Bauer BG 11 H ValueLine User manual

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BG 30
BT 80
BG 38
BS 80
The Rotary drilling rig
BG 11 H ValueLine
Max. drilling diameter: 1,650 mm / 5.4 ft
Max. drilling depth: 40.0 m / 131.2 ft
Torque: 110 kNm / 81,130 ft-lbf
Engine: CAT Tier 4 interim – C6.6 ACERT
CAT Tier 4 final – C7.1 ACERT
Power: 122 kW @ 1,800 U/min
163.6 HP @ 1,800 rpm
Height: 16.5 m / 54.3 ft
1 Undercarriage
2 Uppercarriage
3 Main winch
4 Auxiliary winch
5 Kinematic system
6 Crowd cylinder
7 Mast
8 Masthead
9 Kelly bar
10 KDK Rotary drive
11 Drilling tool

Undercarriage
Solid Bauer-design for –
360° drilling operating
radius
Telescopic with hydraulic –
cylinders
Large footprint to resist –
high overturning moments
High traction forces –
KDK rotary drive:
Single gear drive with strong and –
robust design and high mechanical and
hydraulic efficiency
Protection of the rotary drive with an –
integrated Kelly damping system
Adjustment to various soil conditions –
with 2 selectable modes of operations
Winches
Superior and tested –
effective line pull and
line speed
Load classification –
M6/L3/T5 for main
winch for heavy-duty,
continuous operation
A special grooving –
system on the main
winch drum and a rope
pressure roller reduce
wear on the wire rope
Pinned connection for –
easy mounting and
dismantling of the winch
on the mast
Transparent ring for easy –
oil check (main winch)
Kinematic system
Bauer proven H-kinematic system with –
backstay cylinders and boom cylinders
for best stability
Bright color monitor
Electronic load sensing on main and –
auxiliary rope
Indicator for position of uppercarriage –
Upper Kelly guide
No additional limit switch necessary –
No modification of the electric –
installation needed
No disassembling for transport –
(rathole drilling)
Hydraulically operated –
Economic operation
n
Hydraulic efficiency
n
Easy handling
n
Easy maintenance
n
High safety standard
n
Ergonomic cabin design
n
Long life expectancy and
n
lasting value
Ease of transportation and rigging
n
Spotlights
BG 11 H

Uppercarriage – HSE features
Heavy duty base frame optimized for BG attachment –
Rear view camera, beacon flash light and warning horn –
Multigrade oil for reducing fuel consumption –
Easy access to uppercarriage –
Two mast sections with pin joint for optimized transport –
height
Hydraulically operated upper kelly guide –
Lower noise emission –
Ergonomic cabin design
FOPS compliant –
Bright color monitor –
Clear arrangement of instruments and –
displays
Excellent visibility to drilling spot –
Ease of operation –
Final inspection and test run
Comprehensive Bauer testing programme –
Optimal adjustment and calibration of all components –
Heat transfer test –
Crowd system with crowd cylinder
Crowd system “upside-down” –
installation
Easy handling for transport without –
disconnecting hydraulic hoses

14560
47.8 ft
16540
54.3 ft
0
2420
7.9 ft
5680
18.6 ft
1200
3.9 ft
960
3.2 ft
2860 - 3660
9.4 - 12 ft
2790
9.2 ft
4380
14.4 ft
3650
12 ft
3260
10.7 ft
900
3 ft
6520
21.4 ft
6860
22.5 ft
2740 - 3740
9 - 12.3 ft
600
2 ft
7° 5°5°
15°
1200 3.9 ft
Ø760
2.5 ft
2760
9.1 ft
Dimensions
BG 11 H
Kelly BK 110/305/4/40 (A= 11800 / 38.7 ft)
Operating weight 39 t
(as shown) 85,980 lbs

A B C
D
Technical equipment
KDK rotary drive
Standard
Integrated kelly damping system –
Wear pads exchangeable without –
removal of rotary drive
Exchangeable kelly drive adapter –
Exchangeable kelly drive keys –
2 selectable modes of operation –
Trigger plate –
Uni-directional impact function on KDK –
Optional
Cardanic joint (for casing installation) –
KDK 110 SL (for high effective spin off), –
Fig. A
Main winch
Standard
Hydraulically controlled freewheeling –
Automatic rope tensioning facility –
Swivel alignment function –
Depth measuring device on main rope –
Electronic load sensing –
Winch drum with special grooving –
Transparent ring for easy oil check –
Pin connection –
BG attachment
Standard
Bauer H-kinematic system –
Crowd cylinder upside-down –
Crowd in fast and slow mode –
Hoist limit switch on main and auxiliary –
winches
Swivel for main rope –
Pivoted anchor points for main and –
auxiliary ropes
Two mast sections with pin joint –
Optional
Auxiliary winch 65 kN / 14,610 lbf, –
Fig. B
Swivel for auxiliary rope –
Central lubrication system –
Upper kelly guide (hydraulically –
operated)
Bauer Service Kit –
(Quick-release couplers on hydraulic
hoses,
Fig. C
, Speed measuring device
on rotary drive, Diagnostic panel and
manometers for hydraulic functions,
Fig. D
)
Low head convertible, –
Fig. E
BG 11 H

Configurations
BG 11 H
The BG 11 H ValueLine is a compact
drilling rig which easily can be modified
for various applications:
Standard configuration
Typical basic configuration for standard uncased bored piling
operations in Kelly mode.
It ranges to drilling depths of 40 m (130 ft) with 4-part lockable
Kelly bar and for borehoile diameters up to 1,200 mm (3.9 ft).
An optional casing drive adapter allows the installation of
temporary casings with a maximum section length of 2.5 m
(8.2 ft).
Rathole drill configuration
Special configuration for the construction of preparatory
boreholes when constructing oil and gas wells.
The BG 11 H ValueLine can construct short cellar holes with
big diameter up to 3 m (10 ft), followed by drilling conductor
holes, ratholes and mouseholes.
Special attention was given to the possibility of reducing
the transport weight to a minimum of 34.0 t (74,960 lbs)
by using a specially designed multi-piece, removable
counterweight.
Low head drill configuration
Removing of the upper mast section enables the
construction of boreholes to a maximum depth of
19 m (62.3 ft) with a minimum working height of 10 m
(32.8 ft).
When extending the horizontal reach, the top of the
mast can be lowered to a height of 8.9 m (29.2 ft).
Standard configuration
Rathole drill configuration
Low head drill configuration

Length of casing section
Max. length of
Kelly bar BK 110/305/...
1
3.3
2
6.6
2.5
8.2
m
ft
10
32.8
20
65.6
30
98.4
40
131.2
50
164.0
m
ft
0
0
m
ft
m
ft
m
ft
m
ft
m
ft
...3/21
Ø 1,000 mm (3.3 ft)
...4/30
Ø 1,000 mm (3.3 ft)
tool must be disassembled
for picking up
can be picked up with effective
tool length 700 mm (2.3 ft)
510
1.7
Drill diameter
Drilling depth with
Kelly bar BK 110/...
760
2.5
1,524
5.0
1,000
3.3
1,650
5.4
mm
ft
10
32.8
20
65.6
30
98.4
40
131.2
50
164.0
m
ft
0
0
m
ft
m
ft
m
ft
m
ft
m
ft
...305/3/21
...305/4/30
...305/4/40
...368/5/49
2860 - 3660
9.4 - 12 ft
2790
9.2 ft
16540
54.3 ft
16540
54.3 ft
2860 - 3660
9.4 - 12 ft
2790
9.2 ft
Standard configuration – Kelly drilling
BG 11 H
Cased Kelly drillingUncased Kelly drilling
Data shown are valid for maximum
permitted horizontal mast reach
and using BAUER attachment.

1420 4.7 ft
560
1.8 ft
1430 4.7 ft
50
0.2 ft
G = 32.2 t / 70,988 lbs + Kelly weight
G = 32.2 t / 70,988 lbs
Standard configuration
G = 34.0 t / 74,957 lbs (optional)
B = 2,770 mm / 9.1 ft
G = 2 x 1 t / 2 x 2,205 lbs
1 x 5.4 t / 11,900 lbs
3500
11.5 ft
6830
22.4 ft
15500
50.9 ft
1110 3.6 ft
4290
14.1 ft
4380
14.4 ft
900
3 ft
960
3.2 ft
1470 4.8 ft
2740
9 ft
600
2 ft
2800
9.2 ft
Transport dimensions and weights
BG 11 H
G = Weight
B = Width, overall
Weights shown are approximate values; optional equipment
may change the overall weight and dimensions.

1 Safety
Risk of electric shock!
If the equipment comes into contact with overhead or underground electricity lines a current trans-
fer to the equipment occurs. Persons in the immediate vicinity receive an electric shock as well as
burns, which can cause serious or fatal injuries.
Δ
Before starting work, ask an authorized person about the prescribed safety distance. Always
observe the required safety distance. This also includes the avoidance of swinging loads and/
or components in the danger area.
Δ
Before starting work, inform the company responsible for the power supply.
Δ
Consult the power supply company regarding the measures to be taken in case of emergency.
Δ
If a current transfer does occur, do not leave the cabin. The equipment operator must instruct
the endangered persons accordingly (e.g. keep legs closed and remain still).
Δ
The danger has passed only when the power supplier gives the all-clear.
Risk of electric shock, risk of explosion!
Underground lines (e.g. electricity, gas) may be inadvertently damaged during work. Current trans-
fers, explosions, and/or fire may occur and cause an electric shock and/or burns to persons in the
immediate vicinity.
Δ
If underground lines are discovered in the working area, stop work immediately and report the
incident to the operator.
Δ
In the case of equipment that causes tremors/vibrations, make additional allowance for this po-
tential source of risk and take separate precautionary measures in advance.
Δ
Support or fix exposed lines to prevent them from shifting.
Δ
Maintain a suitable safety distance from sources of danger.
Δ
Do not drive over exposed lines.
Danger of accident!
In the case of equipment with ropes, there is a danger of rope breakage following a current trans-
fer. Persons may be hit by falling loads and thus seriously or fatally injured.
Δ
After a current transfer, the ropes must be replaced without delay.
Safety when working underground or in enclosed spaces
The equipment may only be operated within the specifications and environmental conditions pre-
scribed in the instruction manual. Work carried out underground or in enclosed spaces demands
special protective measures.
The following general safety information about working underground or in enclosed spaces must al-
ways be observed and adhered to:
Risk of explosion, risk of suffocation!
When working underground or in enclosed spaces, explosive or poisonous gases can be gener-
ated. Persons could suffer serious or fatal injuries or suffocation.
Δ
Workplaces and traffic routes must be adequately ventilated, so that no dangerous substances
or exhaust gases can reach the breathable air or the atmosphere.
Δ
Always ensure that ventilation systems are in proper working order.
Safety during assembly/mounting and dismantling/removing
Before starting the assembly or disassembly procedure, the equipment's danger zone/working area
must be made safe by closing off a sufficiently ample area. Work attachments, components and
tools that have been set down must not obstruct traffic routes and they must be secured by appro-
priate measures against shifting, rolling away and toppling over/falling.
Assembly work and disassembly work should always be performed on horizontal, level ground with
sufficient load-bearing capacity.

Safety and protective equipment
EMERGENCY STOP
Risk of causing damage to components!
Components of the equipment could be damaged by heavy loads.
Δ
The EMERGENCY-STOP may only be used in emergencies.
The following figure shows the number and position of the EMERGENCY-STOP on the equipment.
Initial position:
– In case of emergency
• Press the relevant EMERGENCY-STOP.
✓All of the equipment's functions are shut down.
✓Diesel engine shuts down.
✓Indicator light in the switch lights up.
Unlock the relevant EMERGENCY-STOP switch before restarting the diesel engine:
• Pull the relevant EMERGENCY-STOP switch.
✓Indicator light in the switch lights up.
✓EMERGENCY-STOP is unlocked.
"Pilot control" safety lever
The "pilot control" safety lever switches the equipment's hydraulic pilot control on or off.
Danger of accident!
Danger of accident due to uncontrolled movements of the equipment.
Δ
Before leaving the cab switch off the equipment's hydraulic pilot control.
Initial position:
– Equipment operator is in the cab.

"Pilot control" safety lever Position Process
• Move the "pilot control" safety grip (1) forward.
✓The "pilot control" safety stick (2) moves for-
ward.
✓Hydraulic pilot control is switched on.
✓Main winch is selected.
✓All hydraulic functions are operational.
• Move the "pilot control" safety grip (1) back-
ward.
✓The "pilot control" safety stick (2) moves
backward.
✓Hydraulic pilot control is switched off.
✓All hydraulic functions are deactivated.
• Before starting work again, switch on the hy-
draulic pilot control.
Fire extinguishers
The following figure shows the number and position of the fire extinguishers on the equipment.
• Read the operating instructions on the fire extinguisher at regular intervals, to ensure that you
can operate it correctly in case of fire.
First aid box
The following figure shows the position of the first aid box.

Product description
Equipment overview
Base machine
Standard version
1 Masthead
2 Upper mast section
with tilting cylinder and
opening cylinder
3 Auxiliary rope
4 Main rope
5 Backstay cylinders
6 Kinematic triangle
7 Supporting boom
8 Boom cylinders
9 Boom
10 Upper carriage
11 Counterweight
12 Swing mechanism
13 Undercarriage
14 Cab
15 Main winch
16 Auxiliary winch
17 Mast pivot
18 Lower mast section
with crowd cylinder

Product description
Components Function
Boom Movable connection piece between base machine and kinematic
triangle.
Boom cylinders Enable adjustment of the operating radius.
Swing mechanism Enables continuous turning and arresting of the upper carriage in
any position.
Counterweight Ensures stability of the equipment.
Main winch with main rope Lifting equipment for working with the process equipment.
Auxiliary winch with auxiliary
rope
Lifting equipment for assembly work and auxiliary work.
Cab The equipment operator controls the equipment from the cab.
Kinematic triangle Enables parallel adjustment of the mast.
Tilting cylinder Enables folding of the upper mast section when lowering the mast
and alignment of the upper mast section when raising the mast.
The tilting cylinder is mounted in the upper mast section.
Mast
(upper mast section, lower
mast section)
Guides the attached components of the process equipment.
Mast pivot Connection point between the mast and the boom.
Enables inclination of the mast.
Masthead Guides the main rope and the auxiliary rope.
Backstay cylinders Support the mast.
Enable adjustment of the mast inclination and raising and lowering
of the mast.
Upper carriage Carries the attachment with the process equipment as well as all
the components required for the equipment to function.
Opening cylinder Opens and closes the retaining arms of the Kelly guide.
The opening cylinder is mounted on the upper mast section.
Supporting boom Enables parallel adjustment of the mast.
Undercarriage Carries the upper carriage and enables the equipment to be
driven.
Crowd cylinder Generates the crowd forces and crowd movements and transmits
them to the rotary drive.
The crowd cylinder is mounted in the lower mast section.

Product description
Process equipment
Standard version - Uncased drilling
50 Drilling tool
51 Lifting device
52 Rotary drive
53 Shock absorber
54 Kelly driver
55 Kelly bar
56 Kelly guide
57 Rope swivel
Components Function
Lifting device Opens the drilling tool.
Drilling tool Cuts and conveys the drilling debris.
Rotary drive Generates the rotary motion for drilling. The main gear is
driven by hydraulic motors via the planetary gear.
Shock absorber Dampens axial shocks to the Kelly bar.
Kelly guide Guides the Kelly bar along the mast at its upper end.
Kelly driver Transmits the rotary drive torque to the Kelly bar.
Kelly bar (Kelly) Transmits the rotary drive torque directly to the drilling tool.
Its length determines the maximum drilling depth.
Rope swivel Prevents twisting of the main rope.

Operation
Wire ropes
• Check wire ropes for integrity and corrosion before start-up. Treat wire ropes in accordance
with the additional documentation "Maintenance and care of wire ropes".
Process fitting
Kelly bar
• Check that the fully extended Kelly bar is in proper working order before start-up. If necessary,
restore the Kelly bar to its proper condition or replace it with a new one.
Rotary drive
• Service the rotary drive in accordance with the maintenance table before start-up.
Daily start-up
Visual check before daily start-up
Risk of causing damage to equipment!
Any unresolved deficiencies can cause damage to the equipment.
Δ
Visually check the equipment before each start-up.
Δ
Have the defect repaired by skilled personnel immediately.
• Check the entire equipment and accessories for completeness.
• Make sure that the screw connections and plug connections on the machine and accessories
are secure and complete.
• Check all components, particularly load-bearing steel components and rope, for integrity and
wear.
• Check all electrical, hydraulic and pneumatic components for integrity and correct connection.
• Be sure to check for fluid build-ups or leaks.
• Ensure all operating fluids are at required levels.
• Compare the hours on the operating hours meter with the specified maintenance intervals and
perform any pending maintenance tasks.
• Check that lighting equipment is in proper working order.
• Check that signaling devices are in proper working order.
• Check that camera equipment is in proper working order.
✓Visual inspection has been properly carried out.

Operation
Starting the equipment
• Switch the battery main switch to position "I".
• Set the fuse switch of the main fuse "F1" to position "I".
✓The power supply is connected.
• Close all doors and maintenance flaps and mount the protective coverings.
• Risk of causing damage to equipment! Uncontrolled movements of the equipment
can cause damage to the components. Set all operating elements to the "0" position. Unlock
EMERGENCY-STOP. Switch off the hydraulic pilot control.
Starting the diesel engine
Diesel engines have an ether starting aid installed for starting at low ambient temperatures. If the
diesel engine does not start, perhaps the cartridges of the ether starting aid are empty and must be
replaced with new ones. Further information can be found in the enclosed additional documentation
from the diesel engine manufacturer.
Ignition lock overview:
0 Ignition off
1 Ignition on (preheating)
2 Starting the diesel engine
• Risk of causing damage to diesel engine! A cold diesel engine can be damaged
when operated at full load. Cold diesel engines should first be brought to the operating temper-
ature at idling speed.
• Risk of causing damage to the AT system! If the AT system is not fully started, its
electronics can be damaged. First switch ignition key from position (1) to position (2), if the AT
system is not fully started.
• Preheat and start the diesel engine by turning the ignition key.
✓Diesel engine is running.
✓The equipment is ready for operation.

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

Maintenance/repair
○ Once after start-up
● Recurring
+ As needed
Symbol Maintenance inter-
val
Component
*) Must be lubricated by hand
**) Lubricated via the process equipment
● Mast guide rails (13) **
● Inner slewing ring gear teeth (6)
● Slewing ring (ball bearing race and rotor bearing) (7)
● Backstay cylinder joints (2)
● Boom connection points (3)
● Boom cylinder joints (4)
● Supporting boom connection points (5)
● Undercarriage spar sliding surfaces (8) *
● Main winch counter bearing (9)
● Aux. winch counter bearing (10)
● Mast pivot connection point (11)
● Mast pivot guide (12)
● Masthead rope sheaves (1)

Maintenance/repair
Lubricating plan - Process fittings

Maintenance/repair
○ Once after start-up
● Recurring
+ As needed
Symbol Maintenance inter-
val
Component
*) must be lubricated manually
● KDK shaft sealing ring (50) *
● KDK slide rails (51)
● Kelly guide slide rails (52) (if Kelly guide is present)*
● Kelly guide bearing (53) (if Kelly guide is present)*
● Rope swivel (54) *
Lubricants
Risk of causing damage to components!
Non-compliance with the following guidelines can cause damage to the components of the equip-
ment.
Δ
Only use prescribed lubricants.
Δ
Do not mix synthetic and petroleum based lubricants.
Δ
Do not mix zinc-free lubricants with lubricants that contain zinc.
Δ
Only use fresh lubricants.
Incorrect use of lubricants can lead to loss of warranty if damage occurs.
Lubricants table
The following table shows the relevant lubricants of the initial filling.
The specified quantities are guideline values. The specifications on the respective nameplates and
the level indicators of the individual components take priority. Alternative lubricants can be found in
the relevant "Lubricant selection lists" of this instruction manual.
Initial lubricant fill table
Component Quantity
[l]
Quantity
[gal]
Lubricant
type/speci-
fication
Viscosity
class/desig-
nation
Manufac-
turer
Manufac-
turer desig-
nation
Main winch 3.30 0.79 Gear oil/
CLP HC
ISO VG 220 CASTROL Alphasyn
EP 220
Auxiliary winch 2.50 0.66
Crawler drive 2 x 6.00 2 x 1.59
Swing mechanism
gear
8.00 2.11 Gear oil SAE 30 CAT CAT TDTO