................................................2 - 3
2.4.5 Emergency Exit .................................................................................................................2 - 3
2.4.6 Limit Switches....................................................................................................................2 - 4
2.5 STABILITY ........................................................................................................................2 - 5
2.5.1 Stability Guidelines ............................................................................................................2 - 5
2.5.2 Stability With Grab Equipment ...........................................................................................2 - 6
2.5.2.1 Travelling With Equipment .................................................................................................2 - 7
2.6 RISK OF ROPE BREAKING WHEN ADJUSTING BOOM ..................................................2 - 8
2.7 PERMISSIBLE WIND SPEED............................................................................................2 - 9
3 TECHNICAL DATA ...........................................................................................................3 - 1

3.1 DIMENSIONS ....................................................................................................................3 - 1
3.1.1 With Grab Equipment (MDSG) ...........................................................................................3 - 1
3.2 EQUIPMENT DATA ...........................................................................................................3 - 2
3.3 GRAB OPERATING RANGE .............................................................................................3 - 3
GB 34 / 2010 IX
3.3.1 MDSG ...............................................................................................................................3 - 3
3.4 ROPE SPECIFICATIONS ..................................................................................................3 - 4
3.4.1 Main Rope .........................................................................................................................3 - 4
3.5 NOISE EMISSION .............................................................................................................3 - 5
3.6 TEMPERATURE CONDITIONS .........................................................................................3 - 5
3.7 EXPOSURE TO VIBRATIONS...........................................................................................3 - 5
4 CONTROLS AND INDICATORS .......................................................................................4 - 1

4.1 OPERATOR'S CAB ...........................................................................................................4 - 1
4.2 CONTROL PANEL ............................................................................................................4 - 2
4.3 CONTROL PANEL 2..........................................................................................................4 - 3
4.4 MONITOR UNIT ................................................................................................................4 - 4
5 OPERATION .....................................................................................................................5 - 1
5.1 TRAVELLING AND STEERING .........................................................................................5 - 1
5.2 UPPER CARRIAGE SWING ..............................................................................................5 - 2
5.2.1 Swing Brake ......................................................................................................................5 - 2
5.2.2 Swing Control ....................................................................................................................5 - 3
5.3 ADJUSTING THE OPERATING RADIUS...........................................................................5 - 4
5.3.1 Increasing / Reducing the Operating Radius ......................................................................5 - 4
5.3.2 Raising / Lowering the Boom in Rigging Mode ...................................................................5 - 4
5.4 TRAVELLING WITH THE RIG ...........................................................................................5 - 5
5.4.1 Travelling on Level Ground ................................................................................................5 - 5
5.4.2 Travelling Up or Down Gradients .......................................................................................5 - 5
5.4.2.1 With Raised Mast and Without Work Equipment ................................................................5 - 5
5.5 OPERATING THE WINCH.................................................................................................5 - 6
5.5.1 Winding In and Unwinding the Main Winch Rope ...............................................................5 - 6
5.5.2 Operating the Main Winch in Rigging Mode........................................................................5 - 6
5.6 OPERATING MODES........................................................................................................5 - 7
5.6.1 Rope Grab Mode ...............................................................................................................5 - 7
5.6.1.1 Free-Fall Operation............................................................................................................5 - 8
5.6.2 Hydraulic Grab Mode .........................................................................................................5 - 9
5.7 OPERATING THE AUTOMATIC ROPE TENSIONING FACILITY ....................................5 - 10
5.8 OPERATING SPECIAL GRAB FUNCTIONS....................................................................5 - 11
5.8.1 Moveable Suspension * ...................................................................................................5 - 11
5.8.2 Flap Control .....................................................................................................................5 - 12
5.8.2.1 Y Axis Flap Control ..........................................................................................................5 - 12
5.8.2.2 X Axis Flap Control * ........................................................................................................5 - 13
5.8.2.3 Retracting All Flaps..........................................................................................................5 - 13
5.8.3 Turning Device ................................................................................................................5 - 14
5.8.3.1 Rotating the Grab Manually..............................................................................................5 - 14
5.8.3.2 Rotating the Grab in Automatic Mode...............................................................................5 - 15
6 START-UP / SHUT-DOWN ................................................................................................6 - 1

6.1 START-UP ........................................................................................................................6 - 1
6.1.1 Initial Start-Up ....................................................................................................................6 - 1
6.1.2 Visual Inspection Before Start-Up ......................................................................................6 - 1
6.1.3 Daily Start-Up ....................................................................................................................6 - 2
6.1.3.1 Starting the Equipment ......................................................................................................6 - 2
6.1.3.2 Selecting an Operating Mode .............................................................................................6 - 3
6.1.4 Safety Tests before Starting Work......................................................................................6 - 4
6.1.4.1 Checking the Emergency STOP.........................................................................................6 - 4
6.1.4.2 Checking the Pilot Control Safety Stick ..............................................................................6 - 4
6.1.4.3 Checking the Hoist Limit Switch (HS 1) ..............................................................................6 - 4
GB 34 / 2010 X
6.1.4.4 Checking the Winch Free-Fall Function ..............................................................................6 - 5
6.2 SHUT-DOWN ....................................................................................................................6 - 6
6.2.1 Daily Shut-Down ................................................................................................................6 - 6
6.2.2 Shutting Down for a Longer Period.....................................................................................6 - 6
7 RIGGING / DE-RIGGING ...................................................................................................7 - 1

7.1 GUIDELINES FOR RIGGING AND DE-RIGGING ..............................................................7 - 1
7.2 WAX REMOVAL ................................................................................................................7 - 2
7.3 EXTENDING THE CRAWLERS .........................................................................................7 - 3
7.4 MOUNTING THE COUNTERWEIGHT ...............................................................................7 - 4
7.5 ASSEMBLING THE BOOM................................................................................................7 - 5
7.5.1 Mounting the Boom Top .....................................................................................................7 - 5
7.5.2 Assembling the Boom Sections ..........................................................................................7 - 6
7.6 ASSEMBLY INSTRUCTIONS: SPRING ACCUMULATORS ...............................................7 - 8
7.7 ASSEMBLING THE MDSG SYSTEM...............................................................................7 - 11
7.7.1 Installing the MDSG System on the Base Machine ...........................................................7 - 11
7.7.1.1 Assembly: Version 1 ........................................................................................................7 - 12
7.7.1.2 Assembly: Version 2 ........................................................................................................7 - 17
7.8 INSTALLING THE CABLE DRUM ....................................................................................7 - 20
7.9 HYDRAULIC CONNECTIONS .........................................................................................7 - 21
7.10 INSTALLING THE MAIN ROPE .......................................................................................7 - 24
7.10.1 Reeving the Main Rope....................................................................................................7 - 24
7.11 INSTALLING THE ROPE SWIVEL ...................................................................................7 - 26
7.12 INSTALLING THE GRAB .................................................................................................7 - 27
7.13 RAISING THE BOOM ......................................................................................................7 - 28
7.13.1 Attaching Retaining Clamps .............................................................................................7 - 28
7.14 DISASSEMBLING THE EQUIPMENT ..............................................................................7 - 29
7.14.1 Disassembling the Grab ...................................................................................................7 - 29
7.14.2 Disassembling MDSG Equipment ....................................................................................7 - 29
7.15 LOWERING THE BOOM .................................................................................................7 - 30
7.15.1 Removing Retaining Clamps ............................................................................................7 - 30
7.15.2 Lowering the Boom ..........................................................................................................7 - 30
7.16 REMOVING THE COUNTERWEIGHT .............................................................................7 - 31
7.17 RETRACTING THE CRAWLERS.....................................................................................7 - 32
8 TRANSPORT ....................................................................................................................8 - 1
8.1 SAFETY GUIDELINES FOR TRANSPORT........................................................................8 - 1
8.2 MEASURES TO TAKE FOR TRANSPORT ........................................................................8 - 2
8.3 DRIVING ON / OFF A LOW LOADER ................................................................................8 - 3
8.4 LIFTING POINTS...............................................................................................................8 - 4
8.5 TYING DOWN ...................................................................................................................8 - 5
8.6 TRANSPORT DATA ..........................................................................................................8 - 6
9 MAINTENANCE ................................................................................................................9 - 1
9.1 SAFETY GUIDELINES FOR MAINTENANCE ....................................................................9 - 1
9.2 MAINTENANCE INTERVALS ............................................................................................9 - 1
9.3 MAINTENANCE PLAN ......................................................................................................9 - 2
9.3.1 Entire Equipment ...............................................................................................................9 - 2
9.3.2 Attachments ......................................................................................................................9 - 3
9.3.3 Work Equipment ................................................................................................................9 - 6
9.3.4 Upper Carriage ..................................................................................................................9 - 7
9.3.5 Undercarriage ....................................................................................................................9 - 8
9.3.6 Optional Equipment ...........................................................................................................9 - 9
GB 34 / 2010 XI
9.4 MAINTENANCE DURING LONGER PERIODS OF STANDSTILL ....................................9 - 10
9.5 LUBRICATION PLAN ......................................................................................................9 - 11
9.6 HYDRAULIC SYSTEM ....................................................................................................9 - 12
9.6.1 Hose Assemblies .............................................................................................................9 - 12
9.6.2 Hydraulic Cylinders ..........................................................................................................9 - 13
9.6.3 Filter Replacement...........................................................................................................9 - 14
9.6.3.1 Replacing the Line Filters.................................................................................................9 - 14
9.7 WINCHES .......................................................................................................................9 - 16
9.7.1 Checking the Oil Level .....................................................................................................9 - 16
9.7.2 Changing the Gear Oil .....................................................................................................9 - 17
9.8 WIRE ROPE ACCESSORIES ..........................................................................................9 - 18
9.8.1 Rope Swivel ....................................................................................................................9 - 18
9.8.2 Rope Hold-Down Rollers..................................................................................................9 - 18
9.8.3 Rope Fasteners, Thimbles and Sockets ...........................................................................9 - 19
9.8.4 Rope Sheaves .................................................................................................................9 - 20
9.8.4.1 Greasing Rope Sheaves ..................................................................................................9 - 20
9.8.4.2 Checking Rope Sheaves..................................................................................................9 - 21
9.9 MDSG LUBRICATION PLAN ...........................................................................................9 - 22
9.10 CRAWLER TRACK ASSEMBLIES...................................................................................9 - 23
9.10.1 Visual Inspection..............................................................................................................9 - 23
9.10.2 Crawler Tracks ................................................................................................................9 - 24
9.10.2.1 Checking the Track Tension.............................................................................................9 - 24
9.10.2.2 Adjusting the Track Tension .............................................................................................9 - 24
9.10.3 Checking the Mounting Bolts............................................................................................9 - 26
9.10.4 Travel Gear .....................................................................................................................9 - 27
9.10.4.1 Checking the Oil Level .....................................................................................................9 - 27
9.10.4.2 Changing the Oil ..............................................................................................................9 - 27
9.11 BOLTED CONNECTIONS ...............................................................................................9 - 28
10 LUBRICANTS / TABLES ................................................................................................10 - 1

10.1 LUBRICANTS ..................................................................................................................10 - 1
10.1.1 General ...........................................................................................................................10 - 1
10.1.2 Lubricant Table ................................................................................................................10 - 2
10.1.3 Lubricant Guide ...............................................................................................................10 - 4
10.1.3.1 Gear Oils, Petroleum - CLP..............................................................................................10 - 4
10.1.3.2 Gear Oils, Petroleum API ..............................................................................................10 - 5
10.1.3.3 Gear Oils, Synthetic CLP PG ........................................................................................10 - 6
10.1.3.4 Hydraulic Oils, Petroleum HVLP(D) ...............................................................................10 - 7
10.1.3.5 Engine Oils, Petroleum API CI-4 ...................................................................................10 - 8
10.1.3.6 Gear Oils, Synthetic CLP HC ........................................................................................10 - 9
10.1.3.7 Greases, Petroleum KP2N ..........................................................................................10 - 10
10.2 OPERATING FLUIDS ....................................................................................................10 - 11
10.2.1 Coolants ........................................................................................................................10 - 11
10.3 BOLT TORQUE VALUES ..............................................................................................10 - 12
10.4 CONVERSION TABLE ..................................................................................................10 - 14
GB 34 / 2010 XII
ABOUT THE MANUAL
THIS MANUAL IS MADE FOR
Equipment model: Grab System / GB 034

Serial number: 0583 / 0119
Construction year: 2010
Date of 1st operation: .. / .. / ....
THIS MANUAL WAS PUBLISHED IN
04.2010
THE CHAPTERS OF THIS MANUAL
1 DESCRIPTION
2 SAFETY
3 TECHNICAL DATA
4 CONTROLS AND INDICATORS
5 OPERATION
6 START-UP / SHUT-DOWN
7 RIGGING / DERIGGING
8 TRANSPORT
9 MAINTENANCE
10 LUBRICANTS / TABLES
APPENDIX
G:\...\0583_Grab_System_en_0000661694.docx
GB 34 / 2010 XIII
SYMBOLS USED IN THIS MANUAL
DANGER!
"Danger!" is used to identify an immediate hazard. Serious injury or

loss of life will result if the instructions given in the manual are ignored
or incorrectly followed.
WARNING!
"Warning!" is used to identify a potential hazard. Serious injury or

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

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

procedure. In general, observance of the information here will facilitate
NOTE the work.
GB 34 / 2010 XIV
NAMEPLATES
Nameplates on the equipment
Component Location Nameplate

Total equipment
Bauer Maschinen GmbH
D - 86522 Schrobenhausen Made in Germany
Gertetyp Trgergert
type base carrier
nchste Prfung Baujahr Bau - Nr. Inv. - Nr.
year of manufacture serial No Inv. No
Rckzugkraft
kN Vorschubkraft kN
12 1 2 pulling force pushing power
91011
345
max. Druck
2001 max. pressure bar Betriebsdruck
working pressure bar
8 76
Gesamtgewicht
total weight kg Arbeitspannung
working voltage V
Sachkundigenprfung CE - Zeichen Motorleistung
expert test CE sign engine power kW Frequenz
frequency Hz
B0000551.wmf
BK786502.wmf
GB 34 / 2010 XV
AFTER SALES SERVICE
How to reach the After Sales Service
Phone + 49 8252 97-2586

Fax + 49 8252 97-2587
E-mail KVT@bauer.de
Whenever you consult the After Sales Service, please give the following
information so that your inquiry can be dealt with accurately and more
quickly:
NOTE
Equipment description
Name of model:
Serial number:
Operating hours:
Description of damage
Date (DD.MM.YY):
Cause of damage (if known):
Course of events leading to damage:
For possible check-backs
Contact person; Telephone / Fax:
Description of site
Name of site:
Address (post code, town, street):
Route description for a mechanic (as necessary):
GB 34 / 2010 XVI
WARRANTY TERMS
If a warranty agreement was concluded with the client, the following terms shall apply to
warranty procedures:
Warranty period: The contractual agreement is principally decisive for the warranty
period; if no agreement on the warranty period was concluded, the
warranty shall be valid for 12 months from the time of
commissioning.
Commencement: The warranty officially comes into effect when the equipment is put
into initial operation at the Client's, a process which must be
recorded in the "Commissioning Certificate" and verified by the
signatures of both the Client and a representative of BAUER. In
any event, the warranty shall come into effect no later than 1 week
after delivery.
Warranty terms and - Original BAUER spare parts must be used throughout the
conditions: warranty period.
- Components and operating systems must not be dismantled or
repaired at any time during the warranty period without proper
authorisation.
- Any faults must be notified to BAUER in writing on the
appropriate "Warranty Claim" form within 24 hours of their
occurrence.
- The Client or Operator of the BAUER equipment agrees to carry
out all services throughout the warranty period within the
specified service intervals in full compliance with the instruction
manual.
- Any work (servicing, repairs, etc.) carried out on the equipment
must be recorded in the Maintenance and Repair Log provided
for this purpose with each item of equipment.
Warranty exclusions: - Improper use or operation (misuse) of the equipment.

- Failure to adequately maintain or service the equipment leading
to breakdowns and damage.
- Repairs which have been carried out improperly.
- Unauthorised modifications or alterations to the equipment.
- Forceful physical damage.
- Damage resulting from incorrect or improper operation.
- All normal wear and tear.
Note:
Wear and tear parts include drilling tools, kelly bars, ropes etc.
If a buyer can prove that the damage was caused by a
manufacturing defect, the claim shall be dealt with on a warranty
basis.
GB 34 / 2010 XVII
A) Liabilities and Responsibilities of BAUER
BAUER will supply spare parts required for carrying out repairs to BAUER equipment
under warranty to the Client.
Spare parts will be delivered c.i.f. (cost, insurance, freight) to the Client.
If necessary, BAUER will also provide personnel for carrying our repairs under warranty.
Any defective parts replaced under warranty shall become the property of
BAUER.
BAUER shall determine whether defective parts are to be returned to their
NOTE factory at Schrobenhausen, Germany. Transport costs for redeliveries will be
paid by BAUER Maschinen GmbH (after sales service).
Redeliveries / deadlines
Concerning requested redeliveries, the following deadlines are valid from the date of
arrival of the new parts on the jobsite in the assignment country until arrival of the
damaged parts in Schrobenhausen.
Redeliveries via air freight: 4 weeks

Redeliveries via sea freight: 4 months
If the damaged parts, which are redelivered via sea freight, are not redelivered in time
due to the jobsite situation, the after sales service has to be informed correspondingly, at
the latest 6 weeks before expiry of the deadline.
Concerning redeliveries via air freight, an extension of the deadline is principally not
possible.
In case requested redeliveries are not returned within the agreed time period, the
corresponding open amounts according to the sales invoice have to be paid by the
respective customer.
B) Liabilities and Responsibilities of the Client
Any customs duties payable in the country of destination for a consignment of spare
parts supplied under warranty shall be carried by the Client.
Local transport to a final destination (construction site) in connection with a warranty
claim shall also be the responsibility of the client.
Full and meticulous compliance with all operating instructions and observance of proper
operating procedures for all equipment.
Full compliance with the specified and necessary service schedule.
Entering and maintaining full and comprehensive records in the Maintenance and Repair
Log.
GB 34 / 2010 XVIII
To: BAUER Maschinen GmbH
After Sales Service Department
P.O. Box 12 60
86522 Schrobenhausen, Germany
Phone +49 8252 97-2586
Fax +49 8252 97-2587
From (Customer, Agent):
Phone: Fax:
Total number of pages of claim:
WARRANTY CLAIM
1. Product specifications
Serial Constr. Operating
Equipment: number: year: hours:
Current location of the equipment, postal address:
Date of commissioning: Date of damage:
2. Description of damage
Please describe damaged parts and state their material number:
Description Material no. Serial number
Note (symptoms/malfunctions, causes, position of damaged parts):
3. Delivery of new parts and repair

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

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

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

910.395.2
(Signed by authorised BAUER employee)

An: BAUER Maschinen GmbH
Abteilung Kundendienst
Postfach 12 60
D-86522 Schrobenhausen
Tel. +49 8252 97-2586
Fax +49 8252 97-2587
E-Mail kvt@bauer.de
PERSONALANFORDERUNG / STAFF REQUEST

Von Firma / Company:
Besteller / Ordered by: Tel.:
Fax:
Bestell-Nr. / Order no.: E-Mail:
Gert / Ausrstung /
Equipment: Attachment:
Betriebsstd. /
Bau-Nr. / Serial no.:
Working hours:
Standort des Gerts / Location of machine:
Ansprechpartner Baustelle / Baustellentelefon /

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

mechanic electrician operator
Voraussichtliche Dauer / Estimated duration:
Auszufhrende Arbeiten / Works to be carried out:
Besonderheiten / Special requirements:
Ersatzteile / Spare parts:
Kommunikation auf der Baustelle / Communication on jobsite:
deutsch/German englisch/English Landessprache/Language of country
Datum / Date: Unterschrift / Signature:
BAUER Maschinen GmbH D-86529 Schrobenhausen Tel. +49 82 52/97-0 sra 910.097.1+2BMA 08/2008
An/ BAUER Maschinen GmbH
To: Abteilung Kundendienst/
After Sales Service Department
Postfach/P.O. Box 12 60
86522 Schrobenhausen, Germany
Phone: +49 8252 97-2586
Fax: +49 8252 97-2587
E-mail: kvt@bauer.de
REGISTRIERUNG BETREIBER UND GERT/

OWNER AND EQUIPMENT REGISTRATION
Wir mchten dem Betreiber jederzeit eine optimale Dienstleistung bezglich Kundeninformationen
bieten knnen.
Wir bitten deshalb jeden neuen Betreiber, sich und sein Gert ber dieses Formular bei der BAUER
Maschinen GmbH registrieren zu lassen./
We would like to offer the equipment owner an optimum service as regards customer information at all
times.
For this reason, we would ask each new owner to register himself and his equipment with BAUER
Maschinen GmbH by filling out this form.
1. Gertedaten/Equipment Data
Gert/ Baunummer/ Betriebsstunden/

Equipment: Serial number: No. of operating hours:
2. Betreiberdaten/Owner Information
Aktueller Betreiber des Gertes mit Anschrift/ Current owner of the equipment, including address:
Firma/Company:
Abteilung/Department:
Ansprechpartner/Contact person:
Postfach/P.O. Box:
Strae/Street:
Land/Country:
Tel./Tel.:
Fax/Fax:
E-Mail/E-mail:
Datum/ Name des Ausstellers Unterschrift/ Firma/

Date (in Blockbuchstaben)/ Signature Company
Name of issuer
(in capital letters)
BAUER Maschinen GmbH 86522 Schrobenhausen Tel. +49 8252 97-0 shj 910.847.1+zhBMA 11/2009
DESCRIPTION
1 DESCRIPTION
1.1 INTENDED AND AUTHORIZED USE
The equipment shall only be used for the following operations:
Authorized
Operation Abbreviation
use?
Grabbing work with hydraulic grab and
MDSG yes
mechanical hose drum system
Grab applications with hydraulic grab and
TG yes
turning device
Authorized use means use in strict compliance with and strict adherence to all
directives, mandates, precautions and prohibitions contained in this Instruction Manual
as well as in all additional manuals and documents supplied herewith.
Everything contained in the Instruction Manual refers to and applies only to the
equipment as first delivered to the original purchaser including all original attachments
and factory installed options as of the day of delivery.
Any modification of the equipment or its attachments or factory installed options made
after delivery might render the equipment unsafe and therefore invalidates this
Instruction Manual. The equipment shall not be used after any such modifications
are made unless such use after modification has been approved in writing by
BAUER Maschinen GmbH as set forth below.
The manufacturer disclaims any liability of any kind arising from or connected with the
so prohibited and unauthorized use of the equipment in any way unless such use after
modification has been approved in writing by BAUER Maschinen GmbH.
GB 34 / 2010 1-1
DESCRIPTION
After modification of the equipment, the original attachments or factory installed options
as of the day of delivery, the equipment is not authorized for any use whatsoever and
wherever unless or until an authorization is first given by BAUER Maschinen GmbH in
writing. To obtain such an authorization, a Change Request as shown below must be
submitted to BAUER Maschinen GmbH.
The authorization to use the equipment after any modification of the equipment, the
original attachments or factory installed options can only be given by BAUER
Maschinen GmbH after submission and review of a properly completed Change
Request.
No other person, entity or organization, including but not limited any government entity
located anywhere, shall have the right to give such an authorization. Neither any
agents, distributors, importers, dealers or subsidiaries of BAUER Maschinen GmbH
shall have the right to or are able to give such a valid authorization. Only the corporate
headquarters of BAUER Maschinen GmbH can issue a valid authorization after
submission of a properly completed Change Request.
The equipment described in this Instruction Manual is only intended for and therefore shall
only be used in the country for which it was ordered by the original purchaser. All
contractual agreements between the manufacturer and the original purchaser with respect
to the requirements and restrictions of use and operation of the equipment in a country
other than the one the equipment was ordered for are binding on any and all subsequent
purchasers.
Any use of the equipment in any country other than the country for which it was ordered
by the original purchaser is unauthorized use and strictly prohibited unless the prior
written authorization of BAUER Maschinen GmbH has been requested and received.
Any use of the equipment in the United States of America is only allowed if the
equipment was first ordered for and delivered for use within the United States of
America or if the equipment has been expressly approved and authorized in writing for
use within the United States of America by BAUER Maschinen GmbH.
Any use of the equipment other than the use authorized and described in this Instruction
Manual shall constitute unauthorized and strictly prohibited use and is hereby expressly
forbidden. The same applies if the equipment is used as a crane, for levelling purposes
or for the transport of people. These uses are expressly unauthorized and hereby
strictly prohibited.
The manufacturer shall not be liable for any injuries or damages of any kind which are
caused by, directly or indirectly, or are in any way, shape or form connected to, or
arising from any unauthorized use described herein or any use that is not expressly
authorized in this Instruction Manual.
GB 34 / 2010 1-2
DESCRIPTION
An/ BAUER Maschinen GmbH Tel. +49 8252 97-2586

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

Gesamtseitenzahl dieses Antrages/Total number of pages of this request:
1.1.1 nderungsantrag / Change request
fr/for
Gert/Equipment Ausrstung/Attachment Anbauteil/factory installed option
1. Grunddaten/Equipment specifications
Betriebs-
Gert/Anlage Baunummer/ Baujahr/ stunden/
Equipment/ Serial Year of Operating
Plant: number.: manufacture : hours:
Aktueller Standort des Gertes/der Anlage mit Anschrift/
Current location of the equipment/plant with complete address:
Datum der Kommissionierung/Date of commissioning (first use):
Anbauteile (original)/Factory installed options (OEM):
Bezeichnung/Description Materialnummer/Material number Baunummer/Serial number
(N i ti
Ausrstung (original)/Attachment (OEM):

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

Gert/Equipment Ausrstung/Attachment Anbauteil/Factory installed option
nderungsbeschreibung/Description of changes ggf. Angebotsnr. BAUER/BAUER offer no (if applicable)
Es wird hiermit ausdrcklich erklrt und besttigt, dass sich das Gert zum aktuellen Zeitpunkt im
Originalzustand (Auslieferungzustand) befindet und ausschlielich mit BAUER-Originalkomponenten
bestckt ist.
Das Gert befindet sich in einem technisch einwandfreien Zustand./
It is herewith explicitly declared and confirmed that the equipment is presently in its original condition
(as delivered) and contains only genuine original BAUER OEM components.
The equipment is in a technically flawless condition.
Eigentmer bittet um technische berprfung des Gertes./
05/2009 bjm
The owner requests a technical inspection of the equipment.
Name/Name Unterschrift/Signature Datum/Date

3. BAUER-intern (wird von BAUER ausgefllt) / For internal use of BAUER (to be filled in by BAUER)
910.818.1+2BMA
Antrag erhalten am/Request received on:

Antrag weitergeleitet an/ VT Name: Datum/Date:
Request forwarded to: EK Name: Datum/Date:
PM Name: Datum/Date:
andere/other Name: Datum/Date:
Name KVT-Mitarbeiter/Name of KVT employee:
GB 34 / 2010 1-3
DESCRIPTION
1.2 COMPONENTS
1.2.1 Basic Rig / Grab Equipment
1.2.1.1 Components Overview
Basic Rig 23
7
1 Boom
(top / bottom / turning point)
2 Swing mechanism
3 Travel gear
4 Counterweight
5 Hoist winch
6 Hoist rope
7 Boom head ("masthead")
1
8 Boom cylinder
9 Upper carriage 21
10 Undercarriage
8
20
Grab equipment (MDSG)
20 Hose drum system

6
21 Double spring accumulator 5
22 Electric cable reel 9
23 Hydraulic hose guide
22 4
2
10 3
G0040509.wmf
GB 34 / 2010 1-4
DESCRIPTION
1.2.1.2 Components Description
Basic rig components description table
Component Description / function
Consists of a top and bottom part, and is mounted on

Boom the bottom end with a turning point so that it is able to
move on the base machine.
Used for raising/lowering/adjusting the boom, and
Boom cylinders
provide support for it.
Boom head * Guides the grab hoist rope using rope sheaves.
Hoist winch with hoist rope Hoist equipment for the grab.
Upper carriage Houses the engine, hydraulic system and controls.
Swing mechanism Enables the rotation of the upper carriage to both sides.
The undercarriage carries the upper carriage and
Undercarriage enables travelling with the equipment, from one spot to
the next.
Travel gear For driving the undercarriage crawlers.
Counterweight Gives the equipment stability.
* Also referred to as a "masthead"
GB 34 / 2010 1-5
DESCRIPTION
Table: Components description, grab equipment (MDSG)

Component Description / function
Two drums for holding and guiding the hydraulic
Hose drum system (MDSG) hoses required for the grab supply, and the associated
(Mechanical Drum System Grab) spring accumulators for mechanical reeling/unreeling
of the hoses (see below).
Mounted on the boom and flange-connected to the
hose drums.
Double spring accumulator The sets of springs housed in the two tubes are
tensioned and relieved of tension by a wire rope
connected to the relevant hose drum.
The electric cable transfers data from the grab to the
base machine. In automatic mode, the cable is
Electric cable and reel automatically wound onto/unwound from the cable
drum to ensure that data transfer can continue
uninterrupted.
GB 34 / 2010 1-6
SAFETY
2 SAFETY
2.1 GENERAL SAFETY REQUIREMENTS
It is fundamental that the national accident prevention codes be observed where this
equipment is used.
In addition, the "Safety Information" book supplied with this equipment must be read
and understood. It contains general safety requirements and such that have been
compiled by the manufacturer especially for this type of equipment.
Also, the safety messages given in the instruction manual of the equipment must be
followed.
2.2 EQUIPMENT SAFETY

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

In grab applications, the equipment is operated with heavy tools. Being hit by a
moving tool can cause severe or even fatal injuries.
The stability of the equipment must not be compromised. Exceeding the rig's capacity
or operating with faulty limit switches can make the equipment fall violently causing
severe personal injury or even loss of life.
Never remove equipped safety devices nor render them out of order.
Be observant of oil spills from the hydraulic system. Oil spraying with high pressure
from a leak in the hydraulic system can cause severe burns and poisoning.
The cooling system gets very hot from operation. Coming into contact with
components containing coolant can cause burns.
Engine, gear and hydraulic oils get very hot during operation. Touching a component
containing such oil can cause burns.
Be sure the equipment is properly shut down before you begin a maintenance, repair
or cleaning job on it. Set all controls to Off, stop the engine and interrupt the power
supply by setting the battery main switch to Off position.
To prevent abuse and unauthorised starting of the equipment, shut it down, remove
the ignition key and lock the cab whenever you leave the equipment unattended.
GB 34 / 2010 2-1
SAFETY
2.4 SAFETY DEVICES

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

All equipment functions will promptly come to
a stop.
1
To re-start, pull the depressed Emergency
STOP button.
BK786504.wmf
2.4.2 Pilot Control Safety Stick
With the safety stick (1), the operator must 1.2

shut off the pilot control before leaving the
driver's seat. With the stick in the "Off" 1.1
position, all hydraulic functions are blocked.
Pilot control On:

Stick moved to position (1.1)
Pilot control Off:

Stick moved to position (1.2)
BK786505.wmf
2.4.3 Fire Extinguisher
Machines with an engine power of < 200 kW

are equipped with one fire extinguisher.
Machines with an engine power of > 200 kW
are equipped with two fire
extinguishers.
Their location in or on the machine is

identified with a decal (see fig.).
Personnel must re-read the instructions
provided on fire extinguisher from time
to time to ensure that they are able to operate B0000506.wmf
them correctly.
GB 34 / 2010 2-2
SAFETY
2.4.4 Medical Box
A First Aid medical box is found in the

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

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

behind the operators seat.
BS756504.wmf
GB 34 / 2010 2-3
SAFETY
2.4.6 Limit Switches
Table of limit switches
Name Function
HS 1
Switches off the "Wind in rope"
function for the hoist winch in order
HS 1
to prevent a collision with the boom
head.
GO0755002.wmf
GB 34 / 2010 2-4
SAFETY
2.5 STABILITY
2.5.1 Stability Guidelines
Load capacity charts are calculated in compliance with the European standard DIN 996.
WARNING!
Tipping hazard!
The conditions listed in the following must be observed to guarantee the
stability of the rig.
Conditions for operation:

The angles and main rope loads specified in the load capacity charts are maximum
values and must not be exceeded for safety reasons.
The specified loads apply only when not combined with one another or used on an
altered setup of equipment.
If heavier equipment is attached or the centre of gravity is at a higher point, the
stability will need to be recalculated.
Machine on firm, horizontal and even surface. Observe national standards and
guidelines regarding soil and working platform conditions.
When a load is attached to the rope, the upper carriage must only be swung slowly
(max. 3 rpm).
No diagonal pull.
The pulling forces of the winch and the current centre of gravity (position
of the equipment) are factors which also affect stability.
The loads given in the load capacity charts take into consideration the
NOTE most adverse position of the components.
Conditions for on-site travelling:
Risk of accident if driver does not have an all-round view from the cab!
The driver of the rig must be assisted by a person giving hand signals
during travel.
CAUTION
Machine on firm, horizontal and even surface. Observe national standards and
guidelines regarding soil and working platform conditions.
Upper carriage in line with undercarriage.
Equipment and moveable loads must be kept as close to the ground as possible.
Set the boom to its minimum permissible operating radius.
No abrupt movements.
GB 34 / 2010 2-5
SAFETY
2.5.2 Stability With Grab Equipment
Valid only for Counterweight 12.40 t Width of track shoes 700 mm

DHG/SF 800 grab 15.40 t
Conditions for Machine on firm, horizontal and even working platform

operation Max. upper carriage swing speed: 3 rpm
No diagonal pull
Do not exceed the specified maximum values for the angles and loads! The
specified loads apply only when not combined with one another or used on an
CAUTION altered setup of equipment.
Permissible Operating Range

Permissible operating radius during operation: Max. 4.50 m Boom angle 79.4 /
min. 3.50 m Boom angle 83.6
Max. rope force Permissible operating radius
Loading condition in metres Boom angle

Grab above trench 185.07 KN 4.50 79.4
Grab at final depth 156.96 KN 4.50 79.4
Chisel recovery 338.25 KN 4.75 78.4
Note: Specified capacities for the recovery do not meet EN 996 requirements and are therefore
for information purposes only.
BAUER Maschinen GmbH does not assume liability for recovery operations!
Ground pressure in kPa
Grab above trench Lengthwise 306

Crosswise 184
Max. 345
Grab at final depth Lengthwise 229

Crosswise 157
Max. 254
Grab recovery Lengthwise 786

Crosswise 263
Max. 860
Definition: Boom operating radius Distance between centre of slewing ring and centre of
trench
Recovery Raising a grab stuck in the trench.
GB 34 / 2010 2-6
SAFETY
2.5.2.1 Travelling With Equipment
WARNING!
Tipping hazard!
Travelling too fast with a load, travelling with a load across terrain with
an excessively steep incline, and swinging the load may lead to the
equipment tipping over and cause serious injury as a result.
Only travel with a load at the lowest speed setting.
Set the boom angle before travelling up and down slopes.
Only travel with the load over terrain whose working platform inclina-
tion does not exceed the values listed in the table below.
Move the control lever smoothly and carefully.
Working platform an- Working platform

gled upwards angled downwards
Working platform inclination [] Max. -5 (upwards) Max. 3 (downwards)
Upper carriage position in relation
Lengthwise Lengthwise
to crawlers
Position of hook load Facing upwards Facing downwards
Permissible boom
4.50 m - 3.70 m 3.70 m - 3.50 m
operating radius
Permissible boom angle [] 79.4 - 82.8 82.8 - 83.6
GO01085000.wmf
GB 34 / 2010 2-7
SAFETY
2.6 RISK OF ROPE BREAKING WHEN ADJUSTING BOOM
Adjusting the boom will change the length of the rope.

Before adjusting the boom (for rigging or derigging purposes, or in order to make it more
suitable for the application), you must make sure that enough rope has been unwound
to prevent additional pulling forces from being exerted on it as a result of the boom
being adjusted.
To prevent a dangerous situation developing where the rope breaks as a result of its
tension increasing in an uncontrolled manner, any rope ends that are attached to fix
points must be released.
WARNING!
Accident risk!
Excessive strain on the ropes may cause them to break, which could
lead to serious injuries as a result.
Make sure the rope is long enough.
L0000530.wmf
GB 34 / 2010 2-8
SAFETY
2.7 PERMISSIBLE WIND SPEED

The place to measure the wind speed is at the masthead:
Max. permissible wind speed for equipment operation Barrier effect
m/s km/h miles/h Beaufort ktn
20 72 45 8 39 250 (N/m)
WARNING!
Tipping hazard!
Shut down the equipment before the value is exceeded.
Set the suspended grab down on the ground.

Lower movable components as close to the ground as possible.
Adjust the upper carriage in line with the undercarriage and interlock them.
Set the mast to the minimum operating radius.
Extend the ground prop of the mast, if so equipped.
Table of wind forces and speeds

Wind force Wind speed
Wind effects
Beaufort English m/s km/h
0 calm 0 - 0.2 less than 1 Smoke rises straight in the air, sea is calm-glassy
1 light air 0.3 - 1.5 1-5 Smoke drifts but vanes remain still, sea is rippled
2 light breeze 1.6 - 3.3 6 - 11 Wind can be felt on your face, leaves rustle, sea
has wavelets
3 gentle breeze 3.4 - 5.4 12 - 19 Leaves and thin twigs move, pennants stretch,
wave crests begin to break
4 moderate 5.5 - 7.9 20 - 28 Dust and paper lift, twigs and branchlets sway,
breeze waves are growing in length, scattered white-caps
5 fresh breeze 8 - 10.7 29 - 38 Small trees begin to sway, waves are white-
capped all over the sea
6 strong breeze 10.8 - 13.8 39 - 49 Sturdy branches move, wires sing, umbrellas are
hard to handle, sea is rough, crests break
7 near gale 13.9 - 17.1 50 - 61 Whole trees swaying, working towards the wind is
difficult, sea is very rough, foam on crests
8 gale 17.2 - 20.7 62 - 74 Branches break off, walking outdoor is extremely
difficult, waves are high, spray from crests
9 strong gale 20.8 - 24 75 - 88 Minor damage to buildings (roof tiles and chimney
hoods are ripped off); on the sea, waves are very
high and the visibility is obstructed by spray
GB 34 / 2010 2-9
TECHNICAL DATA
3 TECHNICAL DATA
3.1 DIMENSIONS
3.1.1 With Grab Equipment (MDSG)
Dimensions in [mm]
16331
15808
13846
6700
7211
5128
5800

.6
83
2800
1391
1200
0
4440
5360
3500 - 4350 R 3450
GU00745000.wmf
GB 34 / 2010 3-1
TECHNICAL DATA
3.2 EQUIPMENT DATA
Base machine
Upper carriage
Type Hyundai BH 70
Serial number 175
Engine
Type Cummins C8.3-C
Serial number 73034489
Output 194 kW
Speed 2200 rpm
Undercarriage
Type UW 65 DH
Serial number 1318
Width over crawlers 2980 - 4,380 mm
Length of crawlers 5,430 mm
Width of track pads 700 mm
Main winch
Type 4066 WF 08 / 0
Serial number 69418
Pulling force (1st layer, reeved) 170 kN
Rope speed (reeved) 34 m/min
("lifting" with a load of 80 kN)
Working weight
With:
DHG-SF 800 grab approx. 73.0 t
GB 34 / 2010 3-2
TECHNICAL DATA
3.3 GRAB OPERATING RANGE

3.3.1 MDSG
Excavation depth (D): 50 m
Working radius: 4,500 mm / 3,500 mm

Mast inclination: 79.4 - 83.6
G0030514.wmf
GB 34 / 2010 3-3
TECHNICAL DATA
3.4 ROPE SPECIFICATIONS
WARNING!
Accident risk!
Ropes breaking can cause serious accidents.
Ropes installed in hoist winches must have a minimum
breaking load which is at least three times the pulling force.
The ropes' safety factors must comply with the standards
required for the equipment and must be observed.
3.4.1 Main Rope
Technical data:
Finished length 159 m

Diameter 26.00 mm
Characteristics:
Lay and direction Regular lay, right (sz)

Rotation characteristics Non-rotating
Rope end characteristics Pointed - Pointed
GB 34 / 2010 3-4
TECHNICAL DATA
3.5 NOISE EMISSION
1. Inside Cab (door closed)
Measurement in acc. with ISO 6394:

Sound-pressure level in cab LPA = 78.8 dB(A)
2. Outside
Measurements in acc. with DIN 45635 P.33:

Average sound-pressure level LPA = 80.3 dB(A)
Sound-power level LWA = 111.6 dB(A)
3.6 TEMPERATURE CONDITIONS
The equipment can be used at outdoor temperatures ranging from -20 to +40 C (-4 to
+104 F).
For use at temperatures outside the specified range the manufacturer must be
consulted.
3.7 EXPOSURE TO VIBRATIONS

The operators exposure to vibration acceleration during operation with this equipment
is less than 0.5 m/s2.
GB 34 / 2010 3-5
CONTROLS AND INDICATORS
4 CONTROLS AND INDICATORS

4.1 OPERATOR'S CAB
P P
1.1 2.1 3
34 4
33 5
32 6
31 7
30.5 8.1
30.1
1.2 2.2 8.3 8.4
30.3 30.4 8.5 8.6
8.7 8.8
30.2 20 8.2
30.6
10
11
12
13
GO01015001.wmf
1.1 Left crawler travel forward 10 Ignition on/off

1.2 Left crawler travel reverse 11 Set diesel engine speed
2.1 Right crawler travel forward 12 Emergency STOP
2.2 Right crawler travel reverse 13 Adjust track gauge of undercarriage
3 Free-fall / freewheel release
4 Not used 20 Hydraulic pilot control On / Off
5 Not used
6 Horn 30.1 Increase operating radius (short stroke)
7 Not used 30.2 Reduce operating radius (short stroke)
8.1 Unwind rope 30.3 Swing upper carriage left
8.2 Wind in rope 30.4 Swing upper carriage right
8.3 Close grab shovel 30.5 Rigging mode selected:
8.4 Open grab shovel Increase operating radius (long stroke)
8.5 + Retract all flaps 30.6 Rigging mode selected:
8.5 + Retract Y+ flaps Reduce operating radius (long stroke)
8.5 + Retract Y- flaps 31 Not used
8.5 + Retract X+ flaps * 32 Activate diesel engine idle speed /
8.5 + Retract X- flaps * activate selected diesel engine speed
8.6 + Extend Y+ flaps 33 Not used
8.6 + Extend Y- flaps 34 Diesel engine speed 110% for 8 seconds
8.6 + Extend X+ flaps *
8.6 + Extend X- flaps *
*) Not supplied with this version
GB 34 / 2010 4-1
4.2 CONTROL PANEL
P P
GO01055002.wmf
1 Indicator: Rope grab selected 12 Button with indicator: Automatic rope

2 Selection switch: Rope grab / hydraulic grab tensioning facility On / Off
3 Indicator: Hydraulic grab selected 13 Not used
4 Rigging mode 14 Not used
(override winch stroke limit) 15 Button with indicator: Release free fall
5 Warning display: Free-fall oil filter 16 Retract all grab steering flaps *
contaminated 17 Button with indicator: Automatic winding of E
6 Control Y+ flaps * cable roller On / Off
7 Control Y- flaps * 18 Button with indicator: Release swing brake
8 Indicator: Normal winch operation 19 Button with indicator: Apply swing brake
9 Selection switch: 20 Not used
Normal winch operation / free-fall winch 21 Not used
operation
10 Indicator: Free-fall winch operation
11 Potentiometer:
Set automatic rope tensioning facility
* With grab flaps control system
GB 34 / 2010 4-2
4.3 CONTROL PANEL 2
Position Automatik Greifer drehen

speichern Ein links rechts
MEM
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
LN184716501.wmf
1-18 Not used

19 Save the current
grab position as end point
20 Select: Turn to end points saved
for grab
21 Grab turns left and
indicator shows: End point reached
22 Grab turns right and
indicator shows: End point reached
23-24 Not used
GB 34 / 2010 4-3
4.4 MONITOR UNIT
For more detailed information, please see the additional documentation in the appendix.
GB 34 / 2010 4-4
OPERATION
5 OPERATION
5.1 TRAVELLING AND STEERING
Risk of shortening the service life of crawler components due to

incorrect loading!
The main direction of travel should always be - as shown - following the
direction of the arrow (2); the front idlers (1) facing forward and the
CAUTION travelling drive (3) at the back.
During operation, the front idler (1) should bear the main load. Position
the undercarriage accordingly.
1 2 3
CA00005000.wmf
B0000552.wmf
Risk of damaging the crawler components!

The crawlers installed on the equipment are designed for standard
operation with grab loads.
CAUTION This equipment should not travel over longer distances!
Suitable and designated means of transport must be used to reposition

the machine!
NOTE
GB 34 / 2010 5-1
OPERATION
5.2 UPPER CARRIAGE SWING

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

The swing brake may be applied only when the upper carriage has
CAUTION come to a stop.
WARNING!
Risk of getting crushed or hit!
Before swinging the upper carriage, check the danger zone is free. The
rear-view mirror (and tail camera if equipped) must be clean at all times.
To apply the swing brake:

Press button (19). 1
The indicator light in the button will

light up.
To release the swing brake:

Press button (18). P P
The indicator light in the button will
light up.
GO01055002.wmf
GB 34 / 2010 5-2
OPERATION
5.2.2 Swing Control
Upper carriage swing to left:

Release swing brake.
Move control lever (30) to left (30.3)
from centre.
Upper carriage swing to right: 30.3 30.4

Release swing brake.
Move control lever (30) to right (30.4)
from centre.
GO01055003.wmf
Letting the lever return to centre makes the swing slowly come to a stop using
hydraulics.
A quicker stop can be implemented by carefully moving the lever in the opposite
direction.
GB 34 / 2010 5-3
OPERATION
5.3 ADJUSTING THE OPERATING RADIUS

Please refer to the "STABILITY" section for the permissible operating radius.
5.3.1 Increasing / Reducing the Operating Radius
Risk of damaging the hoist rope!

Please pay particular attention to the information in the "OPERATING
CAUTION THE WINCH" section!
30.1
P P
30.2
GO01055002.wmf GO01055004.wmf
Reducing the operating radius (raising) Increasing the operating radius (lowering)
Move the left control lever backwards (30.2) Move the left control lever forwards (30.1)
5.3.2 Raising / Lowering the Boom in Rigging Mode
To raise or lower the boom, the hoist limit switch must remain deactivated (= rigging
mode) whilst the raising / lowering functions are being carried out with the control lever:
Press and hold button (4) on the control panel, and move the left control lever (30) as
shown (see above).
Risk of damaging the boom!

Immediately after the boom is raised, it must be fastened to the bottom
CAUTION (long stroke) of the mast cylinder using clamps.
GB 34 / 2010 5-4
OPERATION
5.4 TRAVELLING WITH THE RIG

5.4.1 Travelling on Level Ground
Risk of accident if driver does not have an all-round view from the cab!
The driver of the rig must be assisted by a person giving hand signals
CAUTION during travel.
Provide an obstacle-free travel path.

Adjust the upper carriage in line with the undercarriage and apply the swing brake.
Lower the equipment and movable loads as close to the ground as possible.
Travel on firm and level surfaces only.
Avoid making abrupt movements.
5.4.2 Travelling Up or Down Gradients
5.4.2.1 With Raised Mast and Without Work Equipment
Tipping hazard!
Observe all instructions found in sect. "Travelling over level ground"!
CAUTION
Tipping hazard!
It is prohibited to travel up/down gradients of more than 5 and also to
CAUTION traverse gradients!
GB 34 / 2010 5-5
OPERATION
5.5 OPERATING THE WINCH
Risk of damaging the rope, mast and components!

Before using the winch, please read the entire "OPERATING MODES"
section carefully.
Do not allow the rope to become slack AT ALL when lowering the load.
A slack rope on the drum could lead to the load sliding down in an
uncontrolled manner and the rope being damaged beyond repair!
CAUTION When unwinding the rope from the winch, always remember that, for
safety reasons, the rope must remain wound around the drum at least
three times!
Particular care must be taken when operating the winch in rigging mode,
as the hoist limit switch is deactivated!
5.5.1 Winding In and Unwinding the Main Winch Rope
8.1
P P 8.2
GO01055002.wmf GO01055005.wmf
Rope grab / Unwinding rope Winding in rope

hydraulic grab mode (lowering grab) (raising grab)
Set selection switch (9) to Move the right control Move the right control
the "Raise winch" position lever forwards (8.1) lever backwards (8.2)
The speed of the winch is controlled by moving the control lever:
the further the control lever is moved, the quicker the process.
5.5.2 Operating the Main Winch in Rigging Mode
Due to the mast inclination, the hoist limit switch must remain deactivated (= rigging
mode) whilst the winding in / unwinding functions for the main winch rope are carried
out with the control lever:
Press and hold button (4) on the control panel, and move the right control lever (5) as
shown (see above).
GB 34 / 2010 5-6
OPERATION
5.6 OPERATING MODES

The GB has been designed for use in the following two operating modes:
Rope grab mode
Hydraulic grab mode
The key difference between the modes lies in how the winch functions when each of
them is activated. The following section outlines each of the operating modes in terms
of their functions.
However, both operating modes have the following in common:
Button 17 must be pressed before operating the winch in order to activate automatic
winding of the elec. cable roller This causes the LED in the button to light up.
Open the grab shovels using the control lever on the right (8.4).
Close the grab shovels using the control lever on the right (8.3).
To avoid damaging the main rope, it should be kept tensioned whilst the grab shovels
are being closed during operation:
To close the grab shovels, move the right-hand control lever to the
left (8.3). To keep the main rope tensioned, move the right-hand 8.3
control lever downwards (8.2) (see graphic on the right).
GO01055010.wmf
5.6.1 Rope Grab Mode
P P
GO01055002.wmf
Set selection switch (2) to the "Rope grab" position.
Once rope grab mode has been selected, the following winch functions can be used:
Raising / lowering load using right control lever (as described)
Lowering load in free-fall mode using right foot pedal
GB 34 / 2010 5-7
OPERATION
5.6.1.1 Free-Fall Operation
Risk of damaging the equipment!

The load on the rope must not exceed 50% of the maximum pulling
CAUTION force for the winch.
8.1
P P 8.2
GO01055002.wmf GO01055006.wmf
Switching on, activating and triggering free-fall operation:

Select "Rope grab" mode (as described).
Press button 17 until the LED in it lights up.
Set selection switch (9) to the "Free fall" position.
Press foot pedal (3) all the way down Free-fall operation switched on.
Press and hold button (15) Free-fall operation activated (LED in button lights
up).
Release button (15) Load is held by foot on pedal!
You can control the free-fall speed by applying more or less pressure to the pedal.
Interrupting free-fall operation briefly and reactivating it:

Move the right control lever backwards (8.2) Free-fall operation deactivated.
Press foot pedal (3) all the way down and press button (15) briefly Free-fall
operation reactivated.
Stopping and switching off free-fall operation:

Set selection switch (9) to the "Raise winch" position again.
GB 34 / 2010 5-8
OPERATION
5.6.2 Hydraulic Grab Mode
P P
GO01055002.wmf
Set selection switch (2) to the "Hydraulic grab" position.

Press button 17 until the LED in it lights up.
Once hydraulic grab mode has been selected, the following winch function can be used:
Raising / lowering load using right control lever (as described).
GB 34 / 2010 5-9
OPERATION
5.7 OPERATING THE AUTOMATIC ROPE TENSIONING FACILITY
This facility prevents the rope from becoming slack when the grab reaches the ground.
As soon as a certain residual winch pulling force (which has been predefined) is no
longer present, the winch will stop unwinding the rope.
P P
GO01055002.wmf
Switching the automatic rope tensioning facility on/off

Press button 12
LED in button (12) does not light up = Automatic rope tensioning facility activated
LED in button (12) lights up = Automatic rope tensioning facility deactivated
Adjusting the automatic rope tensioning facility

Set the potentiometer (11) to the required residual winch pulling force.
The settings are as follows: 0 = Residual winch pulling force of 0 to
10 = Residual winch pulling force of 2 to
GB 34 / 2010 5 - 10
OPERATION
5.8 OPERATING SPECIAL GRAB FUNCTIONS

5.8.1 Moveable Suspension *
The moveable suspension for the grab enables the grab to be tilted along the y axis.
Axis definition
1
+Y
-X +X
P P -Y
GO01055007.wmf
BTS0180F001.wmf
Tilt grab in "y+" direction:

Press button 20 and move control lever to
pos. 8.7.
8.7 8.8
Tilt grab in "y-" direction:
pos. 8.7.
GO01055008.wmf
GB 34 / 2010 5 - 11
OPERATION
5.8.2 Flap Control
The flap control for the grab enables the grab to be tilted along the y axis and the x axis.
Axis definition
1 +Y
-X +X
P P -Y
GO01055007.wmf
BTS0180F001.wmf
5.8.2.1 Y Axis Flap Control
Extend Y+ flaps.
pos. 8.6.
Retract Y+ flaps. 8.5 8.6

pos. 8.5.
Extend Y- flaps.
pos. 8.6.
GO01055009.wmf
Retract Y- flaps.
pos. 8.5.
GB 34 / 2010 5 - 12
OPERATION
5.8.2.2 X Axis Flap Control *
Extend X+ flaps.
pos. 8.6.
Retract X+ flaps.
Press button 13 and move control lever to 8.5 8.6
pos. 8.5.
Extend X- flaps.
pos. 8.6.
Retract X- flaps. GO01055009.wmf

pos. 8.5.
5.8.2.3 Retracting All Flaps
Retract all flaps.

pos. 8.5.
8.5 8.6
GO01055009.wmf
It is recommended that you retract all flaps before raising the grab out
of the trench.
NOTE
GB 34 / 2010 5 - 13
OPERATION
5.8.3 Turning Device
The turning device for the grab enables the grab to be rotated about its longitudinal axis.
5.8.3.1 Rotating the Grab Manually
8.7 8.8

MEM
22 23 24 25 26 27 28 29
GO01055008.wmf GO098501.wmf
The grab can be positioned anywhere within its turning range.
Precondition: The "Automatic" function (25) is deactivated LED (25) is not lit.
Press and hold down button (26) and move the control lever to position (8.7) or (8.8)
to rotate the grab counterclockwise.
to rotate the grab clockwise.
The grab only rotates as long as the button is held down.
The LED (26) / (27) only lights up when a previously saved end position is reached
(see the section entitled "Saving the grab end position").
GB 34 / 2010 5 - 14
OPERATION
5.8.3.2 Rotating the Grab in Automatic Mode
Saving the reference axis
Axis definition
+Y
-X +X
-Y
8.7 8.8

MEM
22 23 24 25 26 27 28 29
GO01055008.wmf GO098501.wmf BTS0180F001.wmf
Define which reference axis the grab rotation is to start from.
Procedure for defining the reference axis:
Press button (27) and move the control lever to position (8.7) or (8.8) until the grab is
aligned in the X direction.
Saving the X axis as the reference axis:
Once the grab is in position, the key-

operated switch in the switch cabinet
should be briefly set to (1).
When the reference axis has been
saved, reset the key-operated switch to
(0).
LQ1094011.jpg
GB 34 / 2010 5 - 15
OPERATION
Saving the grab end position
8.7 8.8

MEM
22 23 24 25 26 27 28 29
GO01055008.wmf GO098501.wmf
Press button (26) / (27) and move the control lever to position (8.7) or (8.8) until the
required end position is reached.
Press button (24) to save the end position. The current position is saved as an end
position along with its counterpart at the other end of the range, which is saved
automatically.
The save procedure is complete when LED (26) or (27) lights up, depending on which
end position has been reached.
Rotating the grab
Press button (25) LED (25) lights up.

to move to the left end position.
to move to the right end position.
LED (26) or (27) lights up, depending on which end position has been reached.
GB 34 / 2010 5 - 16
START-UP / SHUTDOWN
6 START-UP / SHUT-DOWN
6.1 START-UP
6.1.1 Initial Start-Up
The initial start-up of the equipment concerns both the manufacturer and the future
user, the customer. In general, the job required here will be carried out jointly in a
training held at the manufacturer's or in a briefing on the construction site.
Even before the first rigging operations are begun, the operator of the equipment must
be familiar with all the control elements and their capabilities.
6.1.2 Visual Inspection Before Start-Up
A visual inspection and thorough check are required before putting the equipment into
operation:
Inspect the entire equipment for loose connections and missing pins or bolts.
Check all components for wear.
Check all electric lines for damage.
Look for leaks and fluid spills.
Check that all contained oils and fluids have the proper level.
GB 34 / 2010 6-1
START-UP / SHUTDOWN
6.1.3 Daily Start-Up
6.1.3.1 Starting the Equipment
Risk of damaging the equipment!

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

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

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

When starting with the aid of an external power source, first switch off
main fuse F1 (BAUER part)!
CAUTION
Move the pilot control safety stick to the "On" position.
GB 34 / 2010 6-2
START-UP / SHUTDOWN
6.1.3.2 Selecting an Operating Mode
Selecting the maximum engine power
After restarting the engine, select operating mode "M".
NOTE
Press button (1).

Indicator "H" lights up.
Press button (2).
The "Heavy duty work mode" indicator
lights up.
Press button (3).
Indicator "M" lights up.
BK00004000.jpg
For more details, please consult the additional operator's manual

supplied by the manufacturer.
NOTE
GB 34 / 2010 6-3
START-UP / SHUTDOWN
6.1.4 Safety Tests before Starting Work
WARNING!
Severe accident hazard!

Faulty safety devices are dangerous.
All safety devices must be tested prior to starting work, and any faults
found must be repaired by skilled personnel/After Sales Service personnel.
The equipment may be put to work only when all safety devices are in
proper working order.
Initial situation:
Diesel engine is running.
6.1.4.1 Checking the Emergency STOP
Press the EMERGENCY STOP button.

All control elements must be deactivated and the diesel engine must come to a
stop.
6.1.4.2 Checking the Pilot Control Safety Stick
Move the safety stick of the pilot control to "Off" position.

All hydraulic functions must be disabled. The diesel engine remains on.
6.1.4.3 Checking the Hoist Limit Switch (HS 1)
Activate the winch, wind in the rope and slowly lift the attached load (approx. 100 kg)
towards the hoist limit switch contactor weight.
The winch must come to an immediate stop.
GB 34 / 2010 6-4
START-UP / SHUTDOWN
6.1.4.4 Checking the Winch Free-Fall Function
Initial situation: "Rope grab" mode selected (2).
The winch free-fall function must be checked daily before each new work shift, to
ensure it is working correctly.
8.1
P P 8.2
GO01055002.wmf GO01055006.wmf
Set selection switch (9) to the "Free fall" position.

Free-fall operation must remain deactivated.
Press button (15);

Free-fall operation must not be triggered.
Press pedal (3) all the way down and release button (15).
Free-fall operation must be triggered (the load will be held by the pedal).
GB 34 / 2010 6-5
START-UP / SHUTDOWN
6.2 SHUT-DOWN
6.2.1 Daily Shut-Down
Park the machine on firm level ground.

Stop the equipment or moveable loads and use lifting equipment to secure them in
an upright position.
Adjust the upper carriage in line with the crawlers.
Set all control elements to "0" position.
Move the safety stick of the pilot control to "Off" position.
Stop the engine.

If the engine has been operating with a high load, let it run idle for about
5 minutes before stopping, to allow the temperature of coolant and oil
CAUTION
drop and stabilize.
When leaving the equipment, lock the operator's cab.

Set the battery main switch to "Off" position.
6.2.2 Shutting Down for a Longer Period
Fuel tank
Before longer periods of standstill, fill up fuel tank completely with fuel for protection
against corrosion.
GB 34 / 2010 6-6
RIGGING / DERIGGING
7 RIGGING / DE-RIGGING
7.1 GUIDELINES FOR RIGGING AND DE-RIGGING
Have assembly work carried out by qualified personnel only.

The operator must be familiar with all the control elements and their
CAUTION capabilities before he starts rigging operations.
WARNING!
Danger of falling!
Personnel working on the mast or on the upper carriage must wear the
prescribed fall protection equipment.
The equipment must only be mounted on even and horizontal ground with the
necessary load-bearing capacity.
Check all components for damage.
Steel components which are subjected to heavy loads (e.g. the undercarriage, upper
carriage, boom, auxiliary boom, supporting boom, kinematic triangle, mast sections,
masthead, winch trestles and the connection between the piston eyes and the
hydraulic cylinders and piston rods) should undergo visual inspection prior to
mounting to check for fissures.
Before starting assembly, inspect the equipment for a film of protecting wax. All such
wax must be removed (see Chapter Wax Removal).
For lifting and loading, use only the lifting slings forming part of the basic outfit.
Attach lifting slings only to provided lifting eyes.
Tipping hazard!
During rigging operations, the upper carriage must be in line with the
CAUTION undercarriage and be interlocked with it.
Select rigging mode:
Button (4) on the control panel.
GB 34 / 2010 7-1
RIGGING / DERIGGING
7.2 WAX REMOVAL
Prior to putting into service, remove all protecting wax with a hot water jet at a
temperature of 90 95 C (approx. 200 F).
Alternatively, the equipment can be washed down with a cold water

detergent.
NOTE The treatment must be repeated until all the equipment is totally free of
wax.

Detergents used must not be harmful to seals etc.
Check the detergents for their areas of application prior to use.
CAUTION
GB 34 / 2010 7-2
RIGGING / DERIGGING
7.3 EXTENDING THE CRAWLERS
Tipping hazard!
The crawlers must be extended as soon as the machine has been
unloaded from the transporting vehicle and before rigging operations
CAUTION are begun.
First extend the left crawler:
The photo shows the left

crawlers, with the front idler
NOTE (1) at the front and the drive
(2) at the rear. BG594460.jpg
Remove the locking bar between the

upper carriage and undercarriage.
Release the retainers (2) and remove all
the pins (1) from locking position "A".
Use the button to extend the

crawlers (this moves the crawlers
forwards and backwards).
Reinsert the pins (1) in locking position
"B" and secure them with retainers (2).
BV737516.jpg
GB 34 / 2010 7-3
RIGGING / DERIGGING
7.4 MOUNTING THE COUNTERWEIGHT
WARNING!
Tipping hazard!
The machine must be fitted with the appropriate counterweight before
rigging operations are begun.
The counterweight(s) must remain unchanged and installed as long as
the machine is rigged.
WARNING!
No person must stand on or under a counterweight while it is being
mounted.
Persons working on the upper carriage must wear a fall protection belt
secured to the upper carriage (red painted loop).

Counterweights consisting of several parts are to be transported in
upright position.
CAUTION
For further information please refer to the documentation supplied with

the base machine.
NOTE
GB 34 / 2010 7-4
RIGGING / DERIGGING
7.5 ASSEMBLING THE BOOM

7.5.1 Mounting the Boom Top
Align the boom top and the top section of the boom with the lifting equipment.
Use four pins to mount the boom top on the top section of the boom.
Secure the pins with cotter pins.
Establish an electrical connection.
GAALM074.wmf
GB 34 / 2010 7-5
RIGGING / DERIGGING
7.5.2 Assembling the Boom Sections
Set the top section of the boom down horizontally on a firm and level surface, in front
of the bottom section of the boom.

Clean flange faces and locating pins and check for damage.
CAUTION
Move the base machine up to the top section of the boom.
WARNING!
Squashing hazard, shearing hazard and hitting hazard!
Avoid getting limbs in between the mast sections.
Minor backstay cylinder movements can lead to major movements of the
mast sections.
During the assembly operations, the operator must keep the person
working at the mast in view at all times.
Move the boom cylinder to align the bottom section of the boom (3) with the top
section of the boom (1), until the holes for the assembly pins (2) are lined up.
1 2 3
B0000567.wmf
Install the pins and secure.

Retract the boom cylinder to raise the bottom section of the boom until the flange
faces meet.

Take care the locating pins are properly in place!
CAUTION
GB 34 / 2010 7-6
RIGGING / DERIGGING
Bolt the top section of the boom (7) to the bottom section of the boom (6) as
illustrated here.
7 6
1 Hex head bolt
2 Washer
3 Tension bush
4 Hex nut
5 Lock nut
6 Lower mast section
7 Upper mast section
12 3 24 5
B0000568.wmf
Remove transport supports.
Establish hydraulic connections

between the boom sections.
Establish electrical connections

between the boom sections.
To do this, remove plug (1) from
transport socket (2) and plug it
into a different boom section.
BM400462.jpg
GB 34 / 2010 7-7
RIGGING / DERIGGING
7.6 ASSEMBLY INSTRUCTIONS: SPRING ACCUMULATORS
Spring accumulator components:
1 9
2 5 8
3 4 6 7
GM000506.wmf
1 Cap 6 Insert
2 Top insert 7 Spring tube
3 Top 8 Butt
4 Spring tube 9 Bottom insert
5 Set of springs (slot hole)
Arrange the spring tubes next to one another and screw them in place.
MDSG 35 6.00 m
MDSG 40 7.82 m
MDSG 50 9.36 m
GB 34 / 2010 7-8
RIGGING / DERIGGING
Attach the end of the wire rope to the top using pins.
GM000501.wmf
Guide the other end of the wire rope through the spring tube.
Push the first set of springs into the spring tube and then place the insert in after it.
GM000502.wmf
Repeat the process until all the sets of springs are arranged next to one another
(when you reach the last set of springs, place the butt provided in after it instead of
the insert).
MDSG 35 4
MDSG 40 5
MDSG 50 6
GM000503.wmf
GB 34 / 2010 7-9
RIGGING / DERIGGING
Screw the "bottom insert" (slot hole) to the spring tube.
GM000504.wmf
Push the installation tube over the sets of springs above it (this can only be
done with type MDSG 50 or above).
Using appropriate pulling equipment (pulling force of 1000 kg) and the wire rope, pull
the set of springs in until the "top insert" can be put in place.
During the pulling process, stay out of the hazardous areas at the ends
of the spring tubes!
CAUTION
GM000505.wmf
The springs will now be pretensioned to such an extent that they are
able to tension the hydraulic hoses. Always remember that, when the
NOTE hoist rope is not bearing any loads, the entire spring force is supported
by the retaining plate (see arrow).
The set of springs is now pretensioned and ready for operation.

Repeat the process with the second spring accumulator.
GB 34 / 2010 7 - 10
RIGGING / DERIGGING
7.7 ASSEMBLING THE MDSG SYSTEM

7.7.1 Installing the MDSG System on the Base Machine
There are 2 different versions of the equipment that can be installed:
Version 1: The hydraulic hose drum is separate from the set of springs.
Version 2: The hydraulic hose drum is installed with the set of springs.
Initial situation:
Mast installed.
Set the boom down on the ground.
Accident risk!
All persons must vacate the area inside and beneath the boom when
CAUTION the MDSG equipment is being mounted on the boom.
GB 34 / 2010 7 - 11
RIGGING / DERIGGING
7.7.1.1 Assembly: Version 1
Position the mast as shown in the image:
Mount the auxiliary frame for the hose drum system on the bottom part of the boom.
Mount the auxiliary frame for the spring accumulator on the top part of the boom.
AAAAA081.wmf
Follow the procedure outlined below:
Use an auxiliary crane to raise the hose drum onto the auxiliary frame, and connect
the drum and frame using pins.
Secure the pins.
AAAAA082.wmf
GB 34 / 2010 7 - 12
RIGGING / DERIGGING
Use the auxiliary crane to position the spring accumulator on the hose drum system
(as shown in the image) and secure it in place using pins.
AAAAA083.wmf
Attach the spring accumulator to the auxiliary frame of the hose drum system. The
spring accumulator base plate is flange-connected to the retaining plate on the
auxiliary frame. Make sure the base plate is in the correct position (the slot hole on
the plate must be horizontal, as shown in view "A"). Do not fasten the end of the wire
rope to any of the hose drums.
Ansicht "A"
View "A"
Ansicht "A"
View "A"
AAAAA084.wmf
GB 34 / 2010 7 - 13
RIGGING / DERIGGING
Mount the hose guides at the points provided for them.
AAAAA085.wmf
Establish hydraulic connections (SAE 1 1/2" coupling) to the connection plate rotary
lead-through in such a way that they will be unaffected by any axial or radial forces.
AAAAA042.wmf
GB 34 / 2010 7 - 14
RIGGING / DERIGGING
Connect the hydraulic hose to the connection plate of the hose drum (SAE 1 1/4"
coupling) and wind it in:
AAAAA048.wmf
GB 34 / 2010 7 - 15
RIGGING / DERIGGING
Attach the wire rope from the spring accumulator to the appropriate lifting point (see
arrows below).
GR517431.jpg
Turn the hose drum until the rope has been wound around the drum 3 times.
Carefully unwind the hydraulic hose from the hose drum and lead it through the hose
guide and hose guide wheels on the boom head.
The drum is tensioned and must be secured to prevent it from winding the
hose back in whilst you are unwinding it.
CAUTION
The procedure is the same for both drums.
G00005007.wmf
Connecting the hose wheels to the sets of springs increases the

retraction force when the hydraulic hoses are being unwound from the
NOTE drum.
Make sure that the hose drum is secured to prevent it from winding the
GB 34 / 2010 7 - 16
RIGGING / DERIGGING
7.7.1.2 Assembly: Version 2
Position the mast as shown in the image:
Mount the hose drums plus the spring accumulators on the auxiliary frame (see
arrows).
GO030511.wmf
GO0404007.jpg
GB 34 / 2010 7 - 17
RIGGING / DERIGGING
Mount the hose guides at the points provided for them on the mast.
AAAAA085.wmf
Establish hydraulic connections (SAE 1 1/2" coupling) to the connection plate rotary
lead-through in such a way that they will be unaffected by any axial or radial forces.
AAAAA042.wmf
GB 34 / 2010 7 - 18
RIGGING / DERIGGING
Connect the hydraulic hose to the connection plate of the hose drum (SAE 1 1/4"
coupling) and wind it in.
AAAAA048.wmf
Guide the loose ends of the hydraulic hoses through the hose guide and hose guide
wheel.
The drum is tensioned and must be secured to prevent it from winding the
CAUTION
The procedure is the same for both drums.
G00005007.wmf
Connecting the hose wheels to the sets of springs increases the

retraction force when the hydraulic hoses are being unwound from the
NOTE drum.
Make sure that the hose drum is secured to prevent it from winding the
GB 34 / 2010 7 - 19
RIGGING / DERIGGING
7.8 INSTALLING THE CABLE DRUM

Once the MDSG equipment has been installed, the cable drum needs to be put in place.
Installing the cable drum:
Set the cable drum down in the correct position.
Position the mast above the cable drum as shown in the image.
Slowly lower the boom until the cable drum can be connected to the boom.
Connect the cable drum to the hydraulic supply.
Establish an electrical connection to the cable drum and depth indicator.
Guide the loose end of the electric cable through the guide sheave.
GO030505.wmf
GB 34 / 2010 7 - 20
RIGGING / DERIGGING
7.9 HYDRAULIC CONNECTIONS
Table for MDSG hydraulic connections
Connection Function
1 Open grab
2 Close grab
GO0304001.jpg
GB 34 / 2010 7 - 21
RIGGING / DERIGGING
Table for hydraulic connections to the hoist winch
Connection Function
1 Lower grab
2 Raise grab
3 Free fall control
4 Leak oil
5 Winch control
GN012031.tif
GO030506.wmf
GB 34 / 2010 7 - 22
RIGGING / DERIGGING
Table for hydraulic connections to the boom
Connection Function
1 Retract boom cylinder (long distance)
2 Extend boom cylinder (long distance)
3 Elec. cable drum down
4 Elec. cable drum up
5 Elec. cable drum, leak oil
6 Elec. cable drum, pilot oil
7
8 Extend boom cylinder (long distance)
9 Retract boom cylinder (short distance)
GO0304000.jpg
GAALM083.wmf
GB 34 / 2010 7 - 23
RIGGING / DERIGGING
7.10 INSTALLING THE MAIN ROPE

7.10.1 Reeving the Main Rope
The main rope is drawn in when the mast is down.

Main winch in operating position.
Press and hold the rigging mode button.
Switch off the automatic rope tensioning facility.
Remove rope guard pins (1) from the boom and masthead.
1
1
GO01055013.wmf
Use the right control lever to unwind the main rope.

Pulling in the main rope incorrectly can subject both it and the rope-
guiding components to excessive wear.
CAUTION Pull in the main rope in accordance with the position of the pulley
block on the masthead.
Version 1: Position of the pulley block rotated 90 about the longitudinal axis of the grab
GO01055012.wmf
Version 2: Position of the pulley block parallel to the longitudinal axis of the grab
GO01055011.wmf
GB 34 / 2010 7 - 24
RIGGING / DERIGGING
3
2
1
GR517508.WMF
Version 1: Position of the pulley block rotated 90 about the longitudinal axis of the
grab
If the grab is wide enough to install the pulley block in the standard
position on the grab, reeve the main rope as described below. This
NOTE position exerts the least wear on the rope.
Place the rope sheaves in position 2.
Insert the main rope into the hose guide wheels at position 2 and unwind it until the
rope ends reach the contactor weights of the hoist limit switch.
Attach and secure the rope guard pins.
Do not guide the main rope through the contactor weight of the hoist limit switch.
Thread the rope into the pulley block.
Attach the rope to the boom.
Version 2: Position of the pulley block parallel to the longitudinal axis of the grab
If the grab is not wide enough to install the pulley block in the standard
position on the grab, the main rope will need to be reeved as described
NOTE below.
Place the rope sheaves in position 1.
Insert the main rope into the guide wheels in position 1 and unwind it until the rope
ends reach the contactor weights of the hoist limit switch.
Attach and secure the rope guard pins.
Guide the main rope through the contactor weight of the hoist limit switch.
Thread the rope into the pulley block.
Guide the main rope through the contactor weight of the hoist limit switch again.
Attach the rope to the boom.
GB 34 / 2010 7 - 25
RIGGING / DERIGGING
7.11 INSTALLING THE ROPE SWIVEL

Always attach the reeved hoist rope to the top fix point with a rope
swivel.
CAUTION Use only the genuine BAUER Maschinen GmbH rope swivel.
The rope swivel must be designed for the max. pulling force of the
winch used.
Install the rope swivel as shown in the figure below.

Mount the rope swivel in the right position. The lube nipple must face
up.
CAUTION
Following installation, lubricate the rope swivel and test whether it rotates freely.
6
5
1 Hoist rope 2
2 Pin
4
3 Lube nipple
4 Hex head bolt
5 Lock washer 3
6 Washer
B0000572.wmf
GB 34 / 2010 7 - 26
RIGGING / DERIGGING
7.12 INSTALLING THE GRAB
G00005008.wmf
Once the MDSG equipment and cable drum have been installed, position the grab in
front of the base machine or approach the grab using the base machine.
The grab must be positioned in front of the base machine such that the cover of the
hydraulic box in the grab is facing upwards.
Lower the boom and position it in front of the grab as shown above.
Install the pulley block on the grab.
Secure the hose drums to prevent them winding the hoses in unintentionally.
Injury hazard!
Hose drums are tensioned.
Before unwinding hydraulic hoses from the hose drums, secure the
CAUTION drums to prevent them from winding the hoses back in unintentionally.
GO01025003.png
Pull the hydraulic hoses to the grab and connect them (1). *
Unwind the electric cable from the drum and connect it to the grab (2). *
Fasten the hydraulic hoses in place using the clamps provided.
When the boom is raised following this (see the section entitled "Raising the Boom"),
make sure that the grab is not raised along with it.
To raise the grab, move the boom (once raised) to its operating position and raise
the grab using the hoist winch.
*) The positions of the connections on the grab depend on the equipment being used and may vary.
GB 34 / 2010 7 - 27
RIGGING / DERIGGING
7.13 RAISING THE BOOM
WARNING!
Squashing hazard, shearing hazard and hitting hazard!
Minor backstay cylinder movements can lead to major movements of the
mast sections.
During the assembly operations, the operator must keep the person
working at the mast in view at all times.
Danger of being injured by falling parts!

Remove all loose objects from the boom.
CAUTION
Press the button for rigging mode and move the left control lever backwards
smoothly to retract the boom cylinder (long stroke). The boom is now raised.
7.13.1 Attaching Retaining Clamps
Tipping hazard!
These clamps must be attached as soon as the boom has been raised.
CAUTION
Attach the retaining clamps (1) to the boom

cylinder once it has been retracted (long
stroke).
Push O-ring (2) up over the retaining clamps
and insert it in groove (3). 4
Using a rubber hammer, knock locking ring 3

(4) down onto the two retaining clamps. 1
3
1
2
BK331531.wmf
GB 34 / 2010 7 - 28
RIGGING / DERIGGING
7.14 DISASSEMBLING THE EQUIPMENT

7.14.1 Disassembling the Grab
Place the grab down in front of the base machine.

Close the ball cocks for the grab supply on the base machine.
Lower the boom (if necessary).
Secure the hose drums to prevent them winding the hoses in.
Risk of injury!
The hose drums are tensioned.
Before disconnecting hydraulic hoses from the grab, secure the drums
CAUTION to prevent them from winding the hoses back in.
Disconnect the hydraulic hoses from the grab.

Remove the pins from the cable guide roller on the boom head.
Disconnect the electric cables from the grab and wind them in.
Detach the hoist rope from the top fix point.
Remove the pins from the rope guide pins.
Wind in the hoist rope until it reaches the boom head.
Move the base machine away from the grab.
7.14.2 Disassembling MDSG Equipment
Lower the boom (see the "LOWERING THE BOOM" section).

Remove the hose guide from the boom.
Wind in the hydraulic hoses and electric cables.
Disconnect the electric cables from the base machine.
Disconnect the hydraulic hoses from the base machine.
Use the auxiliary crane to secure the hose drum and remove it from the auxiliary
frame on the boom.
Set the hose drum down onto a suitable transport rack.
Repeat the procedure for the second hose drum.
Remove the auxiliary frame from the boom.
GB 34 / 2010 7 - 29
RIGGING / DERIGGING
7.15 LOWERING THE BOOM

7.15.1 Removing Retaining Clamps
Using a hammer, knock the locking ring

(4) off the both retaining clamps (1).
Remove the O-ring (2) from the groove
(3) in the clamp.
4
Remove the retaining clamps from the
boom cylinder. 3
1
3
1
2
B0000671.wmf
7.15.2 Lowering the Boom
Adjust the upper carriage in line with the undercarriage so that the boom is
positioned on the same side as the front idlers of the undercarriage.
There is a risk that the boom could collide with the undercarriage and
any parts attached to it.
CAUTION The upper carriage must be in the correct position.
Unwind the main rope and place it on the ground beside the base machine.
Press the button for rigging mode and move the left control lever forwards smoothly
to extend the boom cylinder (long stroke). The boom is now lowered.
GB 34 / 2010 7 - 30
RIGGING / DERIGGING
7.16 REMOVING THE COUNTERWEIGHT
WARNING!
Risk of getting crushed or hit!
No person must stand on or under a counterweight while it is being
mounted.
Avoid getting limbs in between machine and counterweights.
Persons working on the upper carriage must wear a fall protection belt
secured to the upper carriage.

Counterweights consisting of several parts are to be transported in
upright position.
CAUTION
During their intermediate storage, the counterweights must be secured
against tipping.
For further information please refer to the documentation supplied with

the base machine.
NOTE
GB 34 / 2010 7 - 31
RIGGING / DERIGGING
7.17 RETRACTING THE CRAWLERS
Begin with the right crawler.
The picture shows the left

crawler:
The front idler (1) is on the front
NOTE side, the drive (2) is at the back.
BG594461.jpg
Clean and grease the sliding surfaces (3)

on the crawlers and beams.
BV737445.jpg
Release the retainers (2) and remove all

the pins (1) from locking position "B".
Use the button to retract the

crawlers (this moves the crawlers
forwards and backwards).
Reinsert the pins (1) in locking position
"A" and secure them with retainers (2).
BV737516.jpg
GB 34 / 2010 7 - 32
TRANSPORT
8 TRANSPORT
8.1 SAFETY GUIDELINES FOR TRANSPORT
Only use hoisting equipment and lifting slings that have sufficient bearing capacity.
WARNING!
Attach lifting slings only to the provided and identified lifting points.
Lifting points on the machine are painted GREEN and have a hook
symbol.
In addition, numbers tell the weight picked up at the respective points.
Lifting points on individual components are painted RED.
The hoist rope must be vertical at all times, to prevent swinging. If the
load begins to swing, set it down immediately and readjust until the rope
CAUTION is vertical again.
Arrest and secure movable parts of the equipment.

Check the work platforms are safely latched to the upper carriage.
Put accessories to be stored safely away so they will not be an obstacle to traffic on
the roads or on a construction site and will not be interfered with by accident or
abuse.
Additionally cover up and secure sharp edges, projecting points and cutting blades.
The driver of the transporting vehicle is responsible for checking each time before he
starts to drive that all the equipment, the machine and accessories, are restrained
from movement and properly tied down to the deck of the vehicle.
The haulier in charge is responsible for the transport of the equipment, the machine
and accessories.
The hauler should be informed of the transport dimensions, the weights and the
route.
A road permit must be obtained.
GB 34 / 2010 8-1
TRANSPORT
8.2 MEASURES TO TAKE FOR TRANSPORT
MACHINE
Before loading:
The machine must be in transport position before it may be driven or lifted by a crane on
the low-loading truck:
The machine is in its transport position, if
all of the equipment has been removed from the boom.

the boom has been lowered.
the top section of the boom has been removed.
the bottom section of the boom has been removed (if necessary).
the upper carriage is in line with the crawlers and locked to the undercarriage.
the crawlers are retracted.
the beam extensions (if so equipped) have been removed.
the counterweights have been removed (if necessary).
After loading:
Underpin the lower mast section with transport supports and secure.
Move the safety stick of the pilot control to the "Off" position.
Stop the engine and remove the ignition key.
Lock the operator's cab and remove the key.
Put the battery main switch to the "Off" position.
Tie the machine safely down to the deck of the transporting vehicle.
EQUIPMENT
Take the dimensions and weight of the MDSG equipment into consideration when
transporting it.
GB 34 / 2010 8-2
TRANSPORT
8.3 DRIVING ON / OFF A LOW LOADER
8. 8.
3.
10. 6. 10.
9. 9.
7. 7.
4.
5.
2.
1.
max.40
8 9
10
? ? 10 A
?
BK786512.wmf
1 Battery main switch "ON" 7 Lift bottom section of boom with left control
2 Unlock "EMERGENCY-STOP" lever
3 Move pilot control safety stick to "Off" 8 Travel forwards by pushing both levers forwards
4 Start engine 9 Travel in reverse by pulling both levers
5 Adjust engine speed backwards
6 Move pilot control safety stick to "ON" 10 Lower bottom section of boom with left control
lever
GB 34 / 2010 8-3
TRANSPORT
8.4 LIFTING POINTS
Lifting points on the machine are marked in green and have a hook symbol.
The lifting points for the individual components are marked in red.
BK1162502.wmf
GB 34 / 2010 8-4
TRANSPORT
8.5 TYING DOWN
WARNING!
Attach the lashing chains only at the designated lashing points.
Lashing chains must have sufficient load-bearing capacity.
Tying points
On blue undercarriages, the points provided for tying down are painted YELLOW.
On yellow undercarriages, the points provided for tying down are painted BLUE.
In addition, tying points bear a hook symbol and show the max. permissible pulling
force.
To tie down
Tie the equipment down on the transporting vehicle in the professional manner and in
compliance with national directives.
Principally, the haulier in charge is responsible for tying down the equipment
properly.
Example of tying-down points
CI439400.jpg
GB 34 / 2010 8-5
TRANSPORT
8.6 TRANSPORT DATA

Dimensions in [mm]
2910
2955
1360
870
2200
2325 6935 3455
12715
3400
1765
1200
840
4440 700
5360 3200 - 4400
6700 R 3450
GU035501.wmf
Weights
Component Weight in [t]

Machine
Machine with bottom section of boom and counterweights 47.2
Counterweights 6.2 + 6.2
Boom head with guide wheels 1.6
Equipment
Top section of boom with MDSG equipment 7.6
GB 34 / 2010 8-6
MAINTENANCE
9 MAINTENANCE
9.1 SAFETY GUIDELINES FOR MAINTENANCE
Have maintenance carried out by the after sales service only or by skilled personnel
authorised by the after sales service.
Only use genuine BAUER Maschinen GmbH spare parts.
Observe the "Safety Information" leaflet supplied with the equipment.
Carry out maintenance at the prescribed intervals.
Also observe the other manufacturers' service instructions for components of the
equipment.
9.2 MAINTENANCE INTERVALS

The maintenance for this equipment is organised into the following intervals:
Every 10 hours of operation or daily

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

Maintenance carried out on the equipment must be entered into the
"Maintenance and Repair Log" supplied.
CAUTION In case of a warranty claim, BAUER shall have the right to consult the
log.
GB 34 / 2010 9-1
MAINTENANCE
9.3 MAINTENANCE PLAN

9.3.1 Entire Equipment
Entire equipment table

Components Maintenance interval
Note
3 months
monthly
2 years
weekly
1000 h
2000 h
3000 h
yearly
yearly
250 h
Operation
every
500 h
daily
10 h
50 h
Entire equipment
Visual inspection
- Missing or damaged parts X
- Load-bearing steel components X
(e.g. the undercarriage, upper
carriage, boom, auxiliary boom,
supporting boom, kinematic
triangle, mast sections, masthead,
winch trestles and the connection
between the piston eyes and the
hydraulic cylinders and piston
rods) should undergo visual
inspection prior to mounting to
check for fissures and other
damage.
- Missing or loose X
bolts / bolted connections.
- Missing or damaged X
safety devices, such as
fire extinguisher,
first-aid kits,
warning signs
- Leaks X
Check for proper function of:
- Controls and indicators X
- Safety devices such as X
emergency STOP,
pilot control safety stick,
limit switches,
hoist limit switches
- Free-fall function X
Inspection by competent engineer X
*Only during running-in period
GB 34 / 2010 9-2
MAINTENANCE
9.3.2 Attachments
Table Attachment
Note
3 months
monthly
2 years
weekly
1000 h
2000 h
3000 h
yearly
yearly
250 h
Operation
every
500 h
daily
10 h
50 h
Boom head
- Check that the connecting X*
bolts and screws for the
mast, if provided, are
firmly screwed in;
tighten screws
- Replace the connecting bolts 10000 hrs
for the boom, if these are
being used
Boom
Boom
- Lubricate guide rails X
- Check that the connecting pins X*
and bolts between the
boom components are firmly
inserted (if these are being used);
tighten bolts
- Replace connecting bolts between 5000 hrs
the boom components, if
these are being used
Boom pivot point
- Lubricate the boom pivot point X
- Lubricate mounting bolts X
- Replace flange bolts 10000 hrs
GB 34 / 2010 9-3
MAINTENANCE
Table Attachment
Note
3 months
monthly
2 years
weekly
1000 h
2000 h
3000 h
yearly
yearly
250 h
Operation
every
500 h
daily
10 h
50 h
Winches
- Check oil level
Main winch X
- Change oil
Main winch X* X
- Lubricate counter bearings

Main winch X
- Ensure that mounting bolts of the X*

winch trestles are firm,
tighten bolts
- Replace mounting bolts of the 10000 hrs
winch trestles
Cylinders
- Clean piston rods X
- Check tightness of cylinder X
- Lubricate joints X
Bearings and bearing pins
- Lubricate all bearings and bearing X
pins that are equipped with lube
nipples
GB 34 / 2010 9-4
MAINTENANCE
Table Attachment
Note
3 months
monthly
2 years
weekly
1000 h
2000 h
3000 h
yearly
yearly
250 h
Operation
every
500 h
daily
10 h
50 h
Wire rope and accessories
Ropes, rope fasteners,
thimbles and sleeves
- Inspect for wear and X
damage
Rope swivel
- Lubricate X
- Check if bolts are secure X
- Check slew function X
Rope hold-down rollers
- Check parallel position to cable X
drum
- Inspect for wear X
and damage
Rope sheaves
- Inspect for wear, damage, X
and if bearing gap is exceeded
- Check sheaves are free to rotate X
- Check if bolts are secure X
- Check groove radii for X
deviation and
edge formation
- Put grease in lube nipples,
where fitted:
- Rope sheaves with friction X
bearing X
- Rope sheaves with roller
bearings
Rope roller brackets
- Ensure that mounting bolts of the X*
turning blocks
are firm,
tighten bolts
- Replace mounting bolts of the 10000 hrs
turning blocks
GB 34 / 2010 9-5
MAINTENANCE
9.3.3 Work Equipment
Table Equipment
Note
3 months
monthly
2 years
weekly
1000 h
2000 h
3000 h
yearly
yearly
250 h
Operation
every
500 h
daily
10 h
50 h
MDSG
Visual inspection:
- Missing or loose X* X
pinned/bolted/screwed
connections
Lubrication points X
- Lubricate rotary lead-through Gear X
bearings X
- Hose drum system bearings X
Function check:
- Displays/indicators and control X
equipment
- Safety devices such as hoist limit X
switches
Inspection by competent engineer X
GB 34 / 2010 9-6
MAINTENANCE
9.3.4 Upper Carriage
Upper carriage table

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

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

- Return-flow filters X* X contamination
- Leak-oil filters X* X is indicated
- Free-fall filters X* X (on screen or
- Tank breather filter X filter)
Suction filter X* X
Breather filter X
Pressure accumulators
- Check preload pressure X* X
Oil cooler
- Clean X
- Check for damage X
Swing mechanism
- Grease external slewing ring X
teeth
- Lubricate ball bearing race and X* X
rotor bearing
- Tighten up screws X* X
GB 34 / 2010 9-7
MAINTENANCE
Upper carriage table

Note
3 months
monthly
2 years
weekly
1000 h
2000 h
3000 h
yearly
yearly
250 h
every
500 h
daily
10 h
50 h
Operation
Counterweight
- Check all fastening elements X
are applied and firm
Electrical system
Batteries
- Check electrolyte level X
- Check cable connections X
Fuses
- Check fuses X
Filters
- Replace air filter on
wiring cabinet X
9.3.5 Undercarriage
Undercarriage maintenance table

Note
3 months
monthly
2 years
weekly
1000 h
2000 h
3000 h
yearly
yearly
250 h
every
500 h
daily
10 h
50 h
Operation
Crawler track assemblies
Visual inspection
- Carry out a visual inspection of X
load-bearing steel components
(e.g. centre bridge and crawlers)
to check for fissures and other
damage.
- Perform a visual check of X
the crawler drive wheels, tread
rollers and travel gear to ensure
they are firmly attached;
tighten if necessary
Travel gear
- Check oil level X
- Change oil X* X
Crawler tracks
- Check chain tension X
- Check that the mounting bolts X
for the crawler track shoes
are firm
Telescopic guide
- Clean and grease X
GB 34 / 2010 9-8
MAINTENANCE
9.3.6 Optional Equipment
Optional equipment table

Note
3 months
monthly
2 years
weekly
1000 h
2000 h
3000 h
yearly
yearly
250 h
Operation
every
500 h
daily
10 h
50 h
Air conditioning
- Operate the air conditioning X 2 - 3 weeks
system
- Clean air filters (optional) X
- Clean condenser X
GB 34 / 2010 9-9
MAINTENANCE
9.4 MAINTENANCE DURING LONGER PERIODS OF STANDSTILL
Engine
Every 2 to 3 weeks, start the diesel engine and let it run in the medium rpm range
for about 1 hour.

If it is not possible to start the engine during the standstill, preservation
measures must be taken. Please refer to the diesel engine instruction
CAUTION manual.
Air conditioning
Every 2 to 3 weeks, turn the air conditioning on (if fitted) for a short time.
Slewing ring
Preserve the slewing ring teeth.
From time to time during the standstill, remove dust and inspect the surface of teeth,
slewing ring and drive pinion for the onset of corrosion; clean and grease as required.
Undercarriage telescoping guidance

Preserve telescopic guides with grease.
GB 34 / 2010 9 - 10
MAINTENANCE
9.5 LUBRICATION PLAN
5
5
6
3/4
2
2
8
G0030509.wmf
Every 10 operating hours: Every 250 operating hours:

6 Rope swivel 2 Boom cylinder joint
7 Pulley block 5 Boom head rope sheaves
8 Gear ring (outside)
Every 50 operating hours: Every 1000 operating hours:

1 Main winch bearing
3/4 MDSG gear
8 Slewing ring bearing
8 Undercarriage cylinder joints
Observe the instructions in the manual supplied by the base machine

manufacturer.
NOTE
GB 34 / 2010 9 - 11
MAINTENANCE
9.6 HYDRAULIC SYSTEM

9.6.1 Hose Assemblies
Inspection
Hose lines must be inspected at least once a year by an expert.
Replace the hose lines if the inspection reveals the following:
Damage in the outer layer down to the core of the hose (e.g. abrasion, cuts or
cracks).
The outer layer of the hose is brittle (cracks in the sleeving).
The hose line is no longer in its natural shape, both with and without pressure applied
and while it is bent (e.g. layers separating, bubbles forming). (See also DIN 20066
Part 4.)
Leaks.
Damage or deformation of hose end fittings (tightness impaired); minor damage to
the surface does not require replacement.
Hose slips out of end fitting.
Corrosion on the end fitting, impairing the function and stability.
The hose is not assembled in compliance with instructions.
The storage and service life are exceeded.
Storage and service life

Hoses and hose assemblies must be stored in a cool, dry and dust-free environment.
Avoid exposure to direct sunlight or UV radiation.
Storage and service life:

Hose Hose assembly
Storage time 2 years 2 years
Service life
6 years
(including storage time)
Re-use
Generally, hoses that have been in service as part of a hose assembly ought not to be
re-used in a new hose assembly as they will no longer meet the requirements.
If a hose is re-used despite this, evidence must have been obtained to show that it is
suitable for use and will function correctly with the fitting in question.
GB 34 / 2010 9 - 12
MAINTENANCE
9.6.2 Hydraulic Cylinders
Every 10 operating hours or daily, and every time before starting up again after a
longer period of rest, clean all cylinders and check them for tightness.
Risk of causing damage to the piston rods!

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

Immediately repair or replace cylinders that are not tight.
CAUTION
Every 50 operating hours or once a week, grease the cylinder lugs (holes for pins).
On cylinders that are kept extended during rest:
Risk of corrosion damage in corrosion-supporting environments!

The tasks specified below must be carried out without fail.
CAUTION
Once or twice a week, rub down piston rods with hydraulic oil, or repeatedly retract
and extend the rods.
Before a longer standstill, preserve piston rods with an acid-free grease.
GB 34 / 2010 9 - 13
MAINTENANCE
9.6.3 Filter Replacement
9.6.3.1 Replacing the Line Filters
The element for the line filters must be replaced after the first 250 operating hours or
one month. Following this, the filter element will need to be replaced every 1000 or 2000
operating hours (see maintenance plan for upper carriage) or whenever it is indicated
that the element is contaminated (optional; warning lamp, error message or display on
filter).
WARNING!
Serious injury hazard!
Before replacing a filter element, depressurise the hydraulic system and
allow it to cool down (see the base machine manual).
When the hydraulic oil is cold, the contamination indicator may light up
for a short while.
NOTE
Line filter:
1 Free-fall filter, pos.1 (Bauer component)

2 Pilot oil filter, pos. 2 (Hyundai component)
3 Leak oil filter, pos. 3 (Bauer component)
4 Return-flow filter in hydraulic tank (Hyundai component)
5 Suction filter in hydraulic tank (Hyundai component)
6 Breather filter on hydraulic tank (Hyundai component)
BM00995002.wmf
GB 34 / 2010 9 - 14
MAINTENANCE
Replacing a filter element
Place a suitable container underneath the filter

housing and unscrew the bottom (3).
Remove the filter element (2) from the top (1) of
the housing, and dispose of it along with 1
hazardous waste.
2
Clean the top and bottom of the housing.
Install a new filter element in the top of the
housing.
3
Screw the bottom to the top and tighten.
B0000623.wmf
GB 34 / 2010 9 - 15
MAINTENANCE
9.7 WINCHES
9.7.1 Checking the Oil Level
All equipped winches must be checked for proper level of gear oil every 50 operating
hours or weekly, and whenever the equipment is started up again after a longer
standstill.
Danger of oil spray!

Check the oil level only when the winch is off.
CAUTION
Winches with dipstick

Position winch so that the tube (2) is in an upright
position.
Unscrew the dipstick (1). 1
Dry the dipstick with a clean and lint-free cloth.
Reinsert the stick completely. max.
Pull the stick out again and read it. min.
If the oil has sunk to the MIN mark, top up with 2

new oil and check again. The MAX mark must 3
not be exceeded.
Clean the sealing faces, check seal for damage B0000574.wmf
and wear, replace if necessary.
Reinsert the dipstick and screw it down tight.
Winches with sight glass

The oil level can be checked in any position of the
winch. 2
If the oil level has reached the lower limit (min. =
20 mm below the winch centre line), add oil
through one of the screw plugs (2), then recheck
the oil level. max.
20 mm
Make sure the oil level does not exceed the min.
upper limit ("max." = winch centre line).
Clean the sealing faces, check seal for damage
Reinsert the screw plug and screw it down tight. 1
B0000846.wmf
GB 34 / 2010 9 - 16
MAINTENANCE
9.7.2 Changing the Gear Oil
The oil must be changed after the first 250 operating hours or one month. Subsequent
oil changes are due every 1000 operating hours or once a year.
Danger of oil spray!

Change oil only when the winch is off.
CAUTION
Winches with dipstick

Position winch that the tube (2) is in an upright
position.
Unscrew the dipstick (1).
Remove the drain screw (3) and drain the 1
gearbox.
At low outdoor temperatures, flush the empty max.
gearbox with a warmed-up part of the new oil. min.
Clean the sealing faces, check seal for damage 2

and wear, replace if necessary. 3
Screw in the drain screw.
Fill in new gear oil.
Check the oil level. B0000574.wmf
Reinsert the dipstick (1) and screw it down tight.
Winches with sight glass

The gear oil can be changed in almost any winch
position. 2
Unscrew one of the screw plugs (2).

Unscrew one of the screw plugs (1) and drain the
gear oil.
At low outdoor temperatures, flush the empty
max.
20 mm
min.
gearbox with a warmed-up part of the new oil.
Clean the sealing faces, check seal for damage
Reinsert the screw plug (1).
1
Fill in new gear oil.
B0000846.wmf
Check the oil level.
Reinsert the screw plug (2) and tighten.
GB 34 / 2010 9 - 17
MAINTENANCE
9.8 WIRE ROPE ACCESSORIES

9.8.1 Rope Swivel
Every 10 operating hours or daily:
Lubricate the rope swivel (2) until grease comes out

of the side of the housing. 1
Check that the rope swivel can rotate freely.
Conduct the test manually, with no load suspended 2
from the swivel.
If the rope swivel will not rotate properly after it has
been lubricated, repair or replace it with a new one.
Check mounting bolts (1 and 3) are firmly in place.
Retighten them as required. Replace the bolts with
new ones if they are worn out or demonstrate excessive
play. 3
B0000576.wmf
If the rope swivel is damaged, replace it immediately!

CAUTION
9.8.2 Rope Hold-Down Rollers
Every 50 operating hours or weekly:
Check rope hold-down rollers for wear and

whether they are working correctly.
Check the roller is parallel to the cable drum.
Check the mounting bolts are firmly in place.
Adjust the tension screws until all the tension
springs are equal. Do not tension worn-out
springs too much but replace them with new
ones. B0000509.wmf
Re-align or replace protecting bars that are bent.

Replace the centre pins, sleeves and spacers if they demonstrate excessive play.
If grooves have been created in a roller, reface the roller (by turning it on a lathe), or
replace it with a new one. Refaced rollers have a diminished diameter, so the pre-
stressing of the tension springs must be adjusted accordingly.
GB 34 / 2010 9 - 18
MAINTENANCE
9.8.3 Rope Fasteners, Thimbles and Sockets
Check whether the wire rope is firmly in place in the fitting.

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

If a defect is found on a rope fitting, cut off the rope end and re-fit it.
CAUTION
GB 34 / 2010 9 - 19
MAINTENANCE
9.8.4 Rope Sheaves
Risk of damaging the rope!

Sluggish or seized rope sheaves subject the rope to excessive wear and
abrasion and make the load distribute unevenly on the rope structure.
CAUTION Repair or replace sluggish or seized rope sheaves, if greasing will not do.
9.8.4.1 Greasing Rope Sheaves
Rope sheave type Maintenance interval Maintenance instructions

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

roller bearings Risk of damaging the
bearing seal!
Greasing while rope
1000 operating hours/ sheave is rotating.
yearly Press grease in
CAUTION slowly to prevent
squeezing out
bearing seal.
BM659822.jpg
Rope sheaves greased

by the central
lubrication system
Automatic
BM659823.jpg
GB 34 / 2010 9 - 20
MAINTENANCE
9.8.4.2 Checking Rope Sheaves
Operation Maintenance interval Maintenance instructions
Check whether the rope

250 operating hours/
sheaves are free to
monthly
rotate.
Check sheave
centre pins have the 250 operating hours/
proper bearing play and monthly
are properly in place.
Check for burrs and

edges on the sheaves
Re-machine the groove, or replace
and that the grooves in 1000 operating hours/
the rope sheave with a new one, if
the sheaves still comply yearly
the groove no longer complies.
with the diameter of the
rope used.
GB 34 / 2010 9 - 21
MAINTENANCE
9.9 MDSG LUBRICATION PLAN
Lubricate MDSG equipment every 50 h or weekly.
1 Rotary lead-through
2 Gear bearings
3 Hose drum bearings
Lubricate the gear wheels.
GR517419.jpg
GB 34 / 2010 9 - 22
MAINTENANCE
9.10 CRAWLER TRACK ASSEMBLIES
WARNING!
Crushing hazard, shearing hazard and drawing-in hazard!
The machine must be stationary during work on the undercarriage.
A reliable communication between the person(s) working at the
undercarriage and the operator in the cab must be provided at all times.
9.10.1 Visual Inspection
With the upper carriage positioned crosswise, thoroughly clean crawlers until they
are free of mud and dirt.
Walk around and inspect for wear, damage and loss of oil, especially on following
components:
Track shoes (1)

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

should be kept corrosion protected with grease.
NOTE
GB 34 / 2010 9 - 23
MAINTENANCE
9.10.2 Crawler Tracks
9.10.2.1 Checking the Track Tension
Check the track tension every 10 operating hours or daily.

1 - 1,5 m
2-3 cm
Thoroughly clean each crawler and its
sliding surfaces.
Travel forward a short distance with the
machine and then stop it. 1 - 1,5 m
2-3 cm
Measure the sag over a length of 1 -
1.5 m (see fig.).
The distance between the measuring
rod and track (see fig.) should be
1 - 1,5 m
roughly 2 - 3 cm in the centre.
Otherwise, the track tension will need to 2-3 cm
be readjusted.
B0000680.wmf
9.10.2.2 Adjusting the Track Tension
Tightening the Track
Remove cover plate (5) and clean the grease nipple (2).
2
5
1 3 4
B0000725.wmf
Put a high-pressure grease gun to the grease nipple.

Work the grease gun until the proper track tension is obtained.
Check the chain tension again after a short travel forward and backward, and top up
with more grease as necessary.
Reinstall the cover plate.
GB 34 / 2010 9 - 24
MAINTENANCE
To Loosen the Track
2
5
1 3 4
B0000725.wmf
Remove the cover plate.

Unscrew the safety valve (1) by approx. 3 revolutions (SW 41) until excessive grease
escapes at the spot identified with (4).
WARNING!
Risk of injury from pressurised grease!

Unscrew the safety valve with great care only.
Retighten the safety valve when the proper track tension is obtained.
Check the track tension again after a short distance forward and backward.
Clean the nipple and surroundings so they are free of grease.
Reinstall the cover plate.
WARNING!
Risk of injury due to pretensioned spring element (compressible silicone

oil at 1500 to 2000 bar)!
If the spring elements are defective, replace them completely with new
ones. Do not attempt to repair, for safety reasons.
GB 34 / 2010 9 - 25
MAINTENANCE
9.10.3 Checking the Mounting Bolts
Visually check if the mounting bolts are firmly in place.

Retighten loose bolts.
5 8 2 1
4 3 6
BK587502.wmf
BK587440.jpg BM564683.jpg
Bolt torque value Maintenance interval

Bolted connection
Ma [Nm] in operating hours
Track shoes (1) 570 30 50

Carrier rollers (2) 280 250
Track guide (3) 560 250
Tread rollers (4) 280 250
Crossbeam (5) --- ---
Crawler drive wheels (6) 560 250
Travel gear (7) 560 250
Telescopic cylinder mounting 560 250
Slewing ring (8) 755 After the first 250
and then every 2000
GB 34 / 2010 9 - 26
MAINTENANCE
9.10.4 Travel Gear
9.10.4.1 Checking the Oil Level
Check the oil level every 250 operating hours or monthly.
Move machine until oil drain plug (2) on crawler

drive wheel is at its lowest position.
Unscrew inspection/filler screw (1) together with
seal (if equipped).
The oil must reach the lower edge of the filler
hole. Top up the oil if necessary.
Clean inspection/filler screw and sealing surfaces 1
on housing. Replace with new seals as
necessary.
Reinstall the inspection/filler screw with a new
seal and screw tight. 3
2
B0000514.wmf
9.10.4.2 Changing the Oil
The gear oil must be changed after the first 250 operating hours or after one month.
Subsequent oil changes are due every 1000 operating hours or once a year at least.
Move machine until oil drain plug (2) on

crawler drive wheel is at its lowest position.
Unscrew inspection/filler screw (1) together
with seal (if equipped).
Place an oil collecting container
underneath the drain.
Unscrew the drain plug (2) and let the oil
out. 1
Clean screw and plug and sealing surfaces
on housing.
Reinstall drain plug with new seal and
screw tight.
3
Refill with new oil to the proper level.
2
Reinstall the inspection/filler screw with a
B0000514.wmf
new seal and screw tight.
GB 34 / 2010 9 - 27
MAINTENANCE
9.11 BOLTED CONNECTIONS
After the first 250 operating hours, retighten all bolted connections described in the
following.
Generally, you should apply the prescribed torque on these bolts to

tension them ("torque pretension method").
NOTE
Bolted connections on the boom
After every 5000 hours of ordinary operation, replace all of the elements used in the
bolted connections.
WARNING!
Replace the elements of bolted connections which have been opened
up more than 25 times or which are corroded, fissured, deformed or
have damaged threads.
Bolted connections on the boom pivot point, boom top, winch and rope guide
trestles and masthead
After every 10000 hours of ordinary operation, replace all of the elements used in the
bolted connections.
WARNING!
Replace the elements of bolted connections every time components are
mounted or reassembled and whenever the connections have been
excessively stressed from rig tipping or improper handling.
GB 34 / 2010 9 - 28
LUBRICANTS / TABLES
10 LUBRICANTS / TABLES
10.1 LUBRICANTS
10.1.1 General
Observe instructions given in the supplied "Safety Information" book on this subject.
Use only oils and greases prescribed or suitable for the application in question.
Before changing to another kind of lubricant, check it is compatible with the previous
one used.
The lubricants used must be fresh.

A damage resulting from non-observance of lubricant instructions in this
manual will not be covered by the equipment warranty.
CAUTION
The lubricants listed in the lubricant tables of this manual are suitable
for ambient temperatures from -20 C to + 40 C (-4 F to +104 F).
Information on applications below -20 C and above +40 C can be
NOTE
ordered from the BAUER after sales service.
GB 34 / 2010 10 - 1
LUBRICANTS / TABLES
10.1.2 Lubricant Table
The following table lists the lubricants with which the equipment is filled when leaving
the factory.
Quantities given in the table serve as a guide only. Decisive are the
specifications found on the nameplates of the respective parts and the
NOTE actual fill level found when checking.
Alternative lubricants are listed on the following pages.
Initial lubricant fill table
Name of Qty.
Application Specification Viscosity grade Producer [ litres ]
product
Gear oil, API

petroleum
Swing gear SAE 85W-140 SHELL Shell SAE 85W-140 7.0
Travel gear SAE 85W-140 SHELL Shell SAE 85W-140 2 x 12.0
Gear oil, CLP HC

synthetic
Main winch ISO VG 220 ARAL Degol PAS 220 9.0
GB 34 / 2010 10 - 2
LUBRICANTS / TABLES
ISO viscosity Qty.

grade / Name of [ litres
Application Specification Producer
description product ]
Hydraulic oil, HVLPD

petroleum
Hydraulic oil ISO VG 46 Mobil DTE 25 210.0
Engine oil, API CI-4

petroleum
Engine oil SAE 15W-40 SHELL Rimula Super 19.0
Greases, KP2N-20 Multi-purpose

petroleum NLGI- grease on lithium
class 2 soap base
Roller bearing / ARAL Aralub HLP 2 If
friction bearing require
d
Adhesive spray
Gear ring CASTROL Molub
GB 34 / 2010 10 - 3
LUBRICANTS / TABLES
10.1.3 Lubricant Guide
10.1.3.1 Gear Oils, Petroleum - CLP
Table Gear oils, petroleum - CLP

Specification
Application DIN 51517/
DIN 51502
Gear oil,
CLP
petroleum
Viscosity grade
ISO-VG / DIN 51519 at 40 C in mm2/s
Producer
VG 100 VG 150 VG 220
Description
ARAL ARAL ARAL

ARAL
Degol BG 100 Degol BG 150 Degol BG 220
SHELL OMALA SHELL OMALA
SHELL 100 150 SHELL Omala 220
BP Energol BP Energol BP Energol
BP
GR-XP 100 GR-XP 150 GR-XP 220
MOBIL Mobilgear 627 Mobilgear 629 Mobilgear 630
AVIA Avilub RSX 100 Avilub RSX 150 Avilub RSX 220
CASTROL Alpha SP 100 Alpha SP 150 Alpha SP 220
NL Gear NL Gear NL Gear
CHEVRON
Compound 100 Compound 150 Compound 220
ESSO Spartan EP 100 Spartan EP 150 Spartan EP 220
FINA Giran 150 Giran 220
EP Lubricant EP Lubricant
GULF
HD 150 HD 220
TEXACO Meropa 150 Meropa 220
TOTAL Carter EP 150 Carter EP 220
KLBER Unimoly Oil 100 Unimoly Oil 150 Unimoly Oil 220
ELF Reductelf SP 100 Reductelf SP 150 Reductelf SP 220
Renep
FUCHS
Compound 106
AGIP Blasia 100 Blasia 150 Blasia 220
DEA Falcon 100 Falcon 150 Falcon 220
PANOLIN Mecano ISO 220
GB 34 / 2010 10 - 4
LUBRICANTS / TABLES
10.1.3.2 Gear Oils, Petroleum API
Table of gear oils, petroleum API
Specification
Application
DIN 51502
Gear oil, API GL-5 /

petroleum MIL-L-2105 B
Viscosity grade
SAE / DIN 51511
Producer
SAE 90 SAE 85W-90
Description
Gear oil HYP

ARAL Gear oil HYP 90
SAE 85W-90
SHELL Shell Spirax MB 90
Energear
BP Energear Hypo 90
Hypo 85W-90
Mobilube
MOBIL Mobilube HD-A 90
HD 85W-90
AVIA
AVIA
HYPOID 90 EP
CASTROL Castrol EPX 90
RPM Universal
CHEVRON Gear Lubricants
SAE 80W-90
ESSO GEAR OIL ESSO GEAR OIL
ESSO
GX-D 90 GX-D 85W-90
FINA PONTONIC
FINA
MP 85W-90
Gulf Multi-Purpose
GULF Gear Lubricant
SAE 90
TEXACO
TOTAL
KLBER
TRANSELF
ELF
TYP B SAE 90
Fuchs Titan Gear Fuchs Titan Gear
FUCHS
Hypoid 90 8090 MC
AGIP Agip Rotra MP
Daegear EP-B
DEA
SAE 85W90
Panolin Super Duty Panolin Super Duty
PANOLIN
SAE 90 SAE 80W-90
GB 34 / 2010 10 - 5
LUBRICANTS / TABLES
10.1.3.3 Gear Oils, Synthetic CLP PG
Table of gear oils, synthetic CLP PG

Specification
DIN 51502
Gear oil,
CLP PG
synthetic
Viscosity grade
2
ISO-VG / DIN 51519 at 40 C in mm /s
Producer
VG 100 VG 150 VG 220
Description
ARAL Degol ARAL Degol

ARAL
GS 150 GS 220
SHELL SHELL Tivela WA SHELL Tivela WB
BP Enersym BP Enersym
BP
SG-XP 150 SG-XP 220
MOBIL Mobil Glygoyle 22 Mobil Glygoyle 30
AVIA Avilub VSG 150 Avilub VSG 220
CASTROL
CHEVRON
Circulation oil S
ESSO
220
FINA
GULF
TEXACO
TOTAL
Klbersynth Klbersynth
KLBER
GH 4-150 GH 4-220
ELF Syntherma P 270
FUCHS Renodiol PGP 220
AGIP
DEA
PANOLIN
GB 34 / 2010 10 - 6
LUBRICANTS / TABLES
10.1.3.4 Hydraulic Oils, Petroleum HVLP(D)
Table of hydraulic oils, petroleum HVLP(D)

Specification
DIN 51502
Hydraulic oil,
HVLP(D)
petroleum
Viscosity grade
2
ISO-VG / DIN 51519 at 40 C in mm /s
Producer
VG 32 VG 46 VG 68
Description
AGIP Agip Arnica 32 Agip Arnica 46 Agip Arnica 68

ARAL Vitam HF
ARAL ARAL Vitam VF 46 ARAL Vitam VF 68
32
Avia Fluid HVI 32 Avia Fluid HVI 46 / Avia Fluid HVI 68 /
AVIA
/ Avia Arctic 32 Avia Arctic 46 Avia Arctic 68
BP BP Bartran V 32 BP Bartran V 46 BP Bartran HV 68
Hyspin AWH-M
CASTROL Hyspin AWH-M 46 Hyspin AWH-M 68
32
Mechanism LPS
CHEVRON Mechanism LPS 46 Mechanism LPS 68
32
DEA Astron Z HLP 32 Astron Z HLP 46 Astron Z HLP 68
ELF Hydrelf DS 32 Hydrelf DS 46 Hydrelf DS 68
ESSO Univis N 32 Univis N 46 Univis N 68
FINA Hydran HV 32 Hydran HV 46 Hydran HV 68
Renolin MR 32
FUCHS Renolin MR 1025 MC Renolin MR 68 MC
MC
MOBIL Mobil DTE 13 M Mobil DTE 15 M Mobil DTE 16 M
SHELL SHELL SHELL
SHELL
Tellus Oil T32 TELLUS OIL TD46 TELLUS OIL T68
TEXACO Rando HD-Z 32 Rando HD-Z 46 Rando HD-Z 68
TOTAL Equivis ZS 32 Equivis ZS 46 Equivis ZS 68
GB 34 / 2010 10 - 7
LUBRICANTS / TABLES
10.1.3.5 Engine Oils, Petroleum API CI-4
Table of engine oils, petroleum API CI-4
Specification
Application
DIN 51502
Engine oil,
API CI-4
petroleum
Viscosity grade
SAE / DIN 51511
Producer
SAE 5W-40 SAE 10W-40 SAE 15W-40
Description
AGIP
Aral Plus Turboral
ARAL
SAE 15W-40
Avia Multi HDC Plus
AVIA
15W-40
BP
CASTROL
Chevron Delo 400
CHEVRON
Multigrade SAE 15W-40
DEA
ELF
ESSO
Fina Universal Plus XL
FINA
SAE 15W-40
Titan Truck Plus
FUCHS
SAE 15W-40
Gulf Super Duty Select
GULF
SAE 15W-40
KLBER
Mobil Delvac MX
MOBIL
SAE 15W-40
PANOLIN
Q8 Q8 T 750 SAE 15W-40
Shell Rimula Super
SHELL
SAE 15W-40
TEXACO
TOTAL
GB 34 / 2010 10 - 8
LUBRICANTS / TABLES
10.1.3.6 Gear Oils, Synthetic CLP HC
Table of gear oils, synthetic CLP HC
Specification
Application
DIN 51517
Gear oil,
CLP HC
synthetic
Viscosity grade
ISO-VG / DIN 51562 at 40 C in mm2/s
Producer
VG 100 VG 150 VG 220
Description
ARAL Degol ARAL Degol ARAL Degol

ARAL
PAS 100 PAS 150 PAS 220
AVIA Synthogear AVIA Synthogear AVIA Synthogear
AVIA
EP 100 EP 150 EP 220
BP Enersyn BP Enersyn
BP
EP-XF 150 EP-XF 220
CASTROL Tribol 1710 / 100 Tribol 1710 / 150 Tribol 1710 / 220
DEA Intor HCLP 150 Intor HCLP 220
Spartan Synthetic
ESSO
EP 220
Renolin Unisyn Renolin Unisyn Renolin Unisyn
FUCHS
CLP 100 CLP 150 CLP 220
Klbersynth Klbersynth
KLBER
EG 4-150 EG 4-220
Mobilgear Mobilgear
MOBIL
SHC XMP 150 SHC XMP 220
Optigear Synth
OPTIMOL
A 220
SHELL OMALA SHELL Omala
SHELL HD 150 HD 220
Pinnacle Pinnacle
TEXACO
EP 150 EP 220
TOTAL Carter EP/HAT 150 Carter EP/HAT 220
TRIBOL Tribol 1710 / 100 Tribol 1710 / 150 Tribol 1710 / 220
GB 34 / 2010 10 - 9
LUBRICANTS / TABLES
10.1.3.7 Greases, Petroleum KP2N
Table of greases, petroleum KP2N
Specification
Application
DIN 51502
Greases,
KP2N-20
petroleum
Description
Producer Multipurpose
grease
Description on
lithium soap base
ARAL Aralub HLP 2

SHELL Retinax EP 2
Energrease
BP
LS-EP 2
MOBIL Mobilux EP 2
AVIA
CASTROL
CHEVRON
ESSO Beacon EP 2
FINA Marson EPL 2A
GULF
TEXACO
TOTAL
KLBER
ELF Epexa 2
FUCHS Renolit MP
AGIP Agip GR MUEP 2
DEA Glissando EP 2
PANOLIN EP Grease 2
GB 34 / 2010 10 - 10
LUBRICANTS / TABLES
10.2 OPERATING FLUIDS

10.2.1 Coolants
Risk of damaging the engine cooling system due to coolant gelling and
slime growth!
Only use CAT ELCTM (Caterpillar Extended Life Coolant).
Never mix different types of coolants.
CAUTION Do not use any other additives.
Observe the additional documentation provided by the coolant
manufacturer.
GB 34 / 2010 10 - 11
LUBRICANTS / TABLES
10.3 BOLT TORQUE VALUES
Bolt torque values given in the following tables are valid only for slightly
oiled bolted connections and where the Spare Parts List does not
CAUTION prescribe other torque values.
Bolts with Coarse-Pitch Metric Thread

Strength classes as per DIN/ISO 898
8.8 10.9 12.9
Coarse-pitch
Bolt torque values MA [Nm]
metric thread
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M8 23 34 40
M 10 46 68 79
M 12 79 117 135
M 14 125 185 215
M 16 195 280 330
M 18 280 390 460
M 20 390 560 650
M 22 530 750 880
M 24 670 960 1120
M 27 1000 1400 1650
M 30 1350 1900 2250
M 33 1850 2600 3000
M 36 2350 3300 3900
GB 34 / 2010 10 - 12
LUBRICANTS / TABLES
Bolts with Fine-Pitch Metric Thread

Strength classes as per DIN/ISO 898
8.8 10.9 12.9
Fine-pitch
Bolt torque values MA [Nm]
metric thread
M 8x1 24.5 36 43
M 10x1 52 76 89
M 10x1.25 49 72 84
M 12x1.25 87 125 150
M 12x1.5 83 122 145
M 14x1.5 135 200 235
M 16x1.5 205 300 360
M 18x1.5 310 440 520
M 20x1.5 430 620 720
M 22x1.5 580 820 960
M 24x2 730 1040 1220
M 27x2 1070 1500 1800
M 30x2 1490 2120 2480
M 33x2 2000 2800 3300
M 36x3 2500 3500 4100
GB 34 / 2010 10 - 13
LUBRICANTS / TABLES
10.4 CONVERSION TABLE
Measures for power

N dyn kp Mp p
1 105 0.102 1.0210-4 102
10-5 1 1.0210-4 1.0210-9 1.0210-2
9.81 9.81105 1 10-3 103
9.81103 9.81108 103 1 106
9.8110-3 981 10-3 10-6 1
Measures for energy and operating efficiency

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

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

2
at atm bar N/m Torr Psi
1 0.968 0.981 98100 736 14.22
1.033 1 1.0133 101330 760 14.69
1.02 0.987 1 105 750 14.5
1.0210-5 9.8710-6 10-5 7510 14.510
-4 -5
1
1.3610-3 1.3210-3 1.3310-3 133 1 19.2810-3
0.070 0.0680 0.0689 0.145 51.72 1
Measures for length

in ft yd mm m km
1 0.08333 0.02778 25.4 0.0254 -
12 1 0.3333 304.8 0.3048 -
36 3 1 914.4 0.9144 -
0.03937 328110-6 109410-6 1 0.001 10-6
39.37 3.281 1.094 1000 1 0.001
39370 3281 1094 106 1000 1
GB 34 / 2010 10 - 14

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BAUER Maschinen GmbH

Pokud nerozumte jazyku tohoto nvodu k obsluze, nesmte pstroj / zazen

Hvis du ikke forstr sproget, der er brugt i denne betjeningsvejledning, m du

En caso de no comprender el idioma utilizado en el presente manual de

Kui see kasutusjuhendis on keeles, mida te ei oska, on teile selle

Jos et ymmrr tss kyttohjeessa kytetty kielt, et saa ottaa laitetta /

Ako jezik upotrijebljen u ovim uputama za uporabu ne razumijete, ureaj /

Amennyiben nem rti a jelen hasznlati tmutat nyelvt, akkor nem

Se non si comprende la lingua utilizzata in queste istruzioni d'uso, non

Ja js aj lietoanas instrukcij lietoto valodu nesaprotat, js nedrkstat skt

Jekk mintix familjari mal-lingwa uata f'dan il-manwal ta' taddim, ma

Dersom du ikke frostr det sprket som brukes i denne bruksanvisningen, m

Se no entender o idioma utilizado neste manual de instrues, no pode

Dac nu nelegei limba utilizat n acest manual de utilizare, aparatul /

Frstr du inte sprket i den hr bruksanvisningen fr du inte anvnda

e jezika, uporabljenega v teh navodilih za uporabo, ne razumete, ne smete

Bu kullanm klavuzunda kullanlan dili anlayamadnz taktirde, cihaz / sistem

Before the first use of this equipment PLEASE

Copyright 2010, BAUER Maschinen GmbH

Any duplication, reproduction, translation, micro filming, storage in electronic or

All rights and remedies are hereby expressly reserved.

Violators will be prosecuted.

ABOUT THE MANUAL ........................................................................................................................ XIII

AFTER SALES SERVICE.................................................................................................................... XVI

WARRANTY TERMS.......................................................................................................................... XVII

PERSONALANFORDERUNG / STAFF REQUEST............................................................................... XX

3 TECHNICAL DATA ...........................................................................................................3 - 1

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

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

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

10 LUBRICANTS / TABLES ................................................................................................10 - 1

Equipment model: Grab System / GB 034

THIS MANUAL WAS PUBLISHED IN

THE CHAPTERS OF THIS MANUAL

"Danger!" is used to identify an immediate hazard. Serious injury or

"Warning!" is used to identify a potential hazard. Serious injury or

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

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

Nameplates on the equipment

Component Location Nameplate

How to reach the After Sales Service

Phone + 49 8252 97-2586

For possible check-backs

Contact person; Telephone / Fax:

Warranty exclusions: - Improper use or operation (misuse) of the equipment.

Redeliveries via air freight: 4 weeks

B) Liabilities and Responsibilities of the Client

From (Customer, Agent):

Total number of pages of claim:

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

3. Delivery of new parts and repair

Date Name of claimant Signature Company

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

Estimated working time (hrs):

(Signed by authorised BAUER employee)

PERSONALANFORDERUNG / STAFF REQUEST

Besteller / Ordered by: Tel.:

Bestell-Nr. / Order no.: E-Mail:

Standort des Gerts / Location of machine:

Ansprechpartner Baustelle / Baustellentelefon /

Zielflughafen / Airport of destination: