1604ZW

RAIL-ROAD EXCAVATOR
1604ZW

M+P-05C-2612

OPERATING INSTRUCTIONS

en
Translation of the original operating instructions, language version:
Version: 2010-07

Order number: 6152354

From vehicle ID no.: 168Z302001

 Atlas Maschinen GmbH
Stedinger Strasse 324
27751 Delmenhorst
Deutschland
Tel. + 49(0)4221/491-0

www.atlasgmbh.com
E-Mail: info@atlasgmbh.com

Project number: 6152354

Editorial deadline: 07/2010

Please fill in before commissioning the rail-road excavator:

Vehicle type: .........................................................................................

Vehicle ID no.: .........................................................................................

Year of construction: .........................................................................................

Commissioned on: .........................................................................................

Dealer:

These instructions have limited copyright protection. They can be duplicated and used by the
user/operator.
Contents 1
1 Contents ..................................................................................................................................... 1
2 Introduction ................................................................................................................................. 6
2.1 About these operating instructions ........................................................................... 6
2.1.1 Safety warning system .................................................................................................. 6
2.1.2 Additional instructions .................................................................................................... 6
2.2 Requirements of staff .................................................................................................. 6
2.3 Intended use ................................................................................................................ 7
2.4 Use other than intended ............................................................................................. 8
2.5 Warranty ....................................................................................................................... 8
2.6 Declaration of conformity ........................................................................................... 8
2.7 Ordering spare parts ................................................................................................... 9
3 Safety of the road and off-road operations ........................................................................... 10
3.1 General safety ............................................................................................................ 10
3.1.1 Safety warning system ................................................................................................ 10
3.1.2 Danger classification ................................................................................................... 10
3.1.3 Structure of safety notes .............................................................................................. 10
3.1.4 Description of symbols and danger illustrations .......................................................... 10
3.1.5 Safety signs and information signs .............................................................................. 12
3.1.6 Safety markings – maintenance and replacement ...................................................... 17
3.2 Personal safety .......................................................................................................... 17
3.2.1 Personal protective equipment .................................................................................... 17
3.3 Workspace safety ...................................................................................................... 18
3.3.1 General guidelines for workspaces - safe working methods ....................................... 18
3.3.2 Parking the rail-road excavator and securing it to prevent unauthorised use .............. 18
3.4 General safety notes ................................................................................................. 18
3.5 Safety equipment ....................................................................................................... 20
3.6 Hazard zone ............................................................................................................... 21
3.7 Transporting persons ............................................................................................... 21
3.8 Stability on sloping ground ...................................................................................... 21
3.9 Driving and work operation ...................................................................................... 21
3.9.1 Driving ......................................................................................................................... 21
3.9.2 Work operation ............................................................................................................ 22
3.10 Guides ........................................................................................................................ 23
3.11 Danger due to items dropping down ....................................................................... 23
3.12 Working in the hazard zone of overhead lines and underground lines ............... 23
3.13 Working in confined spaces ..................................................................................... 23
3.14 Changing and maintenance of the attachments .................................................... 24
3.14.1 Hydraulic hoses and lines ............................................................................................ 25
3.15 Recovering, loading and transport .......................................................................... 26
3.16 Fire protection ........................................................................................................... 26
3.17 Fuel ............................................................................................................................. 26
4 Safety rail operation ................................................................................................................ 27
4.1 General safety notes ................................................................................................. 27
4.2 Hazard zone ............................................................................................................... 28
4.3 Railing and derailing ................................................................................................. 28
4.4 Driving ........................................................................................................................ 28
4.5 Work operation .......................................................................................................... 28
4.6 Rail-road excavator operation under overhead lines ............................................. 29
4.7 Recovering, loading and transport .......................................................................... 30
5 Initial installation and settings ............................................................................................... 31
5.1 Initial briefing ............................................................................................................. 31
5.1.1 Handing over the machine and briefing the operator and the maintenance staff ........ 31
6 Description of the rail-road excavator ................................................................................... 32
6.1 Overview of assembliest ........................................................................................... 32

 identifies optional accessories.

1
1 Contents
6.1.1 DB-realted extras ..................................................................................................... 33
6.2 Work attachments ..................................................................................................... 34
6.3 Display and control devices ..................................................................................... 35
6.3.1 Inside the cab .............................................................................................................. 35
6.3.2 Outside the cab ........................................................................................................... 43
6.4 Fuses .......................................................................................................................... 46
6.4.1 Fuse allocation ............................................................................................................ 47
6.5 Type plates ................................................................................................................. 49
6.5.1 Rail-road excavator ..................................................................................................... 49
6.5.2 Engine ......................................................................................................................... 50
7 Inspection ................................................................................................................................. 51
7.1 Inspection intervals ................................................................................................... 51
7.2 Inspection material .................................................................................................... 52
7.2.1 Fuels, lubricants and coolants ..................................................................................... 52
7.3 Service schedule and inspection plan .................................................................... 53
7.3.1 Initial inspection ........................................................................................................... 53
7.3.2 Inspection plan ............................................................................................................ 54
8 Operation .................................................................................................................................. 55
8.1 Before operation ........................................................................................................ 55
8.1.1 Opening and closing .................................................................................................... 55
8.1.2 Battery isolator switch .................................................................................................. 56
8.1.3 Cab doors .................................................................................................................... 56
8.1.4 Side window ................................................................................................................ 58
8.1.5 Windshield ................................................................................................................... 58
8.1.6 Ignition lock .................................................................................................................. 59
8.1.7 Adjusting the seat ........................................................................................................ 59
8.1.8 Safety belt .................................................................................................................... 61
8.1.9 Fold up and down the seat (of the accompanying crew) if necessary ...................... 62
8.1.10 Seat heating ............................................................................................................. 62
8.1.11 Cigarette lighter ........................................................................................................... 63
8.1.12 Ash-tray ....................................................................................................................... 63
8.1.13 Steering column adjustment ........................................................................................ 64
8.1.14 Sunblind ....................................................................................................................... 64
8.1.15 Lighting ........................................................................................................................ 65
8.1.16 Windscreen washer ..................................................................................................... 67
8.1.17 Heating ........................................................................................................................ 68
8.1.18 Setting the nozzles ...................................................................................................... 69
8.1.19 Auxiliary heating ....................................................................................................... 69
9 Road and off-road operations ................................................................................................ 70
9.1 Checks to be carried out prior to starting the engine ............................................ 70
9.1.1 Pilot control .................................................................................................................. 70
9.2 Ignition lock ............................................................................................................... 71
9.3 Test run ...................................................................................................................... 71
9.4 Starting and stopping the engine ............................................................................ 72
9.4.1 Start the engine ........................................................................................................... 72
9.4.2 Starting with the cold start device  ............................................................................ 73
9.4.3 Switching off the engine .............................................................................................. 73
9.5 Before operation ........................................................................................................ 73
9.5.1 Auto-idling system ....................................................................................................... 74
9.5.2 Setting the engine speed ............................................................................................. 74
9.6 Driving the rail-road excavator ................................................................................. 75
9.6.1 Parking brake .............................................................................................................. 75
9.6.2 Starting up ................................................................................................................... 76
9.6.3 Creeper gear ............................................................................................................... 78

 identifies optional accessories.

2
 Contents 1
9.6.4 Travel speed manual adjustment ............................................................................. 78
9.6.5 Speed indication ....................................................................................................... 78
9.7 Stopping and parking ................................................................................................ 78
9.7.1 Stopping ...................................................................................................................... 78
9.7.2 Parking ........................................................................................................................ 79
9.8 Driving on public roads ............................................................................................ 80
9.8.1 Installing and removing the rear reflectors .................................................................. 80
9.8.2 Rear lamps installing and removing ............................................................................ 80
9.8.3 Slewing locking device ................................................................................................ 81
9.9 Works carried out during road or off-road operation ............................................ 82
9.9.1 Work preparation ......................................................................................................... 82
9.9.2 Oscillating axle locking device ..................................................................................... 83
9.9.3 Fine control .................................................................................................................. 83
9.9.4 Outrigger support ......................................................................................................... 83
9.9.5 Pressure activation setting ....................................................................................... 84
9.9.6 Overload warning device .......................................................................................... 85
9.9.7 Activate maximum power for a short period ................................................................ 86
9.9.8 Emergency operation in case of a fault in the load limit sensing control ..................... 87
9.10 Excavator equipment and work attachment ........................................................... 88
9.10.1 Height limitation ........................................................................................................ 92
9.10.2 Slewing limitation ...................................................................................................... 93
9.11 Changing the work attachments .............................................................................. 93
9.11.1 Connecting and disconnecting hydraulic lines ............................................................. 94
9.11.2 Mounting and removing work attachments .................................................................. 94
9.11.3 Quick attach ........................................................................................................... 105
10 Operation within the frame of the railway transport ........................................................... 107
10.1 Before operation ...................................................................................................... 107
10.1.1 Rail operation ............................................................................................................ 107
10.1.2 Height limitation ...................................................................................................... 108
10.1.3 Interlock circuit for the height- and slewing limitation ............................................. 117
10.1.4 Rail light .................................................................................................................. 117
10.1.5 Equipment for rear area monitoring ........................................................................... 117
10.2 Rerailing and derailing on a public railway crossing ........................................... 118
10.2.1 Emergency brake function ......................................................................................... 119
10.2.2 Blocking/unblocking the guide roll axles .................................................................... 119
10.2.3 Pre-selecting the guide roll axles ............................................................................... 119
10.2.4 Lifting/lowering the guide roll axles ............................................................................ 120
10.2.5 Locking and unlock the steering wheel ...................................................................... 120
10.3 Rerailing and derailing between stations .............................................................. 120
10.4 Driving the rail-road excavator ............................................................................... 121
10.4.1 Starting up ................................................................................................................. 121
10.4.2 Improving the traction ................................................................................................ 122
10.4.3 Speed indication ..................................................................................................... 123
10.4.4 Horn, respectively fanfare (Makrofon) .................................................................... 123
10.5 Stopping/parking ..................................................................................................... 123
10.5.1 Stopping .................................................................................................................... 123
10.5.2 Parking ...................................................................................................................... 124
10.6 Running over a switching device (e.g. INDUSI) ................................................... 124
10.6.1 Running over a switching device with momentum ..................................................... 125
10.6.2 Running over the switching device step-by-step ....................................................... 125
10.7 Towing wagons .................................................................................................... 125
10.7.1 Connecting and disconnecting wagons ..................................................................... 126
10.7.2 Wagon brake system .............................................................................................. 128
10.8 Rail operation work ................................................................................................. 128

 identifies optional accessories.

3
1 Contents
10.8.1 Work scheduling ........................................................................................................ 128
10.8.2 Parking the rail-road excavator at the place of work ................................................. 128
10.8.3 Earthing the rail-road excavator ................................................................................ 129
10.8.4 Automatic operation ................................................................................................... 129
10.8.5 Operation in locked state ........................................................................................... 130
10.8.6 Guide roll axle locking device .................................................................................... 131
11 Transport ................................................................................................................................ 132
11.1 Loading the rail-road excavator ............................................................................. 132
11.2 Unloading the rail-road excavator ......................................................................... 133
11.3 Lifting the rail-road excavator ................................................................................ 133
11.4 Transporting the rail-road excavator on a wagon ................................................ 134
11.5 Recovering and towing the rail-road excavator in road and off-road
operations ................................................................................................................ 135
11.5.1 Towing out of the hazard zone .................................................................................. 136
11.6 Recovering and towing during rail operation ....................................................... 137
11.6.1 Derailing by emergency switching ............................................................................. 137
11.6.2 Bringing the rail-road excavator in a position for recovery in case of a break-down
incident ...................................................................................................................... 140
11.6.3 Towing the rail-road excavator .................................................................................. 148
12 Maintenance ........................................................................................................................... 150
12.1 Cleaning the rail-road excavator ............................................................................ 150
12.1.1 Dry cleaning with compressed air .............................................................................. 150
12.1.2 Cleaning with water and cleaning agents .................................................................. 150
12.1.3 Cleaning with a high-pressure washer ...................................................................... 151
12.1.4 Cleaning the outside of the engine ............................................................................ 151
12.1.5 Cleaning the combination cooler ............................................................................... 151
12.1.6 Maintenance and replacement of safety signs .......................................................... 151
12.2 Lubrication ............................................................................................................... 152
12.2.1 Rail-road excavator lubricating points ....................................................................... 152
12.2.2 Lubricating points on the work attachment ................................................................ 153
12.2.3 Central lubricating system, electric ......................................................................... 153
12.2.4 Lubrication in case of fail of the central lubrication system .................................... 154
12.2.5 Filling the central lubricating system ...................................................................... 154
12.3 Maintenance and inspection tasks ........................................................................ 155
12.3.1 Engine maintenance .................................................................................................. 155
12.3.2 Maintaining the cooling system ................................................................................. 159
12.3.3 Maintaining the air filter system ................................................................................. 161
12.3.4 Maintaining the fuel system ....................................................................................... 162
12.3.5 V-belt ......................................................................................................................... 163
12.3.6 Maintaining the transmission ..................................................................................... 166
12.3.7 Maintaining the chassis ............................................................................................. 168
12.3.8 Wheels and tyres ....................................................................................................... 169
12.3.9 Maintaining the compressed air and hydraulic system .............................................. 171
12.3.10 Windshield washer .................................................................................................... 178
12.3.11 Maintaining the electrical system ............................................................................... 178
12.3.12 Maintaining the heating and air conditioning system ................................................. 187
12.4 Shutdown ................................................................................................................. 189
12.4.1 Preserving the rail-road excavator ............................................................................. 189
12.4.2 Disposal of the rail-road excavator ............................................................................ 190
13 Specifications ........................................................................................................................ 191
13.1 Weights and performance data .............................................................................. 191
13.2 Dimensions .............................................................................................................. 192
13.2.1 Main dimensions ........................................................................................................ 192
13.2.2 Loading dimensions ................................................................................................... 193

 identifies optional accessories.

4
 Contents 1
14 Rectifying faults ..................................................................................................................... 195
14.1 Finding and rectifying faults .................................................................................. 195
14.1.1 Malfunctions .............................................................................................................. 196
14.2 Malfunctions and unusual operating states ......................................................... 202
15 Index........................................................................................................................................ 205

 identifies optional accessories.

5
2 Introduction
2 Introduction
2.1 About these operating
instructions
These operating instructions contain important in-
formation on operating the rail-road excavator sa-
fely, properly and economically. They are in-
tended for use by:
 The operator
 Auxiliary staff
 Operating staff
 Maintenance staff
These operating instructions describe how to
operate and maintain the rail-road excavator.
They are not a training manual.
The operating instructions must be read carefully
and understood prior to initial operation of the rail-
road excavator and must always be available
where the rail-road excavator is being used.
These operating instructions describe the rail-
road excavator and its various work attachments.
2.1.1 Safety warning system
In conjunction with the text which follows
it, this safety alert symbol is used as a
"safety alert system" in these operating
instructions.
The safety warning symbol indicates a
risk of personal injury. Follow all instruc-
tions which appear after this safety war-
ning symbol in order to avoid injury or
fatal accidents.
2.1.2 Additional instructions
Note
identifies supplementary information.
 identifies optional accessories.
6
2.2 Requirements of staff
The user must make sure that the staff employed
are in possession of at least the following qualifi-
cations as appropriate for their specific remit.
Auxiliary personnel (guides and slingers):
 must be trained in and able to administer first
aid,
 must show knowledge and understanding of
national safety regulations for slinging, mo-
ving and storing the goods encountered at the
site of operation,
 must be informed of the potential risks emana-
ting from the rail-road excavator,
 must be of the minimum age required by nati-
onal regulations.
The operating staff:
 shall have the same qualifications as the auxi-
liary staff,
 must be physically and mentally capable of
working with the rail-road excavator;
 must hold the relevant national permit for wor-
king with the rail-road excavator;
 must be informed of the potential risks to
which they will be exposed when working with
the rail-road excavator;
 must show knowledge and understanding of
all safety-related instructions, sources of
danger and safety precautions;
 must have been instructed in what to do in the
event of an accident with the rail-road exca-
vator;
 must have read and understood the operating
instructions carefully before putting the rail-
road excavator into operation.
The maintenance staff:
 shall have all the qualifications as the auxiliary
staff and the operating staff,
 must have been given task-related training by
ATLAS or a person authorised by ATLAS for
the maintenance and inspection works de-
scribed in these operating instructions.
 Introduction 2
2.3 Intended use Possible operating conditions
Use the rail-road excavator: The application of the rail-road excavator on rails
 on roads, may be limited by the approval for applications
issued by Deutsche Bahn.
 off-road,
The scope of the operating conditions is indicated
 on rails, in field "Operating data" of the data table, see
 on wagons. page, see page 50.

WARNING WARNING
Danger of accident Danger of accident
The improper operation of the rail-road The improper operation of the rail-road
excavator in the railway network of Deut- excavator in the railway network of Deut-
sche Bahn may cause accidents. sche Bahn may cause accidents.
The rail-road excavator may only be ope-  Consider the operating conditions of
rated by persons, Deutsche Bahn and observe them while
 that possess a driver's certificate related operating the excavator.
to special vehicles other than network wa-
gons and issued in accordance with the
Examples
national regulations.
Within the network of Deutsche Bahn AG,  Pushing and free wheeling is forbidden.
the above mentioned licence corresponds  The rail-road excavator may not be included in
to the operating authorisation and the dri- train formations.
ving licence issued by Deutsche Bahn
AG;  Towing (in case of emergency) is not per-
mitted If a qualified person is in the cab.
 that underwent training in lifting equip-
ment operation and possess the relevant  Maximal permissible speed in the area of swit-
certificate.. ches and crossings is 10 km/h.
 Rail-road excavator may not be steered by
The rail-road excavator is used solely: routing devices.
 to loosen and move earth, stones and other
materials with a work attachment approved for
the corresponding application by ATLAS or a
person authorised by ATLAS to act on its be-
half;
 for moving rails by means of rail tongs;
 for tamping tracks by means of a track tam-
ping equipment;
 for towing of unbraked wagons;
 for towing of unbraked wagons with a wagon
brake system.

Note
All national legislation and regulations in the
country in which the rail-road excavator is used
must be observed. In addition, in Germany the
regulations of Deutsche Bahn must be ob-
served.
The operating instructions and the supplemen-
tary operating instructions enclosed, e.g. the
separate operating instruction for the drive en-
gine, must be carefully read and understood be-
fore commissioning the rail-road excavator. The
separate operating instructions for the drive en-
gine form a part of these operating instructions.
These instructions must be available where the
rail-road excavator is being used.
It is essential that their content, in particular the
safety notes, are observed. Please ask an
ATLAS dealer if you are in any doubt.

7
2 Introduction
2.4 Use other than intended
Any use other than that stated in "Intended use"
shall be considered impermissible.
The manufacturer shall not be held liable for any
resulting damage. The risk is borne by the user
alone.
2.6 Declaration of conformity
The rail-road excavator meets the
requirements of the European di-
rectives on the subject.
ORIGINAL-KONFORMITÄTSERKLÄRUNG / ORIGINAL DECLARATION OF CONFORMITY

2.5 Warranty ATLAS MASCHINEN GMBH

STEDINGER STRASSE 324

Please complete the enclosed handover declara- 27751 DELMENHORST

tion carefully with your Atlas dealer and ask him BESCHEINIGT, DASS DIE BAUMASCHINE / CERTIFIES THAT THE CONSTRUCTION MACHINE

ART / NATURE: WHEELED HYDRAULIKBAGGER / HYDRAULIC EXCAVATOR

de / en

or her to send it in. FABRIKMARKE / TRADE MARK: ATLAS TYP / TYPE: 1604 ZW

NUMMER / NUMBER: 168 Z 30XXXX BAUJAHR / YEAR OF CONSTRUCTION: 2010

The warranty conditions are outlined in the war- DIESELMOTOR / DIESEL ENGINE: DEUTZ TYP / TYPE: TCD 2012 L04 2V

ranty and service documentation supplied with

NENNLEISTUNG / RATED POWER: 95 KW BEI / AT: 2300 min-1

BETREFFEND EG-GERÄUSCHEMISSIONSPEGEL / REGARDING EC- NOISE EMISSION LEVEL

your rail-road excavator or can be obtained from IN ÜBEREINSTIMMUNG MIT DER RICHTLINIE 2000/14/EG HERGESTELLT WORDEN IST, WIE IN

your ATLAS dealer.

DER NACHSTEHENDEN ÜBERSICHT ANGEGEBEN.
HAS BEEN MANUFACTURED ACCORDING TO DIRECTIVE 2000/14/EC, AS STATED IN THE SUMMARY
BELOW MENTIONED.

The manufacturer shall not be held liable for any KONFORMITÄTS-

BEWERTUNGSVERFAHREN
CONFORMITY-
GEMESSENER MITTLERER
SCHALLLEISTUNGSPEGEL LWA
MEASURED MEDIAN
GARANTIERTER
SCHALLLEISTUNGSPEGEL LWA
GUARANTEED
BENANNTE STELLE
NOTIFIED BODY

warranty claims resulting from use other than as ASSESSMENT SOUND POWER LEVEL LWA SOUND POWER LEVEL LWA
FACHAUSSCHÜSSE BAU & TIEFBAU
PRÜF- UND ZERTIFIZIERUNGSSTELLE

intended, improper operation, insufficient mainte- NACH ANHANG VI

ACCORDING TO ANNEX VI
98,8 dB (A) 100 dB (A)
IM BG-PRÜFZERT
LANDSBERGER STRASSE 309
D - 80687 MÜNCHEN

nance or the use of unapproved fuels, lubricants

NOTIFIED BODY NUMBER: 0515

and coolants. BETREFFEND EG-MASCHINENRICHTLINIE / REGARDING EC- MACHINERY DIRECTIVE

DEN BESTIMMUNGEN ENTSPRICHT / CORRESPONDS TO THE REGULATIONS

2006/42/EG
ANGEWENDETE HARMONISIERTE EUROPÄISCHE NORMEN / APPLICABLE HARMONIZED EUROPEAN STANDARDS
EN ISO 12100-1:2003 EN 474-1:2006
EN ISO 12100-2:2003 EN 474-5:2006
EN ISO 14121-1:2007

HEBEZEUGEINSATZ ERFORDERT LEITUNGSBRUCHSICHERUNG AM HEBEZYLINDER UND ÜBERLASTWARNEINRICHTUNG /

LIFTING DEVICE OPERATION REQUIRES PIPE FAILURE PROTECTION ON THE LIFTING RAM AND OVERLOAD
WARNING DEVICE.

BETREFFEND EG-EMV-RICHTLINIE / REGARDING EC- EMC DIRECTIVE

DEN BESTIMMUNGEN ENTSPRICHT / CORRESPONDS TO THE REGULATIONS

2004/108/EG
ANGEWENDETE HARMONISIERTE EUROPÄISCHE NORMEN / APPLICABLE HARMONIZED EUROPEAN STANDARDS
EN 61000-6-3:2007 EN 13309:2000
EN 61000-6-4:2007

DOKUMENTENBEAUFTRAGTER / DOCUMENTS OFFICER UNTERSCHRIFTBEVOLLMÄCHTIGTER/ SIGNATURE AUTHORIZED AGENT

ERIK UNGER RAINER BILKE

ATLAS MASCHINEN GMBH ATLAS MASCHINEN GMBH
STEDINGER STRASSE 324 STEDINGER STRASSE 324
27751 DELMENHORST 27751 DELMENHORST

Ganderkesee 2010.06.10 i.A. Rainer Bilke

ORT / PLACE DATUM / DATE UNTERSCHRIFT / SIGNATURE
QUALITÄTSKONTROLLE / QUALITY ASSURANCE

FB-080/00

Conformity is certified.
Related documentation and a copy of the original
declaration of conformity are available at the ma-
nufacturer.
The original declaration of conformity and a trans-
lation thereof are enclosed to the sales documen-
tation.

8
 Introduction 2
2.7 Ordering spare parts
Only use original Atlas spare parts. The following
information has to be provided when placing or-
ders:
For the rail-road excavator:
 type of vehicle,
 vehicle identification number,
 order no. from the spare parts catalogue.
Type plates, see page 49.

For the engine:

 engine number,
 type of engine.
Type plates, see page 49.

9
3 Safety of the road and off-road operations
3 Safety of the road and off-road operations
3.1 General safety
3.1.1 Safety warning system
In conjunction with the text which follows
it, this safety alert symbol is used as a
"safety alert system" in these operating
instructions.
The safety warning symbol indicates a
risk of personal injury. Follow all instruc-
tions which appear after this safety war-
ning symbol in order to avoid injury or
fatal accidents.
3.1.2 Danger classification
Together with the safety warning symbol, the fol-
lowing signal words indicate the level of possible
danger.
DANGER - indicates situations which are directly
dangerous and which, if not avoided, may result
in fatal or serious injury.
WARNING - indicates dangerous situations
which, if not avoided, may result in fatal or serious
injury.
CAUTION - indicates dangerous situations,
which, if not avoided, may result in slight or mo-
derately serious injury.
NOTICE - indicates dangerous situations, which,
if not avoided, may result in damage to property.
Note
Signal words without a safety warning symbol
indicate possible damage to property.
10
3.1.3 Structure of safety notes
DANGER
Type of danger
Consequence of danger
 Measure to avoid danger
3.1.4 Description of symbols and
danger illustrations
The symbols used in these operating instructions
indicate the following dangers:
Warning of a danger area
 Fatal accidents, serious injuries or
damage may result if the required
precautionary measures are not
taken.
Warning of dangerous voltages
 Fatal accidents, serious injuries or
damage may result from high vol-
tages, high working currents (on
terminals, condensers, parts of
housings and on plug-in boards) if
the required precautionary mea-
sures are not taken.
Warning of a risk of explosion
 Fatal accidents, burns or blindness
may be caused by explosive gases
or by contact with corrosive acids if
the required precautionary mea-
sures are not taken.
Warning of a risk of burns
 Injuries caused by burns may result
if the required precautionary mea-
sures are not taken.
Danger due to rotating parts
 Injuries caused by rotating parts
may result if the required precautio-
nary measures are not taken.
Warning of a risk of crushing
 Injuries caused by crushing may re-
sult if the required precautionary
measures are not taken.
Warning of suspended loads
 Fatal accidents, serious injuries or
damage may result from sus-
pended or falling loads if the re-
quired precautionary measures are
not taken.
 Safety of the road and off-road operations 3
Warning of hazardous dust
 Injuries caused by inhaling hazar-
dous dust may result if the required
precautionary measures are not
taken.
Warning of substances that are
harmful to health
 These substances may cause inju-
ries and damage health if the re-
quired precautionary measures are
not taken.
Warning of environmentally hazardous
substances
 These substances may seriously
harm the environment if the re-
quired precautionary measures are
not taken.

11
3 Safety of the road and off-road operations
3.1.5 Safety signs and information signs

Road and off-road operations

12
 Safety of the road and off-road operations 3
Explanation of safety signs and information 26 Symbol for the drawbar mounts
signs
27 Warning of danger of falling
1 Lubrication schedule
28 Note for lubricating the tooth flanks of the sle-
2 Operational schedule with regard to the road wing ring
and off-road operations
29 Warning of corrosive substances, risk of ex-
3 Symbol for the lifting points for the lifting gear plosion and dangerous pressurised hydraulic
fluid.
4 Symbol for maximum speed

5 Information about the hazard zone of the rail-

road excavator

6 Reflectors

7 Symbol for the main fuse F1

8 Warning of corrosive substances and risk of

explosion when working on the batteries

9 Warning of damage to the electrical system,

switch off the battery isolator switch

10 Symbol for the extinguisher

11 Symbol for a first-aid box

12 Seat position for driving on public roads

13 Symbol for emergency brake

14 No access for unauthorised persons

15 Welding work on the rail-road excavator not

permitted

16 Warning: block the uppercarriage by the sle-

wing locking device.

17 Information about the hazard zone of the rail-

road excavator

18 Reflectors

19 Inspection plan for the engine

20 Warning of a risk of crushing

21 Keep off the bonnet!

Step only on the footsteps and the floor space.

22 Warning of a risk of burns

23 Load chart

24 Note for works carried out with the outrigger

support

25 Information for the tyre pressure

13
3 Safety of the road and off-road operations
Rail operation

2
1
2

5
Operational limitation
Facility is switched on
3
Do not operate as a leading vehicle
in case of train crossing on route
segments with a train protection
system.
6122832

Operational limitation

II Running position
and release position
3
Do not operate as a leading vehicle
in case of train crossing on route
segments with a train protection
system.
6122832

III Final position

V Brake range

M+P-05C-3274

6
2 7 8 9
What to
do if…

WARNING!
Emergency braking of the WARNING!
excavator when coasting Spur wheel cylinder lock
Switch off the ignition
Open when operating on
and test the emergency
brake function after each route segments.
railing. Close when operating the
excavator under load

2
operating on electric route segments
Consider the highest position of the
boom. Earthen your device if

10

Operational limitation

3
Do not operate as a leading vehicle
in case of train crossing on route
segments with a train protection
system.

2
6122832

11

2 2
M+P-05C-3275

14
 Safety of the road and off-road operations 3
Explanation of safety markings and informa-
tion signs

1 Operational schedule for rail operation

2 Warning of electrical voltage

3 Note for operation conditions

4 Symbol for the switching steps of the driver

brake valve of the wagon brake system

5 Rail operation facility is switched on

6 Instructions in case of dangerous voltages

7 Note for operation in emergency mode

8 Note for controlling the emergency brake

function

9 Note for blocking and unblocking the cylinder

of the guide rolls

10 Note for works carried out under oberhead

lines.

11 Warning when climbing up into the rail-road

excavator because of electrical voltages

15
3 Safety of the road and off-road operations
Explanation of safety markings

Danger Description Pictogram for Description

pictogram avoiding the
danger
Risk of crashing and crushing Keep your distance

Risk of burns Do not touch hot surfaces

Risk of crashing and crushing Keep your distance

Falling hazard Use handles and access stairs

Risk of chemical burns Avoid naked flames and

sparks. Relieve pressure from
the system.
Read carefully and understand
the operating instructions
Risk of explosion/ Read the operating instruc-
Risk of chemical burns tions carefully and make sure
you understand them

Risk of short circuits Read the operating instruc-

tions carefully and make sure
you understand them

Risk of crushing and being Only open the bonnet when the
pulled in engine is switched off.

16
 Safety of the road and off-road operations
3.1.6 Safety markings – maintenance and
replacement
 Safety markings and information signs must
be clearly legible.
 Damaged or missing safety markings must be
replaced.
 Use mild cleaning agents and water to clean
safety markings. Do not use any cleaning
agents containing solvents.
 For information on ordering safety markings
see "Ordering spare parts" in the "Introduc-
tion" chapter. Indicate a language if neces-
sary.
3.2 Personal safety
WARNING
Personal injury and damage to pro-
perty
Injury or damage may be caused if the
rail-road excavator is not operated and
maintained by qualified persons.
 The rail-road excavator may only be ope-
rated and serviced by qualified persons.
Also refer to "Requirements of staff" in the
"Introduction" chapter.
 The operating instructions and the safety
markings and information signs must be
read and understood by any person wor-
king with and on the rail-road excavator.
3.2.1 Personal protective equipment
WARNING
Personal injury
Carrying out work without the use of the
appropriate personal protective equip-
ment may cause injuries and damage
health.
 Protective equipment as prescribed by
national regulations and appropriate for
the task at hand must always be worn
when carrying out all work. See "General
guidelines for workspaces – Safe working
methods“, page 18.
 Wear tight-fitting and closed protective
clothing for work.
 Remove rings and scarves.
 Wear a snug-fitting head covering or hair-
net to tie back long hair.
3
Work with protective clothing
 Injuries may be sustained if work is
carried out without wearing protec-
tive clothing as specified.
Work with protective gloves
 Hand injuries may be sustained if
work is carried out without wearing
protective gloves as specified.
Work with safety goggles
 Eye injuries and blindness may be
sustained if work is carried out wit-
hout wearing safety goggles as spe-
cified.
Work with safety shoes
 Foot injuries may be sustained if
work is carried out without wearing
safety shoes as specified.
Work with safety lines
 Injuries may be sustained if work is
carried out without wearing safety
lines as specified.
Work with a safety helmet
 Head injuries may be sustained if
work is carried out without wearing
a safety helmet as specified.
Work with a visor
 Facial injuries may be sustained if
work is carried out without wearing
a visor as specified.
Work with a dust mask
 Working without a dust mask as
specified may be harmful to health.
Work with a high-visibility vest
 Accidents can happen if work is car-
ried out without wearing a high-visi-
bility vest as specified.
Work with hearing protection at noise
levels greater than 85 db (A)
 Hearing may become impaired if
work is carried out without wearing
hearing protection as specified.
Work with breathing protection
 Working without breathing protec-
tion as specified may be harmful to
health.
Work with a protective cap/hairnet
 Head injuries may be sustained if
work is carried out without wearing
a protective cap/hairnet as speci-
fied.
17
3 Safety of the road and off-road operations
3.3 Workspace safety
3.3.1 General guidelines for
workspaces - safe working methods
In addition to the operating instructions, the rele-
vant valid national regulations on the following
must be observed:
 occupational safety;
 accident prevention;
 health protection;
 environmental protection;
 traffic on public roads
WARNING
Danger of accident
Werden die Sicherheitsregeln nicht ein-
gehalten, kann es zu Unfällen kommen.
 The owner and users of the rail-road ex-
cavator are responsible for compliance
with safety regulations.
 Valid local regulations have to be obser-
ved.
3.3.2 Parking the rail-road excavator
and securing it to prevent
unauthorised use
 Park the rail-road excavator on solid ground
which is as level as possible before taking a
break or finishing work.
 Only park the rail-road excavator where it
does not cause obstruction, e.g. blocking pu-
blic roads or traffic to and from construction
sites.
 Lower the work attachment and the outrigger
support to the ground, see page 84 and
page 88.
 Switch off the engine and remove the ignition
key.
 Close the windows and always lock the rail-
road excavator.
18
3.4 General safety notes
DANGER
Personal injury
Serious injury or even death may result if
first aid cannot be administered or cannot
be administered quickly enough in the
event of an accident.
 To ensure that first aid can be administe-
red quickly, operators must find about first
aid and rescue plans in the event of an ac-
cident (paramedics, emergency doctors,
fire brigade, emergency medical services,
etc.) before commencing work.
 Check that a first aid kit is available and
that it has all the necessary equipment as
per applicable regulations.
 Store the first aid kit safely inside the
cab and mark it clearly with corresponding
safety markings.
DANGER
Personal injury and damage to pro-
perty
Injuries or damage may result in the event
of a fire if people do not know where the
fire extinguisher is stored.
 Before commencing work, the operator
must find out where the fire extinguisher
is stored in the rail-road excavator and
how to operate it.
 The operator must find out about local
methods of reporting and fighting fires be-
fore commencing work.
 Store the fire extinguisher safely inside
the cab and mark it clearly with corres-
ponding safety markings.
DANGER
Personal injury
Inhaling toxic gases or fluids can pose
hazard to health and impair the ability to
concentrate.
 Do not store or transport any substances
which are harmful to health in the cab.
WARNING
Personal injury
There is a risk of slipping and falling if the
footsteps and floor space are dirty or icy.
 Keep the footsteps, the floor space and
shoes free of dirt (e.g. mud, clay, snow or
ice) and wear non-slip shoes.
 Do not climb onto excavator equipment;
use a ladder or a work platform instead.
 Safety of the road and off-road operations
WARNING
Personal injury and damage to pro-
perty
Injuries or damage may result from im-
proper operation or maintenance of the
rail-road excavator.
 Do not undertake any operations which
restrict safety.
 The operating instructions must be follo-
wed for operation, maintenance and
transport.
 The rail-road excavator may only be ope-
rated in perfect working order.
 Prior to operation, check all functions very
carefully to detect any potential failures.
 Safety equipment on the rail-road excava-
tor may not be switched off during opera-
tion.
 The user must supplement safety regula-
tions with special instructions adapted to
local operating conditions as and where
necessary.
 The operating instructions, information of
relevance to safety and the safety notes
are to be stored safely at the seat; they
must be complete and legible.
NOTICE
Damage to property
Careless driving and operation of the rail-
road excavator may cause damages.
 Observe the dimensions of the rail-road
excavator.
 Observe overhead clearances when dri-
ving the excavator.
 Ask another person for assistance when
driving in blind areas.
 Loose parts, e.g. tools and other accesso-
ries, must be secured.
3
WARNING
Personal injury and damage to pro-
perty
There is a risk of the rail-road excavator
falling over on downhill edges and ver-
ges. This may lead to injury or damage.
 Prior to commencing work, specify a mini-
mum distance to the edge of a drop, de-
pending on the carrying capacity and the
slope of the subsoil, mark this and main-
tain this distance at all times while wor-
king.
 Secure the rail-road excavator against rol-
ling down or slipping down.
 Pay attention and drive particularly care-
fully on slopes. Note the risk of the rail-
road excavator tipping over.
 Do not swivel the uppercarriage. Drive
with the work attachment in front and
keep it as close to the ground as possible.
 Allow the work attachment to drag on the
ground when driving down a slippery slo-
pe.
WARNING
Personal injury and damage to pro-
perty
Injuries or damage may result if the door,
windows, hoods, flaps etc. are unintenti-
onally slammed shut.
 The door, windows, hoods, flaps, etc.
must be secured against unintentional
closing when they are open.
 Make sure that the open door locks into
place and keep hoods and flaps closed
during operation.

WARNING
Personal injury and damage to pro-
perty
If the hydraulic system is damaged the
work attachment and the outrigger sup-
port may drop down and cause injury or
damage.
 Lower the work attachment and the out-
rigger support to the ground or lock the M+P-05C-0124a

paws when leaving the rail-road excava-

tor.

19
3 Safety of the road and off-road operations
CAUTION
Personal injury and damage to the
environment
Failure to comply with applicable envi-
ronmental regulations may cause injury
and damage the environment.
 Applicable environmental regulations
must be observed.
 Make sure that environmentally hazar-
dous substances such as lubrication gre-
ases, hydraulic and lubricants oils, fuels,
coolants and detergents containing sol-
vents do not enter the ground or sewage M+P-05C-0123a

water systems.
 Safety equipment has to be accessible at all
 Environmentally hazardous substances times.
have to be stored, transported, collected
and disposed of in suitable tanks.
 Check safety equipment regularly and replace
if and when necessary.
 If any of the above fluids get into the
earth, the leak must be stopped and the NOTICE
fluids bound with suitable binding agents.
The earth should be dug out if necessary. Damage to property
Improper handling of a fire extinguisher
may impair the ability of the fire extingu-
3.5 Safety equipment isher to function.
Depending on the national regulations, safety  Protect fire extinguishers from direct
equipment may include: sunlight.
a fire extinguisher, a first aid box, a warning  Follow manufacturer's instructions.
triangle and a high-visibility vest.
 Store safety equipment safely inside the cab.
The fire extinguisher and the first aid box may
be stored under the (accompanying crew) seat.

1 Fire extinguisher
2 First aid box
 By safety markings mark clearly the place of
storage of the fire extinguisher and the first-
aid box.

20
 Safety of the road and off-road operations
3.6 Hazard zone
DANGER
Personal injury
Improper operation of the rail-road exca-
vator may cause a serious or fatal acci-
dent.
 During operation when the engine is run-
ning, only the operator and the accompa-
nying crew for rail operations may stay in
the cab. No other persons are allowed to
stay on the excavator or in the rail-road
excavator's hazard zone during operation
and when the engine is running.
The area around the rail-road excavator is a ha-
zard zone in which persons may be hit:
 by a rotating uppercarriage,
 possible movements of an work attachment,
 suspended loads or
 other hazards resulting from the use of the
may be achieved.
 Persons are not permitted to be within the ha-
zard zone of the rail-road excavator.
 Warning signs have to be given if persons are
at risk.
 Stop any work being carried out with the rail-
road excavator if persons do not leave the ha-
zard zone despite being warned.
 Sufficient clearance (at least 0,5 m/1,64 ft) is
to be maintained all around fixed components
such as structures, scaffolding or other ma-
chines in order to avoid crushing.
Cordon off the working area if it is not possible
to ensure sufficient safety clearance.
 Ask another person for assistance when dri-
ving in blind areas.
3.7 Transporting persons
DANGER
Personal injury
A serious or fatal accident may result if
persons are transported on the rail-road
excavator.
 Other than the accompanying crew for rail
operations, persons must not be transpor-
ted on the rail-road excavator.
 Only transport accompanying crew if they
are sitting and the rear cab door is
closed.
3.8 Stability on sloping ground
 Secure the rail-road excavator against rolling
down or slipping down once it has been
parked.
3
3.9 Driving and work operation
 Carry out a visual inspection for damage,
loose parts and oil, fuel and coolant leaks be-
fore starting the engine.
 Pay attention to unusual noises and vibra-
tions.
 Adjust the seat, the mirror and the controls be-
fore starting up the rail-road excavator.
 Fasten the safety belt.
 Keep the window panes clean and free of ice.
3.9.1 Driving
WARNING
Danger of accident
In case of malfunction of the brake sys-
tem the brake distance of the rail-road ex-
cavator becomes longer. This may cause
an accident.
 Before each driving of the rail-road exca-
vator check the functions of the brake sys-
tem at a low speed.
 When driving the rail-road excavator,
keep an adequate brake distance.
 Persons are not permitted to be within the
hazard zone of the rail-road excavator.
 Prior to travel, determine where the steering
axle is located.
 Switch off the pilot control, see page 70.
 Move the seat to driving position, see
page 60.
 Switch off the oscillating axle locking device,
see page 83.
 Block the slewing locking device, see
page 81.
 Check the carrying capacity before driving on
bridges, cellar ceilings or vaults.
 Consider clearance dimensions of structural
works before driving into subways, tunnels,
etc.
Consider dimensions and weight of the rail-
road excavator, see page 192.
 The user is responsible for ensuring that the
rail-road excavator is fitted in accordance with
the relevant national regulations, for example
with a first-aid box, a warning triangle, a high-
visibility vest and a type-tested warning lamp.
Only qualified persons may be commissioned
to work with/on the rail-road excavator. See
"Requirements of staff" in the "Introduction"
chapter.
 When driving, keep the work attachment as
close as possible to the ground.
21
3 Safety of the road and off-road operations
3.9.2 Work operation
WARNING
Personal injury and damage to pro-
perty
The position of the steering axle may be
reversed when the uppercarriage is rota-
ted. Carelessness may lead to personal
injury or damage to property.
 Operate the rail-road excavator with due
care.
NOTICE
Damage to property
Additional moments of force may cause
damage in certain jib positions and simul-
taneous pressure on the tip of the articu-
lated jib.
 Never use the excavator equipment to
make wiping movements.
 Wear appropriate personal protective equip-
ment, e.g. acid-resistant gloves, safety helmet
and safety goggles, when carrying out all
work.
 Light up the workspace when visibility is poor.
 Do not overload vehicles, and load them in
such a manner that the load cannot be lost or
slip out of place.
 Do not swing round over occupied truck
driver's cabs.
 When working, make sure that the rail-road
excavator does not lift up off the ground.
 Do not drive and dig at the same time.
 When excavating on slopes, starting work
from the top of the hill.
 Break stone with the hydraulic hammer.
 The windshield must be closed when working
with a hydraulic hammer.
 Find out if there are any objects located under
the ground and note this information when
operating the excavator.
 Check the slope and the carrying capacity of
the ground prior to commencing work.
 Do not use the rail-road excavator for work
that would put its stability at risk.
 Always support the rail-road excavator when
carrying out work.
 Use a mattress when digging on soft ground.
 Maintain a safe distance from downhill edges
and verges.
 Never hit rail-road excavator components
(e.g. the cab or cab windows) with jib equip-
ment or suspended loads.
 When using the dipper, the hydraulic hoses
must not be bended, crushed or twisted.
22
 Lift only material that meets the criteria stated
in the specification of the work attachment
(weight and volume).
Hoisting equipment
WARNING
Personal injury and damage to pro-
perty
The rail-road excavator may tip due to an
excessively high load moment when it is
lifting and may cause injury or damage.
 Hoisting equipment (e.g. a load hook) is
only permitted with the overload warning
device switched on.
 Only attach loads to the load hook or to lif-
ting rings, and observe the safe working
load when doing so (see the load chart in
the cab).
WARNING
Personal injury and damage to pro-
perty
Suspending loads on unsuitable work at-
tachments may cause injury and damage
the environment.
 Use work attachments and slinging equip-
ment (e.g. a load hook) that are suitable
for the load.
WARNING
Personal injury
Material may drop down while lifting
loads with a dipper because of vibratory
movements. This may cause injury.
 Persons are not permitted to be within the
hazard zone of the rail-road excavator.
 Wear appropriate personal protective
equipment, e.g. a safety helmet.
 Lift loads only be means of lifting equipment
(e.g. a load hook).
 Use pallet forks to move pallets.
 Distribute load evenly on both pallet fork tines.
 Fasten loads securely so that they sit closely
to the rear side of the pallet forks.
 Use rail tongs to move rails.
 Rail operations must be guided by an accom-
panying crew.
 Switch on the overload warning device.
 Fasten loads as close as possible to the lifting
equipment.
 Fasten loads securely so that they cannot slip
out of place.
 Keep loads as close as possible to the ground.
 Only move the rail-road excavators with loads
if the intended route is level.
 Safety of the road and off-road operations 3
 Persons have to be in the field of vision of the Safety distances from overhead electricity lines:
operator and out of the hazard zone.
Rated voltage Minimum distance
3.10 Guides 0–50 kV 3,0 m/10,0 ft
 Ask a guide for assistance in blind areas. 50–200 kV 4,6 m/15,0 ft
 Agree on hand signals and calls for directing
beforehand. 200–350 kV 6,1 m/20,0 ft
 Guides have to be in the field of vision of the 350–500 kV 7,6 m/25,0 ft
operator and out of the hazard zone.
500–750 kV 10,7 m/35,0 ft

3.11 Danger due to items dropping 750–1000 kV 13,7 m/45,0 ft

down
 The cab must be equipped with cab protection
and an emergency hammer if there is any risk
of objects dropping down onto the rail-road ex-
cavator.
3.12 Working in the hazard zone of
overhead lines and underground
lines
Note
Safety distances do not relate to rail operations.
 Maintain the safety distances from the rotating
uppercarriage and work attachment and from
suspended loads which may move.
 The power supply has to be disconnected if it
is not possible to maintain the safety distance.

DANGER 3.13 Working in confined spaces

Personal injury
A serious or fatal accident may result if
electricity is transferred.
 Do not leave the excavator.
 Drive the rail-road excavator out of the ha-
zard zone or have the power supply cut
off.
 Warn other persons in the hazard zone.
Working close to overhead lines or damaging un-
derground lines and pipes may result in a transfer
of electricity.
 Find out the position of underground lines and
pipes from the works management.
 Mark the position of underground lines and
pipes on the site.
DANGER
Personal injury
Inhaling engine exhaust gases is detri-
mental to health and may lead to uncon-
sciousness and even death.
 Provide sufficient ventilation and an addi-
tional exhaust gas extraction system
when operating in enclosed spaces.
 Observe the relevant national legislation
and regulations.
 Wear appropriate personal protective
equipment, e.g. breathing protection.
 Operate the rail-road excavator out of
confined spaces only, if possible.
DANGER
Personal injury and damage to pro-
perty
The working area and the working height
may be limited when operating in confi-
ned spaces. Damages of the structure or
damages of the rail-road excavator may
cause a serious or fatal accident.
 Specify and maintain safety distances.
 Use the height limiter of the rail-road ex-
cavator if necessary.

23
3 Safety of the road and off-road operations
3.14 Changing and maintenance of
the attachments WARNING
Rail-road excavators may only be retooled and Personal injury
maintained by qualified persons working in com- Battery acid will burn your skin, eyes and
pliance with the operating instructions. clothing.
Observe directions in "Requirements of staff" in  Do not touch your eyes with dirty hands.
the "Introduction" chapter.  Wear appropriate personal protective
equipment, e.g. acid-resistant gloves and
WARNING safety goggles.
Personal injury and damage to pro-  Immediately neutralise any acid which
perty splashes onto your skin or clothing with
soapsuds or with an acid neutraliser and
There is a risk of fire and explosions
then rinse with water.
when maintenance and repair work is car-
ried out.
 Do not smoke. WARNING
 Do not use any open flames. Personal injury
 Keep a fire extinguisher at hand. Oil, lubrication grease, fuel, coolant and
 Store cleaning cloths that are soaked with cleaning agents damage your skin and
inflammable liquids in closed non-flam- eyes.
mable containers.  Use skin protectors.
 Do not touch your eyes with dirty hands.
WARNING Wear appropriate personal protective equip-
ment, e.g. acid-resistant gloves and safety
Personal injury goggles.
Engine, transmission and hydraulic oils
as well as coolants may be hot and can
cause serious burns.
 Unless otherwise indicated, carry out
maintenance and repair work only when
the assemblies have cooled down.
 Wear appropriate personal protective
equipment, e.g. acid-resistant gloves.
 Prior to replacing engine, transmission
and hydraulic oils as well as coolants, em-
pty the relevant pressure tank.

WARNING
Personal injury
Rotating parts may cause injury.
 Unless otherwise indicated, carry out
maintenance and repair work only when
the engine has been switched off.

WARNING
Personal injury
Improper mounting or removal of the
work attachment may lead to injury.
 Never use your fingers to check whether
the bushing of the work attachment and
the articulated jib are aligned.
 Never put your hand between the work at-
tachment and the articulated jib.

24
 Safety of the road and off-road operations
WARNING
Personal injury and damage to pro-
perty
Maintenance work carried out improperly
may result in injury or damage.
 Work on level, solid ground only.
 Secure the rail-road excavator against rol-
ling down by means of the parking brake
and using wheel chocks.
 Lower the work attachment to the ground.
 Lower the outrigger support to the ground
or lock the paws.
 Always switch off the engine before ope-
ning the maintenance bonnet, the bonnet
and the maintenance flaps.
 There must not be anyone near the engi-
ne when it is running with the bonnet
open.
 When fitting devices for lifting the rail-road
excavator, prevent any slipping.
 Use supports to secure the rail-road exca-
vator that is lifted up.
 Do not carry out work under a rail-road ex-
cavator that is only supported by the hyd-
raulic system.
 Parts that need to be adjusted shall be lo-
cked in order not to drop down.
 Remove the ignition key and switch off the
battery isolator switch in order to avoid
damage to the electrical system and to
ensure that the engine does not start up
unintentionally.
 Reduce the charging pressure of the hyd-
raulic reservoir prior to carrying out any
maintenance work on the hydraulic sys-
tem.
 Do not place any metal objects or tools on
the battery.
 Do not carry out any welding or drilling
work on the rail-road excavator.
 Use the fuels, lubricants and coolants
specified.
 All safety equipment must have been fit-
ted and/or closed before the rail-road ex-
cavator is started up again.
 Applicable regulations concerning envi-
ronmental protection, recycling and dis-
posal must be observed.
3
Note
Only use original ATLAS spare parts.
ATLAST recommends that when carrying out
maintenance or inspections works, you replace
sealing rings in order to avoid unnecessary
downtime during operation.
Maintenance and repair work on the heating
and air conditioning system may only be carried
out by qualified specialised employees.
ATLST recommends consulting ATLAS Cus-
tomer Service.
3.14.1 Hydraulic hoses and lines
WARNING
Personal injury and damage to pro-
perty
When hydraulic hoses and lines or other
components of the hydraulic system are
loosening hydraulic oil will escape under
pressure. This may lead to inflammations
(gangrene), other injuries or damage.
 Have all hydraulic hoses and lines che-
cked regularly (at least once a year) for
leaks, evidence of external damage and
service life by an expert and replace them
if necessary.
 Hydraulic hoses and lines may only be
changed by qualified employees.
ATLAS recommends consulting ATLAS
Customer Service.
 Carry out daily checks of all components
of the hydraulic system.
 Observe all national legislation and regu-
lations regarding the duration of use of the
hydraulic hoses and lines.
 Park the rail-road excavator carefully and
release the charging pressure prior to car-
rying out any maintenance and inspection
works on the hydraulic system.
 Relieve pressure from hydraulic lines.
WARNING
Personal injury and damage to pro-
perty
In the event of leaks from hydraulic hoses
and lines or other components of the hy-
draulic system hydraulic oil may ignite if
getting into contact with open flames or
hot surfaces. This may lead to injuries or
damages.
 Do not smoke.
 Do not use any open flames.
 Keep a fire extinguisher filled with a fire-
extinguisher agent (fire classification B) at
hand.
25
3 Safety of the road and off-road operations
3.15 Recovering, loading and 3.16 Fire protection
transport  Always have a fire extinguisher within
reach.
WARNING
Personal injury and damage to pro- 3.17 Fuel
perty
There is an increased risk of accidents WARNING
and danger of injury in unsecured recove-
Personal injury
ry areas.
 Secure the recovery area with flagmen if Improper handling of fuel may be harmful
necessary. to health.
 Since fuel ignites easily, fire, naked fla-
 Wear high-visibility warning clothing. mes and smoking are prohibited when
handling fuel.
WARNING  Do not allow fuel to come into contact with
the skin, eyes or clothing.
Personal injury and damage to pro-
perty  Do not inhale fuel fumes.
Recovering, loading and transporting the  Wear appropriate personal protective
rail-road excavator may cause injuries or equipment, e.g. acid-resistant gloves.
damage if not carried out properly.
 Only qualified persons are permitted to
load and transport the rail-road excavator.
See "Requirements of staff" in the "Intro-
duction" chapter.
 Load the rail-road excavator on level, so-
lid ground only.
 Drive in a straight direction only when dri-
ving the transport vehicle and on ramps;
do not turn the uppercarriage.

 All national legislation and regulations in the

countries in which the rail-road excavator is
used must be observed.
 Observe the loading dimensions of the rail-
road excavator.
 Secure the work attachment and the rail-road
excavator on the transport vehicle.
 Observe the axle loads, the wheel loads and
the permissible gross weight of the transport
vehicle.
 Observe the dimensions and carrying capaci-
ties of roads and bridges as well as overhead
and side clearances.
 Towing trailers by the rail-road excavator is
forbidden.

26

4 Safety rail operation
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before starting up
the rail-road excavator for rail operation.
4.1 General safety notes
WARNING
Personal injury
The improper operation of the rail-road
excavator in the railway network of Deut-
sche Bahn may cause injury.
Therefore the rail-road excavator may
only be operated by persons,
 that possess a driver's certificate related
to special vehicles other than network wa-
gons and issued in accordance with the
national regulations.
Within the network of Deutsche Bahn AG,
the above mentioned licence corresponds
to the operating authorisation and the dri-
ving licence issued by Deutsche Bahn
AG;
 that underwent training in lifting equip-
ment operation and possess the relevant
certificate;
 that attend the recurrent training regularly
and can prove the relevant proof.
Safety rail operation 4
WARNING
Personal injury and damage to pro-
perty
The improper operation of the rail-road
excavator in the railway network of Deut-
sche Bahn may cause injury or damage.
 The rail network operator must provide
the procedures and relevant rules that re-
late to the safety operation of the rail-road
excavator.
 Prior to the rail operation of the rail-road
excavator, become familiarized with the
operation procedures of the rail network
operator.
 The exact framework conditions with re-
gard to the rail-road excavator operation
are to be agreed with the rail network ope-
rator.
 The rules and requirements of the respon-
sible rail network operator must be obser-
ved.
DANGER
Personal injury
A serious or fatal accident may result if
the rail-road excavator is driven on rails
that are not cordoned off.
 The rail-road excavator may be operated
in the rail network of Deutsche Bahn only
under concession and permission from
the competent authority.
WARNING
Danger of accident
The operation of the rail-road excavator
in the railway network of Deutsche Bahn
may cause accidents, if the operator is
not acquainted with the railway routes.
 If an operator who does not possess a le-
gitimate brake-test related qualification
has to transport a towable load that is fitted
with a brake, there must be an appropria-
tely qualified accompanying crew present.
 The accompanying crew must be informed
for the location of the emergency brake,
the driver brake valve of the wagon brake
system and the fanfare (Makrofon).
WARNING
Danger of accident
Driving the rail-road excavator on dama-
ged rails may cause accidents.
 The rails on which the excavator will be
driven must be in proper condition (solid
base in roadworthy condition).
27
4 Safety rail operation
WARNING
Danger of accident
The rail-road excavator may be operated
only be persons that have been instruc-
ted by a competent authority, otherwise
there is a risk of accidents.
 The requirements of the competent au-
thority must be observed.
 The warning signals must be observed
and any measures that are required must
be immediately taken.
4.2 Hazard zone
The area around the excavator when performing
rail operation is a hazard zone, in which persons
or trains on the neighbouring track may be hit by
a rotating uppercarriage, a work attachment or
suspended loads.
 Persons are not permitted to be within the ha-
zard zone of the rail-road excavator.
 Warning signs have to be given if persons are
at risk.
 Stop any work being carried out with the rail-
road excavator if persons do not leave the ha-
zard zone despite being warned.
 Before railing, if the neighbouring track is not
cordoned off, the slewing limitation must be
switched on, checked and set in accordance
with the required minimal distance, see
page 29.
 Climb in and out only at the safe side (where
the neighbouring tracks are secured or there
aren't any neighbouring tracks).
 Ask another person for assistance when dri-
ving in blind areas.
4.3 Railing and derailing
WARNING
Danger of accident
Railing and derailing the rail-road excava-
tor on bridges and slopes, particularly in
the case of canted tracks, may cause ac-
cidents.
 The rail-road excavator must not be railed
and derailed on bridges and slopes.
 If such a railing or derailing is absolutely
necessary, it must be carried out very ca-
refully.
 The neighbouring tracks must be secured.
 Vehicle traffic must be properly secured in the
case of a public railway crossing (e.g. by bar-
riers or traffic lights).
28
WARNING
Danger of accident
If the electrical system fails while the ex-
cavator is running with momentum, the
rail-road excavator is automatically lowe-
red and the emergency brake mode is ac-
tivated. The regular lowering of the rail-
road excavator becomes impossible.
This may cause an accident.
 As soon as the railing of the rail-road ex-
cavator is finished, the excavator must be
secured against rolling down and the pro-
per operation of the emergency brake
must be checked on a straight and level
railway.
4.4 Driving
WARNING
Danger of accident
Exceeding the maximal speed that is
prescribed may cause accidents.
 Maximal permissible speed when driving
on rails is 20 km/h.
 Maximal permissible speed in the area of
crossings and switches is 10 km/h.
 Check horn, fanfare (Makrofon), lighting and
brakes.
 Check the tyre pressure, see page 170.
 Placing the guide roll axles on rails, see
page 120.
 Unlock the steering wheel, see page 120.
 Switch off the oscillating axle locking device,
see page 83.
4.5 Work operation
 The competent authority must provide the re-
quired safety regulations (construction and
operating instructions or general service inst-
ructions).
 The competent authority must specify the sa-
fety supervision.
 Do not swing round over the drivers' cabs of
rail vehicles.
 Do not overload rail vehicles, and load them in
such a manner that the load cannot be lost or
slip out of place.
 When loading and unloading transport ve-
hicles, neither the excavator equipment nor
the load may hang out of vehicle's sides.
 Store components, construction material and
devices properly so that rail vehicles do not
touch them and the air stream generated by
the speed does not move them.
 Keep roads and passing points near the rail
way uncluttered.

WARNING
Danger of accident
Improper works during rail operation may
cause accidents.
 Connecting wagons both at the front and
at the rear of the excavator is not permit-
ted.
 Pushing wagons is only permitted in case
of shunting works.
A guide at the head of the wagon must
give signal the operator.
 When connecting and disconnecting the
rail-road excavator and a wagon, persons
are not permitted to stay therebetween.
WARNING
Danger of accident
Accidents can happen, when working
transversely to the direction of travel and
on slopes or canted tracks.
 Perform the work with extreme caution.
 Observe the admissible load capacity.
 Secure the rail-road excavator by the out-
rigger support.
Safety rail operation 4
 When working under overhead lines, always
observe rail operator's guidelines 824.0106,
e.g. the guidelines of Deutsche Bahn.
 Before railing, the height limitation must be
switched on, checked and set in accordance
with the required minimal distance to the over-
head lines, see page 29.
 In case of poor visibility, the working area and
the overhead lines must be adequately lit.
Safety distances from overhead lines
The rated voltage and the overhead line height
above rails must be provided in writing by the
competent authority.
In the case of disconnected overhead lines
In case the overhead lines are disconnected and
earthed (earth path), maintain a safety distance
of 100 mm.
Note
In case of lifting and rolling, maintain additio-
nally a safety distance of 300 mm from the ex-
cavator equipment to the lines.
In the case of connected overhead lines

WARNING Rated voltage Minimum distance

Danger of accident 0–15 kV 300 mm
Accidents can happen, when working out
15–25 kV 500 mm
of a wagon on slopes or canted tracks.
 Perform the work with extreme caution.
Note
 Observe the admissible load capacity.
 The stability depends on the wagon tip-
In case of lifting and rolling, maintain additio-
over limit. nally a safety distance of 300 mm from the ex-
cavator equipment to the lines.

4.6 Rail-road excavator operation
under overhead lines
DANGER
Personal injury
A serious or fatal accident may result if
electricity is transferred.
 Do not leave the excavator.
 Drive the rail-road excavator out of the ha-
zard zone or have the power supply cut
off.
 Warn other persons in the hazard zone.
 In case of works carried out under connected
overhead lines, respectively if the safety dis-
tance is less than 1,5 m, the rail-road exca-
vator must be earthed by means of an
earthing device.
 Hoisting equipment (e.g. a load hook) and the
load-guiding wire must be insulated.
 If the overhead catenary system carries over
110 kV railway electricity, maintain a safety di-
stance of 2,0 m.

DANGER
Personal injury
If the rail-road excavator is under over-
head lines, this may cause injuries.
 Never board on areas of the rail-road ex-
cavator that are marked by lightning flash,
see page 12.

29
4 Safety rail operation
4.7 Recovering, loading and
transport
If the engine of the hydraulic system fails, there is
a break-down incident, see page 140.
 Only tow the rail-road excavator in the event of
emergency .
 Inform the competent authority for the incident
as soon as possible and provide a proper to-
wing vehicle.
 Secure the area of rescuing (e.g. by guarding
and stopping signals, signal lights, etc.).
 Wear high-visibility warning clothing.
 Stay only at the safe side (where the neigh-
bouring tracks are secured or there aren't any
neighbouring tracks).
 The rail-road excavator may not be included in
train formations.
 Only tow the rail-road excavator by means of
a special towbar (Robel).
 When towing the rail-road excavator, it must
be manned.
 The rail-road excavator must be towed of the
hazard zone of the railway network as soon as
possible.
 The rail-road excavator may not be towed
further in the area of the road traffic.
 When derailing the rail-road excavator from a
public railway crossing (in the area of the pu-
blic road traffic), the excavator must be loaded
on a transport vehicle, see page 132.

30

5 Initial installation and settings
5.1 Initial briefing
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before starting up
the rail-road excavator for rail operation.
Initial installation and settings 5
 Discuss lubrication intervals and lubricating
points.
 Handover separate operating instructions for
the drive engine.
Warranty
 Explain the warranty regulations.
 Explain the cards to be looked through with re-
ference to the service schedule and inspec-
tion plan.
 Please complete the enclosed handover de-
claration carefully with your Atlas dealer and
ask him or her to send it in.

WARNING
Personal injury and damage to pro-
perty
Failure to carry out an initial inspection
may result in injury or damage.
 The initial inspection must be carried out
after 50 operating hours.

Only employees who have been trained and inst-

ructed accordingly may operate the rail-road ex-
cavator. When the rail-road excavator is handed
over, an appropriate briefing and training must be
provided.

5.1.1 Handing over the machine and

briefing the operator and the
maintenance staff

Operating instructions
Go through the operating instructions page by
page and supplement this with hands-on practical
training on the rail-road excavator.
Very important:
 All national legislation and regulations for pre-
vention of accidents in the countries in which
the rail-road excavator is used must be ob-
served.
 The "Specifications" chapter.
 Discuss display and control devices.
 Discuss checks to be carried out prior to star-
ting the engine.
 Discuss regulations for running-in the engine.
 Start and switch off the engine.
 Rescuing and transporting the rail-road exca-
vator.
 Discuss the operation of all functions.
 Explain the maintenance intervals and items
according to the service schedule and inspec-
tion plan for the rail-road excavator.

31
6 Description of the rail-road excavator
6 Description of the rail-road excavator
6.1 Overview of assembliest

1
2

3
7

6 7
4

M+P-05C-2613

Uppercarriage Undercarriage
1 Cab 4 Outrigger support
2 Engine 5 Solid axle
3 Excavator equipment 6 Steering axle
7 Guide roll axles
8 Chassis

32
 Description of the rail-road excavator 6
6.1.1 DB-realted extras

1
PAR DEL

4 6

17
bar

2
2 8

18 7 0 10

13 3
16
7
13 19

14
11 7

10 8
7
4 5
12 9
6

15

M+P-05C-2724

1 Signal flag 8 Brake hoses of the wagon brake system

2 Dimmable red-light torch 9 Coupling devices
3 Compressed air manometer 10 Special towbar (Robel)
 Brake system 11 Sensors for the electronic slewing limitation
 Wagon brake system 12 Compressed air tank of the wagon brake
4 Grounding cable system
5 Compressor oil collection vessel for the com- 13 Sensors for the electronic height limitation
pressed air system 14 Hand pump for operation in emergency
6 Bag for oil and chemicals spills mode
Oil binding agent and catching canvas 15 Electric pump for operation in emergency
Stuff sack for collection of the catching canvas mode
already used 16 Fanfare (Makrofon)
Disposal bag for collection of the oily binding
17 Crew cab
agent
Oil- and solvent-resistant gauntlet gloves 18 Pipe rupture valve
Overload warning device
7 Rail light/DB- lights
19 Monitor for monitoring the rear area

33
6 Description of the rail-road excavator
6.2 Work attachments

1 2 3 4 5

9
6 7 8

M+P-05C-2342

1 Trench digger
2 Trench digger with pallet forks
3 Trench digger with a load hook
4 Trench digger with rail tongs
5 Dipper
6 Load hook
7 Grab
8 Hydraulic hammer
9 Track tamping equipment

Note
Other work attachments (such as sorting grabs,
etc.) may be mounted and operated after being
approved by an ATLAS dealer or by a person
authorised by ATLAS.

34
 Description of the rail-road excavator 6
6.3 Display and control devices
6.3.1 Inside the cab

1 Console, left ............................................... 36

2 Console, right............................................. 36
3 Drive and control unit ................................. 39
4 Switch and display panel, front .................. 40
5 Nozzles ...................................................... 69
6 Slewing locking device............................... 81
7 Seat............................................................ 59
8 Special functions..................................... 41
9 Handles for side windows .......................... 58
10 Door unlatching device .............................. 56
11 Windshield unlatching device..................... 58
12 Sunblind ..................................................... 64
13 Inside mirror

35
6 Description of the rail-road excavator
Console, left
1 Fanfare (Makrofon)................................123
2 Quick attach...........................................105
3 Heating output ............................................68
4 Gear shift
 On-road gear .........................................77
 Off-road gear .........................................77
5 Parking brake..............................................75
6 Pre-selection of special functions, right .162
7 Pre-selection of special functions, left ...162
8 Blower.........................................................68
9 Wagon brake system.............................128
10 Joystick
 Bending..................................................89
 Turning...................................................89
11 Horn ....................................................70, 123
Fanfare (Makrofon)................................123
12 Button toggle for special functions, left
13 Button toggle for special functions, right
14 No function
15 Pilot control .................................................70
36
Console, right
16 Display panel.............................................. 37
17 Speed indication ..................................... 78
18 Setting the engine speed ........................... 74
19 Joystick
 Lifting/lowering ...................................... 89
 Spooning up/gripping ............................ 89
20 Rotating the dipper..................................... 89
21 Pre-selection of the direction of travel........ 77
Pre-selection of outrigger support direction 84
22 Suspending fine control.............................. 83
Maximum power......................................... 86
23 Improving the traction............................... 122
24 Oscillating axle locking device ................... 83
25 Outrigger support ....................................... 83
26 Locking the guide roll axles...................... 131
27 EEC-button toggle for diagnostics. See the
separate operating instructions for the drive
engine
28 Cigarette lighter/socket .............................. 63
29 Ignition lock ................................................ 59
30 Air conditioner ............................................ 68
31 Fine control ................................................ 83
32 Interior lights............................................... 66
33 Windshield wiper ........................................ 67
34 Side lights and dipped beam...................... 65
35 Warning lights ............................................ 65
36 Operating hours counter ............................ 73
 Description of the rail-road excavator
Display panel
Rotating warning light ...................... 66
Warning lights ..................................... 65
Rotary cutter1)
Defective filament lamp .................... 184
Malfunction ....................................... 196
Height and depth limiter
- +
Overload warning device ................. 85
Pressure activation setting .............. 84
Hydraulic hammer ........................... 91
Direction indicator ............................... 65
1) No function on 1604 ZW
6
Engine oil level1)
Centralised lubricating system ....... 153
Defective fuses.................................. 182
Hydraulic oil level .............................. 173
Hydraulic oil filter element ................. 174
Charge control generator .................... 71
Auxiliary heating............................... 69
Hydraulic oil temperature1)
Engine stop
Coolant overheating .......................... 197
Coolant level too low ......................... 197
Insufficient engine oil pressure.......... 196
Charging pressure of the hydraulic
reservoir1)
Air filter .............................................. 161
Fuel pre-filter ..................................... 198
Load limit sensing control.................... 87
37
6 Description of the rail-road excavator
Cold start device...............................73 V Guide roll pressure, front ............... 118

1) No function on 1604 ZW H Guide roll pressure, rear ................ 118

Slewing limitation switched off ....... 200

Side lights and dipped beam ...............65

Intermittent wiping ............................... 67

Rear fog lamp1)
Windshield washer .............................. 68
Quick attach ................................... 105
Main-beam headlight ...........................65

No function
Working floodlights ...........................67

Changeover from dozer blade to

1) No function on 1604 ZW outrigger support1)
Auto-idling system............................... 74
Reserve
L V Pre-selection for outrigger support1)

R V 1) No function on 1604 ZW

L H
Coolant overheating/
Coolant temperature ............... 197
R H

Parking brake.......................................75
Fuel supply ............................. 196

Pre-selection for the oscillating axle lo-

cking device .........................................83
Permanent locking of the oscillating
Engine oil pressure ................. 196
axle ......................................................83
Creeper gear........................................78

V Pre-selection of the direction of travel .77

H Pre-selection of outrigger support
direction ...............................................84

1) No function on 1604 ZW

38
 Description of the rail-road excavator
Extras
Note
The assignment of the switch panel varies, de-
pending on the rail-road excavator equipment.
1 Rail light, front (three-light head
end signal) ............................................... 117
2 Rail light, rear (final signal) ................... 117
3 Adjustment of oil pressure and oil level .. 91
4 Auto-idling system...................................... 74
5 Centralised lubricating system,
electrical................................................ 153
6 Pressure activation setting...................... 84
rotating beacon ....................................... 66
7 Working floodlights, rear ......................... 67
8 Working floodlights, front ........................ 67
9 Overload warning device ........................ 85
10 Hydraulic hammer................................... 91
11 Seat heating............................................ 62
6
Drive and control unitt
1 Travel speed manual adjustment ............ 78
2 Steering column adjustment....................... 64
3 Multifunctional lever
 Creeper gear ......................................... 78
 Intermittent wiping ................................. 67
 Windshield washer ................................ 68
 Pre-selection of the direction of travel... 77
 Pre-selection of outrigger support
direction84
4 Locking and unlock the steering wheel .... 120
5 Multifunctional lever
 Side lights and dipped beam................. 65
 Main-beam headlight............................. 65
 Horn ...................................................... 70
 Fanfare (Makrofon) .......................... 123
 Direction indicator ................................. 65
6 Driving pedal .............................................. 77
Lifting/lowering the paws ............................ 84
7 Driving brake pedal .................................... 77
8 Locking the driving brake pedal.................. 77
9 Extend or retract the jib .............................. 89
10 Slewing brake pedal ................................... 92
11 Latching device for the slewing brake
pedal........................................................... 92
39
6 Description of the rail-road excavator
Switch and display panel, front

1 Slewing limitation control light ...............113

2 Control light for suspending the slewing
limitation ...............................................114
3 Control light for suspending the height
limitation ...............................................109
4 Height limitation control light..................108
5 Suspending the height limitation............109
6 Height limitation .....................................108
7 Rail operation............................................107
8 Control light for lowering the guide
roll axles....................................................120
9 Control light for rail operation....................107
10 Lifting/lowering the guide roll axles ...........120
11 Pre-selection of guide roll axles front
and rear ....................................................119
12 Blocking/unblocking the guide roll axles ...119
Switching device (e.g. INDUSI).crossing .124
13 Suspending the slewing limitation.............114
14 Interlock circuit for the height and slewing
limitation ................................................117
15 Slewing limitation...................................113

40
 Description of the rail-road excavator 6
Special functions A switch symbol indicates the switch position for
the pre-selection of tool/ function and respectively
Note the special functions (A) or (B).
The assignment of special functions to the A Tool/function pre-selection switch: special
switch varies depending on the equipment of function, at the left side, for the special func-
the rail-road excavator. tion button toggle, at the left side, see
page 36.
B Tool/function pre-selection switch: special
function, at the right side, for the special
function button toggle, at the right side rechts,
see page 36.

1 2 3

0 I
4 5 6

0 I 0 I

7 8 9
0 I

10 11 12 L

1
A
0 I 2

13 14 15
3

4
R

0 I
1

2
B
16 17 18 3

19 20 21

I II

M+P-05C-2349

1 Tank refuelling pump ............................ 162 14 Ram

2 Extending the telescope 15 Rotator
3 Retracting the telescope 16 Tipping the dipper
4 Manual hydraulic hammer 17 Closing the tamping pick ......................... 90
5 Hydraulic hammer frequency switching 18 Opening the tamping pick ....................... 90
6 Magnet system 19 Swinging the main boom
7 Sorting grab 20 Tool 1
8 Trench cutter 21 Tool 2
9 Shears
10 Quick attach.......................................... 105
11 Mower
12 Extending the pulling cylinders
13 Retracting the pulling cylinders

41
6 Description of the rail-road excavator
Cab rear area

1 Interior lights, rear .......................................66 Display for the height limitation

2 Door unlatching device ...............................56
3 Nozzles .......................................................69
4 Seat (accompanying crew) ..........................
5 Holder of the signal flag/alarm device
6 Display for the height limitation................42

1 Display key............................................... 111

2 Display ..................................................... 109
3 Selection keys:
minus ( - ) and plus ( + ) .......................... 111
4 Enter key .................................................. 111
5 Operation control light .............................. 109
6 Mode key.................................................. 111
7 Warning lights: RED, YELLOW, GREEN . 112

42
 Description of the rail-road excavator 6
6.3.2 Outside the cab

2
1
3
4

7
8

6 8

M+P-05C-2725

In the engine compartment

1 Engine oil dipstick .................................... 158
2 Sealing cover of the engine oil filler neck. 158
3 Coolant expansion tank ........................... 160
4 Coolant level sight glass .......................... 159

Behind the right-hand maintenance flap

5 Electric pump for operation in emergency
mode..................................................... 147
6 Emergency switch for load limit sensing
control ........................................................ 87

Under the maintenance bonnet

7 Hand pump for operation in emergency
mode..................................................... 140
8 Lever for operation in emergency mode 140
9 Windshield washer reservoir.................... 178

43
6 Description of the rail-road excavator
10

11

12

14
16 13
15

M+P-05C-2726

On the rail-road excavator

10 Release lever for the charging pressure
of the hydraulic oil tank ............................173
11 Hydraulic oil level sight glass ....................173
12 Coolant level sight glass
Air conditioner...........................................187
13 Coupling devices lock tab1) ...................126
14 Coupling devices lever1) ........................126
15 Brake liquid reservoir ................................169
16 Oscillating axle locking device ..................139
1) At the front and at the rear of the rail-road excavator.

44
 Description of the rail-road excavator 6

17
18

19

20

M+P-05C-2727

17 Change-over lever
 Dipper operation ................................... 95
 Grab operation ...................................... 98
18 Tank cap/filler neck
Fuel tank .................................................. 162
19 Shut-off valve for connection of the wagon
brake system1) ...................................... 128
1) At the front and at the rear of the rail-road excavator.

Behind the left-hand maintenance flap

20 Battery isolator switch ................................ 56
21 Oil drain of the compressed air system.... 172

45
6 Description of the rail-road excavator
6.4 Fuses
The fuses are located:
 in the switch box under the seat (accompa-
nying crew),
 behind the left-hand maintenance flap (main
fuse F1 and cold start device fuse F2),
 behind the right-hand maintenance flap (EEC-
fuse).

3
M+P-05C-3288

3 Main fuse F1

5
4

M+P-05C-2728

1
4 EEC-fuse
5 Reserve
M+P-05C-2616 Follow the instructions for replacing fuses, see
page 182.
1 Switch box

M+P-05C-2617

2 Main fuse F1

46
 Description of the rail-road excavator 6
6.4.1 Fuse allocation

5.1

5.1

4
3.1
1
2.1

M+P-05C-2618

Consumer Rated
current

F1 Main fuse 80 A

F2 Cold start device 125 A

Consumer Rated
PCB 1 current

F3 Input fuse 10 A

F4 Input fuse 5A

F5 Operating hours counter, hydraulic oil level, coolant level 1A

F6 Display panel 3A

F7 24 V potential transformer, radio 4A

F8 Cigarette lighter, interior lights 15 A

F9 Switch illumination 3A

F10 Side lights 7,5 A

F11 Side lights, left 3A

F12 Dipped beam headlight, left 5A

F13 Main-beam headlight, left 5A

F14 Side lights, right 3A

F15 Dipped beam headlight, right 7,5 A

F16 Main-beam headlight, right 5A

F17 Dipped and main-beam headlight 10 A

F18 Brake light 5A

F19 Direction indicator 5A

F20 Warning lights 7,5 A

47
6 Description of the rail-road excavator
Consumer Rated
PCB 1 current

F21 Horn, fanfare (Makrofon), engine shut-off, surplus quantity valve) 10 A

F22 External accumulating and isolating circuit, central lubricating system 20 A

F23 Windshield wiper, windshield washer 10 A

F24 Blower 7,5 A

F25 Gear shift, forwards / reverse travel, creeper gear, engine adjustment MV, 7,5 A
theft protection

F26 Oscillating axle locking device, grab rotation, outrigger support 4A

F27 Overload warning device, fine control, pressure activation setting 5A

F28 Load limit sensing control 4A

F29 Additional functions, e.g. tank filling pump 20 A

Consumer Rated
PCB 2.1 current

F35 Input fuse 20 A

F36 Input fuse 20 A

F37 Lighting 25 A

F38 Protective ventilation system 15 A

F39 Heating for the fuel pre-filter, heating for the pressure oil 25 A

F40 Air conditioner, lighting 20 A

Consumer Rated
PCB 3.1 current

F45 Input fuse 20 A

F46 Input fuse 20 A

F47 Auxiliary heating 25 A

F48 Comfort seat 15 A

F49 Vario cab1), cab lift1), emergency lowering1), mirror heating1), mirror adjustment1) 7,5 A

1) No function on 1604 ZW

Consumer Rated
PCB 4 current

F55 Input fuse 20 A

F56 Input fuse 20 A

F57 Auto-idling system, pressure activation setting, electrical window regulators, 10 A

fuse for the rear area

F58 Rear windshield wiper, rotating beacon 15 A

F59 Working floodlights 20 A

Consumer Rated
PCB 5.1 current

F65 Input fuse, PCB 5.1 25 A

F66 Input fuse, PCB 5.1 25 A

F67 Input fuse, computer circuit board REC 2 5A

48
 Description of the rail-road excavator 6
Consumer Rated
PCB 5.1 current

F68 Key for rail operation, pilot control shut-down, emergency mode activation 10 A

F69 Rail light, front (three-light head end signal) 5A

F70 Rail light, rear (final signal) 3A

F71 Fanfare (Makrofon) 10 A

F72 Input fuse, PCB, under carriage and D64 20 A

F73 Height and slewing limitation, speed indication 5A

F74 Input fuse, DB65, control lamps, reserve 15 A

6.5 Type plates Rail operation

6.5.1 Rail-road excavator 1

M+P-05C-2620

1 Approval number
The approval number (1) confirms the approval of
1 Type plate the design and the acceptance of the rail-road ex-
2 Vehicle identification number cavator by the Federal Railway Authority.
3 Type of vehicle
4 Manufacturer
The vehicle identification number is also punch-
marked on the chassis and on the frame of the
cab.

49
6 Description of the rail-road excavator
6.5.2 Engine

3
3 2 1
2

M+P-05C-2621

2 Data table M+P-05C-2622

3 Rail car no. 1 Type plate

4 Operating conditions: in rail-operation related 2 Engine number
label of the operating company 3 Type of engine
5 Rail operation data. The engine number is also punch-marked on the
The data table (2) confirms the approval for appli- engine crankcase.
cations issued by Deutsche Bahn.

50
 Inspection 7
7 Inspection

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance and inspection tasks.

WARNING
Personal injury and damage to pro-
perty
Maintenance work which is not carried
out properly may lead to injury or dama-
ge.
 Carry out only those maintenance activi-
ties that are described in these mainte-
nance instructions and possibly in the
supplementary operating instructions at-
tached.
 Read the maintenance instructions care-
fully!
 Only start the rail-road excavator up again
once maintenance work has been com-
pleted.

7.1 Inspection intervals

Note
The inspection intervals are indicated on the
service schedule and inspection plan, see
page 53.

51
7 Inspection

7.2 Inspection material

7.2.1 Fuels, lubricants and coolants

Note
Warranty claims may be restricted if fuels, lubri-
cants and coolants which have not been autho-
rised are used.
Only use fuels, lubricants and coolants autho-
rised by ATLAS.

Specification for fuels, lubricants and

coolants

Designation Viscosity/Order no./DIN

Engine
See separate operating instructions for the drive engine.
Hydraulics
ATLAS special hydraulic oil1)
Brake fluid
Brake fluid DOT 4 SAE J 1703
ISO 4925
FMVSS-Nr. 116 DOT 4 and DOT 3
Differentials, planetary gear
Transmission oil API GL5-GO 90 LS –10 °C - 15 °C: SAE 80 W-902)
5 °C - 30 °C: SAE 903)
above 30 °C: SAE 1403
Powershift gearbox
API-CD /-CE /-CF -20 °C - 40 °C: SAE 10 W-30 /-404)
-15 °C - 40 °C: SAE 15 W-404)
-10 °C - 40 °C: SAE 20 W-204)
0 °C -50 °C: SAE 304)
Slewing ring lubricating point (tooth flanks)
ATLAS special grease Order no. 3620153
Other lubricating points
Multi-purpose grease with MoS2 DIN 51818, NLGI-2 (lithium soap grease)

1) If not available, use engine oil API-CD-SAE 10 W for an ambient temperature of less than15°C or engine oil API-CD–SAE 20
W-20 for an ambient temperature of more than15°C.
These viscosity categories are also equivalent to viscosity categories MIL-L-2104 C or MIL-L-46152.
2) This viscosity category is also equivalent to viscosity category MIL-L-2105 C.
3) This viscosity category is also equivalent to viscosity category MIL-L-2105 B.

4) These viscosity categories are also equivalent to viscosity categories MIL-L-2104 C /-D /-E or MIL-L-46152 C /-D /-E.
5) This viscosity category is also equivalent to viscosity category MIL-L-2105 C.

52
 Inspection 7
Filling quantities

Note
The filling quantities indicated are approximate
figures. Readings from dipsticks, sight glass,
etc. take priority.

Oscillating axle of the differential 10,0 l

Solid axle of the differential 12,0 l
Per planetary gear 3,0 l
Powershift gearbox 3,0 l
Engine (filling quantity for changing engine oil and engine oil filters) 15,5 l
Cooling system 19,0 l
Hydraulic oil tank 300,0 l
Fuel tank 230,0 l

7.3 Service schedule and inspection

plan
7.3.1 Initial inspection

Note
Inspection and maintenance work has to be car-
ried out by qualified employees after 50 opera-
ting hours (initial inspection) and every 500 ope-
rating hours. ATLAS recommends consulting
ATLAS Customer Service.
Inspection and maintenance work must be en-
tered and signed on the enclosed inspection
cards. The inspection cards are to be returned
to the manufacturer in order to maintain the war-
ranty.

Initial inspection Page

Check to ensure that the operating instructions for the machine are on the rail-road excavator.

Check the fuel level.

Lubricating the rail-road excavator. 152

Check the level of engine oil. 158

Check the coolant level. 159

Check the level of hydraulic oil. 173

Check the oil level of the powershift gearbox, the planetary gear and the differential. 166

Check the level of the brake fluid. 169

Check that the warning lights and control lights work. 40

Check the state of charge of the battery. 180

Test run, hydraulic function check and test operation

Visual inspection for leaks on all pipes, hoses and hydraulic cylinders.

Fill in the enclosed warranty transfer declaration properly and send it in. 8

53
7 Inspection

7.3.2 Inspection plan

Note
The lubricating points and lubrication intervals
are listed and illustrated in the "Lubrication"
chapter, see page 152.

Every Every Every Every Every Every Every Page

day 50 Oh 100 Oh 500 Oh 1000 Oh 2000 Oh 3000 Oh
10 Oh

Lubrication 152

Engine 155

See the separate operating instructions for the drive engine.

Combined cooler 151

Compressed air system and hydraulic system 171

Oil separator 172

Air dryer 172

Hydraulic oil 173

Filter element (1. ) 174

High pressure (1. ) 175

filter element

Combined cooler 151

Transmission 166

Powershift gearbox (1. ) (1. ) 166

Differentials (1. ) (1. ) 167

Planetary gear (1. ) (1. ) 168

Wheels and tyres 169

Tyre pressure 170

Wheel nuts (1. ) 170

Brake fluid 169

Electrical system 178

Batteries 179

Heating and air conditioning system 187

Refrigerant 187

V-belt (1. ) 163

Air filter 187

Condenser 188

Refrigerant circuit/ 189

Dryer

Oh Operating hours Check

(1.) Initial Cleaning
 Repeat more frequently if there is a lot of dust! Replacing
Drain off fluids

54
 Operation 8
8 Operation
The rail-road excavator is supplied with two ve-
WARNING hicle keys each for:
Personal injury and damage to pro-  Interlock circuit for the height and slewing limi-
perty tation,
Failure to follow the instructions contai-  rail operation
ned in the introductory chapters may re-  display for the height limiter,
sult in injury or damage.
 ignition lock, cab door, front and rear, main-
 Observe all the instructions in the "Intro- tenance flaps, maintenance bonnet,
duction", "Safety of the road and off-road
operations" and "Safety rail operation"  tank cap and
chapters in particular before starting up  the tool boxes.
the rail-road excavator.

WARNING
Danger of accident
Risk of accident due to incorrect actuati-
on and uncontrolled equipment move-
ments.
 Make a note of all the display and control
devices before starting up the rail-road
excavator, see page 35.

8.1 Before operation

8.1.1 Opening and closing

WARNING
Danger of accident
Misuse and improper operation by unau-
thorised persons may cause accidents.
 Close the windows and always lock the
rail-road excavator when you leave it.
 Switch the electrical system off using the
battery isolator switch if stationary for long
periods.
1 Interlock circuit for the height and slewing limi-
Vehicle key tation
2 Rail operation
WARNING 3 Display for the height limiter
Danger of accident 4 Ignition lock
Misuse and improper operation by unau- 5 Cab door, front and rear
thorised persons may cause accidents. 6 Maintenance flaps (left and right)
 Those responsible for operation have to
7 Maintenance bonnet
store the vehicle keys in a safe place so
that they are not accessible to third par- 8 Tank cap
ties. 9 Tool boxes (left and right)
 The keys to the vehicle may only be han-
ded over to qualified persons who know
how to handle the rail-road excavator and
have read and understood these opera-
ting instructions.

55
8 Operation
8.1.2 Battery isolator switch
WARNING
NOTICE
Personal injury and damage to pro-
Damage to property perty
The electrical system may be damaged if Uncontrolled movement of the rail-road
the battery isolator switch is activated excavator caused by accidentally tou-
when the ignition is switched on. ching the joysticks or pedals may cause
 Use the battery isolator switch only when injury or damage.
the ignition is switched off.  Switch off the pilot control before climbing
in or out, see page 70.

WARNING
Personal injury
When opening the cab door, there is a
risk of injury.
 Only open the front cab door if the rear
one is closed.
 Only open the rear cab door if the front
1 I one is closed.

II WARNING
M+P-05C-2624 Personal injury
The battery isolator switch is operated with the Improper operation of the rail-road exca-
key (1). vator may cause injury to the accompany-
ing crew .
I Pull the key out/put the key (1) in.
 Only transport accompanying crew if they
Electrical system is switched off are sitting and the rear cab door is
II Electrical system is switched on. closed.
After switching off the excavator, pull the key (1)
out of the battery isolator switch. Climbing in: the operator

WARNING
Personal injury and damage to pro-
I II
perty
There is a risk of fire, a risk of misuse by 2
unauthorised persons and static current
consumption when the electrical system
is switched on.
 Switch the electrical system off using the
battery isolator switch when the excavator
3
is being maintained and when it is statio- 1
nary for a long time.

8.1.3 Cab doors M+P-05C-2625

WARNING 1 Door handle

2 Door lock
Personal injury
I Unlocking
There is a risk of slipping and falling if the
footsteps and floor space are dirty or icy. II Locking
 Keep the footsteps, the floor space and 3 Door holder
shoes free of dirt (e.g. mud, clay, snow or
ice) and wear non-slip shoes.

56
 Operation 8
Climbing in: the accompanying crew

6
4

7
6

8
1
I II
5 M+P-05C-2626
2
4 Pilot control lever
M+P-05C-2627

5 Footsteps 1 Door handle

6 Handles 2 Door lock
7 Outside mirror I Unlocking
8 Cab door unlocking lever II Locking
1. Close the rear cab door if necessary.
2. Unlock the door lock (2), use the door handle
to open the cab door (1) and lock in door
holder (3). 4
3. Swing the pilot control lever (4) upwards if ne-
cessary.
4. Enter the cabin, using the footsteps (5) and
the handles (6).
5. Adjust the outside (7) and the inside mirror.
6. Press the unlocking lever (8) if necessary, un-
lock the front cab door and close it.

Climbing out: the operator 3 M+P-05C-2628

3 Footsteps
4 Handles
1. Close the front cab door if necessary.
2. Unlock the door lock (2) and use the door
handle (1) to open the rear cab door.
3. Fold down the seat (of the accompanying
crew), see page 62 if necessary.
4. Enter the cabin, using the footsteps (3) and
the handles (4).

1. Swing the pilot control lever (1) up.

2. Press the door opener (2) down and open the
front cab door.
3. Leave the cabin using the footsteps and
handles.

57
8 Operation
Climbing out: the accompanying crew 8.1.5 Windshield

WARNING
Danger of accident
If the windscreen has not engaged pro-
perly it may open or close suddenly du-
ring operation. This may cause an acci-
dent.
 Engage the windshield properly.

WARNING
Personal injury
Pushing the windshield upwards, if the
front cab door is closed, may cause inju-
1. Unlock the door lock (1) and open the rear cab ry.
door.  Before opening and closing the winds-
2. Leave the cabin using the footsteps and hield, open the front cab door and lock in
handles. door holder.

8.1.4 Side window Note

In order to provide clearance of the windshield,
tilt the steering column backwards, see
page 64. Then push the seat with consoles
backwards, see page 60.
3
1
Opening and closing

2
2
L

2 M+P-05C-2354

Opening
Pull the handle (1) for the side window (2) or (3),
push forwards or backwards.

Closing
Hold the handle (1) and push the side window (2)
or (3) forwards or backwards until it locks into
place.

M+P-05C-2355

1. Push the lever (1) towards the front to the right

and left.
2. Hold the windshield by the handles (2) and
push it upwards or downwards until it en-
gages.

58
 Operation 8
8.1.6 Ignition lock Adjusting the height of the seat and the seat
suspension
0 I 1. Turn the ignition key to position I, see
II page 59.
2. Sit still on the seat.
1

0
1
2

M+P-05C-2356

0 Ignition off
This is the only position in which the ignition
key (1) can be inserted or removed.
I Ignition on M+P-05C-3456

II Start the engine
WARNING
Danger of accident
When the engine is switched off, steering
and brakes of the rail-road excavator are
partially operational. This may cause an
accident.
 Only switch on the ignition when the rail-
road excavator is stationary.
8.1.7 Adjusting the seat
WARNING
Danger of accident
If the seat is adjusted while driving, the
operator may lose control of the rail-road
excavator due to unexpected seat move-
ments, thereby causing an accident.
 Only adjust the seat when the rail-road
excavator is stationary.
3. Pull or push the lever (1) completely until the
green area on the display (2) becomes visible.
Note
Pulling: Pulling increases seat height and hard-
ness of suspension.
Pushing: Pushing decreases seat height and
hardness of suspension.
4. If necessary, lock (a) or unlock (b) the hori-
zontal suspension with the lever (3).
Comfort seat
Seat suspension:
1. Pull the lever (1) briefly.
The seat will automatically be adjusted accor-
ding to the operator's weight.
2. If necessary, lock (a) or unlock (b) the hori-
zontal suspension with the lever (3).
Seat height:
Pull or push the lever (1) completely and set the
continuously variable seat height.

NOTICE
Damage to property
Operating the lever for too long may da-
mage the seat.
 Do not operate the lever for longer than
one minute.

Note
When the upper or lower stop of the height set-
ting has been reached the seat height will be au-
tomatically adjusted to keep the spring travel as
small as possible.

59
8 Operation
Adjusting the surface of the seat cushion Moving the seat forward/backward

WARNING
Personal injury
Holding other elements while adjusting 1
the surface of the seat cushion may result
in crushing fingers.
 Actuate only the relevant lever when ad-
justing the surface of the seat cushion and
do not touch by the other hand behind the
seat cushion.

Adjusting the angle 2

M+P-05C-3459

Without consoles
Pull lever (1) and move the seat forward or back-
ward.

Note
After releasing the lever, the seat has to lock
into place audibly.

With consoles
1
Pull lever (2) and move the seat forward or back-
M+P-05C-3457
ward.
Pull the lever (1) and by increasing or decreasing
the load on the seat cushion set the desired Note
angel. After releasing the lever, the seat has to lock
into place audibly.
Note
After releasing the lever, the seat cushion has to Move the seat into driving position
lock into place audibly.

Moving the seat cushion forward/backward

M+P-05C-3460

1 Seat that is centered between the consoles is to

be pushed completely forward along with the con-
M+P-05C-3458
soles, see page 60.
Pull the lever (1) and by increasing or decreasing Arrows (1) must be in line.
the load on the seat cushion relocate it.

Note
After releasing the lever, the seat cushion has to
lock into place audibly.

60
 Operation 8
Adjusting the backrest Adjusting the headrest

M+P-05C-3461 M+P-05C-3463

Adjusting the angle Adjusting the angle

Pull the lever (1) and set the desired angle.
Note
After releasing the lever, the backrest has to
lock into place audibly.
Press the headrest (1) forward or backward until
the required angle has been set.
Adjusting the height
Push the headrest (1) outwards or inwards until
the required height has been set.

Adjusting the lumbar support Note

Turn the hand wheel (2) until the required curve
Headrest shall perceptibly engage into the va-
has been set.
rious detents .
Adjusting the angle of the armrests In order to remove the headrest (1) push it out
above the last detent.
1. Relieving the armrests.

8.1.8 Safety belt

All national legislation and regulations in the
countries in which the industrial machine is used
must be observed.

WARNING
Personal injury
The restraint function may be limited if
1
the safety belt has not been put on cor-
rectly or has not snapped into the buckle
properly. This may cause injury in the
event of an accident.
M+P-05C-3462  The safety belt must have a tight fit.

2. Turn the hand wheel (1) until the required  The safety belt must not be twisted.
angle has been set.  The safety belt must be positioned as low
as possible around the driver's pelvis.
 The safety belt must not be led over any
sharp edges.

61
8 Operation
8.1.9 Fold up and down the seat (of the
accompanying crew) if necessary
In order that access to the fire extinguisher, the
first-aid box and the fuses is secured, the
1
seat (accompanying crew) may be folded up.
1. Push the seat (of the operator) completely for-
ward, see page 60.

2. Fold up/down the seat (accompanying

crew) (1).
M+P-05C-3464

Attention
1 Belt retractor
2 Buckle flap The seat (accompanying crew) (1) is held in
folded-up position by a pneumatic spring.
3 Buckle
4 Release button
8.1.10 Seat heating
WARNING 1. Turn the ignition key to position I, see
page 59.
Personal injury
If the buckle flap and/or the buckle of the
safety belt are dirty or damaged, the safe-
ty belt will not be able to fully snap into 1
the buckle. During an accident, when bra-
king or if the direction of drive is changed
abruptly, the restraint function may be re-
stricted. This may cause injury.
 Always keep the buckle flap and the buck-
le clean.

WARNING
Personal injury
The restraint function may be restricted if M+P-05C-3465

the safety belt is damaged or has been

subjected to great strain during an acci- 2. Press the switch (1).
dent. This may cause injury in the event 0 Switch off
of an accident.
I Switching on
 Replace the safety belt and if necessa-
ry have the belt bracing checked by a sui-
tably qualified employee.

62
 Operation 8
8.1.11 Cigarette lighter

WARNING
Personal injury
Hot metal parts of the cigarette lighter
may cause burns.
 Only hold the cigarette lighter by the
handle.

1. Turn the ignition key to position I, see

page 59.

Opening and closing

Hold the cover by the handle (1) and push it up-
wards or downwards.

Removal
1. Hold the cover by the handle (1) and push it
downwards.
2. Remove the ash-tray (2) from above, taking it
from the holes.

Inserting back
2. Press the inner part (1) of the cigarette lighter
(2). 1. Insert the ash-tray (2) underneath into the
The inner part (1) automatically jumps back- holes.
ward until the spiral begins to glow. 2. Press the ash-tray (2) from above until it locks
3. Taking out the cigarette lighter (2). into the place.
3. Hold the cover by the handle (1) and push it
upwards.
Note
The socket of the cigarette lighter is inteded for
24 V (15 A) appliances of up to max. 360 W.

8.1.12 Ash-tray

WARNING
Danger of accident
If the ash-tray is being taken out or inser-
ted back while operating the rail-road ex-
cavator, the operator may lose control
over the excavator. This may cause an ac-
cident.
 Only take the ash-tray out and insert it
back when the rail-road excavator is stati-
onary.

63
8 Operation
8.1.13 Steering column adjustment 8.1.14 Sunblind

WARNING 7
Danger of accident
There is a risk of injury if the steering co-
lumn is being adjusted at the time of dri- 6
ving.
 Only adjust the steering column if the rail-
road excavator is stationary.
3
1 5
Note
The steering columnt is spring loaded. While ad- 2
justing the steering column, always hold it firmly.
3
4

M+P-05C-2359

Height
Pull the lever (1) upwards. Set the desired posi-
tion of the steering column.
Note
After releasing the lever, the steering column
has to lock into place audibly.
Angle
Pull the lever (1) downwards. Set the desired po-
sition of the steering column.
Note
After releasing the lever, the steering column
has to lock into place audibly.
Windshield
Use the handles (2) to pull the sunblind (1) down
or up and hook into the brackets (3) or (4).
Roof panel
Use the handles (6) to pull the sunblind (5) down
and hook into the brackets (7).
Rolling up
To roll up, hold the sunblinds (1) and (5) by the
handles (2) and (6), unhook and retract.
Note
The sunblinds (1) and (5) are pulled back by
means of spring force.

64
 Operation 8
8.1.15 Lighting Direction indicator
1. Turn the ignition key to position I, see
page 59.
2. Switch off the rail operation, see page 107.

Actuate the lever (1).

The control light (2) flashes and a buzzer sounds.
I Left flashing
II Right flashing

Warning lights

Side lights and dipped beam

1. Push the lever (1) into position 0.
2. Press the switch (2).
0 Switch off
I Side lights
The control light (3) lights up.
II Dipped beam
The control light (3) lights up.

Main-beam headlight

WARNING
Danger of accident
Working main-beam headlight may dazz-
le other road users when switched on,
thereby causing an accident.
 Make sure that main-beam headlights are Press the switch (1).
used in accordance with traffic regulati-
ons. 0 Switch off
I Switch on
1. Push the switch (2) into position II. The control lights (2) and (3) are flashing.
2. Actuate the lever (1).
0 Switch off
The control light (3) lights up.
I Switch on
The control lights (3) and (4) light up.

65
8 Operation
Interior lights At the rear

At the front

1
II I

0
2

I
0 I 0

1
M+P-05C-2364

Press the switch (1).

M+P-05C-2729

0 Switch off
1. Press the switch (1).
I Switching on
0 Switch off
II No function
I Switching on.
Rotating warning light
The respective national regulations have to be
observed when using the rotating warning light.

2. Press the switch (2).

0 Switch off
I Switching on.

Note
To switch on the interior lights, the switch (1)
must be in position I, so that the interior lights
can be switched on with the switch (2).

Press the switch (1).

0 Switch off
I Switch on
The control light (2) lights up.

66
 Operation 8
Working floodlights 8.1.16 Windscreen washer

WARNING Note
Danger of accident Switch the windscreen washer on only when the
Working floodlights may dazzle other windshield is closed
road users when switched on, thereby
causing an accident.
Turn the ignition key to position I.
 Make sure that the working floodlights 
are used in accordance with traffic regula-
Windshield wiper
tions.

The working floodlights (at the front and at the

rear) light up the workspace.

Press the switch (1).

0 Switch off
I Normal wiping
II Fast wiping

Intermittent windshield wiper

At the front
Press the switch (1). 1
0 Switch off
I Switch on
M+P-05C-2368
The control light (2) lights up.
Switching on
At the rear
Press the button toggle (1) briefly.
Press the switch (3).
The control light (2) on the display panel lights up.
0 Switch off
I Switch on Switch off
The control light (2) lights up. Press the button toggle (1) briefly again.
The control light (2) lights up.

67
8 Operation
Windshield washer Air conditioning system

2 WARNING
Personal injury

1 Checks carried out improperly on the

heating and air conditioning system may
result in injury.
 Have the heating and air conditioning sys-
tem checked every 24 months by a quali-
fied employee. ATLAS recommends con-
sulting an ATLAS Customer Service.
1
NOTICE
M+P-05C-2368
Damage to property
Damage may be caused if the compres-
Switching on sor of the heating and air conditioning
Press and hold the button toggle (1). system is not lubricated regularly.
 Switch on the air conditioning system for
The control light (2) on the display panel lights up.
a short period at least once a month.

Switch off
Note
Release button toggle (1).
The control light (2) goes out. The air conditioning system can also be used to
dehumidify the air and demist the cab windows.
8.1.17 Heating
1. Close windows and cab doors.
Turn the ignition key to position I.
2. Turn the ignition key to position I.
3. Set the blower to the desired blow level, see
page 68.

Heating output adjustment

1. Turn the pull switch (1) and pull it to the
desired heating output. 4. Press the switch (1).
I Heating output increases 0 Switch off
II Heating output decreases I Switching on
2. Turn the pull switch (1) back and lock it.

Setting the blower

The blower has four blow levels.
Press the switch (2) to set the desired blow level.

68
 Operation 8
8.1.18 Setting the nozzles Windshield
Heating for the windshield may be increased by
At the front the nozzles (1).

1
M+P-05C-1992

Press the fins (1) and turn the marked edge.

At the rear

1. Turn the pull switch (2) back and lock it com-

pletely.
2. Turn the pull switch (2) back and lock it.

Press the fins (2).

3
M+P-05C-1994

3. Choke or close the rear nozzles and

nozzles (3).

8.1.19 Auxiliary heating

Auxiliary heating may be operated by the timer
in the cab. See the separate operating instruc-
tions.

69
9 Road and off-road operations
9 Road and off-road operations

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before starting up
the rail-road excavator.

DANGER
Personal injury
Sudden movements of the equipment
may cause personal injury.
 Before starting up the engine make sure
that nobody is within the hazard zone of
the rail-road excavator.
9.1 Checks to be carried out prior to
starting the engine
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before starting up
the rail-road excavator.
1. Turn the ignition key to position I, see
page 71.
2. Press the button toggle (1) or (2).
The horn must sound.
9.1.1 Pilot control
For jib adjustment use the pilot control to switch
on/off the functions of the joysticks and the pe-
dals.
WARNING
Personal injury and damage to pro-
perty
Uncontrolled movement of the rail-road
excavator caused by accidentally tou-
ching the joysticks or pedals may cause
injury or damage.
 Switch off the pilot control before taking a
break and before entering or leaving the
excavator.

Daily before starting the engine for the first 1

time
 Switch on the electrical system using the bat-
tery isolator switch, see page 56.
 Carry out daily checks in accordance with the
inspection plan, see page 54.
 Carry out a visual inspection for damage,
loose parts and oil, fuel and coolant leaks.
 Ensure that the pilot control has been deacti-
vated, see page 70.
M+P-05C-2629
 Switch off the rail operation, see page 107.
Switching on
Swing the pilot control lever (1) down.

Switching off
Swing the pilot control lever (1) up.

70
 Road and off-road operations 9
9.2 Ignition lock The following warning and control lights have to
be lit on the display panel until the engine is
started and then have to go out:
0 I
II Warning light: generator charge control
- +
1
Warning light: engine stop

1
Control light: load limit sensing control
0
1
2

Warning light: engine oil pressure

(1)
M+P-05C-2356

0 Ignition off
This is the only position in which the ignition
key (1) can be inserted or removed.
I Ignition on NOTICE
II Start the engine
Damage to property
WARNING If the warning lights go out straight after
the test run, a malfunction has occurred
Danger of accident which may result in damage.
When the engine is switched off, steering  The malfunction has to be rectified imme-
and brakes of the rail-road excavator are diately
partially operational. This may cause an
accident.
WARNING
 Only switch on the ignition when the rail-
road excavator is stationary. Personal injury and damage to pro-
perty
If the warning lights continue to be lit, a
9.3 Test run malfunction has occurred which may
cause damage or injury.
WARNING  The malfunction has to be rectified imme-
diately.
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
The following warning and control lights as well
ned in the introductory chapters may re- as the bar indicators may continue to be lit on the
sult in injury or damage. display panel or may light up during operation:
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation" Warning light: defective fuses
chapters in particular before starting up
the rail-road excavator.
Warning light: malfunction
Turn the ignition key to position I.
All warning and control lights light up.
Warning light: hydraulic oil level
NOTICE
Damage to property Control light: hydraulic oil filter
If some of the warning and control lights
do not light up, a malfunction has occur-
red which may result in damage. Control light: air filter
 The malfunction has to be rectified imme-
diately.

71
9 Road and off-road operations
9.4.1 Start the engine
Bar indicator: engine oil pressure
1. Switch pre-selection for direction of travel to
position Neutral, see page 77.

Bar indicator or warning light: fuel

level (1)

PAR DEL

4 6
Warning light: coolant overheating/ 2
bar

coolant level (1) or bar indicator: 0 10

coolant temperature
I 1

Note M+P-05C-2387

Possible causes of malfunctions being indi- 2. Turn the switch (1) to position I.
cated, see page 196.

9.4 Starting and stopping the engine

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before starting up 3. Ensure that the driving brake pedal (2) and the
the rail-road excavator. slewing brake pedal (3) are locked with the lat-
ching devices (4) and (5).
WARNING 4. Turn the ignition key to position I. The test run
Danger of accident will start, see page 71.
Misuse and improper operation by unau- 5. Turn the ignition key to position II and hold it
thorised persons may cause accidents. there.
 Close the windows and always lock the The engine will start.
rail-road excavator when you leave it.
NOTICE
 Switch the electrical system off using the
battery isolator switch if stationary for long Damage to property
periods.
A lengthy engine start may damage the
batteries.
WARNING  Do not start for longer than 20 seconds
without a break.
Danger of accident
 Wait at least 2 minutes before trying to
Failure to fulfil all of the necessary requi-
start the engine again.
rements prior to starting up the engine
may result in accidents during operation. 6. As soon as the engine is running smoothly re-
 All of the essential checks before starting lease the ignition key.
the engine have to be carried out, see
page 70. The control light in the display panel lights
up.

72
 Road and off-road operations 9
NOTICE NOTICE
Damage to property Damage to property
All warning lights must go out; if they do All warning lights must go out; if they do
not, a malfunction has occurred which not, a malfunction has occurred which
may cause damage. may cause damage.
 The malfunction has to be rectified imme-  The malfunction has to be rectified imme-
diately diately.

9.4.3 Switching off the engine

PAR DEL

00000 0 h

4 6
6 bar

2 8

0 10

I 1
M+P-05C-2385

7. Check whether the control wheel (6) of the

operating hours counter can be turned.
9.4.2 Starting with the cold start device 
The engine can be started up with the help of the
cold start device even if outdoor temperature
is extremely low.
1. Turn the ignition key to position I. The test run
will start.
The control light will light up on the dis-
play panel after the test run.
2. When the control light goes out, turn the igni-
tion key to position II and hold it there.
The engine starts up.
NOTICE
Damage to property
A lengthy engine start may damage the
batteries.
 Do not start for longer than 20 seconds
without a break.
 Wait at least 2 minutes before trying to
start the engine again.
M+P-05C-2387
1. Turn the switch (1) to position I.
2. Turn the ignition key to position 0.
The engine will switch off.
Note
All settings made before the engine is switched
off will be automatically reselected when the en-
gine is started.
9.5 Before operation
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before starting up
the rail-road excavator

3. As soon as the engine is running smoothly re-

lease the ignition key.
The control light in the display panel lights
up.

73
9 Road and off-road operations
9.5.1 Auto-idling system 9.5.2 Setting the engine speed
The automatic idling mode serves to preserve the
engine and to cut down on fuel consumption. It is
activated around 6 seconds after the last rail-road
excavator operation and switches the engine to
idling speed. PAR DEL

II
III 4 6
I bar

2 8

IV 0 10

M+P-05C-2392

Turn the switch (1) to the desired engine speed.

I 1000–1600 min-1
(idle/warm-up)
II 1600–1900 min-1
(optimum speed range)
III 1900–2100 min-1
(more economical but increased speed
range)
IV 2100–2400 min-1
(less economical but possible speed range)

Press the switch (1).

0 Switch off
I Switch on
The control light (2) lights up.

74
 Road and off-road operations 9
9.6 Driving the rail-road excavator 9.6.1 Parking brake
Turn the ignition key to position I.
WARNING
NOTICE
Personal injury and damage to pro-
perty Damage to property
Failure to follow the instructions contai- Switching on the parking brake while dri-
ned in the introductory chapters may re- ving the rail-road excavator may damage
sult in injury or damage. the traction motor and the transmission.
 Observe all the instructions in the "Intro-  Only adjust the parking brake when the
duction", "Safety of the road and off-road rail-road excavator is stationary.
operations" and "Safety rail operation"  In case of emergency, if the service bra-
chapters before driving the rail-road exca- king device fails, an emergency braking
vator. may be performed by the parking brake,
see page 79.
WARNING
Danger of accident Switching on the parking brake
Setting off in the wrong direction can lead
to accidents.
 Prior to travel, determine where the travel
drive is located.
 Operate the rail-road excavator with due
care.
 If possible, always turn the uppercarriage
so that the travel drive is at the front.
 Prior to reverse travel switch on the rear
area monitoring, see page 117.
 Ask another person to guide by using
hand signals, if necessary.
 Persons are not permitted to be within the
hazard zone of the rail-road excavator.

WARNING
Danger of accident
In case of amalfunction of the brake sys-
tem the brake distance of the rail-road ex-
cavator becomes longer. This may cause
an accident.
 Before each driving of the rail-road exca-
vator check the functions of the brake sys-
tem at a low speed.
1. Actuate the lever (1) and the button toggle (2)
 When driving the rail-road excavator, in the center position.
keep an adequate brake distance.
 Persons are not permitted to stay within
the hazard zone of the rail-road excava-
tor.

75
9 Road and off-road operations
9.6.2 Starting up
 Prepare the rail-road excavator for operation,
see page 73.
 Start the engine, see page 72.
 Lift the outrigger support up to the limit stop,
see page 83.

Note
When driving the excavator and the paws are lo-
wered, the actuation of the driving pedal lifts
them up automatically.

 Parking brake deactivation, see page 76.

 Lifting up the guide roll axles, see page 120.

PAR DEL
1
4 6
bar

2 8

0 10

2. Press the brake switch (3) backwards.

The control light (4) in the display panel lights
up.
M+P-05C-3283

Parking brake deactivation
Press the brake switch (3) forwards.
The control light (4) goes out
 The indicator (1) of the compressed air mano-
meter must indicate approx. 5 bar.
WARNING
Danger of accident
Carelessness when starting up and while
driving may lead to accidents.
 Warning signs have to be given if persons
are at risk.
 Before starting up make sure that nobody
is within the hazard zone of the rail-road
excavator.

76

Changing gear
The gear may be changed also when driving.
Gear changing is monitored by an overwind pro-
tection device.
Push the switch (1) into the direction of the
desired gear.
I Off-road gear
II On-road gear
Note
The transmission shifts from on-road gear to off-
road gear if the driving speed is too low and
there is a risk of damage for the transmission.
Shifting from on-road gear to off-road gear may
be performed immediately at any driving speed.
Road and off-road operations 9
Travel direction pre-selection
1. Find out where the travel drive is located.
2. Actuate the lever (1) or the button toggle (2).
0 Neutral
I Forward
The control light (3) lights up.
II Backward
The control light (4) lights up.
Starting up
1. Unlock the driving brake pedal (1) with the lat-
ching device (2).
2. Actuate the driving pedal (3).
Note
When driving the excavator and the paws are lo-
wered, the actuation of the driving pedal (3) lifts
them up automatically.
77
9 Road and off-road operations
9.6.3 Creeper gear 9.6.5 Speed indication
For sensitive driving (e.g. transporting heavy
loads, driving in confined spaces ,etc.) switch on
the creep gear.

The driving speed may be seen on the speed in-

dication display (1).

Actuate the lever (1). Note

I Switch off No functions are assigned to button toggles (2)
II Switch on and (3).
The control light (2) lights up.
9.7 Stopping and parking
9.6.4 Travel speed manual adjustment
WARNING
I Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
1  Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
II chapters in particular before starting up
the rail-road excavator.

9.7.1 Stopping
M+P-05C-2401

Actuate the lever (1).

I Zero position
II Max. travel speed

1. Operate the driving brake pedal (1).

The rail-road excavator is stopped.
2. Lock the driving brake pedal (1) with the lat-
ching device (2).
3. Turn the switch (3) to position I, if necessary.
4. Switching on the parking brake, see page 75.

78
 Road and off-road operations 9
4. Switch off the pilot control, see page 70.
WARNING 5. Switch off the engine.
Personal injury 6. Switch off the electrical system via the battery
Stopping the rail-road excavator on up- isolator switch, see page 56.
ward or downward slopes may result in
injury when the parking brake is released. WARNING
 Persons are not permitted to be within the
Danger of accident
hazard zone of the rail-road excavator.
Misuse and improper operation by unau-
thorised persons may cause accidents.
Emergency braking  Close the windows and always lock the
If the service braking device fails, an emergency rail-road excavator when you leave it.
braking may be performed by the parking brake.  Switch the electrical system off using the
Switching on the parking brake, see page 75. battery isolator switch if stationary for long
periods.
WARNING
Personal injury and damage to pro-
perty
Performing an emergency braking by me-
ans of the parking brake while driving the
rail-road excavator may cause injury to
the operator because of the uncontrolled
brake force. The tracton motor and the
transmission may be damaged.
 Perform emergency braking only to pre-
vent accidents

9.7.2 Parking
 Park the rail-road excavator only on solid
ground which is as level as possible.
 Turn the uppercarriage so that the travel drive
is at the front (given the direction of travel),
see page 89.
 Only park the rail-road excavator where it
does not cause obstruction; if necessary se-
cure it with a warning triangle, marking lines,
etc.
 Secure the rail-road excavator to prevent it
from slipping down on upward or downward
slopes.

WARNING
Personal injury and damage to pro-
perty
If the hydraulic system is damaged the
work attachment and the outrigger sup-
port may drop down and cause injury or
damage.
 Lower the work attachment and the out-
rigger support to the ground when leaving
the rail-road excavator.

1. Stopping the rail-road excavator, see

page 78.
2. Lower the work attachment and the outrigger
support to the ground, see page 84 and
page 88.
3. Switch the travel direction pre-selection to po-
sition Neutral, see page 77.

79
9 Road and off-road operations
9.8 Driving on public roads 9.8.1 Installing and removing the rear
reflectors
WARNING
Note
Personal injury and damage to pro-
You will find the rear reflectors in the tool box,
perty
see page 55.
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters before driving the rail-road exca-
vator on public roads.

Observe the national regulations of the countries

in which the rail-road excavator is used.
 In Germany, a permission for road transport
with regard to the rail-road excavator is re-
quired. Consider to the picture of the driving
position in the cab.
 Clean the rail-road excavator thoroughly be-
fore driving it on public roads and check its 4
operational and road safety. 2
 Turn the uppercarriage so that the travel drive
is at the front (given the direction of travel),
see page 89.
 Maximal permissible height of the vehicle and
the cantilever lengths must not be exceeded.
3 1
 Move the seat into driving position, see
page 60.
 Position the steering column vertically, see M+P-05C-2630

page 64.
 Apply equipment, e.g. warning flags, a rota-
ting warning light, that complies with nati-
onal regulations.
 Check that lighting, direction indicator and
horn work.
 If necessary, remove the work attachment,
see page 93.
 Retract the dipper tipping cylinder or the
dipper cylinder completely, see page 89.
Insert the rear reflector (1) into the rear holder (2)
and secure it with a pin (3) and a splint pin (4).
9.8.2 Rear lamps installing and removing
Note
The rear lamp extension described below is not
available for rail-road excavators whose rotation
radius of the rear end is 2000 mm.
1. Open the left-hand maintenance flap.

M+P-05C-2571

Secure the paws (1) with the relevant pins (2)

and splint pins (3) whereupon the paws must be
in fully retracted position.

80
 Road and off-road operations 9
1

8 9
4 2
3
8
9
M+P-05C-2632

7. Use the handle (3) to push the rear lamp (2)

into the extension (4).
8. Tighten screws (8) with nuts (9).

2 9.8.3 Slewing locking device

3
Blocking
1. Turn the uppercarriage so that the travel drive
is at the front (given the direction of travel),
M+P-05C-2631 see page 89.
2. Loosen the screw (1).
3. Hold the rear lamp (2) by the handle (3) and
pull it out.
2
1 7 I 1

4
6
II M+P-05C-2408

I Blocking
II Unblocking
M+P-05C-2406
2. Swing the lever (1) down and swivel the lat-
4. Insert the extension (4) in the holder (5) until ching device (2).
the balls (6) snap into the holes (7). 3. Push the lever (1) into position I.
5. Tighten the screw (1).
6. Close the left-hand maintenance flap.

81
9 Road and off-road operations
9.9.1 Work preparation
 Carry out daily checks in accordance with the
inspection plan, see page 54.
4
 Start the engine, see page 72.
 Drive the rail-road excavator to the work site,
see page 75.
 Secure the rail-road excavator by the out-
3 rigger support, see page 83.
 Switch on the pilot control, see page 70.
 Release the parking brake, see page 76.
 Switching on the oscillating axle locking de-
vice, see page 83.
 In order to take advantage of the maximal te-
M+P-05C-2409

4. Check if the pin (3) engages into the holder aring and breakout force, actuate the driving
(4). brake (driving brake pedal) and block it, see
page 78.
Unblocking

WARNING
Danger of accident
Accidents can happen if the slewing lo- PAR DEL
1
cking device is unblocked during operati-
on on public roads. 4 6
bar

 Unblock the slewing locking device if the 2 8

rail-road excavator has left the public 0 10

road.

Push the lever (1) into position II and secure by

the latching device (2).
M+P-05C-3283

9.9 Works carried out during road or  The indicator (1) of the compressed air mano-
off-road operation meter is to indicate approx. 5 bar.

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before rail-road ex-
cavator road and off-road operation.

82
 Road and off-road operations 9
9.9.2 Oscillating axle locking device 1 Minimum sensitivity
The oscillating axle can be blocked in any posi- 2 Normal sensitivity
tion during the work via the brake pedal or perma- 3 Maximum sensitivity
nently.
1. Turn the ignition key to position I. Suspending fine control

Keep button (1) pressed.

Fine control is suspended during this time.

9.9.4 Outrigger support

The outrigger support serves for enhancing the
stability of the rail-road excavator.
The paws are activated simultaneously.

Adjusting the angle of the paws

3
2. Press the switch (1). II
0 Switch off
I Pre-select
The control light (2) lights up and the os-
cillating axle locks only if the driving brake 1
pedal is actuated and locked.
II Switch on I
The control light (3) lights up and the os-
2
cillating axle is permanenly blocked

9.9.3 Fine control

M+P-05C-2572

1. Pull out the splint pin (1) and the pin (2).
2. Secure the paws (3) in the desired position by
means of the relevant pins (2) and splint pins
(1).
I The support area is at the same height as
the contact area of the rail-road exca-
vator, e.g. on levelled surface or levelled
rails.
II The support area is lower than the con-
tact area of the rail-road excavator, in the
case of open rails.

Note
Relieve the pins by lifting the paws completely,
Turn the thumb roller (1) to the desired sensitivity.
if necessary, see page 83.
– Switch off

83
9 Road and off-road operations
Outrigger support switching on/off
1. Block the driving brake pedal with the latching
device, see page 78.
Moving
WARNING
Personal injury and damage to pro-
perty
When moving the outrigger support, the-
re is a risk of injury or damage.
 Neither people nor any obstacles may
stay within the range of the outrigger sup-
port.

2. Press the switch (1).

0 Switch off
I Switch on

Pre-selecting the travel direction

Operate the driving pedal (1).

The paws lift or lower depending on the travel di-
rection that is pre-selected.

Note
For work purposes always completely lower the
outrigger support.

9.9.5 Pressure activation setting

Pressure activation setting of the rail-road ex-
cavator enhances the working pressure so as to
enable the lifting of heavy loads.

NOTICE
Damage to property
If the pressure activation setting is al-
ways switched on, damage may be
caused.
 The pressure activation setting may be
activated only for lifting heavy loads as re-
quired.

Actuate the lever (1) or the switch (2).

0 Switch off
I Lower the paws
The control light (3) lights up.
II LIft the paws
The control light (4) lights up.

Note
If the travel direction is to be pre-selected by
means of the switch (2), push the lever (1) into
position 0.

84
 Road and off-road operations 9

Press the switch (1). Press the switch (1).

0 Switch off 0 Switch off
I Switch on I Switch on
The control light (2) lights up. The control light (2) lights up.

9.9.6 Overload warning device Overload warning

If the load lifted is too high or is moved within the
WARNING overload range, the control light (2) starts to flash
Personal injury and damage to pro- and a buzzer sounds.
perty The load moment must be reduced immedia-
The rail-road excavator may tip due to an tely by moving the load nearer to the rail-road
excessively high load moment when it is excavator.
lifting and may cause injury or damage.
 Hoisting equipment (e.g. a load hook) is
only permitted with the overload warning
device switched on.
 Only attach loads to the load hook or to lif-
ting rings, and observe the safe working
load when doing so (see the load chart in
the cab).

85
9 Road and off-road operations
9.9.7 Activate maximum power for a short
period
The pressure differential can be raised to 100%
for a short time or fine control can be switched off.

Keep button (1) pressed.

The working speed is increased to the maximum
as long as the button is pressed.

86
 Road and off-road operations 9
9.9.8 Emergency operation in case of a
fault in the load limit sensing control
In case of a fault in the load limit sensing control,
the rail-road excavator can be operated in emer-
gency mode at a reduced output.

I
The control light (1) lights up if there is a fault in
2
the load limit sensing control.
II
NOTICE
Damage to property M+P-05C-2633

If the load limit sensing control fails, it 3. Actuate the lever (2).
can cause the engine to overload. This I Switch on emergency mode
may lead to damage.
 Use the emergency mode in a case of
II Switch off emergency mode
emergency only. 4. Close the right-hand maintenance flap.
 Have the load limit sensing control re-
paired immediately.
ATLAS recommends consulting ATLAS
Customer Service.

1. Parking the rail-road excavator, see page 78.

2. Open the right-hand maintenance flap.

5. Remove the plug (3) from the electronics box

(4).
6. Start the engine, see page 72.
The control light (1) lights up if emergency
mode is switched on.

87
9 Road and off-road operations
9.10 Excavator equipment and work
attachment

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters before moving the excavator
equipment and using the work attach-
ments.

88
 Road and off-road operations 9
Uppercarriage Main boom
Operate the joystick (1). Operate the joystick (5). The lifting cylinders (6)
I Turning anti-clockwise move.
II Turning clockwise VII Lowering
VIII Lifting
Articulated jib
Operate the joystick (1). The articulated cylinder Work attachment
(2) moves. 1. Operate the joystick (5). The dipper tipping
III Straightening cylinder (7) or the dipper cylinder moves.
IV Bending IX Close the dipper/the grab
Bend the hydraulic hammer/the track
Jib tamping equipment
Press the pedal (3). The adjustment cylinder (4) X Open the dipper/the grab
moves. Straighten the hydraulic hammer/ the
track tamping equipment
V Lifting
2. Actuate the slide controller (8).
VI Lowering
XI Rotate the grab anti-clockwise
Rotate the track tamping equipment anti-
clockwise
Swivel the tamping unit downwards
XII Rotate the dipper clockwise
Rotate the track tamping equipment
clockwise
Swivel the tamping unit upwards

89
9 Road and off-road operations
Track tamping equipment Tamping pick
1. Turn the ignition key to position I.

3
II II
I

I 4

1 2

2. Press the switch (1).

For the switch position for the tamping equip-
ment see the display for special functions
(2).

M+P-05C-2574

Rotating the track tamping equipment:

1. Fit the pins (1) and (2) and secure them.
2. Push the levers (3) and (4) into position I.
The track tamping equipment may be ro-
tated by the button toggles that are on the right
joystick, see page 89.

Swivel the tamping unit:

1. Loosen the pins (1) and (2) and remove them. 3. Press the button toggle (3) or (4).
2. Push the levers (3) and (4) into position II. 3 Opening
The tamping unit may be swivelled by the
4 Closing
button toggles on the right joystick, see
page 89.

90

Hydraulic hammer
1. Turn the ignition key to position I.
2. Press the switch (1) into position I.
0 Switch off
I Pre-select the button function for the foot
switch (2).
The control light (3) lights.
3. Press and hold the foot switch (2).
The hydraulic hammerstrikes.
4. Release the foot switch (2).
The hydraulic hammerstops.
5. Press the switch (1) into position 0.
Road and off-road operations 9
Adjustment of oil pressure and oil level (com-
fort version)
Pre-selection:
Set the switch (1) to the desired position.
Oil pressure and oil level current values of the va-
rious work attachment are indicated on plate (2).
Work attachment actuation (temporarily):
1. Press and hold the foot switch (3).
The work attachment is activated.
2. Press and hold the foot switch (3).
The work attachment is stopped.
Work attachment actuation (continuously):
1. Set the switch (1) to the desired position.
For the switch position for the integrated work
attachment see the display for special func-
tions (2).
2. Press the button (3) or (4).
The work attachment is activated
91
9 Road and off-road operations
Stopping movements
Uppercarriage
NOTICE
Damage to property
Stopping the uppercarriage and steering
it at the same time in the opposide direc-
tion by means of the hydraulics may
cause damage.
 When braking, avoid steering in the oppo-
site direction by means of the hydraulics.
Block the slewing brake pedal (1) by the latching
device (2).
The slewing movement stops.
Boom, articulated jib, work attachment
Release the respective control element (joystick,
pedal or button toggle); the movement stops im-
mediately.
Controlling the movement speed
 Operate the joystick or pedal carefully in the
corresponding direction.
 Setting the fine control, see page 83.
Note
If the slewing limitation is switched on, the
uppercarriage slewing speed is automatically li-
mited to 6 min-1.
NOTICE
Damage to property
Improper operation of the joysticks and
pedals may damage the hydraulic cylin-
ders.
 Do not operate the joysticks and pedals in
the respective direction any further if the
hydraulic cylinders are fully extended or
retracted.
92
Emergency lowering of the excavator equip-
ment
A pressure reserve is built up in a hydraulic accu-
mulator in functional rail-road excavators.
This pressure reserve is used to lower the exca-
vator equipment should the engine/hydraulic
system fail.
WARNING
Danger of accident
Lowering the excavator equipment on
dangerous places, . e.g. on downhill
edges and verges, may cause accidents.
 Lower the excavator equipment very ca-
refully.
1. Turn the ignition key to position I.
2. Switch on the pilot control, see page 70.
3. Operate the joystick or the pedal carefully in
the corresponding direction.
The respective excavator equipment will be
lowered by its own weight.
9.10.1 Height limitation
When working in buildings, the height limiter
enables the adjustment of the maximal height of
the excavator equipment.
NOTICE
Damage to property
If the vertical distance is not enough, a
damaged may result.
 Before starting work in buildings and such
like, set the height limiter to a proper
distance value.
Note
The height limiter may not be used as a
height measuring device, as the height that is in-
dicated depends on the adjustment of the rele-
vant jib.

Green warning light (1)
The excavator is withing the permissible work-
space (< 90 %).
Yellow warning light (2), early warning level
As soon as the early warning level is reached
(90 % of the pre-selected height limitation value),
the warning light (2) lights up and a buzzer
sounds.
Red warning light (3), alarm stage
As soon as the pre-selected height limitation
value is achieved, the warning light (3) lights up
and a buzzer sounds. Further movement of the
main boom and of the jib is not possible.
Note
Buzzer may be switched off by pressing the
button (4). The function of the sound alarm re-
sets automatically. In the event of a new alert
condition, the sound alarm function is active
again.
Calculating the height limitation value
A C
M+P-05C-2634
A Total height
B Minimal distance to the ceiling
C Height limitation value
Road and off-road operations 9
Example
A=5m
B = 0,3 m
C=A–B
C = 5 m – 0,3 m
C = 4,7 m
The height limitation must be adjusted to the
relevant height limitation value, see page 111.
Note
The change-over lever for dipper/grab operation
must be set to the position for the relevant inte-
grated work attachment, see page 96 and
page 99.
9.10.2 Slewing limitation
Slewing limitation is designed for rail operation
only.
For the purposes of the road and off-road opera-
tion, the undercarriage must always remain par-
allely situated with regard to the hazard zone.
Check the slewing limitation after each trans-
portation of the rail-road excavator and after each
work attachment change, see page 113.
9.11 Changing the work attachments
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters before changing any work at-
tachment.
M+P-05C-0124a
 Observe environmental standards!
 Wear work gloves.
 Clean and lubricate pins.
93
9 Road and off-road operations
 Check the seals on the boreholes. Screw couplings
 Fasten bolt clips.
 Grease bolts regularly.
2
9.11.1 Connecting and disconnecting 1
hydraulic lines
 Relieve pressure from hydraulic lines, see 3
page 176. 5
Quick-release couplings
4

M+P-05C-1379

3
4 Connecting
1
5 1. Unscrew the dust cap (1) from the fitting (2).
2
M+P-05C-1378
Connecting
1. Push the bush (1) to the direction of the arrow
and pull the dust plug (2) out of the fitting (3).
2. Remove the dust cap (4) from the plug (5).
3. Assemble the dust cap (4) and the dust plug
(2).
4. Push the bush (1) to the direction of the arrow
and connect the fitting (3) and the plug (5).
Disconnecting
1. Disconnect the dust cap (4) and the dust plug
(2).
2. Press the fitting (3) against the plug (5), push
the bush (1) in the direction of the arrow and
disconnect the plug and the fitting.
3. Push the bush (1) to the direction of the arrow
and the dust plug (2) — into the fitting (3).
4. Push the dust cap (4) on the plug (5).
5. Hydraulic oil which has escaped have to be
collected by means of a suitable container and
disposed of in accordance with regulations, if
necessary.
2. Unscrew the dust plug (3) and remove it from
the plug (4).
3. Connect the plug (4) and the fitting (2) and
screw the nut (5) tight.
4. Screw the dust cap (1) and the dust plug (3)
together.
Disconnecting
1. Put a suitable container underneath the res-
pective connection.
2. Disconnect the dust cap (1) and the dust plug
(3).
3. Unscrew the nut (5) and disconnect the fitting
(2) and the plug (4).
4. Screw the dust cap (1) to the fitting (2).
5. Screw the dust cap (3) into the plug (4).
6. Dispose of hydraulic oil which has escaped in
accordance with regulations, if necessary.
9.11.2 Mounting and removing work
attachments
Removing the dipper
WARNING
Personal injury and damage to pro-
perty
The dipper may tip backwards when the
pins have been removed. This may lead
to injuries or damages.
 As soon as the dipper is lowered onto the
ground, support it with a suitable object
(e.g. by a block of wood).

1. Lower the dipper down onto the ground and

support it to prevent tipping (e.g. by a block of
wood).

94
 Road and off-road operations 9
Note
If necessary use minimal movements of the ex-
cavator equipment to change the position of the
dipper and relieve the pins (4) and (9).

7. Draw the end of the articulated jib out of the

dipper holder.

Mounting the dipper

1
WARNING
Personal injury
M+P-05C-2635
Improper mounting or removal of the
2. If necessary, disconnect the hydraulic hoses work attachment may lead to injury.
(1) leading to the dipper at the left and at the  Never use your fingers to check whether
right side from the articulated jib, see page 94. the bushing of the work attachment and
the articulated jib are aligned.
9 4
8
B

3 9
2 A

6
5
7

M+P-05C-2636

3. Remove the splint pin (2) with the flat washer M+P-05C-1382

(3). The following must be taken into account when

mounting various dippers:
Note
The design of the pin retention varies depending Mounting in hole (A) results in:
on to the dipper manufacturer. It is essential to  a greater break-away force,
follow the manufacturer's operating instructions.  a lower dumping height and
4. Drive out the bolt (4) with a suitable mandrel  a smaller closing angle.
and hammer.
Mounting in hole (B) results in:
5. Remove the splint pin (5) and the castle nut
(6), and take off the flat washer (7).  a lower break-away force,
 a greater dumping height and
Note  a larger closing angle.
The design of the pin retention varies depending
on to the dipper manufacturer. It is essential to
follow the manufacturer's operating instructions.

6. Screw the protective threaded cap (8) to the

pin (9) and drive out the pin (9) with a suitable
stake and hammer.

Note
You will find the protective threaded cap (8) in
the tool box, see page 55.

95
9 Road and off-road operations
3 Note
3
4 The design of the pin retention varies depending
on to the dipper manufacturer. It is essential to
follow the manufacturer's operating instructions.
1
2
WARNING
6 Personal injury
3 Hydraulic lines which have not been
5
mounted properly may come loose. This
may cause injury.
7  Disconnect the couplings with due care.
M+P-05C-2637

1. Insert the end of the articulated jib (1) and the

pressure rod (2) into the holder of the dipper
and orientate them towards the holes.
12
WARNING
Danger of accident
Work attachments which have not been a
mounted properly may come loose. This
may cause an accident.
 Always secure the pins carefully.
11

2. Grease the bolt (3) and the protective th-

readed cap (4) and drive in with a hammer.
Make sure that the bolt (3) is fastened
M+P-05C-2639

(arrow). 6. If necessary, connect the hydraulic hoses (11)

3. Unscrew the protective threaded cap (4) from
the pin (3).
4. Screw the castle nut (5) tight with a flat washer
(6), and secure it with a splint pin (7).
Note
The design of the pin retention varies depending
on to the dipper manufacturer. It is essential to
follow the manufacturer's operating instructions.
at the left and at the right side with the articu-
lated jib, see page 94.
Note
Mixing up the hydraulic hoses during connection
results in reversing the functions.
7. Set the change-over lever (12) to the position
for dipper operation (a).
Removing the grab

8 WARNING
Personal injury and damage to pro-
perty
The grab may tip backwards when the
pins have been removed. This may lead
8 to injuries or damages.
 If the grab must be lowered when it is
10 closed, as soon as it is on the ground,
9 support it by suitable objects (e.g. by
blocks of wood).
8
M+P-05C-2638

5. Grease the pin (8), drive in with a hammer and

secure with a flat washer (9) and a splint pin
(10).
Make sure that the pin (8) is fastened (arrow).

96
 Road and off-road operations 9
8

7
1

6
5

M+P-05C-2640 M+P-05C-2642

1. Lower the opened grab (1) to the ground. 5. Disconnect the hydraulic hoses (5) and (6)
from the couplings (7) und (8) of the articu-
lated jib, see page 94.
I
3

2 13
11 10
II

13
12
M+P-05C-2643

4 6. Remove the splint pin (9) and the castle nut

(10), and take off the flat washer (11).

Note
The design of the pin retainer varies depending
on the manufacturer of the grab. It is essential to
follow the manufacturer's operating instructions.
M+P-05C-2641
7. Screw the protective threaded cap (12) to the
2. Set the clip (2) to position I. pin (13) and drive out the pin (13) with a sui-
3. Set the pressure rod (3) to position II. table stake and hammer.
4. Set the reverse gear (4) to the centered posi-
Note
tion.
You will find the protective threaded cap (12) in
the tool box, see page 55.

Note
If necessary, use minimal movements of the ex-
cavator equipment to change the position of the
grab and relieve the pin (13).

8. Draw the end of the articulated jib out of the

grab holder.

97
9 Road and off-road operations
Mounting the grab

WARNING
Personal injury 5
Improper mounting or removal of the 6 5
work attachment may lead to injury.
 Never use your fingers to check whether
the bushing of the work attachment and
the articulated jib are aligned. 7
5 8

9
1
M+P-05C-2645

2 4. Grease the bolt (5) and the protective th-

readed cap (6) and drive in with a hammer.
Make sure that the bolt (5) is fastened
(arrow).
5. Unscrew the protective threaded cap (6).
6. Screw the castle nut (7) tight with a flat
washer (8) and secure it with a splint pin (9).

Note
M+P-05C-2437

The design of the pin retention varies depending

1. Connect the hydraulic lines (1) and (2) to the
on to the dipper manufacturer. It is essential to
grab before its initial start-up.
follow the manufacturer's operating instructions.

WARNING
Personal injury
3
Hydraulic lines which have not been
mounted properly may come loose. This
may cause injury.
 Connect the couplings with due care.
4
)

13

M+P-05C-2644
12

2. Set the reverse gear (3) to the centered posi-

tion. 12
3. Insert the end of the articulated jib (4) into the
holder of the grab and orientate it towards the
holes. 11
10
WARNING
Danger of accident M+P-05C-2646

Work attachments which have not been
mounted properly may come loose. This
may cause an accident.
 Always secure the pins carefully.
7. Connect the hydraulic hoses (10) and (11)
with the couplings (12) und (13) of the articu-
lated jib, see page 94.
Note
Mixing up the hydraulic hoses during connection
results in reversing the functions.

8. Fully retract the dipper tipping cylinder.

98
 Road and off-road operations 9
Note
You will find the protective threaded cap (4) in
14
the tool box, see page 55.

15 Note
If necessary, use minimal movements of the ex-
I cavator equipment to change the position of the
load hook and relieve the pin (5).

4. Extend the end of the articulated jib (6) out of

the load hook holder.
)

I
9

16
7

a
M+P-05C-2647

9. Set the pressure rod (14) to position I and se-

cure by a clip (15).
10.Set the change-over lever (16) to the position
for grab operation (a).
8
Removing the load hook
1. Lower the load hook down to the ground.

5 M+P-05C-2649
4
5. If necessary, set the clip (7) to position I.
The reverse gear (8) and the pressure rod (9)
6 are loosened for mounting other work attach-
ments.

Mounting the load hook

5
3 2 1 WARNING
M+P-05C-2648

Personal injury
2. Remove the splint pin (1) and the castle nut
Improper mounting or removal of the
(2), and take off the flat washer (3).
work attachment may lead to injury.
Note  Never use your fingers to check whether
the bushing of the work attachment and
The design of the pin retainer varies depending the articulated jib are aligned.
on the manufacturer of the load hook. It is es-
1. Fully retract the dipper tipping cylinder.
sential to follow the manufacturer's operating in-
structions.

3. Screw the protective threaded cap (4) to the

pin (5) and drive out the pin (5) with a suitable
stake and hammer.

99
9 Road and off-road operations
4. Grease the pin (4) and the protective th-
)

readed cap (5) and drive in with a hammer.

Make sure that the pin (4) is fastened (arrow).
1 5. Unscrew the protective threaded cap (5).
6. Screw the castle nut (6) tight with a flat
washer (7) and secure it with a splint pin (8).
2
Note
I The design of the pin retainer varies depending
on the manufacturer of the load hook. It is es-
sential to follow the manufacturer's operating in-
structions.

Removing and mounting the hydraulic

hammer
The hydraulic hammer is removed and
mounted in the same way as the dipper, see
page 94.

Connecting and disconnecting hydraulic

lines

M+P-05C-2650

2. If necessary, set the pressure rod (1) to posi-

tion I and secure by a clip (2). 3

4
5
1
3
2

M+P-05C-3277

4 6
Disconnecting:
1. Remove the splint pins (1) at the left and at the
8 right side.
4 7
M+P-05C-2651
2. Disconnect the hydraulic hoses (2) at the left
and at the right side from the couplings (3),
3. Insert the end of the articulated jib (3) into the see page 94.
holder of the load hook and orientate it to the
hole. Connecting:

WARNING WARNING
Danger of accident Personal injury
Work attachments which have not been Hydraulic lines which have not been
mounted properly may come loose. This mounted properly may come loose. This
may cause an accident. may cause injury.
 Always secure the pins carefully.  Connect the couplings with due care.

100

NOTICE
Damage to property
Mixing up the hydraulic hoses during
connection can cause damage.
 Connect the hydraulic hoses according to
the manufacturer's instructions.
Contact a member of ATLAS Customer
Service if necessary.
1. Connect the hydraulic hoses (2) at the left and
at the right side with the couplings (3), see
page 94.
2. Secure the couplings (3) (left and right) by
splint pins (1).
Road and off-road operations 9
Mounting the pallet forks onto the trench
digger
WARNING
Personal injury
Improper mounting or removal of the
work attachment may lead to injury.
 Never use your fingers to check whether
the bushing of the work attachment is ali-
gned.
1. Place the pallet fork tines onto the ground and,
in order to prevent tipping, support them (e.g.
by a block of wood).

Removing the pallet forks from the trench 6

digger
4
WARNING
Personal injury and damage to pro-
perty
Pallet fork tines may tip backwards when
pins are removed. This may lead to inju- 5
ries or damages.
3
2
 As soon as the pallet fork tines are placed
1
onto the ground, support them with a sui-
table object (e.g. by a block of wood). M+P-05C-2653

 Remove the pallet fork tines one by one. 2. Turn the holder of the trench digger (1) to the
pallet fork tine (2) and insert it in the hole.
1. Place the pallet fork tines onto the ground and,
in order to prevent tipping, support them (e.g.
WARNING
by a block of wood).
Danger of accident
Work attachments which have not been
mounted properly may come loose. This
may cause an accident.
2 6  Always secure the pins carefully.
4
3. Grease the pins (3) and (4), drive in with a
hammer and secure with a splint pin (5) and
(6).
Make sure that the pin (4) is fastened (arrow).
1
3 7 Note
The design of the pin retainer varies depending
5
M+P-05C-2652
on the manufacturer of the pallet forks. It is es-
sential to follow the manufacturer's operating in-
2. Remove the splint pins (1) and (2) and drive structions.
out the pins (3) and (4) with a suitable mandrel
and hammer. 4. Remove the second pallet fork tine accor-
dingly.
Note
The design of the pin retainer varies depending
on the manufacturer of the pallet forks. It is es-
sential to follow the manufacturer's operating in-
structions.

3. Take the pallet fork tine (5) out of the holder of

the trench digger (6).
4. Remove the pallet fork (7) tine accordingly.

101
9 Road and off-road operations
Removing the load hook from the trench
digger WARNING
Danger of accident
Work attachments which have not been
mounted properly may come loose. This
may cause an accident.
4  Always secure the pins carefully.

2. Grease the pin (3), drive in with a hammer and

secure with a splint pin (4).

Note

3 The design of the pin retainer varies depending

on the manufacturer of the load hook. It is es-
2
1 sential to follow the manufacturer's operating in-
M+P-05C-2654
structions.
1. Remove the splint pin (1) and drive out the pin
(2) with a suitable mandrel and hammer. Removing the rail tongs from the trench
digger
Note
The design of the pin retainer varies depending
on the manufacturer of the load hook. It is es-
sential to follow the manufacturer's operating in-
structions.
2. Remove the load hook (3) from the holder of
the trench digger (4).
2
Mounting the load hook onto the trench
digger

WARNING 1

Personal injury M+P-05C-2656

Improper mounting or removal of the
work attachment may lead to injury.
 Never use your fingers to check whether
the bushing of the work attachment is ali-
gned.
4
3 work attachment may lead to injury.
Unhitch the rail tongs (1) from the load hook (2).
Mounting the rail tongs onto the trench digger
WARNING
Personal injury
Improper mounting or removal of the
 Never use your fingers to check whether
the bushing of the work attachment is ali-
gned.

2
WARNING
Danger of accident
Work attachments which have not been
1 mounted properly may come loose. This
may cause an accident.
M+P-05C-2655  Always secure the pins carefully.
1. Insert the load hook (1) into the holder of the 1. Mount the load hook if necessary, see
trench digger (2). page 102.

102
 Road and off-road operations 9

9
8
10 11

2 3

3 6

4 7
1
5
M+P-05C-2657 M+P-05C-2658

2. Hitch the rail tong (1) into the load hook (2).
Close the safety mechanism (3) completely as
soon as the rail tong has been hitched.
Dismantling the track tamping equipment
3. Remove the splint pin (3) of the relevant cou-
pling.
4. Disconnect the hydraulic hoses (4), (5), (6)
and (7) from the couplings (8), (9), (10) and
(11), see page 94.

18

12
1
16 17
14
1 15
13
M+P-05C-2585
M+P-05C-2659

1. Place the spacer (1) between the tamping 5. Remove the splint pin (12) of the relevant cou-
picks. pling.
6. Disconnect the hydraulic hoses (13), (14) and
WARNING
(15) from the couplings (16), (17) and (18),
Personal injury and damage to pro- see page 94.
perty
The track tamping equipment may tip 20
backwards when the pins have been re- 19
moved. This may lead to injuries or dama-
ges.
 As soon as the track tamping equip- 22
ment is lowered onto the ground, sup-
port it by pipe supports
21
2. Lower the track tamping equipment (2)
onto the ground and, in order to prevent tip-
ping, support it by pipe supports.

M+P-05C-2660

7. Remove the screw (19) and drive out the pin

(20) with a suitable mandrel and hammer.
8. Unscrew the pins (21) and (22) and pull them
out.

103
9 Road and off-road operations
Mounting the track tamping equipment

WARNING
23 24 Personal injury
Improper mounting or removal of the
work attachment may lead to injury.
 Never use your fingers to check whether
the bushing of the work attachment and
the articulated jib are aligned.

1
M+P-05C-2661

2 3
9. Hold the pins (23) and the centring piece (24)
and swing them (arrow).

Note
Use minimal movements of the excavator
equipment to change the position of the track
tamping equipment and relieve the pins (23)
and the centring piece (24).
M+P-05C-2663

1. Insert the end of the articulated jib (1) into the

23 holder of the track tamping equipment and
24 turn it to the holes.
2. Grease the pin (2), drive in with a hammer and
insert the centring piece (3).

2 3

M+P-05C-2662

10.Remove the centring piece (24) from the pin

(23) and drive out the pin (23) with a suitable
mandrel and hammer.

M+P-05C-2664

3. Hold the pins (2) and the centring piece (3)

and swing them (arrow).

WARNING
Danger of accident
Work attachments which have not been
mounted properly may come loose. This
may cause an accident.
 Always secure the pins carefully.

104
 Road and off-road operations 9
6
7
20
19
3 21 22
2 5
4 23

17

15 18

16
M+P-05C-2665 M+P-05C-2667

4. Grease the pins (4) and (5), drive in with a
hammer and screw the pins (2) and the cent-
ring piece (3) in order to secure them.
5. Grease the pin (6), drive in with a hammer and
tighten the screw (7).
8. Connect the hydraulic hoses (15), (16), (17)
and (18) with the couplings (19), (20), (21) and
(22), see page 94.
9. If necessary, secure the coupling by a splint
pin (23).

WARNING 9.11.3 Quick attach

Personal injury
Hydraulic lines which have not been
mounted properly may come loose. This
may cause injury.
 Secure the couplings with due care.
The rail-road excavator may be equipped with a
mechanic or a hydraulic quick attach.
Work attachments have to be equipped with the
relevant adapter.
Note

NOTICE When furnishing the quick attach with the re-

levant adapter and when changing the work at-
Damage to property tachment, follow the manufacturer's operating
Mixing up the hydraulic hoses during instructions.
connection can cause damage.
 Connect the hydraulic hoses according to
the manufacturer's instructions.
Contact a member of ATLAS Customer
Service if necessary.

13

14
11 12
9

8 10
M+P-05C-2666

6. Connect the hydraulic hoses (8), (9) and (10)

with the couplings (11), (12) and (13), see
page 94.
7. If necessary, secure the coupling by a splint
pin (14).

105
9 Road and off-road operations
Hydraulic quick attach
1. Disconnect the hydraulic hoses from the work
attachment if necessary, see page 94.
2. Turn the ignition key to position I.

3. Press the switch (1).

For the switch position for the quick attach
see the display for special functions (2).
4. Press and hold the switch (3) into position II.
0 Switch off
I Locking
5. Actuate the slide controller (4) (XII).
II Unlocking
The control light (5) lights up. The quick at-
tach has been unlocked.
6. Connect the quick attach with the relevant
work attachment.
7. Press the switch (3) into position I.
The control light (5) lights up. The quick at-
tach is locked.
8. Connect the hydraulic hoses with the work at-
tachment if necessary, see page 94.

106
 Operation within the frame of the railway transport 10
10 Operation within the frame of the railway transport
10.1.1 Rail operation
WARNING
Personal injury and damage to pro-
1
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before starting up 0 I
the rail-road excavator. 2
1
DANGER
M+P-05C-2446
Personal injury
Sudden movements of the equipment Turn the key (1).
may cause personal injury. 0 Switch off
 Before starting up the engine make sure The ignition key (1) can only be inserted or
that nobody is within the hazard zone of removed in this position.
the rail-road excavator.
I Switch on
The control light (2) lights up.
10.1 Before operation
Rail operating functions
If rail operation is switched on, the following func-
WARNING
tions may be switched on/off or it may be swit-
Personal injury and damage to pro- ched between them:
perty  Pre-selection of the guide roll axles at the front
Failure to follow the instructions contai- and at the rear switches on;
ned in the introductory chapters may re-
 Guide roll axle lifting and lowering switches
sult in injury or damage.
on;
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road  Guide roll axle locking device switches on;
operations" and "Safety rail operation"  Switching device (e.g. INDUSI) running over
chapters in particular before starting up switches on;
the rail-road excavator.
 Rail lights, at the front and at the rear switch
on;
 Horn switches to fanfare (Makrofon);
 Side lights, dipped and main beam headlight
switch off;
 Direction indicator and warning lights switch
off;
 Rotating warning light switches off.

107
10 Operation within the frame of the railway transport
The following warning and control lights light up
on the display:
V Warning light for the guide roll pressure,
at the front
Warning light for the guide roll pressure,
H
at the rear
Control light for rail operation
The following warning and control lights may light
up in the display panel if the relevant special func-
tion is activated:
Control light for suspending the height li-
mitation
Control light for suspending the slewing li-
mitation
Slewing limitation control light
Control light for the height limitation
The following warning lights may light up on the
display field during rail operation:
V Warning light for the guide roll pressure,
at the front
Warning light for the guide roll pressure,
H
at the rear
Warning light for track control malfunction
Data transmission error
The control light for the slewing limita-
tion is switched off
108
10.1.2 Height limitation
The role of the height limiter is to assist the ope-
rator in carrying out the work and, by means of vi-
sual and sound messages, to advise the operator
for approaching /reaching limit conditions. Height
limitation prevents parts of the excavator equip-
ment from getting into the hazard zone of the
overhead lines.
DANGER
Personal injury and damage to pro-
perty
If the hеight limitation is not activated
or if it is not properly adjusted, the over-
head lines may be damaged. A serious or
fatal accident may result if electricity is
transferred.
 Prior to working in the hazard zone of the
overhead lines, activate and adjust the
height limitation according to the rele-
vant regulations.
 Height limitation does not replace ope-
rator's attention and responsibility while
working.
Height limitation switching on/off
1. Prepare the rail-road excavator for road and
off-road operation. See "Operation" and
"Road and off-road operation" chapters.
2. Start the engine, see page 72.
3. Lower the excavator equipment completely,
see page 89.
4. Switch off the interlock circuit for the height
and slewing limitation, see page 117.
2 1
0
M+P-05C-2448
5. Press the switch (1).
0 Switch off
I Switch on
The control light (2) lights up.
 Operation within the frame of the railway transport 10
Function test Suspending
As soon as the height limitation is activated, a
function test is automatically performed. WARNING
Danger of accident
Exceeding the minimum distance from
the overhead lines may cause accidents.
 Suspend the height limitation only if the
excavator equipment is not under over-
head lines.

1. Switch off the interlock circuit for the height

and slewing limitation, see page 117.

2 1

I
The control light (1) lights up.
The display (2) visualizes the latest adjusted va-
lues (prior to last system switching off).
Max. height (3) in meter to one decimal place
Current height (4) in meter to one decimal place
Main boom (5) angle in degrees (boom 1)
Adjustable boom (6) angle in degrees (boom 2) M+P-05C-2450

(7) No function is assigned.

2. Press and hold the switch (1) into position I
until the excavator equipment is lifted further
NOTICE than the stored height limitation value.
Damage to property 0 Switch off
If error codes are visualized on the dis- I Height limitation and speed reduction
play after the function test run, a malfunc- are suspended.
tion has occurred which may result in da-
The warning light (2) lights up.
mage.
 The malfunction has to be rectified imme-
diately.

109
10 Operation within the frame of the railway transport
Calculating the height limitation value Wagon

Rails A

A
A C
B

B
B C
C

D
M+P-05C-2669

A Double minimum distance to the overhead

M+P-05C-2668
lines
A Double minimum distance to the overhead B Overhead line height above the upper rail
lines edge
B Overhead line height above the upper rail C Height limitation value
edge
D Wagon loading area height beginning from the
C Height limitation value upper rail edge

Note Note
When lifting or rolling, maintain a double mi- When lifting or rolling, maintain a double mi-
nimum distance from the excavator equipment nimum distance from the excavator equipment
to the overhead lines. to the overhead lines.

Example: Example:
A = 0,3 m (rated voltage up to 15 kV) + 0,3 m (sa- A = 0,3 m (rated voltage up to 15 kV) + 0,3 m (sa-
fety factor) fety factor)
B = 5,5 m B = 5,5 m
D = 1,3 m
C= B – A
C= B – A – D
C= 5,5 m – 0,3 m – 0,3 m
C= 4,9 m C= 5,5 m – 0,3 m – 0,3 m – 1,3 m
The display must be set to a height limitation C= 3,6 m
value of 4,9 m.
The display must be set to a height limitation
value of 3,6 m.

110
 Operation within the frame of the railway transport
Setting the height limitation value
WARNING
Danger of accident
Accidents can happen, if the rail-road ex-
cavator equipment is under overhead li-
nes when adjusting the height limitation
value. Working motions are not to be
shut off during adjustment.
 Adjust the height limitation only if the
excavator is not under overhead lines.
1. Switch on the height limitation, see
page 108.
V fit because of the differing dimensions of
2. Turn the key (1) to position I.
0 The adjustment function is disabled
I The adjustment function is enabled
3. Press the button toggle (2).
The current arm height is visualized on the
display (3).
4. Press the button toggle (4).
Decrease the height limitation value.
(Step size: 0.1 m).
5. Press the button toggle (5).
Increase the height limitation value.
(Step size: 0.1 m).
Note
In order to decrease the height limitation value,
press the button (4) until the desired value is set.
In order to increase the height limitation value,
press the button (5) until the desired value is set.
The height limitation value that has been set is
visualized on the display (3).
6. Press the button (2).
The setting is saved.
The height limitation value that has been set is
visualized on the display (3).
7. Turn the key (1) to position 0 and remove the
key.
8. Check the height limitation, see page 111.
10
Checking the height limitation
Note
The factory setting of the height limitation has
been performed under consideration of the di-
mensions of the largest work attachment that is
applied.
WARNING
Danger of accident
If the work attachment is changed, the
height limitation that is set may no longer
the work attachment. This may cause an
accident.
 After changing the work attachment,
check the height limitation and set it in
accordance with the minimum distance
specified for overhead lines.
 Changing the factory setting of the height
limitation is prohibited.
WARNING
Danger of accident
Accidents can happen, if the rail-road ex-
cavator equipment is under overhead li-
nes when checking the height limitati-
on.
 Check the height limitation only if the
excavator is not under overhead lines.
Note
The change-over lever for dipper/grab operation
must be set to the position for the mounted work
attachment, see page 96 and page 99.
1. Retract the bucket tipping cylinder completely,
see page 88.
2. Lower the excavator equipment completely.
3. Switch on the height limitation, see
page 108.
4. Check if the specified minimum distances to
overhead lines are considered. Calculate and
set a new height limitation value if necessary,
see page 110 and page 111.
5. Lift the excavator equipment carefully until
achieving the height limitation value that is
saved.
111
10 Operation within the frame of the railway transport
Height limitation display contrast value: set-
ting

Auto contrast
1. Switch on the height limitation, see
page 108.

Note
The setting of the contrast values of the display
(3) is done via the starting menu and can not be
performed in height set up mode.

Green warning light (1)

The excavator is within the permissible work area
(< 90 %).

Yellow warning light (2), early warning level

As soon as the early warning level is reached (90
% of the pre-selected height limitation value), the
warning light (2) lights up and a buzzer sounds.

Red warning light (3), alarm stage

As soon as the pre-selected height limitation
value is achieved, the warning light (3) lights up
and a buzzer sounds. Further movement of the
main boom and of the jib is not possible.
Note
Buzzer may be switched off by pressing the
button (4). The function of the sound alarm re-
sets automatically.
In the event of a new alert condition, the sound
alarm function is active again.
1. Press the button toggle (1).
Contrast values are continuously visualized
on the display (3).
Note
Contrast values from 85 to 145 can be selected
in steps of 5.
2. As soon as the desired contrast value is visu-
alized on the display (3), press the button
toggle (4).
The setting will be saved.

112
 Operation within the frame of the railway transport 10
Slewing limitation 4. Press the switch (1).
Slewing limitation prevents parts of the exca- 0 Switch off
vator equipment from getting into the scope of the I The left hand slewing area is limited
neighbouring track. The control light (2) lights up.
II The right hand slewing area is limited
WARNING
The control light (2) lights up.
Danger of accident
Operating the rail-road excavator when Note
the neighbouring tracks are not cordoned If the slewing limitation is switched on, the up-
off may cause accidents.
percarriage slewing speed is automatically li-
 Before operating the rail-road excavator, mited to 6 min-1.
if the neighbouring track is not cordoned
off, the slewing limitation must be che- As soon as the slewing limit is reached, the up-
cked and set in accordance with the spe- percarriage may not be slewed further.
cified minimum distance to the neighbou-
ring track.
 Check and set the slewing limitation
only if the rail-road excavator is in the
area of a cordoned off neighbouring track
or if it is derailed.
 The requested minimum distance from
the track centre to the neighbouring track
must be provided by the competent au-
thority.

WARNING
Danger of accident
If the work attachment is changed, the
slewing limitation that is set may no
longer fit because of the differing dimen-
sions of the work attachment. This may
cause an accident.
 After changing the work attachment,
check the setting of the slewing limitati-
on and adjust it in accordance with the
specified minimum distance to neighbou-
ring tracks.

Slewing limitation switching on/off

1. Prepare the rail-road excavator for road and
off-road operation. See "Operation" and
"Road and off-road operation" chapters.
2. Start the engine, see page 72.
3. Switch off the interlock circuit for the height
and slewing limitation, see page 117.

1 2

I
0
II

M+P-05C-2455

113
10 Operation within the frame of the railway transport
Suspending

WARNING
Personal injury and damage to pro-
perty
Suspending the slewing limitation may
lead to injuries or damages. 1
 Only suspend the slewing limitation in
the presence of a permission from the re- A
levant competent authority and if suspen-
ding does not endanger objects or per-
sons.

1. Switch off the interlock circuit for the height

and slewing limitation, see page 117.

1 2

M+P-05C-2670

3. Set the excavator equipment (1) so that it has

the furthest reach (A).
M+P-05C-2456
4. Switch off the interlock circuit for the height
and slewing limitation, see page 117.
2. Press and hold the switch (1) into position I
until the excavator equipment goes beyond Symmetrical setting of the slewing limita-
the specified slewing limitation. tion
0 Switch off 1. Switch off the rail operation, see page 107.
I Height limitation and speed reduction 2. Switch off the slewing limitation, see
are suspended. page 113.
The warning light (2) lights up and a
buzzer sounds.
1 2 3
Setting the slewing limitation 0
1. Prepare the rail-road excavator for road and
off-road operation. See "Operation" and
I
"Road and off-road operation" chapters.
2. Start the engine, see page 72.

M+P-05C-2458

3. Press and hold the switch (1) into position I

and switch on the rail operation, see
page 107.
The control light (2) and the warning light (3)
start flashing.
4. Release the switch (1) and slew the uppercar-
riage until reaching the desired slewing limita-
tion, see page 89.

114
 Operation within the frame of the railway transport 10
6. Check the slewing limitation, see page 115.
Note
Check the slewing limitation
If the switch is not activated within a frame of 25
sec., the current slewing limitation will not be 1. Prepare the rail-road excavator for road and
changed and the setting mode will be automati- off-road operation. See "Operation" and
cally terminated. "Road and off-road operation" chapters.
2. Start the engine, see page 72.
5. Press and hold the switch (1) into position I
until the control light (2) and the warning light
(3) light up.
6. The control light (2) and the warning light (3)
flash for a short time and go out.
Slewing limitation is saved.
7. Check the slewing limitation, see page 115. 1
Setting the slewing limitation individually
A
1. Switch off the rail operation, see page 107.
2. Limit the slewing limitation to the left or to
the right side, see page 114.

Note
If the switch is not activated within a frame of 25
sec., the current slewing limitation will not be
changed and the setting mode will be automati-
cally terminated.

1 2 3

M+P-05C-2670
I
3. Set the excavator equipment (1) so that it has
the furthest reach (A).
4. Switch off the interlock circuit for the height
and slewing limitation, see page 117.
5. Limit the slewing limitation to the left or to
the right side, see page 114.
M+P-05C-2458
WARNING
3. Press and hold the switch (1) into position I Accidental damage
and switch on the rail operation, see
When slewing the rail-road excavator,
page 107.
there is a risk of accidents.
The control light (2) or the warning light (3)
 Secure the slewing area of the excavator
starts flashing.
equipment so as to avoid unauthorized
access.
Note
 Neither persons nor any objects may stay
The control light (2) flashes if the left-hand area in the slewing area.
is limited.
The warning light (3) flashes if the right-hand
area is limited.

4. Release the switch (1) and slew the uppercar-

riage to the relevant direction until reaching
the desired slewing limitation, see page 89.
5. Press and hold the switch (1) into position I
until the control light (2) or the warning light (3)
lights up.
The slewing limitation is saved.

115
10 Operation within the frame of the railway transport
M+P-05C-2671
6. Slew the uppercarriage (2) approx. 90 de-
grees to the left or to the right.
7. Slew the uppercarriage (2) and the joystick,
which is completely deflected, to the left or to
the right until the slewing limitation fits.
116
B
M+P-05C-2672
8. Check if the excavator equipment went
beyond the permissible slewing limitation(B)
and, if necessary, set a new slewing limitation
value.
WARNING
Accidental damage
Oscillating and roll motion of the rail-road
excavator may cause accidents.
 It must be ensured that the permissible
slewing limitation from the track centre
to the neighbouring track is not exceeded.
 Operation within the frame of the railway transport 10
10.1.3 Interlock circuit for the height- and 10.1.4 Rail light
slewing limitation 1. Turn the ignition key to position I, see
The interlock circuit prevents the valid height and page 59.
slewing limitation from being changed by unin- 2. Switch on the rail operation, see page 107.
tentional pressing of a switch or a button toggle.

0 I

1
M+P-05C-2461

Turn the key (1).

0 Switch off
Now the desired values for height- and sle-
wing limitation may be set up.
I Switch on
Switch- and button-toggle pressing is effect-
less.

At the front
Press the switch (1).
0 Switch off
I Switch on
The control lights (2) and (3) light up.

At the rear
Press the switch (4).
0 Switch off
I Switch on
The control lights (2) and (3) light up.

10.1.5 Equipment for rear area monitoring

The equipment for rear area monitor enables the
operator to see the area behind the rail-road ex-
cavator without having direct visual contact.
See the separate operating instructions for de-
scription of how to operate the rear area monitor.

117
10 Operation within the frame of the railway transport
WARNING
Personal injury and damage to pro-
perty
When people or obstacles stay out of the
scope of the rear area monitoring or when
they do not appear or if they are partially
viewed on the monitor, injury or damages
may result.
 The equipment for rear area monitoring is
just a technical aid that enables the ope-
rator to see the area behind the rail-road
excavator.
 Rear area monitoring does not replace
operator's attention and responsibility du-
ring reverse travel or while working.
 Monitor for monitoring the rear area shall
not be used when visibility is poor.
4. Drive the rail-road excavator to enter the track
and direct it so that the inner wheels (arrow)
are aligned with the track.
5. Align the undercarriage so that the articulated
jib (1) is above the track centre.
6. Switch on the rail operation, see page 107.
V The warning light that is on the display
field lights up and a buzzer sounds.
H
7. Switch the guide roll axles into automatic ope-
ration, see page 119.
8. Pre-selection of both guide roll axles, see
page 119.
9. Lower the guide roll axles, see page 120.

 Neither people nor any obstacles may

stay within the hazard zone of the excava-
tor.
 Always keep camera lens clean.

10.2 Rerailing and derailing on a

public railway crossing

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
10.Lock the driving brake pedal (2) with the lat-
ching device (3).
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road 11.Lock the steering wheel, see page 120.
operations" and "Safety rail operation" 12.Make sure that all guide rolls are placed onto
chapters in particular before rerailing and the track.
derailing the rail-road excavator.

1. Prepare the rail-road excavator for road and WARNING

off-road operation. See "Operation" and
"Road and off-road operation" chapters.
2. Start the engine, see page 72.
3. Drive the rail-road excavator to the railway
crossing, see page 75.
Personal injury and damage to pro-
perty
If not all guide rolls are placed on the
track, there is a risk of in injury or dama-
ge.
 Only operate the rail-road excavator on
rails, if all guide rolls are placed onto the
track.

WARNING
Personal injury and damage to pro-
perty
Improper rerailing of the rail-road excava-
tor may result in injury or damage.
1  Operate the rail-road excavator on rails
only if the wheels are in a straight-ahead
position and the steering wheel is locked.

M+P-05C-2673

118
 Operation within the frame of the railway transport 10
10.2.1 Emergency brake function 10.2.2 Blocking/unblocking the guide roll
axles
WARNING
Danger of accident
If the electrical system fails while the ex-
cavator is running with momentum, lowe-
ring the rail-road excavator in a normal
way is not possible. This may cause an
accident.
1
 As soon as the rail-road excavator is
rerailed, it must be secured against rolling
I
down and the proper operation of the
emergency brake must be checked on a 0
straight and level railway. II

M+P-05C-2465

Press the switch (1).

0 Automatic operation
The guide roll axles are unlocked.
I Operation in locked state
1 The guide roll axle of the load-facing side is
locked.
I
II Lifting the axle with the pre-selected guide
0 roll axle
II To enable running over a switching device,
e.g. INDUSI.
M+P-05C-2465
Note

Note To enable running over a switching device, e.g.

INDUSI, press and hold the switch (1) into
A prerequisite for the check of the emergency position II until the switching device is comple-
brake function is that the rail-road excavator is in tely run over.
automatic operation, see page 129.
1. Press and hold the switch (1) into position II 10.2.3 Pre-selecting the guide roll axles
until the rail-road excavator rises above both
guide roll axles.
2. Press and hold the switch (1) and turn the ig-
nition key to position 0, see page 59.
3. The rail-road excavator will be lowered onto
the solid axle and braked.
1

I
0
II

M+P-05C-2466

Press the switch (1).

0 Pre-select both guide roll axles.
I Pre-select the guide roll axle at the front.
II Pre-select the guide roll axle at the rear.

119
10 Operation within the frame of the railway transport
10.2.4 Lifting/lowering the guide roll axles 10.2.5 Locking and unlock the steering
wheel
1 2
Locking
I 1. Keep the wheels of the steering axle straight.
0
II
3

2
1
M+P-05C-2467

1. Press and hold the switch (1) into position I

until the rail-road excavator starts to lift up
slightly.
M+P-05C-2468
0 Switch off
I Lower the guide roll axles. 2. Loosen the screw (1), push the latch (2) up-
The control light (2) flashes. wards and lock the steering wheel (3).
II Lift the guide roll axles 3. Tighten the screw (1).
2. Release the switch (1).
Unlocking
The adjustment of the desired guide roll pres-
sure takes place automatically. 4. Loosen the screw (1), push the latch (2) down-
wards and unlock the steering wheel (3).
V The control lights go out and the buzzer 5. Tighten the screw (1).
stops.
H 10.3 Rerailing and derailing between
stations

WARNING
WARNING
Personal injury and damage to pro-
Danger of accident
perty
When lifted up, the rail-road excavator
Failure to follow the instructions contai-
may not be braked. This may cause an ac-
ned in the introductory chapters may re-
cident.
sult in injury or damage.
 Lower the rail-road excavator back on the
 Observe all the instructions in the "Intro-
rails.
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before rerailing and
derailing the rail-road excavator.

1. Prepare the rail-road excavator for road and

off-road operation. See "Operation" and
"Road and off-road operation" chapters.
2. Start the engine, see page 72.
3. Drive the rail-road excavator to the place of
rerailing, see page 75.
4. Drive the rail-road excavator to enter the track
and align it so that there is a distance between
the wheels and the track.
5. Keep the wheels of the steering axle straight.
6. Support the rail-road excavator along with the
equipment and let the inner wheels of the
steering axle to land onto the track.
7. Switch on the oscillating axle locking device,
see page 83.

120
 Operation within the frame of the railway transport
8. Lock the driving brake pedal (1) with the lat-
ching device (2).
9. Slew the uppercarriage by 180 degrees.
10.Unlock the driving brake pedal (1) with the lat-
ching device (2).
11.Support the rail-road excavator along with the
equipment and let the inner wheels of the solid
axle to land onto the track.
12.Lock the steering wheel, see page 120.
13.Switch on the rail operation, see page 107.
V The control lights go out and the buzzer
stops.
H
14.Switch the guide roll axles into automatic ope-
ration, see page 119.
15.Pre-select both guide roll axles, see
page 119.
16.Lower the guide roll axles, see page 120.
17.Lock the driving brake pedal (1) with the lat-
ching device (2).
18.Activate the parking brake, see page 75.
19.Make sure that all guide rolls are placed onto
the track.
WARNING
Personal injury and damage to pro-
perty
If not all guide rolls are placed on the
track, there is a risk of in injury or dama-
ge.
 Only operate the rail-road excavator on
rails, if all guide rolls are placed onto the
track.
10
WARNING
Personal injury and damage to pro-
perty
Improper rerailing of the rail-road excava-
tor may result in injury or damage.
 Operate the rail-road excavator on rails
only if the wheels are in a straight-ahead
position and the steering wheel is locked.
20.Switch off the oscillating axle locking device,
see page 83.
10.4 Driving the rail-road excavator
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters before driving the rail-road exca-
vator.
WARNING
Danger of accident
Setting off in the wrong direction can lead
to accidents.
 Prior to travel, determine where the stee-
ring axle is located.
 Operate the rail-road excavator with due
care.
 If possible, always turn the uppercarriage
so that the steering axle is at the front.
10.4.1 Starting up
1. Prepare the rail-road excavator for road and
off-road operation. See "Operation" and
"Road and off-road operation" chapters.
2. Release the wagon brake, see page 128.
3. Start the engine, see page 72.
PAR DEL
1
4 6
bar
2 8
0 10
M+P-05C-3283
121
10 Operation within the frame of the railway transport
4. The indicator (1) of the compressed air mano- 3. Release the parking brake, see page 75.
meter is to indicate approx. 5 bar. 4. Start up the rail-road excavator, see page 76.
V When the warning lights on the display
Note
light up and a buzzer sounds, the guide
roll pressure of the front/rear guide roll Travel speed may be manually adjusted as
H
axle is to low and must be increased. well, see page 78.

5. Switch the guide roll axles into automatic ope- 10.4.2 Improving the traction
ration, see page 119.
6. Pre-select the relevant guide roll axle, see
page 119.
7. Lower the guide roll axles, see page 120.
8. Make sure that all guide rolls are placed onto
the track.

WARNING
Personal injury and damage to pro-
perty
If not all guide rolls are placed on the
track, there is a risk of in injury or dama-
ge.
 Only operate the rail-road excavator on
rails, if all guide rolls are placed onto the
Press and hold the button toggle (1).
track. The contact pressure of the guide rolls decre-
ases. Thus, the contact pressure of the wheels on
9. Switch off the outrigger support, see page 84. the rails increases.

Starting up without load

When starting up without load, guide roll axles
must be unlocked.
Thus, guide roll axles may adjust to the given
track conditions.
1. Pre-select both guide roll axles, see
page 119.
2. Switch the guide roll axles into automatic ope-
ration, see page 119.

Note
For long trips without load, switch the guide roll
axles into automatic operation.

Starting up with load

When starting up with load, guide roll axles must
be locked.
1. Switch on the overload warning device, see
page 85.
2. Pre-select both guide roll axles, see
page 119.
3. Switch the guide roll axles to operation in lo-
cked state, see page 119.

Starting up
1. Shift the transmission to the desired gear, see
page 77.
2. Pre-select the desired direction of travel, see
page 77.

122
 Operation within the frame of the railway transport 10
10.4.3 Speed indication

Operator
The driving speed may be seen on the speed in-
Press the button toggle (1) or (2).
dication display (1).
Accompanying crew
Note
Press the button (3).
No functions are assigned to button toggles (2)
and (3).
10.5 Stopping/parking

WARNING WARNING
Danger of accident Personal injury and damage to pro-
Exceeding the maximum speed that is perty
prescribed may cause accidents. Failure to follow the instructions contai-
 The maximum speed that is permitted ned in the introductory chapters may re-
when driving on rails is 20 km/h. sult in injury or damage.
 The maximum speed that is permitted in  Observe all the instructions in the "Intro-
the area of crossings and switches is 10 duction", "Safety of the road and off-road
km/h. operations" and "Safety rail operation"
chapters in particular before starting up
the rail-road excavator.
10.4.4 Horn, respectively fanfare
(Makrofon)
10.5.1 Stopping
WARNING Stop the rail-road excavator, see page 78.
Personal injury
Where functional checks of the horn, res-
pectively of the fanfare (Makrofon) are
performed, there is a risk of damage to
hearing for the people that are in close vi-
cinity.
 Warn people that stay in close vicinity.
 Ask people that stay in close vicinity to
wear hearing protectors.

123
10 Operation within the frame of the railway transport
10.5.2 Parking
 If possible, do not park the rail-road excavator
on the rails.
 Agree on the rail-road excavator parking with
the relevant competent authority.
 Park the rail-road excavator, see page 78.
NOTICE
Damage to property
Lowering paws in the area of the rails
may cause damage.
 Do not lower the paws in the area of slope
gravel paths and do not lower them direct-
ly on to the sleepers.
WARNING
Accidental damage
If the electrical system or the engine fails
while the excavator is running with mo-
mentum, there is a risk of accidents.
 Apply the emergency brake function to lo-
wer the rail-road excavator, see
page 121.
Before lifting up the rail-road excavator under
overhead lines, the height limitation must be
switched on, checked and set in accordance with
the required minimal distance to the overhead
lines, see page 29.

 Switch off the rail operation, see page 107. NOTICE

If the rail-road excavator must be stopped on
the rails
 Park the rail-road excavator only on a track
that is cordoned off.
 Place wheel chocks in front of the guide rolls
and behind them.
 Provide track locks and guarding and stopping
signal in front of, and behind the rail-road ex-
cavator.
10.6 Running over a switching device
(e.g. INDUSI)
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before running over
a switching device.
Damage to property
If the rail-road excavator is not lifted in
good time, there is a risk of damaging the
switching device.
 Raise the rail-road excavator in good time
sufficiently, so that the switching device
can be run over with momentum.
WARNING
Danger of accident
When lifted up, the rail-road excavator
may not be braked. This may cause an ac-
cident.
 For safety reasons become acquainted
with the lowering of the rail-road excava-
tor.
 Become acquainted with the activation of
the parking brake.
The activation of the parking brake (the
accompanying crew may activate it, too)
lowers the rail-road excavator onto the
rails and brakes it.

WARNING
Personal injury and damage to pro-
perty
Improper running over a switching device
with momentum may result in injuries or
damage.
 When running over, respect rail operator's
guidelines no. 931.0201, e.g. the guideli-
nes of Deutsche Bahn.
 If it is not possible to respect the guideli-
nes, the rail-road excavator is to run over
the switching device step-by-step, see
page 125.

124
 Operation within the frame of the railway transport 10
10.6.1 Running over a switching device with 9. Release the switch (1).
momentum The solid axle will be lowered.
1. Pre-select both guide roll axles, see
page 119. Note
The adjustment of the desired guide roll pres-
sure takes place automatically.
10.Pre-select both guide roll axles, see
page 119.

10.7 Towing wagons

1 2
WARNING
I
Personal injury and damage to pro-
0
perty
II
Failure to follow the instructions contai-
ned in the introductory chapters may re-
M+P-05C-2478
sult in injury or damage.
2. Press and hold the switch (1) into position II  Observe all the instructions in the "Intro-
until the rail-road excavator rises above both duction", "Safety of the road and off-road
guide roll axles and runs over the switching operations" and "Safety rail operation"
device. chapters in particular before towing wa-
The control light (2) lights up. gons.

3. Release the switch (1).

The rail-road excavator will be lowered. Maximum permis-
sible towable mass
10.6.2 Running over the switching device
Unbraked 40 t
step-by-step
1. Drive the rail-road excavator onto the swit- Braked by means of the 120 t
ching device. wagon brake system

1 2

I
0
II

M+P-05C-2478

2. Pre-select the guide roll axle at the front, see

page 119.
3. Press and hold the switch (1) into position II
until the steering axle is lifted.
4. Drive slowly to pass over through the swit-
ching device.
5. Release the switch (1).
The steering axle will be lowered.
6. Pre-select the guide roll axle at the rear, see
page 119.
7. Press and hold the switch (1) into position II
until the solid axle gets lifted.
8. Drive slowly over the switching device.

125
10 Operation within the frame of the railway transport
10.7.1 Connecting and disconnecting
wagons
5
WARNING
Danger of accident
Improper connecting and disconnecting
of the wagons may cause accidents.
 Maximum permissible towable mass is 4
120 t and should not exceeded 12 axles.
 Connecting wagons both at the front and 3
at the rear of the rail-road excavator is not
permitted.
 Only tow the wagons by means of a
M+P-05C-3280
special towbar (Robel).
3. Hitch the special towbar (Robel) (3) in the
1. Switch on the wagon brake, see page 128. drawbar coupling (4) of the wagon.
WARNING Note
Personal injury The special towbar (Robel) is in the holder si-
Carelessness when connecting and dis- tuated on the undercarriage, see page 33.
connecting the wagons may cause perso-
nal injury. 4. Turn the hand wheel (5) until the special
 Never put your hand into the coupling towbar (Robel) (3) is at the level of the exca-
mouth of the drawbar coupling. vator drawbar coupling.

WARNING
Personal injury and damage to pro-
perty
Careless driving backwards when con-
necting may lead to injury or damage.
 Drive the rail-road excavator backwards
with extreme caution.
2
1  No persons are allowed to stand between
the rail-road excavator and the wagon.
Berne rectangle clearances are not fore-
seen.
 When driving backwards, involve a se-
M+P-05C-3279 cond person to guide by using signals.

2. Remove the latch (1) and actuate the lever (2).

1
7

6
M+P-05C-3281

5. Drive the rail-road excavator backwards until

the coupling pin (6) locks into place.
6. Check to ensure that the latch (1) has a tight
fit (arrow) to the securing bush (7).
7. Use the latching device to lock the driving
brake pedal.

126
 Operation within the frame of the railway transport 10
8. Make sure that the parking brake is released,
see page 75.

10

M+P-05C-2674

12.Open the shut-off valve (10) that is on the

undercarriage.
M+P-05C-2482

9. Remove the coupling (8) from the holder that

is situated on the undercarriage and remove
the brake hose from the holder.
10.Remove the protective cover from the coup-
ling head if necessary.
Note
When mounting the coupling to the undercar-
riage, make sure that the protective cap is on
the coupling head.
WARNING
Danger of accident
If the wagons are improperly connected,
there is a risk of accidents.
 Check to ensure that all of the wagons are
connected.
 Check to ensure that all of the wagons are
connected to the wagon brake system.

11
9

M+P-05C-2485

M+P-05C-2483
13.Open the wagon shut-off valve (11).
11.Connect coupling (9) to the wagon com- 14.Perform a brake test.
pressed-air coupling head. The wagons may be towed.

127
10 Operation within the frame of the railway transport
10.7.2 Wagon brake system Braking fully /wagon brake
Push the lever (2) into position V.
The indicator (1) is to indicate 0 bar.
The wagons will be fully braked.

PAR DEL
1
10.8 Rail operation work

4
bar
6
WARNING
2 8

0 10 Personal injury and damage to pro-

perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
M+P-05C-3283
 Observe all the instructions in the "Intro-
If the brake is released, the indicator (1) of the duction", "Safety of the road and off-road
compressed air manometer is to indicate ap- operations" and "Safety rail operation"
prox. 5 bar. chapters in particular before carrying out
any works during rail operation.

10.8.1 Work scheduling

 Carry out daily checks in accordance with the
inspection plan, see page 54.
 Prepare the rail-road excavator for road and
off-road operation. See "Operation" and
"Road and off-road operation" chapters.
 Start the engine, see page 72.
 Prepare the rail-road excavator for rail opera-
tion, see page 107.
 Rerail the rail-road excavator, see page 118
or page 120.
 Check the height limitation, see page 111.
II Running position and release position
 Check the slewing limitation, see page 115.
(release the brake)
 Drive the rail-road excavator to the work site,
see page 75.
III Final position
 Switch on the pilot control, see page 70.
 off II The brake is released.
 Release the parking brake, see page 76.
 off V The brake is put on
 In order to take advantage of the maximum
tear-off and breakout force, actuate the ser-
V Braking fully vice braking device, see page 78.

10.8.2 Parking the rail-road excavator at the

place of work
Running position and release position
Push the lever (2) to position II. NOTICE
The indicator (1) is to indicate 5 bar. Damage to property
Lowering paws in the area of the rails
Final position may cause damage.
1. Push the lever (2) between position III and V  Do not lower the paws in the area of slope
until the desired braking effect is achieved. gravel paths and do not lower them direct-
The indicator (1) is to indicate less than 5 bar. ly on to the sleepers.

Note
Lower the paws, see page 84.
The less the pressure indicated by the indicator
(1) of the compressed air manometer, the
more strongly the braking effect.

2. Push the lever (2) into position II.

128
 Operation within the frame of the railway transport
10.8.3 Earthing the rail-road excavator
DANGER
Personal injury
A serious or fatal accident may result if
electricity is transferred.
 When working in the area of overhead li-
nes, maintain a sufficient safety distance.
 Before rerailing, switched on, check and
set the height limitation in accordance
with the required minimal distance to the
overhead lines.
 To ensure the short-circuit passage of
current, earth the rail-road excavator ad-
ditionally if it is not rerailed.
 Before earthing the rail-road excavator,
make sure that the electric connection of
the return duct is not interrupted (e.g. be-
cause of flame cutting or loosening of the
brackets).
10
10.8.4 Automatic operation
If the rail-road excavator is in automatic opera-
tion, the contact pressure of the guide rolls axles
is automatically regulated during driving within an
area of approx. 5° to the side of the direction of
travel.
The guide roll axles may adjust to the given track
conditions.
Within the area of approx. 5° to the side of the di-
rection of travel the guide roll axles switch on au-
tomatically into operation in locked state.
Switch the guide roll axles into automatic opera-
tion, see page 119.
Note
For long trips without load, switch the guide roll
axles into automatic operation.

NOTICE
Damage to property
Improper connection of the earthing de-
vice may result in damage.
 Earthing connection contact surfaces (of
the rail-road excavator, the rails and the
earthing cable) must be metallically
bright.
 During operation, regularly check tight-
ness of the connecting terminals.

1 2

3
M+P-05C-2675

1. Connect the earthing cable (1) to the rear

and to the front connection (2), as well as to a
rail (3).
129
10 Operation within the frame of the railway transport
10.8.5 Operation in locked state The uppercarriage stands against the direc-
In order to enable stable work and movement of tion of travel Z
loads, the guide roll axles beyond the area of ap-
Z
prox. 5° to the side of the direction of travel get lo-
cked automatically.
Within the area of approx. 5° the guide roll axles 3 4
must be manually switched to operation in locked
state.

Switch the guide roll axles manually to operation

in locked state, see page 119.

The uppercarriage is facing the direction of

travel Z
Z

2 1

1 2
M+P-05C-2677

4 3
The guide roll axle cylinders (1) and (2) get locked
(only large cylinder sides), i.e. only retraction
beyond the current position is prevented. The
"sinking" of the rail-road excavator is reduced.
It is necessary to apply pressure on the guide roll
axle cylinders (3) and (4) in order to provide a firm
grip with the rails.
The guide rolls may adjust to the given track con-
ditions.

M+P-05C-2676

130
 Operation within the frame of the railway transport 10
If the uppercarriage is slewed out of the direc- 10.8.6 Guide roll axle locking device
tion of travel Z more than 5 degrees to the left To enhance stability when working or driving, the
or to the right guide roll axle may be hydraulically locked at the
side of the solid axle.
Z
WARNING
Danger of accident
5° 5° When driving on rails
and the guide roll axle is locked before
running over railway crossings (the up-
per rail edge = altitude), there is a risk of
accidents.
 Before passing over railway crossings
1 2
switch off the guide roll axle locking de-
vice.

1. Switch on the rail operation, see page 107.

4 3
M+P-05C-2678

All guide roll axle cylinders (1), (2), (3) and (4) get
locked (only large cylinder sides), i.e. only retrac-
tion beyond the current position is prevented. The
"sinking" of the rail-road excavator is reduced.
The oscillating axle locking device switches on
and the control light (5) in the display panel lights
up. Guide roll adjustment to the given track con-
ditions is only limitedly possible.

2. Press the switch (1).

0 Switch off
I Switch on

131
11 Transport
11 Transport
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before transporting
the rail-road excavator.
WARNING
Personal injury and damage to pro-
perty
Loading and transporting the rail-road
excavator is extremely dangerous if not
carried out properly. This may lead to in-
juries or damages.
 Only qualified persons are permitted to
load and transport the rail-road excavator.
 Load the rail-road excavator on level, so-
lid ground only.
Observe the following points closely:
 National regulations of the countries in which
the rail-road excavator is used;
 Loading dimensions of the rail-road exca-
vator;
 Carrying capacity of the transport vehicle;
 Dimensions and carrying capacities of roads,
bridges and overhead clearances;
 If necessary, remove the work attachment,
see page 93.
 Secure the rail-road excavator on the trans-
port vehicle.
11.1 Loading the rail-road excavator
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before loading the
rail-road excavator.
 Remove any mud, snow or ice from the loa-
ding area and the ramps of the transport ve-
132
hicle and from the tyres of the rail-road exca-
vator.
If the rail-road excavator is defective (e.g. da-
mage to the brake system/the steering)
 Drag the rail-road excavator on the transport
vehicle using a drawbar installation or lift it on
the transportation vehicle, see page 133.
Rail-road excavator that is in working order
WARNING
Danger of accident
Loading the rail-road excavator may
cause accidents if not carried out proper-
ly.
 Do not drive onto transport vehicles wit-
hout guides.
 Only qualified persons are permitted to
load the excavator.
 Drive in a straight direction only when dri-
ving on ramps; do not turn the uppercarri-
age.
 Start the engine, see page 72.
 Align the rail-road excavator in front of the
ramps so that it can be driven onto the loading
area without having to change direction.
 Keep the excavator equipment lowered so
that the centre of gravity is low down.
 Drive the rail-road excavator slowly onto the
loading area. Do not stop on the ramps and
drive particularly carefully on the transition
area between the ramps and the loading area.
 Slew the excavator equipment to the back and
lower it.
 Parking the rail-road excavator, see page 78.
 Lock the slewing brake pedal and the driving
brake pedal using the latching device.
 Activate the parking brake, see page 75.
 Switch off the engine, see page 72.
 Use chains to secure the rail-road excavator
at the front and rear drawbar mounts.
Use suitable D-links for the drawbar mounts.
 Secure the excavator equipment.
WARNING
Danger of accident
Accidents can happen if the rail-road ex-
cavator is not lashed down.
 Secure the rail-road excavator against
slipping and tipping over.
 Transport 11
11.2 Unloading the rail-road travel), see page 89.
excavator 2. Use the slewing locking device to lock the up-
percarriage, see page 81.
WARNING 3. Lift the outrigger support, see page 83.
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro- 2
duction", "Safety of the road and off-road
operations" and "Safety rail operation" 1
3
chapters in particular before unloading
the rail-road excavator.

1. Remove the harnessing and the chain blocks. 4

2. Start the engine, see page 72.
3. Release the parking brake, see page 75. M+P-05C-2825

4. Unlock the slewing brake pedal and the dri-

ving brake pedal using the latching device.
5. Keep the excavator equipment lowered so
that the centre of gravity is low down.
WARNING
Danger of accident
Unloading the rail-road excavator may
cause accidents if not carried out proper-
ly.
 Do not drive onto transport vehicles wit-
hout guides.
 Only qualified persons are permitted to
unload the rail-road excavator.
 The steering axle can be at the front (gi-
ven the direction of travel).
 Drive in a straight direction only when dri-
ving on ramps; do not turn the uppercarri-
age.
6. Drive the rail-road excavator slowly off the loa-
ding area. Drive particularly carefully on the
transition between the loading area and the
ramp.
11.3 Lifting the rail-road excavator
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before lifting the rail-
road excavator.
4. Fully extend the lifting cylinder (1).
5. Fully retract the adjustment cylinder (2).
6. Move the work attachment (3) as close to the
rail-road excavator as possible. Place the
work attachment on the dipper bracket (4) or
mount it.
7. Use the latching device to lock the slewing
brake pedal.
8. Park the rail-road excavator, see page 78.
WARNING
Personal injury and damage to pro-
perty
Lifting the rail-road excavator without
any lifting gear or without suitable lifting
gear may result in serious accidents and
damage.
 The rail-road excavator may only be lifted
with suitable lifting gear of a sufficient size
attached to the rings specified here.
WARNING
Personal injury
Rotating parts or hot parts may cause in-
jury.
 Only fasten stop bolts when the engine is
switched off.
9. Open the bonnet.

1. Turn the undercarriage so that the steering

axle is at the front (given the direction of

133
11 Transport
DANGER
6 5
Personal injury
A lifted rail-road excavator is a danger to
people in its close vicinity and may cause
a serious or fatal injury.
 Make sure that there are no people within
the range of the lifted rail-road excavator.
7

8 11.4 Transporting the rail-road

excavator on a wagon

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before transporting
the rail-road excavator.
M+P-05C-2679

 Load the rail-road excavator only on a suitable

10.Insert stop bolts (5) into the holes on the coun-
ramp.
terweight (6).
 Observe the carrying capacity of the wagon.
11.Screw the stop bolts (5) tight with flat washers
(7) and nuts (8).  Observe the loading dimensions, see
page 192.
12.Close the bonnet.
 Remove any mud, snow or ice from the ramp
and the loading area of the wagon and from
the tyres of the rail-road excavator.
 Make sure that the specified minimum dis-
tance from overhead lines are considered
when loading, see page 29.
 When loading, involve a second person to
guide by using signals.
 Drive the rail-road excavator slowly onto the
5 loading area. Drive particularly carefully on
the transition between the ramp and the loa-
ding area.
 Use the slewing locking device and the sle-
wing brake to secure the uppercarriage.
 Use the parking brake and wheel chocks to
secure the rail-road excavator.
 To prevent the rail-road excavator from slip-
ping secure it at the sides.
 Place the excavator equipment onto the loa-
9 ding area and to prevent it from tipping, secure
it by harnessing.
 Secure the rail-road excavator by harnessing.
 Do not lower the outrigger support onto the
M+P-05C-2680
wagon.
13.Attach the lifting gear to the stop bolts (5) and  Switch off the engine.
(9).

134

11.5 Recovering and towing the rail-
WARNING
Danger of accident
Misuse and improper operation by unau-
thorised persons may cause accidents.
 Close the windows and always lock the
rail-road excavator when you leave it.
G2
Transport 11
road excavator in road and off-
road operations
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before recovering
and towing the rail-road excavator.

WARNING
Personal injury and damage to pro-
perty
When recovering or towing the excava-
tor, there is a risk of injury or damage.
 Do not tow the rail-road excavator, if it is
in the area of the traffic on public roads.
 Do not tow the rail-road excavator, if the
brake system or the steering is defective.

WARNING
Danger of accident
When the engine is switched off or in
SO
case of fail of the hydraulic system, stee-
M+P-05C-2681
ring and brakes of the rail-road excavator
G2 Reference line are partially operational. This may cause
an accident.
SO Rail upper edge
 Operate the rail-road excavator with due
 In the rail network of Deutsche Bahn, the rail- care.
road excavator must be loaded in a proper
way, so that the reference line (G2) is never
crossed. NOTICE
 Place the rail-road excavator on the wagon so Damage to property
that the wheels are as close to the side plank Improper recovering and towing may re-
as possible (arrow). sult in damages.
 Place the excavator equipment on the wagon  Set the powershift transmission to zero.
so that the reference line (G2) is never  Respect the maximum towing speed and
crossed. the maximum towing distance.

 Observe the national regulations of the coun-

tries, in which the rail-road excavator is used.
 Prior to work secure the rail-road excavator
against rolling down.
 Use adequate tension-proof tow bars only to
tow the rail-road excavator.
 Attach the tow bar to the tow lug provided for
that purpose only or to one of the drawbar
couplings.
 Wear work gloves.
 Improper towing may seriously damage the
rail-road excavator and the towing vehicle.
 Observe environmental standards.

135
11 Transport
If the rail-road excavator is defective, (e.g. da-
mage to the brake system/the steering)
 Load the rail-road excavator on a transport ve-
hicle, see page 132.
11.5.1 Towing out of the hazard zone
Set the powershift transmission to zero posi-
tion
WARNING
Personal injury and damage to pro-
perty
Accidents can happen if the powershift
transmission is out of operation.
 Prior to any works on the powershift trans-
mission secure the excavator against rol-
ling down.
 Place a slip of paper in the cab to inform
other people that the powershift transmis-
sion is out of operation.
1. Take the protective cap off the grease nipple
(1) and the relief valve (2).
2. Clean the grease nipple (1) thoroughly and lu-
bricate it until grease escapes from the relief
valve (2).
136
As soon as the rail-road excavator is repaired,
stop the emergency operation
1. Take the protective cap off the venting valve
(3).
2. Put a suitable container underneath the ven-
ting valve (3) and undo.
3. Start the engine.
4. Make sure that no travel direction is pre-se-
lected and switch on the powershift transmis-
sion several times.
Grease escapes from the venting valve (3).
5. Switch off the engine.
6. Tighten the venting valve (3).
7. Emergency operation is disabled.
8. Dispose of that oil that has been collected in
accordance with regulations.
Towing the rail-road excavator
 People are not permitted to be within the ha-
zard zone of the tow bar.
 Avoid jerky start up and towing the rail-road
excavator.
 When towing, travel slowly.
 Avoid towing the rail-road excavator on slo-
ping ground.
Attaching a towing bar
WARNING
Personal injury
Improper works when attaching the tow
lug to the coupling mouth may cause per-
sonal injury.
 Never put your hand into the coupling
mouth of the drawbar coupling.
2
M+P-05C-2495
1. Remove the latch (1) and actuate the lever (2).

WARNING
Danger of accident
Using unsuitable towing bar for towing
the rail-road excavator may cause acci-
dents.
 Make sure that the towing bar is of suffici-
ent size.
1 6
5 Personal injury and damage to pro-
4 duction", "Safety of the road and off-road
3 M+P-05C-2496
2. Insert the tow lug (3) in the coupling mouth (4)
and slide it in until the coupling pin (5) locks
into place.
3. Check to ensure that the latch (1) has a tight
fit (arrow) to the securing bush (6).
4. Orientate the tow lug to the towing vehicle and
carefully drive backwards until the tow lug gets
connected.
Check the relevant fuse.
NOTICE
Damage to property
Using a towing lug when manoeuvring
may result in damage.
 When manoeuvring, maintain a maximum
lateral slewing angle of 60° to the towing
lug.
5. Set the powershift transmission to zero posi-
tion, see page 136.
If the rail-road excavator got stuck
 Using the work attachment, try to put the rail-
road excavator back into operation.
 Only place chocks under the drive wheels
when the rail-road excavator is stationary.
 People are not permitted to be in the area
where chocks may be hurtled when the rail-
road excavator is started up.
 Where possible, drive out the rail-road exca-
vator so as to go back in the trace went
through before.
If not possible:
 Tow the rail-road excavator out of the hazard
zone, see page 136.
Transport 11
 Set the powershift transmission to zero posi-
tion, see page 136.
 Pull out the rail-road excavator back in the
trace went through before.
 If pulling out the rail-road excavator is not pos-
sible, lift out it by a crane.
11.6 Recovering and towing during
rail operation
WARNING
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
operations" and "Safety rail operation"
chapters in particular before recovering
and towing the rail-road excavator.
 Secure the area of rescuing (e.g. by guarding
and stopping signals, signal lights, etc.).
 When derailing the rail-road excavator from a
public railway crossing, vehicle traffic must be
properly secured (e.g. by barriers or traffic
lights).
 Derail the rail-road excavator at the nearest
suitable place and remove it from the hazard
area.
 People are not permitted to be within the ha-
zard zone of the tow bar.
 The rail-road excavator must be manned.
 Avoid jerky start up and towing the rail-road
excavator.
 When towing, travel slowly.
11.6.1 Derailing by emergency switching
NOTICE
Damage to property
Operating the rail-road excavator by
emergency switching may cause dama-
ge.
 The malfunction has to be rectified imme-
diately.
Emergency switching in the event of cable
break in the rotary feed system
Note
You will find the appliances for emergency swit-
ching in the tool box, see page 55.
137
11 Transport

2 3

6 4

2
2
6

M+P-05C-2684 M+P-05C-2686

1. Open the rear cab door  (1) and plug a short 3. Plug the connecting cables (2) and (4) into the
connecting cable (2) into the plug (3). distributor (6).
4. Start the engine, see page 72.

0
1
2

4
5

M+P-05C-2685
6
2. Plug a long connecting cable (4) into the plug M+P-05C-2687

(5). 5. Plug the distributor (6) into the socket (7).

Automatically, the guide roll axles are lifted up,
the oscillating axle locking device - switched
off, the off-road gear - switched on, the exca-
vator equipment blocking - cancelled and the
slewing brake - released.

138
 Transport 11
6. Unlock the steering wheel, see page 120. Release the oscillating axle locking device
The rail-road excavator may be driven out of manually
the track. Cable connection must stay con-
nected during derailing.

Note
If the guide roll axles do not lift up, there is a
break-down incident. Recovering the rail-road
excavator in case of a break-down incident,
see page 140.

Emergency switching by a button toggle wit-

hout any function
1. Start the engine, see page 72.
2. Switch off the rail operation, see page 107.

0
l ll
I

M+P-05C-2688

Push the lever (1) into position II.

I The oscillating axle locking device may be
M+P-05C-2474
activated by the switch in the right console
3. During derailing, press and hold the switch (1) (normal switching).
into position I. Automatically, the guide roll II Oscillating axle locking device is switched off
axles are lifted up, the oscillating axle locking (emergency switching)
device - switched off, the off-road gear - swit-
Emergency switching in case of malfunction of
ched on, the excavator equipment blocking -
the CARSY system and the slewing limitation
cancelled and the slewing brake - released.
1. Slew the uppercarriage in longitudinal direc-
4. Unlock the steering wheel, see page 120.
tion to the track.
The rail-road excavator may be towed from
the track.
1
Note
0
If the guide roll axles do not lift up, there is a
cable break in the rotary feed system. Derailing
I
the rail-road excavator in the event of cable
break in the rotary feed system, see page 137.

M+P-05C-2476

2. During derailing, press and hold the switch (1)

into position I.
Automatically, the lock of the guide roll axle
cylinder and the oscillating axle locking device
get unlocked.
3. Unlock the steering wheel, see page 120.
The rail-road excavator may be driven out of
the track.
139
11 Transport
11.6.2 Bringing the rail-road excavator in a
position for recovery in case of a 3 6
break-down incident 2
Hand emergency pump function overview 10

NOTICE
4
Damage to property 1 5
If the sequence is not respected when at-
taching or removing connections and ho- 11 9 7
ses, there is a risk of damage.
 When attaching or removing hoses, res-
pect the sequence of the connections and 8
hoses that is specified with regard to the
relevant function.

WARNING 1 12
Personal injury 15
Hydraulic oil will escape under pressure
14
when pipes or parts are removed. Esca-
ping hydraulic oil, the parts to be remo-
ved or parts which move as a result of a 13
drop in pressure may cause injuries.
 Reduce the charging pressure of the hyd-
raulic reservoir prior to carrying out any M+P-05C-2730

maintenance work on the hydraulic sys-

tem. 2. Remove the lever (1) from the holder that is on
the uppercarriage and insert it in the hand
1. Open the maintenance bonnet. pump (2).

Function Position of the lever Linking the connections

(3) (4) (5)

Lifting the excavator equipment, see page 141. O X X (6) – (7), (8) – (9)

Slewing the uppercarriage, see page 141. X O X (10) – (11),

Slewing brake is released, the ignition
key is switched on

Lifting the paws, see page 142. O X X (6) – (12)

Lifting the rail-road excavator, see page 143. O X X (6) – (13), (8) – (15)

Lowering the rail-road excavator, see page 148. X X O

Lifting the guide roll axles, see page 145. O X X (8) – (13), (6) – (15), (8) – (14)
O Open
X Closed

140
 Transport 11
Lifting the excavator equipment 5. Push the lever (4) into position III.
1. Open the maintenance bonnet. III Closed
IV Open
6. Set the valve (5) to position V.
16 V Closed
7 17
9 VI Open

WARNING
Danger of accident
Exceeding the minimum distance from
the overhead lines may cause accidents.
17  Make sure that the specified minimum di-
stance from overhead lines are conside-
red even whit the rail-road excavator lifted
up.
16
7. Use the lever (1) to actuate the hand pump
(2).
The excavator equipment will be lifted up.
6 8. Push the lever (3) into position I.
16 9. Beginning with connection (9), remove the
hose (17) therefrom and then remove the
17 8 hose (16) from connection (7).
10.Remove the lever (1) from the hand pump (2)
and insert it in the holder of the uppercarriage.
11.Close the maintenance bonnet.
M+P-05C-2731

2. Use a hose (16, 6,600 mm) to link the connec-

tions (6) and (7). Slewing the uppercarriage
3. Use a hose (17, 4300 mm) to link the connec- 1. Open the maintenance bonnet.
tions (8) and (9). 2. Open the bonnet.

11 21 20
19
17

16 18

19
3
4 II 3
2 II
I
I 10
IV IV 19
1 4
V III V III
5 5
VI VI
M+P-05C-2732
M+P-05C-2733

4. Push the lever (3) into position II. 3. Trennwand (18) ausbauen.
I Closed 4. Anschlüsse (10) und (11) mit Schlauch (19,
II Open 2000 mm) verbinden.

141
11 Transport
5. Push the lever (3) into position I. Lifting the paws
I Closed 1. Open the maintenance bonnet.
II Open
6. Push the lever (4) into position IV.
III Closed
IV Open
7. Set the valve (5) to position V.
V Closed
VI Open
8. Turn the ignition key to position I, see
page 59.
9. Lock the slewing brake pedal (20) with the lat-
ching device (21).

18

19

2. Use a hose (17, 4,300 mm) to link the connec-

tions (6) and (12).
3. Push the lever (3) into position II.
I Closed
2 4 II Open
19 4. Push the lever (4) into position III.
IV III Closed
III IV Open
1 5. Set the valve (5) to position V.
V Closed
VI Open
M+P-05C-2734

10.Use the lever (1) to actuate the hand pump (2) 6. Use the lever (1) to actuate the hand pump
and slew the uppercarriage by hand opposite (2).
to the direction of towing . The paws will be lifted up.
11.Unlock the slewing brake pedal (20) with the 7. Beginning with connection (12), remove the
latching device (21). hose (17).
12.Turn the ignition key to position 0, see 8. Push the lever (3) into position I.
page 59.
9. Remove the lever (1) from the hand pump (2)
13.Beginning with connection (11), remove the and insert it in the holder of the uppercarriage.
hose (19).
10.Close the maintenance bonnet.
14.Install the partition wall (18).
15.Close the bonnet.
16.Push the lever (4) into position III.
17.Remove the lever (1) from the hand pump (2)
and insert it in the holder of the uppercarriage.
18.Close the maintenance bonnet.

142

Rail-road-excavator-connecting to/discon-
necting from a towing vehicle
WARNING
Personal injury
Carelessness when connecting and dis-
connecting the wagons may cause perso-
nal injury.
 Never put your hand into the coupling
mouth of the drawbar coupling.
23
22
M+P-05C-2479
1. Remove the latch (22) and actuate the lever
(23).
26
25
24
M+P-05C-2480
2. Take out the special towbar (Robel) (24)
from the holder that is situated on the under-
carriage and hitch into the drawbar coupling of
the towing vehicle.
3. Turn the hand wheel (26) until the special
towbar (Robel) (24) is at the level of the ex-
cavator drawbar coupling.
Transport 11
WARNING
Personal injury and damage to pro-
perty
Careless driving backwards when con-
necting may lead to injury or damage.
 Drive the rail-road excavator backwards
with extreme caution.
 Persons are not permitted to stay bet-
ween the rail-road excavator and the wa-
gon.
 When driving backwards, involve a se-
cond person to guide by using signals.
22
28
27
M+P-05C-2481
4. Drive the rail-road excavator backwards until
the coupling pin (27) locks into place.
5. Check to ensure that the latch (22) has a tight
fit (arrow) to the securing bush (28).
Lifting the rail-road excavator with the guide
roll axles
WARNING
Danger of accident
When lifted up, the rail-road excavator
may not be braked. This may cause an ac-
cident.
 Connect the rail-road excavator to a to-
wing vehicle.
143
11 Transport
Steering axle 5. Push the lever (4) into position III.
1. Open the maintenance bonnet. III Closed
IV Open
17 6. Set the valve (5) to position V.
V Closed
VI Open
17 8 15
WARNING
Danger of accident
Exceeding the specified minimum dis-
tance from overhead lines may cause ac-
cidents.
 Make sure that the specified minimum di-
stance from overhead lines is considered
17
even whit the rail-road excavator lifted up.

7. Use the lever (1) to actuate the hand pump

16 (2).
The steering axle will be lifted up.
6 8. At the same time, unscrew the hose (16) from
16 13 the connections (13).
16
Solid axle

3
6
M+P-05C-2736 2 16

2. Use a hose (16, 6,600 mm) to link the connec- I II

tions (6) and (13).
3. Use a hose (17, 4,300 mm) to link the connec-
tions (8) and (15). 1

3
4
2 II
I
IV
1
V III 17
16
5
VI 15

29 14

16

M+P-05C-2738

1. Sever the screw couplings (29), see page 94.

16 2. Move the hose (16) backwards and, at the
same time, connect it with both connections
(14).

M+P-05C-2737

4. Push the lever (3) into position II.

I Closed
II Open

144
 Transport 11
Lift the guide roll axles
WARNING
WARNING
Danger of accident
Exceeding the specified minimum dis- Danger of accident
tance from overhead lines may cause ac- When lifted up, the rail-road excavator
cidents. may not be braked. This may cause an ac-
 Make sure that the specified minimum di- cident.
stance from overhead lines is considered  Connect the rail-road excavator to the to-
even whit the rail-road excavator lifted up. wing vehicle.

3. Use the lever (1) to actuate the hand pump

(2). Lifting the guide roll axle on the steering axle
The solid axle will be lifted up. 1. Open the maintenance bonnet.
4. Push the lever (3) into position I.
I Closed 17
II Open
5. At the same time, unscrew the hose (16) from
16 8 15
the connections (14).
Screw couplings (29) must remain separated.
6. Unscrew the hose (16) at connection (6).
7. Beginning with connection (15), remove the
hose (17). 17
8. Remove the lever (1) from the hand pump (2)
and insert it in the holder of the uppercarriage.
9. Close the maintenance bonnet.

16

6 13
17
16

M+P-05C-2739

2. Use a hose (16, 6,600 mm) to link the connec-

tions (8) and (13).
3. Use a hose (17, 4,300 mm) to link the connec-
tions (6) and (15).

145
11 Transport
Lifting the guide roll axles on the solid axle
3
4 3
2 II
I 2 II 17
IV I
1
V III
5
1
VI

8
16

17

14 17

15
16
16

M+P-05C-2740

4. Push the lever (3) into position II. M+P-05C-2741

I Closed 1. Move the hose (16) backwards and, at the

same time, connect it with both connections
II Open
(14).
5. Push the lever (4) into position III.
2. Use the lever (1) to actuate the hand pump
III Closed (2).
IV Open The guide roll axle of the solid axle will be
6. Set the valve (5) to position V. lifted up.
V Closed 3. At the same time, unscrew the hose (16) from
the connections (14).
VI Open
Screw couplings need to remain separated.
7. Use the lever (1) to actuate the hand pump
4. Push the lever (3) into position I.
(2).
The guide roll axle on the steering axle will be I Closed
lifted up. II Open
8. At the same time, unscrew the hose (16) from 5. Unscrew the hose (16) at connection (8).
the connections (13). 6. Beginning with connection (15), remove the
hose (17).
7. Remove the lever (1) from the hand pump (2)
and insert it in the holder of the uppercarriage.
8. Close the maintenance bonnet.

146
 Transport 11
Electric emergency pump function over- 5. Use the relevant control elements to bring the
view rail-road excavator in a position wherein it can
be safety recovered (in a position for reco-
very).

1. Unscrew the hoses (1) from the fittings (2).

Close the hoses (1) and the fittings (2) with
sealing caps (3).
2. Open the right-hand maintenance flap.
6. Press and hold the switch (1) until the rail-road
excavator is completely lifted up.
7. Turn the ignition key to position 0, see
page 59.
8. Remove the key (30) from the electric emer-
gency pump.
9. Close the right-hand maintenance flap.

30

II

M+P-05C-2742

3. Turn the key (30) into position I.

I Switching on
II Switch off
4. Turn the ignition key to position I, see
page 59.
147
11 Transport
11.6.3 Towing the rail-road excavator (Use the hand emergency pump to) lower the
Use the hand emergency pump to bring the rail- rail-road excavator
road excavator in a position for recovery, see 1. Open the maintenance bonnet.
page 140. Use the electric emergency pump to
bring the rail-road excavator in a position for reco-
very, see page 147.

In case of darkness, driving through a tunnel

or poor visibility, if the electrical system is in
working order

32

33

31

M+P-05C-2689
I
1. Apply a black cover glass on the rail light 5
(31) and (32) to fade it. II
2. Apply a red cover glass to fade the rail light M+P-05C-2743
(33) as a final signal.
3. Turn the ignition key to position I, see 2. Set the valve (5) to position II.
page 59. The rail-road excavator will be lowered by its
own weight.
4. Switch on the rail operation, see page 107.
I Closed
5. Switch on the rail light at the front, see
page 117. II Open
3. Close the maintenance bonnet.
Note
As the uppercarriage is slewed opposite to the
direction of towing, the final signal switches on.
6. Tow away the rail-road excavator.

In case of darkness, driving through a tunnel

or poor visibility, if the electrical system is de-
fective
1. Attach a red-faded signal lamp to the rail-road
excavator as a final signal.
2. Tow away the rail-road excavator.

148
 Transport 11
(Use the electric emergency pump to) lower
the rail-road excavator
1. Turn the ignition key to position I, see
page 59.
The rail-road excavator will be lowered by its
own weight.

2. Remove the sealing caps (3) from the hoses

(1) and the fittings (2). Connect the hoses (1)
to the fittings (2).

Removing the rail-road excavator from the

track
1. Disconnect the rail-road excavator from the
towing vehicle, see page 143.
2. Load the rail-road excavator on the transport
vehicle, see page 132.

149
12 Maintenance
12 Maintenance
12.1 Cleaning the rail-road excavator
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any cleaning works.
WARNING
Personal injury
Severe burns may result from cleaning
the rail-road excavator at operating tem-
perature.
 Only clean the rail-road excavator when
the engine is switched off and has cooled
down.
WARNING
Personal injury
There is an increased risk of slipping and
falling down when the rail-road excavator
is being cleaned.
 Do not climb onto the rail-road excavator
when it is being cleaned with water and/or
a high-pressure washer; use a work plat-
form instead.
CAUTION
Damage to the environment
Cleaning the excavator if no oil separator
is available may damage the environ-
ment.
 Only clean the rail-road excavator if an oil
separator is available.
NOTICE
Damage to property
The machine may be damaged if it is clea-
ned with water or a high-pressure
washer.
 Do not spray water into the air filter and
exhaust system.
12.1.1 Dry cleaning with compressed air
If the excavator is slightly soiled with dry dust, dry
clean with compressed air.
12.1.2 Cleaning with water and cleaning
agents
If slightly contaminated with dust as well as oil
and fuel:
 Use neutral or alkaline cleaning agents only.
 Apply cleaning agents with a brush, leave for
a while and rinse off with water.
 Lubricate the rail-road excavator after it has
been cleaned, see page 152.

WARNING
Personal injury and damage to pro-
perty
There is a greater risk of explosion as a
result of sparks (electrostatic charging or
a short circuit) when cleaning material
containing metal is used.
 Only use brushes without any metal parts.

WARNING
Personal injury
Wearing inappropriate clothing when
cleaning components with compressed
air may result in injury.
 Wear suitable protective clothing.

150

12.1.3 Cleaning with a high-pressure washer
NOTICE
Damage to property
The machine may be damaged if it is clea-
ned with a high-pressure washer.
 The rail-road excavator may only be clea-
ned with a high-pressure washer for the
first time four weeks after it has been
commissioned; by this time the paint on
the rail-road excavator will have hardened
completely.
 Do not clean insulating material with a
high-pressure washer.
Maintenance 12
12.1.6 Maintenance and replacement of
safety signs
 Safety markings have to be in a perfect condi-
tion and have to be easy to read.
 Damaged or missing safety markings must be
replaced.
 Use mild cleaning agents and water to clean
safety markings. Do not use any cleaning
agents containing solvents.
 For information on ordering safety markings
see page 8, "Warranty". Indicate a language if
necessary.

In case of heavy soiling as well as oil and fuel:

 The nozzle on the high-pressure washer must
be kept at least 300 mm away from the sur-
face of the rail-road excavator.
 The jet pressure of the high-pressure washer
may not exceed 100 bar.
 The jet temperature should be 80–90°C.
 Use neutral or alkaline cleaning agents only.
 In case of stubborn dirt, use a brush or similar
to help remove the dirt.
 Lubricate the rail-road excavator after it has
been cleaned, see page 152.

12.1.4 Cleaning the outside of the engine

Depending on the degree of pollution, various
cleaning procedures may be used, see page 150.

NOTICE
Damage to property
The machine may be damaged when
cleaning it with water.
 Protect electric components and seals
against direct streams of water.

Switch on the engine and allow it to warm up after

cleaning so that residual water will be able to eva-
porate, hence avoiding the formation of rust.

12.1.5 Cleaning the combination cooler

The combination cooler for the engine and the hy-
draulic oil cooler are located behind the left-hand
maintenance flap.
Depending on the degree of pollution, various
cleaning procedures may be used.

NOTICE
Damage to property
The machine may be damaged if it is clea-
ned with a high-pressure washer.
 Use only low pressure to clean the fins on
the combination cooler.

151
12 Maintenance
12.2 Lubrication

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any lubrication works.

12.2.1 Rail-road excavator lubricating points

Every 10 operating hours (daily) Every 100 operating hours

Central lubrication point under the mainte- Every 100 operating hours
nance bonnet of the lubricant metering de- approx. 1 cartridge of special grease for the
vice: Apply the grease gun to the grease slewing ring
nipple and lubricate until the control pin (1) on
(Order Nr. 3620153)
the lubricant metering device has moved four-
teen times back and forth. Every 500 operating hours

Every 50 operating hours

 Clean lubricating points thoroughly.
 Lubricate them until grease escapes.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
 Grease the piston rods which never or seldom
run down into the hydraulic cylinders with
acid-free Vaseline.
 Before lubricating the king pins, lift the rail-
road excavator so that the wheel of the stee-
ring axle are off the ground and secure by A-
frames.
 Use a small amount of grease only to lubricate
the lubricating points of the cab door hinges.

152
 Maintenance 12
12.2.2 Lubricating points on the work Starting a lubrication procedure
attachment 1. Turn the ignition key to position I, see
Follow the manufacturer's operating instructions page 59.
when lubricating the work attachment.

12.2.3 Central lubricating system,

electric
The central lubricating system automatically lu-
bricates certain lubrication points on the exca-
vator equipment and the live ring every four
hours.

Note
The control light on the display will light
up during the automatic lubrication pro-
cess.

2. Press the switch (1).

0 Switch off
1 I Switch on
The control light (2) lights up.

3
2

M+P-05C-2745

1 Central lubricant metering device

2 Protective cap of the control pin
3 Control pin

Note
During the lubrication, the control pin (3) below
the protective cap (2) has to be moved back and
forth for about a minute. If that is not the case,
the central lubricating system has to be che-
cked.

If required, an additional lubricating process can

be started.

153
12 Maintenance
12.2.4 Lubrication in case of fail of the 4. Apply the grease gun to the grease nipple (1).
central lubrication system Lubricate until the control pin (3) has moved
fourteen times back and forth.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
5. Remove the grease gun and attach the pro-
tective cap (1).
6. Close the maintenance bonnet.

12.2.5 Filling the central lubricating

system

M+P-05C-2746

1 Grease nipple

M+P-05C-2748

1 Connection for grease pump

2 Grease nipple

By a grease pump
1. Open the maintenance bonnet.
2. Screw the grease pump up tight to the con-
nection (1) of the central lubricating pump.
3. Fill up with grease.
Fuels, lubricants and coolants and filling
3
quantities, see page 52 and page 53.
2 4. Remove the grease pump.
5. Close the maintenance bonnet.

By a grease gun
1. Open the maintenance bonnet.
M+P-05C-2747

2. Clean the grease nipple (2) thoroughly.

2 Protective cap of the control pin
3. Apply the grease gun to the grease nipple (2)
3 Control pin and fill up with grease.
1. Open the maintenance bonnet. Fuels, lubricants and coolants and filling
2. Clean the grease nipple (1) thoroughly. quantities, see page 52 and page 53.
3. Remove the protective cap of the control pin 4. Remove the grease gun.
(2). 5. Close the maintenance bonnet.

154
 Maintenance 12
12.3 Maintenance and inspection
tasks

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance and inspection tasks.

WARNING
Personal injury and damage to pro-
perty
Maintenance and repair work carried out
improperly may result in injuries or dama-
ge.
 Carry out only those maintenance activi-
ties that are described in these mainte-
nance instructions and possibly in the
supplementary operating instructions at-
tached.
 Read the maintenance instructions care-
fully!
 Only start the rail-road excavator up again
once maintenance work has been com-
pleted.

12.3.1 Engine maintenance

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance work on the engine.

WARNING
Personal injury and damage to pro-
perty
Maintenance work on the engine which is
not carried out properly may lead to inju-
ry or damage.
 Follow the instructions in the separate
operating instructions for the engine.

155
12 Maintenance
Overview of engine assemblies

In the engine compartment

10

3 5

11
6

7 8 4
M+P-05C-2749

1 Exhaust system Under the engine compartment

2 Sealing cover of the engine oil filler neck
3 Compressor for the air conditioning system
4 Generator
5 Coolant fluid tank
6 Coolant level sight glass
7 Engine radiator
8 Fuel pump
9 Engine oil dipstick
10 Combination cooler
11 Compressor of the compressed air system

M+P-05C-2690

1 Coolant drain plug

156
 Maintenance 12

2
5

6
M+P-05C-2691 M+P-05C-2750

2 Oil drain valve 4 Fuel filter

5 Fuel pre-filter
Behind the maintenance flaps
6 Engine oil filter

On the rail-road excavator

1 3

M+P-05C-2826

1 Desiccant container for the air dryer

2 Condenser or the air conditioner M+P-05C-2692

3 Air filter 1 Air conditioning system filter dryer

157
12 Maintenance
Checking the engine oil level
Note
1. Check the engine oil level daily.
When operating temperature is
2. Allow the engine to run at idling speed for ap- reached, the centre bar lights up.
prox.2 minutes immediately prior to checking
the engine.
3. Park the rail-road excavator, see page 78.
4. Open the bonnet.
WARNING
Personal injury
MAX Hot engine oil can cause serious burns.
 Wear suitable protective clothing and pro-
MIN 2 tective gloves.

2. Park the rail-road excavator, see page 78.

Engine oil draining off

M+P-05C-2751

5. Pull out the oil dipstick (1) and wipe it with a

clean, lint-free cloth.
6. Reinsert the oil dipstick (1) and take it out
again.
The engine oil level has to come up to bet-
ween the two markers (MIN and MAX).
1
NOTICE
Damage to property
Operating the rail-road excavator with an
insufficient engine oil level may cause da-
mage.
 The level must not drop below the MIN 3
mark.
 Engine oil will need to be added if the en-
gine oil level is just above the MIN mark.
2
7. Reinsert the oil dipstick (1).
If engine oil needs to be added: M+P-05C-2693

8. Unscrew the sealing cover (2) and top up with

1. Remove the floor plate (1) from the engine
engine oil through the filler neck.
compartment.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53. 2. Put a suitable container underneath the oil
pan.
9. Close the bonnet.
3. Unscrew the protective cap (2) from the oil
Changing the engine oil drain valve.
4. Hang the oil drain hose (3) into the collection
Note vessel and screw it to the oil drain valve.
Screwing on the oil drain hose will open the oil
Initially after 50 operating hours, and then every
drain valve.
500 operating hours (after 12 months at the la-
test). 5. Engine oil comes out.
When the engine oil has completely drained
1. Bring the engine up to operating temperature off, remove the oil drain hose (3) and screw
of approx. 80 °C. the protective cap (2) tightly to the oil drain
valve.
6. Dispose of used oil in accordance with regula-
tions.
158
 Maintenance 12
Filling up with engine oil 12.3.2 Maintaining the cooling system
1. Open the bonnet.
WARNING
Personal injury and damage to pro-
perty
MAX Failure to follow the instructions contai-
ned in the introductory chapters may re-
MIN 1 sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance work on the cooling sys-
2 tem.
 Follow the instructions in the separate
operating instructions for the engine.
M+P-05C-2752

2. Unscrew the sealing cover (1) and fill with en-

Checking the coolant level
gine oil through the filler neck until the level
reaches the MAX mark on the oil dipstick (2).
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
3. Tighten the sealing cover (1).
4. Allow the engine to run at idling speed for a
while, switch it off and check the engine oil
filter for leaks.
5. Check the engine oil level once again and top
up with oil if necessary.
6. Close the bonnet.
7. Install the floor plate of the engine compart-
ment.

Changing the engine oil filter
See the separate operating manual for the engine
for a description of how to change the engine oil
filter.
When the warning lights(1) and (2) light up and a
buzzer sounds, check the coolant level and top
up with coolant if necessary.
NOTICE
Damage to property
Operating the rail-road excavator with an
insufficient coolant level may cause da-
mage.
 If the warning lights light up, switch off the
engine immediately and check the coolant
level, topping up with coolant if necessa-
ry.

159
12 Maintenance
NOTICE
Damage to property
The incorrect mixture of anti-corrosion
and anti-freeze compounds and water
may result in damage.
 In order to avoid damage, follow the inst-
ructions for the mixing ratio of anti-corro-
sion and anti-freeze compounds and wa-
ter; see the separate operating
instructions for the engine.
1. Park the rail-road excavator, see page 78.
2. Open the bonnet.
4 1. Set the heating to the maximum temperature,
3 Coolant draining off
M+P-05C-2753
3. The coolant level has to reach the bottom
edge of the sight glass (3).
4. If necessary, carefully unscrew the sealing
cover (4) and top up with coolant as far as the
middle of the sight glass (3).
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
160
Note
Observe the mixing ratio of anti-corrosion and
anti-freeze compounds, see separate operating
instructions for engine.
5. Tighten the sealing cover (4).
6. Close the bonnet.
Changing the coolant
Note
Every 2000 operating hours (after 24 months at
the latest).
see page 68.
2. Park the rail-road excavator, see page 78.
3
2
M+P-05C-2694
1. Remove the floor plate (1) from the engine
compartment.
2. Put a suitable container underneath the
coolant drain plug (2).
3. Unscrew the coolant drain plug (2) and re-
move it with the sealing ring (3).
Coolant escapes.
4. Carefully remove the sealing cover on the
coolant expansion tank, see page 159.
5. Once the coolant has been drained off com-
pletely, screw the coolant drain plug (2) mit –
back on again with a sealing ring (3). Use a
new sealing ring if necessary.

NOTICE
Damage to property
Damage may result if the combined coo-
ler or coolant expansion tank become
soiled on the inside, e.g. with mud or de-
posits.
 Do not start up the engine again. Contact
the ATLAS Customer Service Depart-
ment.
6. Open the bonnet.
7. Put a suitable container underneath the en-
gine.
5 tion)
4 ture (frost protection).
M+P-05C-2695
8. Unscrew the coolant drain plug (4) and re-
move it with the sealing ring (5).
Coolant escapes.
9. Once the coolant has been drained off com-
pletely, screw the coolant drain plug (4) back
on again with a sealing ring (5). Use a new
sealing ring if necessary.
10.Install the floor plate (1) of the engine com-
partment.
11.Dispose of used coolant in accordance with
regulations.
Maintenance 12
Filling with coolant
1. Pour coolant into the expansion tank.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
Note
Observe the mixing ratio of anti-corrosion and
anti-freeze compounds, see separate operating
instructions for engine.
2. Tighten the sealing cover, see page 160.
3. Bring the engine up to operating temperature
and then switch it off.
4. Check the coolant level and top up if neces-
sary, see page 159.
5. Close the bonnet.
Checking the coolant mixture (frost protec-
See the separate operating manual for the engine
for a description of how to check the coolant mix-
12.3.3 Maintaining the air filter system
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance work on the air filter sys-
tem.
 Follow the instructions in the separate
operating instructions for the engine.
Cleaning and replacing air filter elements
Note
If the control light lights up on the dis-
play, the main element of the air filter
needs to be cleaned.
See the separate operating instructions for the
engine for a description of how to clean and re-
place the air filter elements.
161
12 Maintenance
12.3.4 Maintaining the fuel system Filling up with the tank filling pump
The tank filling pump serves for pumping fuel
WARNING into the fuel tank, e.g. from a barrel.
Personal injury and damage to pro- 1. Turn the ignition key to position I.
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance work on the fuel system.
 Follow the instructions in the separate
operating instructions for the engine.

Filling up the rail-road excavator with fuel

1. Park the rail-road excavator, see page 78.
2. Press the switch (1).
For the switch position for the refuelling
pump see the display for special
functions (2).

Note
Work attachment that is pre-selected is automa-
tically switched off, if the refuelling pump  is
pre-selected.
3. Remove the cover of the fuel tank.
4. Open the right-hand maintenance flap.

2
3

M+P-05C-2696

2. Remove the cover on the fuel tank (1).

Note
Do not take the fuel tank strainer (2) out of the
filler neck (3).
4
3. Fill diesel through the filler neck (3). Do not
overfill the fuel tank.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
3
4. Close the cover on the fuel tank (1).
M+P-05C-2754

5. Remove the fuel hose (3) from the holder (4).

6. Open the left-hand maintenance flap.

162

5 for a description of how to change the fuel pre-
8 6
3
7
M+P-05C-2755
7. If necessary, open the cover (5) of the local
task lighting (6) and light up the connection
compartment.
8. Unscrew the sealing cap (7).
9. Screw on the fuel hose (3) and put the other
end into the vessel (e.g. fuel barrel).
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
10.Press the button toggle (8).
Fuel is pumped.
The tank filling pump switches off automati-
cally when the fuel tank has been filled to
approx. 90 %.
Note
Press the button toggle (8) again at any time to
interrupt the pumping process.
11.The pumping process can be resumed by
pressing the button toggle (8) again and hol-
ding it down (in order to fill up the fuel tank to
the maximum filling quantity or to empty the
fuel hose).
Note
Take the fuel hose out of the vessel (e.g. fuel
barrel) to empty it.
12.Remove the fuel hose (3) and place the hol-
ders (4).
13.Tighten the sealing cap (7).
14.If necessary, close the cover (5) of the local
task lighting (6).
Maintenance 12
15.Close both the left-hand and the right-hand
maintenance flap.
16.Close the tank cap.
Draining water off the fuel pre-filter
Note
If the control light lights up on the dis-
play, the fuel pre-filter has to be drained.
See the separate operating instructions for the
engine for a description of how to drain water off
the fuel pre-filter.
Replacing the fuel pre-filter
See the separate operating manual for the engine
filter.
Replacing the fuel filter
See the separate operating manual for the engine
for a description of how to change the fuel filter.
Bleeding the fuel system
It may be necessary to bleed the system if the fuel
pre-filter or the fuel filter have been cleaned or re-
placed or if the machine was driven until the fuel
tank was empty.
See the separate operating instructions for the
engine for a description of how to bleed the fuel
system.
12.3.5 V-belt
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance work on the V-belt.
 Follow the instructions in the separate
operating instructions for the engine.
Generator V-belt/fuel pump V-belt
See the separate operating instructions for the
engine for a description of how to check and re-
place the generator V-belt and the fuel pump V-
belt.
163
12 Maintenance
Air conditioning compressor V-belt 4. Turn the display arm (2) so that it is level with
the tension measuring device (3).
Checking the V-belt tension 5. Put the tension measuring device (3) on the
place marked by an arrow on the V-belt.
Note Make sure that the side of the stop makes
Initially after 50 operating hours and then every contact with the air conditioning compressor
500 operating hours. V-belt.
6. Press the pushbutton (4) evenly at a right
angle to the air conditioning compressor V-
WARNING belt until you either hear or feel the spring un-
Personal injury lock.
Rotating parts may cause injury. 7. Carefully remove the tension measuring de-
 Only handle the air conditioning compres- vice (3). Make sure that the position of the dis-
sor V-belt if the engine and the electrical play arm (2) is not altered.
system are switched off.

1. Park the rail-road excavator, see page 78.

2. Open the bonnet.

N.

20
LB

0
S.
50

50
0
15
0
M+P-05C-1430

1 8. Take a reading from the point where the scale

and display arm intersect (arrow).
The set value for the air conditioning com-
pressor V-belt is 300±50N. If necessary,
tighten the V-belt for the air conditioning com-
pressor.
9. Close the bonnet.

M+P-05C-2756

3. Carry out a visual inspection of the entire air

conditioning compressor V-belt (1) and re-
place it if necessary.

2 3

M+P-05C-1429

164
 Maintenance 12
Tightening the air conditioning compressor Replacing the air conditioning compressor V-
V-belt belt
1. Park the rail-road excavator, see page 78. 1. Park the rail-road excavator, see page 78.
2. Open the bonnet. 2. Open the bonnet.

1 1
2 2
a

b
1 1

3 3

M+P-05C-2757 M+P-05C-2758

3. Loosen the screws (1) that are one the com- 3. Loosen the screws (1) that are one the com-
pressor (2). pressor (2).
4. Tighten the air conditioning compressor V-belt 4. Tighten the air conditioning compressor V-belt
(3) by slewing the compressor (2) to the direc- (3) by slewing the compressor (2) to position
tion of the arrow. (a).
5. Tighten the screws (1). 5. Remove the air conditioning compressor V-
6. Check the V-belt tension. belt (3) from the pulleys.
7. Close the bonnet. 6. Fit new air conditioning compressor V-belt (3)
and tighten it by slewing the compressor (2) to
position (b).
7. Pretension the air conditioning compressor V-
belt (3) to 550±50N.
8. Tighten the screws (1).
9. Let the engine run for approx. 15 minutes and
retension the air conditioning compressor V-
belt (3) to 300±50N.
10.Close the bonnet.

165
12 Maintenance
12.3.6 Maintaining the transmission
WARNING
Personal injury and damage to pro-
perty
Failure to observe the instructions con-
tained in the "Introduction" and "Safety"
chapters may result in injury or damage.
 Observe the instructions in the chapters
titled "Introduction" and "Safety" in parti-
cular before carrying out any mainte-
nance work.
NOTICE
Damage to property
If the gearbox was submerged in water
while the excavator was in operation,
contaminated transmission oil may
cause damage.
The quality of the transmission oil must be
checked and the oil changed if necessary.
Gearbox
The gearbox is mounted centrally under the
chassis.
166
Checking the level of transmission oil
Note
Initially after 50 operating hours and then every
100 operating hours.
1. Park the rail-road excavator, see page 78.
2. Unscrew the filler plug (1) and remove it with
the sealing ring.
3. Checking the level of transmission oil
The transmission oil has to come up to the
bottom edge of the oil filler inlet; top up with
transmission oil if necessary.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
4. Tighten the filler plug (1). Use a new sealing
ring if necessary.
Transmission oil replacement
Note
Initially after 500 operating hours, and then
every 2000 operating hours (after 12 months at
the latest).
1. Park the rail-road excavator, see page 78.
2. Put a suitable container under the gearbox.
3. Unscrew the filler plug (1) and the oil drain
plug (3) and remove them with the sealing
rings.
4. Drain the transmission oil completely.
5. Screw the oil drain plug (2) on again with the
sealing ring. Use a new sealing ring if neces-
sary.
Filling up with transmission oil
1. Pour in transmission oil to the bottom edge of
the oil filler inlet (1).
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
2. Tighten the filler plug (1). Use a new sealing
ring if necessary.
3. Dispose of used oil in accordance with regula-
tions.
 Maintenance 12
Differentials Checking the level of transmission oil
The differentials are mounted centrally to each
axle. Note
Initially after 50 operating hours and then every
Solid axle 100 operating hours.
1. Park the rail-road excavator, see page 78.
2. Unscrew the filler plug (1) and remove it with
the sealing ring (2).
3. The transmission oil has to come up to the
bottom edge of the oil filler inlet; top up with
transmission oil if necessary.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
4. Tighten the filler plug (1). Use a new sealing
ring (2) if necessary.

Transmission oil replacement

Note
Initially after 500 operating hours, and then
every 2000 operating hours (after 12 months at
the latest).
1. Put a suitable container under the differential.
1 2
2. Unscrew the filler plug (1) and the oil drain
plug (3) with sealing rings (2) and (4).
4
Transmission oil escapes.
3 3. Once the transmission oil has been comple-
M+P-05C-2759

tely drained off, screw the oil drain plug (3) on

Steering axle again with the sealing ring (4). Use a new
sealing ring if necessary.

Filling up with transmission oil

1. Pour in transmission oil to the bottom edge of
the oil filler inlet.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
2. Tighten the filler plug (1). Use a new sealing
ring (2) if necessary.
3. Dispose of used oil in accordance with regula-
tions.

2
1

4
3
M+P-05C-2760

167
12 Maintenance
Planetary gear 3. Put a suitable container under the planetary
gear.
Checking the level of transmission oil 4. Unscrew the filler plug (1) and the oil drain
plug (3) with sealing rings (2) and (4).
Note Transmission oil escapes.
Initially after 50 operating hours and then every 5. Once the transmission oil has been comple-
100 operating hours. tely drained off, screw the oil drain plug (4) on
again with the sealing ring (5). Use a new
sealing ring if necessary.

Filling up with transmission oil

3
2
1
M+P-05C-2531

3
1. Set the filler plug (1) into a horizontal position. 2
1
2. Park the rail-road excavator, see page 78.
M+P-05C-2531

3. Unscrew the filler plug (1) and remove it with

the sealing ring (2).
4. The transmission oil has to come up to the
bottom edge of the oil filler inlet (3); top up with
transmission oil if necessary.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
5. Screw the filler plug (1) on again with the
sealing ring (2). Use a new sealing ring if ne-
cessary.
Transmission oil replacement
Note
Initially after 500 operating hours, and then
every 2000 operating hours (after 12 months at
the latest).
1. Set the filler plug (1) into a horizontal position.
2. Park the rail-road excavator, see page 78.
3. Pour in transmission oil to the bottom edge of
the oil filler inlet (3).
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
4. Screw the filler plug (1) on again with the
sealing ring (2). Use a new sealing ring if ne-
cessary.
5. Dispose of used oil in accordance with regula-
tions.
12.3.7 Maintaining the chassis
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance work on the chassis.

5
4 2
1
M+P-05C-2532

1. Set the oil drain plug (4) into a lower vertical

position.
2. Park the rail-road excavator, see page 78.
168
 Maintenance 12
WARNING WARNING
Personal injury and damage to pro- Danger of accident
perty Low level of the brake fluid may indicate
Brake fluid can damage the skin and the worn brake linings or leakage in the bra-
paintwork. king system. This may cause an accident.
 Wear acid-resistant gloves and safety  Check the thickness of the brake linings
goggles. and replace with new ones if necessary
ATLAS recommends consulting ATLAS
 Wipe the spilled brake fluid immediately.
Customer Service.
 Have the braking system checked by a
Checking the brake fluid qualified employee.
ATLAS recommends consulting ATLAS
Note Customer Service.
Every 100 operating hours. 3. Fit the cover (1).

Changing the brake fluid

2 Note
Every 2000 operating hours.
MAX.
MIN.

WARNING
Personal injury and damage to pro-
perty
Improper changing of the brake fluid may
lead to injury or damage.
 Only qualified employees may change the
brake fluid.

12.3.8 Wheels and tyres

WARNING
1
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
M+P-05C-2701
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
1. Remove the cover (1). operations" and "Safety rail operation"
chapters in particular before carrying out
Note any maintenance work on the wheels and
tyres.
There are two reservoirs under the cover (1).

2. The brake fluid level has to come up to bet- WARNING

ween the two markers (MIN and MAX) of the
reservoir (2). Top up with brake fluid if neces- Danger of accident
sary, see page 52. Damaged wheels and tyres may cause ac-
cidents.
Note  Check the tyres every day.

Low level of the brake fluid may indicate worn

brake linings. Check the thickness of the brake
linings if necessary.

169
12 Maintenance
Checking the tyre pressure 3. Support the rail-road excavator, e.g. by A-
frames.
Note
Regularly, at least every 100 operating hours.
4

WARNING
Danger of accident
Improper tyre pressure may cause dama- 2
ges or accidents.
1
 Check the tyre pressure every 100
operating hours.
 Tyre pressure, see page 191.

3
NOTICE M+P-05C-2702

Damage to property 1 Wheel nuts

Missing valve protective caps may allow 2 Spherical spring ring
moisture and dirt to get into the valve and 3 Valves
cause damages.
4 Twin wheel
 When screwing the protective cap onto
the valve, always tighten it. 4. Loosen the wheel nuts (1) and remove them
with the spherical spring ring (2).
Checking tightness of the wheel nuts 5. Remove the twin wheel (4); use cross rim
wrench if necessary.
Note
Replacing a defective wheel
Initially after 10 operating hours and after each
wheel replacement; then every 100 operating
hours.

2 2
WARNING 3 3
Danger of accident
Loose wheel nuts may cause accidents. 4 4
 Check tightness of the wheel nuts regular-
ly and after each wheel replacement,
each 100 operating hours, at the latest.
1
Tightening torque is to be 550 Nm.
M+P-05C-2535

Replacing a wheel
1. Lower the twin wheel with the inner wheel (1)
to the ground.
WARNING
2. Loosen the nuts (2) alternately and remove
Danger of accident them with flat washer (3).
Improper wheel replacement may cause The centring screws (4) fall on the ground.
accidents.
 Wheel replacement may only be perfor-
med by qualified persons using suitable
tools.
 Wheel nut tightness must be checked
each 10 operating hours after the wheel
replacement and tightened if necessary.

Twin wheel removing

1. Park the rail-road excavator, see page 78.
2. Lift the axle until achieving the ground clea-
rance of the wheel that is to be replaced.

170

6
M+P-05C-2536
3. Remove the outer wheel (5).
4. Replace the defective wheel.
5. Clean contact surfaces of the wheel rims
(arrow).
6. Place the outer wheel (5) and align it so that
the holes of both wheel rims and the valve (6)
of the inner wheel (1) coincide with the hole (7)
for the valve of the outer wheel (5).
7. Insert new centring screws (4) (DIN 7991 –
10.9, M8x80) from underneath if necessary
and place flat washer (3).
8. Screw the nuts (2) alternately and pretension
the wheels evenly.
Twin wheel mounting
WARNING
Personal injury and damage to pro-
perty
Applying damaged components when
mounting a twin wheel may cause injury
or damages.
 Replace damaged wheel nuts and spheri-
cal spring rings.
 Do not mount the twin wheel if the threa-
ded bolts of the planetary gear are dama-
ged. Contact ATLAS Customer Service.
 Do not oil or grease the threaded bolts of
the planetary gear and the wheel nuts.
1. Clean the threaded bolts, the contact surfaces
of the inner wheel and the brake drum.
2. Push the twin wheel onto the planetary gear
(use cross rim wrench if necessary), align it
with the threaded bolts and press.
Maintenance 12
1
2
M+P-05C-2537
M+P-05C-2537
3. Place the spherical spring ring (1). In doing so
consider the correct installation position of the
spherical spring ring.
4. By hand tighten the wheel nuts (2) evenly
crosswise.
5. Check the tyre pressure and increase it if ne-
cessary, see page 170.
6. Remove the A-frames and lower the rail-road
excavator.
7. Put on the cover (2) and tighten the screws (1)
evenly crosswise.
Tightening torque: 550 Nm.
12.3.9 Maintaining the compressed air and
hydraulic system
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance work on the com-
pressed air and hydraulic system.
WARNING
Personal injury
Hydraulic oil will escape under pressure
when pipes or parts are removed. Esca-
ping hydraulic oil, the parts to be remo-
ved or parts that move as a result of a
drop in pressure may cause injuries.
 Reduce the charging pressure of the hyd-
raulic reservoir prior to carrying out any
maintenance work on the hydraulic sys-
tem.
171
12 Maintenance
Replacing the desiccant container of the air Draining the compressor oil of the com-
dryer pressed air system

Note Note
Every 2000 operating hours. Every 500 operating hours.
1. Park the rail-road excavator, see page 78. 1. Park the rail-road excavator, see page 78.
2. Open the bonnet and the left-hand mainte- 2. Open the left-hand maintenance flap.
nance flap.

ll
3
l

3 2

4
2

1
M+P-05C-2762

3. Put a collection vessel (1) underneath the

M+P-05C-2761

3. Unscrew the protective cap (1) and exhaust
the air from the compressed air system.
4. Tighten the protective cap (1).
5. Unscrew the desiccant container (2) and dis-
pose in accordance with regulations.
6. Lightly grease the sealing ring (3) of the new
desiccant container and the threaded pin (4).
7. Place a new desiccant container (2) and
screw until the sealing ring fits. Then, tighten
by screwing half a turn.
8. Close both the bonnet and the left-hand main-
tenance flap.
draining hose (2).
Note
You will find the collection vessel (1) in the
tool box.
4. Push the lever (3) of the oil separator into
position II.
I Collect the compressor oil
II Drain off the compressor oil
5. Once the compressor oil is completely drained
off, push the lever (3) to position I .
6. Close the left-hand maintenance flap.
7. Dispose of used oil in accordance with regula-
tions.

172
 Maintenance 12
Charging pressure of the hydraulic reservoir

WARNING
Personal injury
Hydraulic oil will escape under pressure
when pipes or parts are removed. Esca-
ping hydraulic oil, the parts to be remo- 1
ved or parts that move as a result of a
drop in pressure may cause injuries.
 Reduce the charging pressure of the hyd-
raulic reservoir prior to carrying out any
maintenance work on the hydraulic sys-
tem.

1. Park the rail-road excavator, see page 78.

II

M+P-05C-2764

2. The hydraulic oil level has to be between the

top and bottom marking (arrow) on the sight
glass (1).

Topping up hydraulic oil

1. Park the rail-road excavator, see page 78.
2. Reduce the charging pressure of the hydraulic
oil tank, see page 173.

1
2
M+P-05C-2763

2. Operate the release lever (1). 3

I Reduce
II Build up 4

Note
Return the lever to position II once the charging
pressure has been reduced. Charging pressure M+P-05C-2705

will be built up again when the engine is next

started.
Checking the level of hydraulic oil
Note
Check the hydraulic oil level every day whe-
reupon the rail-road excavator must be in a ho-
rizontal position.
1. Park the rail-road excavator, see page 78.
3. Remove the screws (1) and the cap (2) with
the o-ring (3).
4. Top up with hydraulic oil through the filter pack
(4) until the hydraulic oil level reaches the
centre mark on the sight glass.
Fuels, lubricants and coolants and filling
quantities, see page 52 and page 53.
5. Replace the cover (2) - with a new o-ring (3) if
necessary - and tighten the screws (1) evenly
crosswise.

173
12 Maintenance
Changing the hydraulic oil

Note
Every 3000 operating hours (after 24 months at 10 7
the latest).

9
WARNING
Personal injury and damage to pro-
perty 8
Injury or damage may result if hydraulic
oil is not changed as specified.
6
 Hydraulic oil may only be changed by
qualified specialist employees. M+P-05C-2544

ATLAS recommends consulting ATLAS
Customer Service.
Replacing the hydraulic oil filter element
Note
Initially after 50 operating hours and then every
500 operating hours.
If the warning light lights up on the dis-
play panel, the hydraulic oil filter ele-
ment has to be changed as well.
1. Park the rail-road excavator, see page 78.
2. Reduce the charging pressure of the hydraulic
oil tank, see page 173.
3. Have suitable containers available for the hy-
draulic oil filter and for the hydraulic oil which
will be drained off.
1
2 18.Check the hydraulic oil level and top up with
4 hydraulic oil if necessary, see page 173.
3
5
7. Unscrew the spring assembly with nut (6) from
the filter element (7).
8. Remove the sealing ring (8) and the o-ring (9).
9. Clean the magnetic pillar (10).
10.If necessary, fit a new sealing ring (8) and o-
ring (9).
11.Fit new filter element (7) and use spring as-
sembly with nut (6) to screw tight.
12.Insert a new hydraulic oil filter (5) into the hy-
draulic oil tank and apply the spring (4).
13.If necessary, insert a new o-ring (3) into the
cover (2).
14.Put on the cover (2) and tighten the screws (1)
evenly crosswise.
15.Dispose of hydraulic oil which has escaped in
accordance with regulations.
16.Start the engine, see page 72.
17.Move the excavator equipment a few times,
see page 88.

M+P-05C-2706

4. Remove the screws (1) and the cap (2) with

the o-ring (3).
5. Take the spring (4) off the hydraulic oil filter
(5).
6. Remove the hydraulic oil filter (5) and drain off
hydraulic oil through the hydraulic oil filter.

174
 Maintenance 12
Checking the filter element of the high pres- 3. Have suitable containers available for the
sure filter soiled filter element and for the hydraulic oil
which will be drained off.
Note
Every 100 operating hours.
1. Slew the uppercarriage to a position that pro-
vides free access to the rear cover panel of
the vehicle frame.
2. Switch off the engine.
3. Remove the rear cover panel of the vehicle
frame.

4. Unscrew the housing lower part (2) of the

high-pressure filter (1) and remove it with the
o-ring (3).

4. Check the filter element contamination level at

the optic contamination indicator (2) of the
high-pressure filter (1).
 Green - the filter element is not soiled
 Red - the filter element is soiled
Replace the filter element, see page 175.
5. Install the rear cover panel of the vehicle
frame.

Replacing the filter element of the high pres- 5. Replace the filter element (4) that is contami-
sure filter nated with a new one.
6. Fit the o-ring (3) to the housing lower part (2).
Note Use a new o-ring if necessary
Every 500 operating hours. 7. Dispose of the hydraulic oil, which has es-
caped, and the soiled filter element in ac-
If the colour of the optic contamination indicator
cordance with regulations.
changes from green to red, the high-pressure
filter element must also be changed.
1. Park the rail-road excavator, see page 78.
2. Reduce the charging pressure of the hydraulic
oil tank, see page 173.

175
12 Maintenance
Changing hydraulic lines Observe the following tightening torques:

WARNING Flange Thread Torque

Personal injury 1/2" M8x1,25 22 Nm

Hydraulic oil will escape under high pres- 3/4" M10x1,5 43 Nm
sure when hoses, pipes or other parts are
removed. This may cause injuries. 1" M12x1,75 75 Nm
 Relieve pressure from hydraulic lines, see 1 1/4" M14x2 120 Nm
page 176.
3. Dispose of hydraulic oil which has escaped in
Hydraulic hoses have to be replaced when they accordance with regulations.
are damaged or deformed.
Hose connections
Rectifying leaks on hydraulic lines
2
1. Switch off the engine.
2. Turn the ignition key to position I. 1
3. Switch on the pilot control, see page 70. 4
6
4. Operate the control lever or the pedal in the 3
corresponding direction, see page 88. 5
The pressure of the respective hydraulic hose
will be lowered.
5. Reduce the charging pressure of the hydraulic
7
oil tank, see page 173.
4
6. Switch off the ignition.
7. Put a suitable container underneath the res- 5 M+P-05C-1487
pective connection.
1. Unscrew the union nut (1), remove the hose
Flange connections (2) and renew the o-ring (3).
2. Unscrew the screws (4) on the SAE-flange (5),
remove the hose (6) and renew the o-ring (7).

Note
1 On installation, make sure that the flange halves
are screwed tight evenly.
3. Dispose of hydraulic oil which has escaped in
accordance with regulations.
1
2
Pipe connections

M+P-05C-1486

1
1. Unscrew the screws (1), sever the connection,
remove the hose (2) and replace the seal.
2
Note
Take care not to damage the sealing ring when
inserting the hose.
2. Attach the hose (2) and tighten the screws (1)
evenly.

M+P-05C-1488

1. In most cases leaks can be rectified by tighte-

ning the union nut (1) as the cutting ring (2) will
cut further into the pipe.
2. Dispose of hydraulic oil which has escaped in
accordance with regulations.

176
 Maintenance 12
Screwed pipe connections
The description applies only to screwed pipe con- 4
5 6
nections with an injection opening in the union
nut.

1 2
3 5 4
6

1 2

3 M+P-05C-1441

3. Mark the union nut (4) and the screw connec-

tion (5) (arrow). Remove or paint over old mar-
kings, if necessary.
4. If necessary, secure the screwed pipe con-
M+P-05C-1440

1. The union nut (1) is not to be tightened in the
event of leaks; loosen it and remove the
screwed pipe connection (2).
2. Fit the screwed pipe connection with a new o-
ring (3) or fit a new screwed pipe connection
and tighten the union nut (1) by hand.
5. Dispose of hydraulic oil which has escaped in
nection (6) to prevent twisting or support it and
screw the union nut (4) tight.
Note
If it is not possible to measure the torque, a used
screwed pipe connection will need to be tigh-
tened by a one-third turn at the most and a new
screwed pipe connection by a three-quarter turn
at the most. This is to be carried out with a
spanner after tightening the nuts by hand.
accordance with regulations.

Tightening torques

Type Pipe OD Thread W/F Torque Type Pipe OD Thread W/F Torque

L 6 mm M12x1,5 14 20 Nm S 6 mm M14x1,5 17 25 Nm

L 8 mm M14x1,5 17 30 Nm S 8 mm M16x1,5 19 40 Nm

L 10 mm M16x1,5 19 40 Nm S 10 mm M18x1,5 22 50 Nm

L 12 mm M18x1,5 22 50 Nm S 12 mm M20x1,5 24 60 Nm

L 15 mm M22x1,5 27 70 Nm S 15 mm M22x1,5 27 75 Nm

L 18 mm M26x1,5 32 90 Nm S 18 mm M24x1,5 30 85 Nm

L 22 mm M30x2 36 120 Nm S 22 mm M30x2 36 140 Nm

L 28 mm M36x2 41 160 Nm S 28 mm M36x2 46 190 Nm

L 35 mm M45x2 50 250 Nm S 35 mm M42x2 50 270 Nm

L 42 mm M52x2 60 380 Nm S 42 mm M52x2 60 400 Nm

OD = outer diameter W/F = width across flats

177
12 Maintenance
12.3.10 Windshield washer
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance work on the windshield
washer.
1. Open the maintenance bonnet.
1
M+P-05C-2765
2. Check the level of fluid in the reservoir (1) re-
gularly and top up in good time.
Note
For a clear view add suitable anti-freeze and
cleaning agent to the washing water.
3. Close the maintenance bonnet.
4. Check the wiper blade regularly for any signs
of wear and tear or damage; replace if neces-
sary.
178
12.3.11 Maintaining the electrical system
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any maintenance and inspection tasks on
the electrical system.
WARNING
Personal injury and damage to pro-
perty
There is a risk of injury and damage if the
electrical system is not in perfect working
order.
 The electrical system has to be kept in
working order.
 All fuses have to be installed at all times.
 Defective fuses and filament lamps have
to be replaced immediately.
 Prior to working on the electrical system
and in particular before disconnecting
electric cables switch off the electrical
system via the battery isolator switch.
 Never allow the engine to run with discon-
nected batteries or with the electrical sys-
tem switched off.
 If jump starting is required, the external
voltage has to be 24 volts.
 Only work with a digital multimeter or a
voltage tester when carrying out testing
work on the electrical system. Do not use
test lamps.
Note
We would recommend keeping additional fuses
and filament lamps with the accessories as
spare parts.
 Maintenance 12
Batteries Connecting and disconnecting batteries

WARNING CAUTION
Personal injury Personal injury
Battery gases, which are produced in par- Short circuits may occur when batteries
ticular when the batteries are being char- are being disconnected or connected and
ged, are explosive and may cause inju- sparks may result.
ries.  Only disconnect and connect batteries
 Keep sparks and naked flames away from when the electrical system has been swit-
the batteries. ched off at the battery isolator switch.
 Provide sufficient ventilation when opera-  It is essential that the sequence stipulated
ting in enclosed spaces. is observed at all times when disconnec-
ting and connecting batteries.
 Wear appropriate personal protective
equipment, e.g. acid-resistant gloves and  Wear appropriate personal protective
safety goggles. equipment, e.g. acid-resistant gloves and
safety goggles.
WARNING
Personal injury
Battery acid will burn your skin, eyes and
clothing.
 Do not touch your eyes with dirty hands.
 Wear appropriate personal protective
equipment, e.g. acid-resistant gloves and
safety goggles.
 Immediately neutralise any acid which
splashes onto your skin or clothing with
soapsuds or with an acid neutraliser and
then rinse with water.

NOTICE
Damage to property
Improper handling of batteries may be
harmful to health.
 Do not allow the positive pole of the batte-
ries to make contact with machine compo-
nents.
 Do not place any metal objects or tools on
the batteries.
 Keep the battery poles, the terminals and
the surface of the batteries clean and dry,
since leak currents may result and the Disconnecting:
batteries may be drained.
1. Park the rail-road excavator, see page 78.
 Use standard commercial cleaning 2. Open the left-hand maintenance flap.
agents only; do not use cleaning agents
containing fuel. 3. Disconnect the negative terminal (1).
Make sure that the terminal no longer makes
contact with the negative pole.
Note
4. Disconnect the positive terminal (2).
Batteries will only last for as long as their in- 5. Disconnect the negative terminal (3).
tended life span if they are sufficiently charged
at all times. 6. Disconnect the positive terminal (4).
7. Close the left-hand maintenance flap.

Connecting:
1. Open the left-hand maintenance flap.
2. Grease the pole ends and the cable clamps
with acid-free grease.
3. Connect the positive terminal (4).

179
12 Maintenance
4. Connect the negative terminal (3).
5. Connect the positive terminal (2).
6. Connect the negative terminal (1).
7. Close the left-hand maintenance flap.

Checking the state of charge of the battery

Note
Every 100 operating hours.

WARNING
Personal injury 1
Battery gases, which are produced in par- 2
ticular when the batteries are being char- 4
ged, are explosive and may cause inju-
ries. 3
 Keep sparks and naked flames away from
the batteries.
 Provide sufficient ventilation when opera-
ting in enclosed spaces.
 Wear appropriate personal protective
equipment, e.g. acid-resistant gloves and
safety goggles. M+P-05C-2546
M+P-05C-2708

1 Green - battery is fully charged

WARNING
Personal injury
Battery acid will burn your skin, eyes and
clothing.
 Do not touch your eyes with dirty hands.
 Wear appropriate personal protective
equipment, e.g. acid-resistant gloves and
safety goggles.
 Immediately neutralise any acid which
splashes onto your skin or clothing with
soapsuds or with an acid neutraliser and
then rinse with water.
1. Park the rail-road excavator, see page 78.
2. Open the left-hand maintenance flap.
2 Black - battery is flat.
3 White - battery is defective.
4 Charge control display
3. Check the state of charge of the batteries on
the charge control display (4).
4. Close the left-hand maintenance flap.
Charging the batteries
WARNING
Personal injury
Battery gases, which are produced in par-
ticular when the batteries are being char-
ged, are explosive and may cause inju-
ries.
 Keep sparks and naked flames away from
the batteries.
 Provide sufficient ventilation when opera-
ting in enclosed spaces.
 Wear appropriate personal protective
equipment, e.g. acid-resistant gloves and
safety goggles.

180

WARNING
Personal injury
Battery acid will burn your skin, eyes and
clothing.
 Do not touch your eyes with dirty hands.
 Wear appropriate personal protective
equipment, e.g. acid-resistant gloves and
safety goggles.
 Immediately neutralise any acid which
splashes onto your skin or clothing with
soapsuds or with an acid neutraliser and
then rinse with water.
CAUTION
Personal injury and damage to pro-
perty
Improper charging of discharged or fro-
zen batteries may cause injuries or dama-
ge.
 Discharged batteries may even freeze at -
10 °C.
 Check frozen batteries for frost damage
(cracks in the housing).
 Frozen batteries which are not damaged
must be thawed before being charged.
 Wear appropriate personal protective
equipment, e.g. acid-resistant gloves and
safety goggles.
1. Park the rail-road excavator, see page 78.
2. Open the left-hand maintenance flap.
4 2
3
5
1
1
M+P-05C-2709
3. Check the state of charge of the batteries on
the charge control display (1).
Maintenance 12
4. Connect the positive cable (2) to the positive
pole (3).
5. Connect the negative cable (4) to the negative
pole (5).
6. Adjust the charger according to the manufac-
turer's operating instructions and switch it on.
Note
During standard charging the charging current
should be no more than 10 % of the battery ca-
pacity, e.g. for a 143 Ah battery no more than 14
A.
7. Switch off the charger.
8. Check the state of charge of the batteries.
9. Disconnect the negative cable (4) from the ne-
gative pole (5).
10.Disconnect the positive cable (2) from the po-
sitive pole (3).
11.Close the left-hand maintenance flap.
Jump start
If the batteries are discharged,
 another vehicle with an on-board voltage of 24
volts can jump start the engine or
 it can be started with the help of a suitable
charger.
NOTICE
Damage to property
The electrical system may be damaged
when jump starting.
 The external voltage has to be 24 volts.
 If the engine is started with the help of a
charger, only use one with a regulated,
stabilised terminal.
 Always make sure that the terminals are
correctly poled.
 Only use jump start cables with sufficient
dimensions (min. 95 mm2).
 Do not jump start the engine if the batte-
ries have been removed or disconnected.
 Do not jump start the engine if the batte-
ries are damaged.
 Do not jump start the engine if the electri-
cal system is switched off, see page 56.
181
12 Maintenance
1. Park the rail-road excavator, see page 78.
2. Open the left-hand maintenance flap.
 in the switch box under the seat (accompa-
nying crew);
 behind the left-hand maintenance flap (main
fuse F1 and cold start device fuse F2);
 behind the right-hand maintenance flap (EEC-
fuse).

NOTICE
Damage to property
The electrical system may be damaged if
the fuses are faulty.
 Rectify the failure that caused the fuse to
develop a fault.
 Replace the fuse immediately and make
sure that the amperage is correct.
 Never repair or bypass fuses.

Replacing fuses
1. Park the rail-road excavator, see page 78.
2. Fold up the seat (accompanying crew), see
page 62.
3. Remove the fire extinguisher and the first
aid box.
4. Remove the cab floor cover.

3. Connect the positive cable (1) to the positive

pole on the external battery you are using to
jump start the rail-road excavator. 1
4. Connect the positive cable (1) to the positive
pole (2).
5. Connect the negative cable to the negative
pole on the external battery you are using to
jump start the rail-road excavator.
6. Connect the negative cable to the rail-road ex-
cavator earth (e.g. the engine or the frame of
the cab).
7. Start the engine of the vehicle supplying the
power for jump starting.
8. Start the engine of the rail-road excavator, see
page 72.
9. When the engine has started, firstly discon-
nect the negative cable with the engine run-
ning idle. Always start with the external bat-
tery.
10.Then disconnect the positive cable (1) from
the positive pole (2). Always start with the ex-
ternal battery.
M+P-05C-2711
11.Close the left-hand maintenance flap.
5. Find out which of the fuses are defective and
Fuses replace them.
Fuse allocation, see page 47.
Note
The warning light on the display panel
lights up if the fuses are defective.

The fuses are located:

182
 Maintenance 12
Replacing the main fuse
Note 1. Park the rail-road excavator, see page 78.
Defective fuses are indicated by a LED directly 2. Open the left-hand maintenance flap.
adjacent to the corresponding fuse. 3. Switch off the battery isolator switch, see
If the LED (1) lights up, the main fuse F1 is de- page 56.
fective.

Note
All fuses have to be plugged in so that the fuse
monitoring device can function.

6. Fit the cab floor cover.

7. Put inside fire extinguisher and the first aid
box.
8. Fold down the seat (accompanying crew).

1
2

2 3

M+P-05C-2712

4. Remove the cover (1).

5. Undo the fastening nuts (2) and remove the
main fuse (3).
6. Fit a new main fuse (3) and tighten the faste-
ning nuts (2).
7. Fit the cover (1).
8. Switch on the battery isolator switch, see
page 56.
9. Close the left-hand maintenance flap.

Changing the fuse of the cold start device

The fuse for the cold start device F2 is changed
in the same way as the main fuse F1, see
page 183.

183
12 Maintenance
Changing the EEC-fuse Replacing filament lamps
1. Park the rail-road excavator, see page 78.
Note
2. Switch off the battery isolator switch, see
page 56. The warning light on the display panel
flashes if the filament lamps are defec-
3. Open the right-hand maintenance flap.
tive.

CAUTION
Personal injury
Filament lamps and lamp holders get hot
when the lamps are switched on and may
cause injury if touched.
 Switch the lamps off in good time before
replacing a filament lamp.
 Allow the lighting system to cool down be-
fore replacing a filament lamp.

NOTICE
Damage to property
1 Short circuits may result if the filament
lamps are not replaced properly.
1
 Allow the lighting system to cool down be-
fore replacing a filament lamp.
2  Touch the filament lamps with a clean,
lint-free, dry cloth only.
1
1  Observe the type, voltage and wattage of
the filament lamps.

Park the rail-road excavator, see page 78.

M+P-05C-2768

4. Undo the screw (1) and remove the cap (2).

2 2

5
4 1 4 1 3
M+P-05C-1461

M+P-05C-2728
1 Headlight fastening screws
5. Replace the defective fuse (3). 2 Fastening screws of the direction indicator
6. Tighten the cover (2) with screws (1). 3 Direction indicator lens
4 Headlight housing
Note
Fuse (4) serves as a reserve.
7. Switch on the battery isolator switch, see
page 56.
8. Close the right-hand maintenance flap.

184
 Maintenance 12
Rear lamps
5

7 6

9 8 M+P-05C-1462

5 Plug
6 Protective cover
Note
7 Filament lamp holder
8 Retaining spring LED rear lamps (1) are maintenance free and, if
9 Filament lamp defective, they must be replaced with new ones.
ATLAS recommends consulting an ATLAS Cus-
Dipped and main-beam headlight tomer Service.
Filament lamps: H4 75/70 W
1. Unscrew the fastening screws (1) and remove
the headlight housing (4).
2. Remove the plug (5) from the filament lamp
(9).
3. Remove the protective cover (6).
4. Release the retaining spring (8) and remove
the defective filament lamp (9).
5. Fit a new filament lamp and make sure that
the direction nose is correctly positioned.

Side lights
Filament lamp: 4 W
1. Unscrew the fastening screws (1) and remove
the headlight housing (4) from the holder.
2. Turn the lamp holder (7) and remove it from
the reflector with the filament lamp.
3. Remove the defective filament lamps and
press new filament lamps into the lamp hol-
ders.

Front direction indicator

Filament lamp: 21 W
1. Unscrew the fastening screws (2) and remove
the lens (3).
2. Considering the correct installation position,
press the defective filament lamp upwards or
downwards, turn it anti-clockwise and replace
it.

185
12 Maintenance
Interior lights
Filament lamps: 5 W

At the front: 2

M+P-05C-2553

2 Filament lamps
3 Holders
M+P-05C-2040
1. Use a suitable tool (e.g. a screwdriver) to re-
move the cap (1) from the interior lining.
1 Lamp housing 2. Remove the defective filament lamps (2) from
the holders (3) and replace.

Rail light/DB-lamp
3 3 Filament lamps:
 At the front, on top: 21 W
 At the rear: 21 W
 At the front, below: 45 W

2 2
4

M+P-05C-2041

2 Filament lamp
3 Holders
3
At the rear: 1

1
M+P-05C-2554

1. Unscrew the fastening screw (1) and carefully

remove the headlight glass (2).
2. Press the defective filament lamp (3) down,
turn it anti-clockwise and replace it.
3. First, hook the headlight glass (2) on the top of
the headlight housing (4) (arrow), and then,
screw it tight by a fastening screw (1).
4. Check tightness of the headlight glass (2).

M+P-05C-2552
Additional floodlights and additional lights
1 Lamp housing To replace filament lamps, e.g. in the working
floodlights or rotating beacons, follow the re-
spective manufacturer's instructions.

186
 Maintenance 12
12.3.12 Maintaining the heating and air
conditioning system WARNING
Personal injury
WARNING
Liquid refrigerant can damage the skin
Personal injury and damage to pro- and eyes.
perty  Wear acid-resistant gloves and safety
Failure to follow the instructions contai- goggles.
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out 1
any maintenance and inspection tasks on
the heating and air conditioning system.

WARNING
Personal injury and damage to pro-
perty
Maintenance work and repair work car-
ried out improperly on the heating and air
conditioning system may cause injuries
or damage.
 Maintenance work and repair work on the
heating and air conditioning system may
only be carried out by qualified emplo-
yees.
 Have the heating and air conditioning sys-
tem checked every 24 months by a quali-
fied employee. ATLAS recommends con-
sulting an ATLAS Customer Service.

M+P-05C-2766

NOTICE
Damage to property
Damage may be caused if the compres-
sor of the heating and air conditioning
system is not lubricated regularly.
 Die Klimaanlage mindestens einmal im
Monat für kurze Zeit Switch on.
Checking the refrigerant level
4. The refrigerant has to be visible in the sight
glass (1) and it must not contain any bubbles.
Have a qualified employee check the quantity
of refrigerant if necessary. ATLAS recom-
mends consulting an ATLAS Customer Ser-
vice.
Cleaning and replacing the circulation air
filter and the fresh air filter

Note Note

Every 100 operating hours. Every 100 operating hours.

1. Park the rail-road excavator, see page 78. 1. Slew the uppercarriage to a position that pro-
2. Start the engine, see page 72. vides free access to the area under the cab.
3. Switch on the air conditioner, see page 68. 2. Switch off the engine.

WARNING
Personal injury
Rotating parts and working carelessly on
the engine when it is running may cause
injuries.
 Make sure that the rail-road excavator
cannot move while work is being carried
out.

187
12 Maintenance
6. Clean the filter cassette (3) and beat out the
filter mat (4). Replace the filter mat if neces-
sary.
7. Place the filter mat (4) and close the filter cas-
sette (3).
8. Install the filter cassette (3) and attach it by a
quick release fastener (2).
9. Install the floor plate (1) in the cab.

Checking and cleaning the condenser

1
Note
Every 100 operating hours.

3 WARNING
Personal injury
2 The fins on the condenser have sharp
edges which may cause injuries.
 Be extremely careful when cleaning the
condenser.

M+P-05C-2713

3. Remove the floor plate (1) that is in the cab.

1
NOTICE 2
Damage to property
Damage may occur if dust enters the
housing of the circulation air filter and the
fresh air filter.
 When cleaning or replacing the circulation
air filter or the fresh air filter, make sure
that no dust gets into the housing.
M+P-05C-2767
4. Loosen the quick release fastener (2) and take
out the filter cassette (3). 1. Check the perforated plate (1) and the con-
denser (2) for contamination.
2. Remove and clean the perforated plate (1), if
necessary, see page 150.
3
Note
Use only compressed air to clean the fins of the
4 condenser (2) (do not use a high-pressure
washer).

M+P-05C-2042

5. Open the filter cassette (3) and remove the

filter mat (4).

Note
Do not rinse or brush off the filter mat.

188

Checking the refrigerant circuit/replacing the
filter dryer
WARNING
Personal injury and damage to pro-
perty
Maintenance work and repair work car-
ried out improperly on the refrigerant cir-
cuit and the filter dryer may cause inju-
ries or damage.
 Have the refrigerant circuit checked every
12 months by a qualified employee. AT-
LAS recommends consulting an ATLAS
Customer Service.
 Have the filter dryer checked every 24
months by a qualified employee. ATLAS
recommends consulting an ATLAS Cus-
tomer Service.
12.4 Shutdown
WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before carrying out
any shutdown work.
 Follow the instructions in the separate
operating instructions for the engine.
12.4.1 Preserving the rail-road excavator
If the rail-road excavator is out of operation
for more than 2 months
 Thoroughly grease the lubricating points, see
page 152.
 Replace the engine oil with anti-corrosion oil
(see separate operating instructions for en-
gine).
Allow the engine to run for a few minutes so
that the anti-corrosion oil is distributed.
 Check the coolant mixture and adjust the mi-
xing ratio of the anti-corrosion agent, the anti-
frost agent and water if necessary; see sepa-
rate operating instructions for engine.
 Add 10% anti-corrosion oil to the fuel (see se-
parate operating instructions for the drive en-
gine).
Allow the engine to run for a few minutes so
that the internal parts of the injection system
are covered with anti-corrosion oil.
 Coat exposed hydraulic cylinder piston rods
with anti-corrosion grease (e.g. with Shell
anti-corrosion grease).
Maintenance 12
 Remove the batteries, store them where they
are protected from frost and recharge them re-
gularly, see page 179.
 Fill the fuel tank right to the top with diesel fuel,
see page 162.
 Remove and store the V-belts, see page 163.
 Spray the grooves of the V-belt pulleys with
anti-corrosion oil.
 Close up inlet and exhaust openings with
sturdy foil and adhesive tape.
 Release air from the compressed air system
 Remove the compressed air hose from the
compressed air system and add approx. 250
ml anti-corrosion oil (see the separate opera-
ting instructions for the drive engine).
 Connect the compressed air hose to the com-
pressed air tank and fill up the compressed air
system (operational pressure: 8 bar).
Actuate the compressed-air driven functions a
few times so that the internal parts of the com-
pressed air system are covered with anti-cor-
rosion oil.
 Release air from the compressed air system
once again.
In the case of a high level of humidity (tropical
climate)
 Fill the hydraulic oil tank right up to the top,
see page 173.
What to do before starting up again
 Open up inlet and exhaust openings.
 Charge the batteries and install them, see
page 179.
 Install and tighten the V-belts, see page 163.
 Remove the anti-corrosion oil from the V-belt
pulleys, see page 150.
 Adjust the level of hydraulic oil, see page 173.
 Remove the anti-corrosion grease from the
hydraulic cylinder piston rods, see page 150.
 Replace the anti-corrosion oil with engine oil,
see page 158.
Note
It is not necessary to rinse the engine and the
fuel system.
If the rail-road excavator has been out of ope-
ration for more than 12 months
 Change the hydraulic oil, see page 174.
 Replace the transmission oil, see page 166.
189
12 Maintenance
12.4.2 Disposal of the rail-road excavator

CAUTION
Personal injury and damage to the
environment
Unprofessional disposal of the rail-road
excavator at the end of its service life may
result in injury or environmental dama-
ges.
 Only have the rail-road excavator dispo-
sed by a suitable waste disposal compa-
ny.
 ATLAS recommends returning the rail-
road excavator to an ATLAS dealer.

190
 Specifications 13
13 Specifications
13.1 Weights and performance data

Operating weight 21,0–22,0 t1)

Engine Deutz - TCD 2012 L04/2V
Driving power 95 kW (129 HP)/2300 min-1
Travel speed
Creeper gear Continuously variable 0–3 km/h
Off-road gear Continuously variable 0–5 km/h
On-road gear Continuously variable 0–20 km/h
On rails 20 km/h
Over switches and crossings 10 km/h
Tractive power 96 kN
Maximum climbing ability 44–46 %
Towable mass2)
Unbraked max. 40 t
3)
Braked max. 120 t
Hydraulic system
Pump capacity max. 300 l/min
Operating pressure max. 340 bar
Forces
Tear-off force max. 112 kN
Breakaway force max. 196 kN
Clamp force of the dipper max. 62 kN
Filling quantities
Hydraulic oil tank 300 l
Fuel tank 230 l
Engine 15,5 l
(filling quantity for changing engine oil and engine oil filters)
Tyres 8-tyres
Tyre size 10.00-20
Tyre pressure inside 9,00 bar / outside 7,5 bar
Noise level
Outside level LWA = 100 dB(A)
Cab level LPA = 78 dB(A)
Slewing gear
The slewing limitation of the uppercarriage slewing speed is switched off Continuously variable 0–9 min-1
The slewing limitation of the uppercarriage slewing speed  is switched on Continuously variable 0–6 min-1
Electrical system
Battery voltage 24 V
2 batteries each 12 V, 100 Ah
Vibration
Upper section dimensions < 0,5 m/s2
Obere Körpergliedmaße < 2,5 m/s2

1) Operating weight with operator, fully-loaded rail-road excavator and 1.5 t for attachments.
2) If the rail-road excavator has a drawbar coupling.
3) If the rail-road excavator is with a wagon brake system.

191
13 Specifications

13.2 Dimensions
13.2.1 Main dimensions

B K

A L

J M N

C O

E D F P

G Q
R
H

M+P-05C-2714

Measurements in mm, unless

otherwise indicated
A Cab length 2305
B Rotation radius of the rear end (depending on the counterweight ver- 1750/2000
sion)
C From the middle of the slewing ring to the middle of the solid axle 970
D Wheel base 2550
E From the middle of the solid axle up to the outrigger support at the rear 1005
F From the middle of the steering axle up to the outrigger support at the 1095
front
G Distance from the guide roll axles 5475
H Undercarriage length, incl. the guide roll axles (the guide roll axles are 5940
lowered)
I Internal height up to the uppercarriage (depending on the counter- 1195/1235
weight version)
J Cab overhead clearance, incl. the rail light 3180
K Uppercarriage width 2490
L Cab width 935
M Cab overhead clearance 3010
N Bonnet height 2385
O Track width (rails) 1435
P Track width (rail-road excavator) 1884
Q Undercarriage width, incl. the paws (paws are fully lifted up) 2500
R Undercarriage width, incl. the paws (paws are lowered) 2570

192
 Specifications 13
13.2.2 Loading dimensions

Bemerkung
Incl. the excavator equipment: C53.41P, C53.46
and D41.22.

Rail-road excavator positioned on a wagon

G2
A

E F G

D
H K
J

L
SO
M
N
M+P-05C-2716

G2 Reference line
SO Rail upper edge
Measurements in mm, unless
otherwise indicated
A Half the width of G2-reference line in the E-height 785
B Half the width of G2-reference line in the F-height 1470
C Half the width of G2-reference line for G-H height range 1645
D Half the width of G2-reference line for H-J height range 1620
E Height beginning from the upper rail edge 4680
F Height beginning from the upper rail edge 3835
G Height beginning from the upper rail edge 3530
H Height beginning from the upper rail edge 1170
J Height beginning from the upper rail edge 400
K Wagon loading area height beginning from the upper rail edge 1180/1238
L Undercarriage width 2500
M Uppercarriage width 2490
N Wagon loading area width 2770

193
13 Specifications

With a trench digger

Bemerkung
Incl. the excavator equipment: A67.5, C67.41P,
C66.46, D67.22, F66.1 and G624.

A B

D C

M+P-05C-2715

Measurements in mm, unless

otherwise indicated
A Cab height 3010
B Cab height, incl. the rail light 3180
C Excavator equipment cantilever length 3365
D Excavator length, incl. the guide roll axles (the guide roll axles are 5955
lifted up)
E Outrigger support ground clearance (The outrigger support is lifted.) 372
F Total length 9320

194
 Rectifying faults 14
14 Rectifying faults
14.1 Finding and rectifying faults

WARNING
Personal injury and damage to pro-
perty
Failure to follow the instructions contai-
ned in the introductory chapters may re-
sult in injury or damage.
 Observe all the instructions in the "Intro-
duction", "Safety of the road and off-road
operations" and "Safety rail operation"
chapters in particular before finding and
rectifying faults.

WARNING
Personal injury and damage to pro-
perty
Injury or damage may be caused if the ex-
cavator malfunctions.
 Stop as soon as possible at a suitable
place, park the rail-road excavator and
secure it.
 Determine the cause of the malfunction
and rectify the fault immediately.

NOTICE
Damage to property
If a highlighted warning note includes the
additional STOP statement, damages
may result.
 Park the rail-road excavator at a suitable
place as soon as possible and switch off
the engine.

Note
In the event of an engine malfunction follow the
separate operating instructions for the engine.

195
14 Rectifying faults
14.1.1 Malfunctions

Malfunction
The warning light (1) lights up.

Cause Remedy
 Fuel level is too low.  Check the fuel level and top up with diesel fuel if ne-
cessary, see page 162.

Malfunction
The centre bar starts flashing.

Cause Remedy
 Cable or sensor for the bar indicator is  Contact the ATLAS Customer Service Department.
defective.

Malfunction
The warning light (1) flashes and a buzzer sounds.

The warning light flashes.

Cause Remedy
 Engine oil pressure is too low.  Immediately switch off the engine.
 Contact the ATLAS Customer Service Department.

Malfunction
The centre bar starts flashing.

Cause Remedy
 Cable or sensor for the bar indicator is  Immediately switch off the engine.
defective.  Contact the ATLAS Customer Service Department.

196
 Rectifying faults 14
Malfunction
The lower bar lights up.

Cause Remedy
 Cable or sensor for the bar indicator is  Immediately switch off the engine.
defective.  Contact the ATLAS Customer Service Department.

Malfunction
All green bars light up.

Cause Remedy
 Short circuit in the cable, or sensor for  Immediately switch off the engine.
the bar indicator is defective.  Contact the ATLAS Customer Service Department.

Malfunction
The warning light (1) lights up and a buzzer sounds.

The warning light lights up.

Cause Remedy
 Coolant level is too low.  Immediately switch off the engine.
 Check the coolant level and top up with coolant, if ne-
cessary, see page 159.

Malfunction
The warning light (1) flashes and a buzzer sounds.

The warning light lights up.

Cause Remedy
 Coolant temperature is too high.  Immediately switch off the engine.
 Check to see whether the combined cooler for the en-
gine has become clogged and clean, if necessary,
see page 151.
 Contact the ATLAS Customer Service Department.

197
14 Rectifying faults
Malfunction
The lower bar lights up.

Cause Remedy
 Cable or sensor for the bar indicator is  Immediately switch off the engine.
defective.  Contact the ATLAS Customer Service Department.

Malfunction
All the green bars and the warning light (1) light up and a buzzer sounds.

The warning light lights up.

Cause Remedy
 Short circuit in the cable, or sensor for  Immediately switch off the engine.
the bar indicator is defective.  Contact the ATLAS Customer Service Department.

Malfunction
The control light lights up.

Cause Remedy
 Dirt in the air filter.  Clean the air filter element, replace if necessary, see
separate operating manual for the engine.

Malfunction
The control light flashes.

Cause Remedy
 Water in the fuel pre-filter.  Drain the fuel pre-filter replace if necessary, see sepa-
rate operating instructions for the engine.

Malfunction
The control light flashes.

Cause Remedy
 Filament lamp is defective.  Replace the defective filament lamp, see page 184.

198
 Rectifying faults 14
Malfunction
The control light lights up.

Cause Remedy
 Fault in the computer.  Contact the ATLAS Customer Service Department.

Malfunction
The warning light lights up.

Cause Remedy
 Fuse is defective.  Replace the fuse, see page 182.

Malfunction
The warning light lights up.
- +

Cause
 Generator V-belt is defective.
 Fault in the electric loading equipment.
Remedy
 Check the generator V-belt and replace it if neces-
sary, see separate operating instructions for the en-
gine.
 Contact the ATLAS Customer Service Department.

Malfunction
The control light lights up.

Cause
 Emergency switching is activated.
 Load limit sensing control is defective.
Remedy
 Deactivate switching if necessary, see page 87.
 Use the emergency switching to operate the rail-road
excavator if necessary, see page 87.
 Contact the ATLAS Customer Service Department.

Malfunction
The control light lights up.

Cause Remedy
 Dirt in the hydraulic oil filter.  Replace the hydraulic oil filter element, see page 174.

199
14 Rectifying faults
Malfunction
V The warning light lights up and a buzzer sounds.

Cause Remedy
 The guide rolls at the front are lifted.  Lowering the guide roll axles onto rails, see page 120.
 Contact the ATLAS Customer Service Department.
 Guide roll pressure at the front is to low.  Change the guide roll pressure at the front, see
page 120.
 Contact the ATLAS Customer Service Department.

Malfunction
H The warning light lights up and a buzzer sounds.

Cause Remedy
 The guide rolls at the rear are lifted.  Low the guide rolls onto the track, see page 120.
 Contact the ATLAS Customer Service Department.
 Guide roll pressure at the rear is to low.  Change the guide roll pressure at the rear, see
page 120.
 Contact the ATLAS Customer Service Department.

Malfunction
The warning light flashes and a buzzer sounds (at intervals).
The slewing limitation is switched off.

Cause Remedy
 Angle measurement error  Automatically, the oscillating axle and the guide roll
axles get locked and the speed of the slewing limita-
tion decreases.
 Slew the uppercarriage and the jib once from left and
once from the right, over the steering axle, see
page 88.
 Use the emergency switching to derail the rail-road
excavator, see page 139.
 Contact the ATLAS Customer Service Department.

Malfunction
The warning light lights up and a buzzer sounds.
The slewing limitation is switched off.

Cause Remedy
 Malfunction of a computer, REC 2  Contact the ATLAS Customer Service Department.
 Data transmission error

200
 Rectifying faults 14
Height limitation malfunction

Error messages are visualized on the display (1).

Note
In addition to the error message, a buzzer
sounds to warn for some errors.

Malfunction


Cause Remedy
 Database error; data EPROM error  Restart the facility.
 Contact the ATLAS Customer Service Department.

Malfunction


Cause Remedy
 Bypass switch is activated  Cancel bypass.

Malfunction


Cause Remedy
 Height limitation malfunction  Contact the ATLAS Customer Service Department.

201
14 Rectifying faults
14.2 Malfunctions and unusual operating states
Malfunction
The starter is turning too slowly or is not turning at all.
Cause
 Batteries are flat or defective.
 Starter is defective.
Malfunction
The engine will not start.
Cause
 The starter inhibitor is activated.
 Fuel tank is empty.
 Dirt in the fuel system.
Malfunction
The rail-road excavator has no power.
Cause
 Dirt in the fuel system.
 Dirt in the air filter.
 Engine is overheating.
 Working pressure is too low.
 Hydraulic pump is not set correctly.
 Hydraulic pumps defective.
202
Remedy
 Jump start, see page 181.
 Charge batteries, see page 180.
 Replace batteries, see page 179.
 Contact the ATLAS Customer Service Department.
Remedy
 Switch the travel direction pre-selection to position
Neutral, see page 77.
 Bleed the fuel system, see separate operating instruc-
tions for the engine.
 Check the fuel level and top up with diesel fuel if neces-
sary, see page 162.
 Bleed the fuel system if necessary, see separate ope-
rating instructions for the engine.
 Clean the fuel system.
Replace the fuel filter if necessary. See separate ope-
rating instructions for the drive engine.
Remedy
 Clean the fuel system.
Replace the fuel filter if necessary. See separate ope-
rating instructions for the drive engine.
 Clean the air filter elements, replace if necessary, see
separate operating manual for the engine.
 Check the coolant level and top up with coolant if ne-
cessary, see page 159.
 Contact the ATLAS Customer Service Department.
 Contact the ATLAS Customer Service Department.
 Contact the ATLAS Customer Service Department.
 Rectifying faults 14
Malfunction
The rail-road excavator will not drive properly or will not drive at all

Cause Remedy
 Multi-disk brake does not release.  Contact the ATLAS Customer Service Department.
 Service braking system is defective.  Contact the ATLAS Customer Service Department.
 Traction motor or brake valve is defec-  Contact the ATLAS Customer Service Department.
tive.

Malfunction
The rail-road excavator does not drive properly or does not drive at all.

Cause Remedy
 Lock the uppercarriage by the slewing  Unlock the slewing locking device, see page 81.
locking device.
 Slewing brake is defective.  Contact the ATLAS Customer Service Department.
 Oil motor, transmission or valves are  Contact the ATLAS Customer Service Department.
defective.

Malfunction
Hydraulic pump is making noises.

Cause Remedy
 Hydraulic pump defective.  Contact the ATLAS Customer Service Department.

Malfunction
Hydraulic cylinders are slack (e.g. excavator equipment drops down).

Cause Remedy
 Secondary pressure is defective.  Contact the ATLAS Customer Service Department.
 Zero-leakage oil shut-off device is de-  Contact the ATLAS Customer Service Department.
fective.
 Hydraulic cylinder is defective.  Contact the ATLAS Customer Service Department.

Malfunction
Hydraulic system is too hot.

Cause
 Hydraulic oil level is too low.
 Dirt in hydraulic oil cooler.
 Dirt in hydraulic oil filter.
Remedy
 Check the hydraulic oil level and top up with hydraulic oil,
if necessary, see page 173.
 Clean the hydraulic oil cooler, see page 151.
 Replace the hydraulic oil filter element, see page 174.

203
14 Rectifying faults
Malfunction
The oscillating axle locking device does not lock.

Cause Remedy
 Pilot operated non-return valves do not  Contact the ATLAS Customer Service Department.
close correctly.
 Lock-up piston seizes.  Contact the ATLAS Customer Service Department.
 Solenoid valve does not switch.  Contact the ATLAS Customer Service Department.

Malfunction
The cab heating/blower is not working properly or is not working at all.

Cause Remedy
 Nozzles are closed.  Open and set the nozzles, see page 69.
 Blower is not set.  Set the blower, see page 68.
 Blower is defective.  Contact the ATLAS Customer Service Department.
 Dirt in the circulation air filter and fresh  Clean the circulation air filter and the fresh air filter; re-
air filter. place them if necessary, see page 187.
 Heat exchanger is defective.  Contact the ATLAS Customer Service Department.
 Heating and air conditioning system de-  Contact the ATLAS Customer Service Department.
fective.
 Fuse is defective.  Replace the fuse, see page 182.

Malfunction
Cab air cooling is insufficient or the cab air cooling system is not working at all.

Cause Remedy
 Nozzles are closed.  Open and set the nozzles, see page 69.
 Blower is not set.  Set the blower, see page 68.
 Dirt in the circulation air filter and fresh  Clean the circulation air filter and the fresh air filter; re-
air filter. place them if necessary, see page 187.
 Air conditioning compressor V-belt is  Check the air conditioning compressor V-belt; replace
defective. it if necessary, see page 163.
 Refrigerant gas level is too high/low.  Check the coolant level and top up with coolant if ne-
cessary, see page 187.
 Contact the ATLAS Customer Service Department.
 Compressor clutch is defective.  Contact the ATLAS Customer Service Department.
 Compressor or expansion valve is de-  Contact the ATLAS Customer Service Department.
fective.
 Condenser or pipes clogged.  Contact the ATLAS Customer Service Department.
 Filter/drier is saturated or clogged.  Contact the ATLAS Customer Service Department.
 Thermostat is defective; the evaporator  Contact the ATLAS Customer Service Department.
is iced up.
 Fuse is defective.  Replace the fuse, see page 182.
 Blower is defective.  Contact the ATLAS Customer Service Department.
 Heating and air conditioning system de-  Contact the ATLAS Customer Service Department.
fective.
 Dirt in the condenser or condenser fan  Clean the condenser, see page 188.
is defective.  Contact the ATLAS Customer Service Department.

204
Index
A overview ................................................. 147
Accompanying crew
Folding up/down the seat ........................ 62
Additional floodlights and additional lights
Replacing filament lamps ...................... 186
Adjusting the armrests ................................... 61
Air conditioner ................................................ 68
Air conditioning compressor V-belt .............. 164
Replacing ............................................... 165
Tightening .............................................. 165
Air conditioning system
Checking and cleaning the condenser .. 188
Checking the refrigerant circuit .............. 189
Checking the refrigerant level ................ 187
Cleaning the circulation air filter ............ 187
Cleaning the fresh air filter ..................... 187
Maintenance .......................................... 187
Replacing the circulation air filter ........... 187
Replacing the filter dryer ........................ 189
Replacing the fresh air filter ................... 187
Air filter
Cleaning ................................................ 161
Replacing ............................................... 161
Angle .............................................................. 61
Anti-corrosion oil .......................................... 189
Articulated jib
Straightening and bending ....................... 89
Ash-tray .......................................................... 63
Inserting ................................................... 63
Opening and closing ................................ 63
Taking out ................................................ 63
Attaching a towing bar ................................. 136
Auto-idling system .......................................... 74
Automatic operation of the guide roll axles .. 129
B Replacing ............................................... 187
Backrest ......................................................... 61
Batteries ....................................................... 179
Charging ................................................ 180
Checking the state of charge ................. 180
Connecting and disconnecting .............. 179
Jump start .............................................. 181
Battery
Battery voltage ....................................... 191
Battery emergency switch, see Battery
isolator switch ................................................ 56
Battery isolator switch .................................... 56
Before operation .............................. 55, 73, 107
On rails .................................................. 107
Road and off-road operations .................. 73
Behind the left-hand maintenance flap .......... 45
Behind the right-hand maintenance flap ........ 43
Belt, see Safety belt ................................. 59, 61
Blower ............................................................ 68
Brake fluid
Changing ............................................... 169
Checking ................................................ 169
Break ............................................................ 140
Connecting to/disconnecting from
a towing vehicle ..................................... 143
Electric emergency pump ...................... 147
15
Electric emergency pump function
Function overview .................................. 140
Hand emergency pump function
overview ................................................. 140
Lift the guide roll axles ........................... 145
Lifting the excavator equipment ............. 141
Lifting the paws ...................................... 142
Lifting the rail-road excavator with the
guide roll axles ....................................... 143
Slewing the uppercarriage ..................... 141
Breakaway force ........................................... 191
C
Cab doors ....................................................... 56
Cab rear area ................................................. 42
Cable break in the rotary feed system .......... 137
Central lubricating system ............................ 153
Filling ...................................................... 154
Lubrication in case of fail ....................... 154
Starting a lubrication procedure ............. 153
Changing attachments, maintenance
and servicing .................................................. 24
Changing the EEC-fuse ................................ 184
Charging pressure of the hydraulic reservoir 173
Checking and cleaning the condenser ......... 188
Checking the oil level
Engine oil ............................................... 158
Checking the refrigerant circuit ..................... 189
Checking the refrigerant level ....................... 187
Checking the state of charge of the battery .. 180
Checking the tyre pressure .......................... 170
Checks prior to starting .................................. 70
Cigarette lighter .............................................. 63
Circulation air filter
Cleaning ................................................. 187
Cleaning
Cleaning procedure ................................ 150
Combination cooler ................................ 151
Dry cleaning with compressed air .......... 150
Engine .................................................... 151
With a high-pressure washer ................. 151
With water and cleaning agents ............. 150
Cleaning the combination cooler .................. 151
Climbing in ...................................................... 56
Accompanying crew ................................. 57
Operator ................................................... 56
Climbing out ............................................. 56, 57
Accompanying crew ................................. 58
Cold start device ............................................. 73
Comfort seat ................................................... 59
Compressed air system
Draining the compressor oil ................... 172
Maintenance .......................................... 171
Replacing the desiccant container
of the air dryer ........................................ 172
Connecting
To a towing vehicle ................................ 143
To a wagon ............................................ 126
Console, left ................................................... 36
Console, right ................................................. 36
205
15 Index
Controlling the movement speed ....................92
Controls
Behind the left-hand maintenance flap .....45
Behind the right-hand maintenance flap ...43
In the engine compartment .......................43
On the rail-road excavator ........................44
Under the maintenance bonnet ................43
Coolant
Changing ................................................160
Checking the level ..................................159
Draining off .............................................160
Filling up .................................................161
Frost protection ......................................161
Coolant mixture (frost protection) ..................161
Crane operations ............................................22
Creeper gear ...........................................78, 191
Cut the power supply, see Battery
isolator switch .................................................56
D Speed indication ...................................... 78
Danger by items dropping down .....................23
Danger classification .......................................10
DB extras ........................................................33
Declaration of conformity ..................................8
Derailing ..........................................................28
Between stations ....................................120
Emergency switching .............................137
Public railway crossing ...........................118
Description of symbols and illustrations
of dangers .......................................................10
Differentials ...................................................167
Checking the level of transmission oil ....167
Filling up with transmission oil ................167
Solid axle ................................................167
Steering axle ..........................................167
Transmission oil replacement .................167
Dimensions ...................................................192
Loading dimensions ...............................193
Main dimensions ....................................192
Rail-road excavator on a wagon .............193
With a trench digger ...............................194
Dipped beam .............................................63, 65
Replacing filament lamps .......................185
Dipper
Mounting ...................................................95
Moving ......................................................89
Removing .................................................94
Direction indicator ...........................................65
Disconnecting
From a towing vehicle ............................143
Wagons ..................................................126
Display and control device ..............................35
Cab rear area ...........................................42
Console, left .............................................36
Console, right ...........................................36
Display for the height limiter .....................42
Drive and control unit ...............................39
Extras .......................................................39
Inside the cab ...........................................35
Outside the cab ........................................43
Special functions ......................................41
Switch and display panel, front .................40
206
Display for the height limiter ........................... 42
Display panel .................................................. 37
Draining the compressor oil .......................... 172
Drive and control unit ..................................... 39
Drive engine, see Engine ............................. 156
Driver’s door, see Cab doors .......................... 56
Driving .............................................. 21, 75, 121
Auto-idling system ................................... 74
Changing gear ......................................... 77
Creeper gear ............................................ 78
Malfunctions ........................................... 203
Manual speed adjustment ........................ 78
Off-road gear ......................................... 191
On public roads ........................................ 80
On-road gear ......................................... 191
Parking ..................................................... 78
Rail operation ........................................... 28
Road/off-road operation ........................... 21
Setting the engine speed ......................... 74
Starting up ................................. 76, 77, 121
Stopping ................................................... 78
Travel direction pre-selection ................... 77
Driving position of the seat ............................. 60
E
Earthing the rail-road excavator ................... 129
Electric fuses .................................................. 46
Fuse allocation ......................................... 47
Electrical fuses ............................................. 182
Replacing ............................................... 182
Electrical system
Batteries ................................................. 179
Charging the battery .............................. 180
Checking the state of charge of
the battery .............................................. 180
Connecting and disconnecting batteries 179
Disconnect ............................................... 56
Fuse allocation ......................................... 47
Fuses ............................................... 46, 182
Jump start .............................................. 181
Maintenance .......................................... 178
Replacing filament lamps ....................... 184
Emergency brake function ............................ 119
Emergency lowering ....................................... 92
Emergency operation
Load limit sensing control ........................ 87
Emergency switching
Button toggles without functions ............ 139
Cable break in the rotary feed system ... 137
Derailing ................................................. 137
Malfunction of the CARSY system ......... 139
Manual release of the oscillating
axle locking device ................................. 139
Slewing limitation ................................... 139
Engine .......................................................... 156
Anti-freeze agent ..................................... 52
Changing the engine oil ......................... 158
Changing the oil filter ............................. 158
Checking the oil level ............................. 158
Cleaning ................................................. 151
Cold start device ...................................... 73
 Index 15
Coolant mixture (frost protection) .......... 161 Fuses, electric ................................................ 46
Engine number ........................................ 50 Fuse allocation ......................................... 47
Engine oil ................................................. 52 Fuses, electrical ........................................... 182
Filling quantities ....................................... 53 EEC-fuse ................................................ 184
Maintenance .......................................... 155 Main fuse ............................................... 183
Starting .................................................... 72
Stopping ............................................ 72, 73 G
Technical data ....................................... 191
Gearbox ........................................................ 166
Type plate ................................................ 50
Checking the level of transmission oil .... 166
Engine assemblies
Filling quantities ....................................... 53
Behind the maintenance flaps ............... 157
Filling up with transmission oil ............... 166
On the rail-road excavator ..................... 157
Transmission oil replacement ................ 166
Under the engine compartment ............. 156
General guidelines for workspaces ................ 18
Engine compartment .................................... 156
General safety ................................................ 10
Engine oil
Generator V-belt ........................................... 163
Changing ............................................... 158
Grab
Changing the oil filter ............................. 159
Mounting .................................................. 98
Checking the oil level ............................. 158
Moving ..................................................... 89
Draining off ............................................ 158
Removing ................................................. 96
Filling up ................................................ 159
Guide roll axle locking device ....................... 131
Equipment for rear area monitoring ............. 117
Guide roll axles
Excavator equipment
Automatic operation ............................... 129
Emergency lowering ................................ 92
Lifting ..................................................... 120
Moving ..................................................... 88
Locking ................................................... 119
Extras ............................................................. 39
Lowering ................................................ 120
Operation in locked state ....................... 130
F Pre-selection .......................................... 119
Fanfare (Makrofon) ...................................... 123 Unlocking ............................................... 119
Filling quantities ..................................... 53, 191 Guides ............................................................ 23
Filling up with fuel ........................................ 162
Tank filling pump ................................... 162 H
Filter
Hand brake, see Parking brake ...................... 75
Air filter .................................................. 161
Handing over the rail-road excavator ............. 31
Circulation air filter and the fresh air filter 187
Hazard zone
Engine oil filter ....................................... 159
Rail operation ........................................... 28
Fuel filter ................................................ 163
Road/off-road operation ........................... 21
High pressure filter ................................ 175
Headlight
Hydraulic oil filter ................................... 174
See Lighting ............................................. 65
Fine control
Headrest ......................................................... 61
Adjusting .................................................. 83
Heated seat .................................................... 62
Suspending .............................................. 83
Heating ........................................................... 68
Fire extinguisher, see Safety equipment ........ 20
Air conditioner .......................................... 68
Fire protection ................................................ 26
Heating output .......................................... 68
First aid kit, see Safety equipment ................. 20
Malfunctions ........................................... 204
Flange connections ...................................... 176
Setting the blower .................................... 68
Fresh air filter
Heating and air conditioning system
Cleaning ................................................ 187
Maintenance .......................................... 187
Replacing ............................................... 187
Height limitation ...................................... 92, 108
Front direction indicator
Calculating ............................................... 93
Replacing filament lamps ...................... 185
Calculating the height limitation value .... 110
Fuel ................................................................ 26
Calculating the value ................................ 93
Bleeding the fuel system ....................... 163
Checking ................................................ 111
Filling quantities ....................................... 53
Function test .......................................... 109
Filling up ................................................ 162
Interlock circuit ....................................... 117
Replacing the fuel filter .......................... 163
Malfunctions ........................................... 201
Fuel pre-filter
Setting the contrast value ...................... 112
Draining water ....................................... 163
Setting the height limitation value .......... 111
Replacing ............................................... 163
Suspending ............................................ 109
Water draining off .................................. 163
Switching on/off ...................................... 108
Fuel pump V-belt .......................................... 163
Height limitation value
Fuels, lubricants and coolants ....................... 52
Calculating ............................................. 110
Fuse allocation ............................................... 47

207
15 Index
Rails .......................................................110 Interlock circuit for the height- and
Setting ............................................111, 112 slewing limitation .......................................... 117
Wagon ....................................................110 Intermittent windshield wiper .......................... 67
High pressure filter Introduction ....................................................... 6
Checking ................................................175
Replacing the filter element ....................175 J
High-visibility vest, see Safety equipment .......20
Jib
Horn ........................................................70, 123
Lifting and lowering .................................. 89
Hose connections .........................................176
Jump start ..................................................... 181
Hydraulic hammer
Mounting .................................................100
Moving ................................................89, 91 K
Removing ...............................................100 Key ................................................................. 55
Hydraulic hoses and lines ...............................25
Hydraulic lines .................................................94 L
Changing ................................................176
Lifting ............................................................ 133
Connecting and disconnecting .................94
Lifting the guide roll axles
Flange connections ................................176
Solid axle ............................................... 144
Hose connections ...................................176
Steering axle .......................................... 144
Pipe connections ....................................176
Light, see Lighting .................................... 63, 65
Quick-release couplings ...........................94
Lighting
Rectifying leaks ......................................176
Dipped beam ........................................... 65
Screw couplings .......................................94
Direction indicator .................................... 65
Screwed pipe connections .....................177
Interior lights ............................................ 66
Tightening torques ..................................177
Main-beam headlight ............................... 65
Hydraulic oil ....................................................52
Replacing filament lamps ....................... 184
Changing ................................................174
Rotating beacon ....................................... 66
Checking the level ..................................173
Side lights ................................................ 65
Filling quantities ................................53, 191
Warning lights .......................................... 65
Replacing the filter element ....................174
Load hook
Topping up .............................................173
Mounting .................................................. 99
Hydraulic pump
Removing ................................................. 99
Malfunction .............................................203
Load hook of the trench digger
Hydraulic quick attach ...................................106
Mounting ................................................ 102
Hydraulic shut-off ............................................70
Removing ............................................... 102
Hydraulic system ...........................................191
Load limit sensing control
Charging pressure of the hydraulic
Emergency operation ............................... 87
reservoir ..................................................173
Fault ......................................................... 87
Maintenance ...........................................171
Loading........................................................... 30
Road and off-road operations .................. 26
I Loading dimensions ..................................... 193
Identification ....................................................49 Rail-road excavator on a wagon ............ 193
Ignition lock ...............................................59, 71 With a trench digger ............................... 194
In the engine compartment .............................43 Lubricating points
Inclination angle Rail-road excavator ................................ 152
Armrests ...................................................61 Work attachment .................................... 153
Information signs .............................................12 Lubrication .................................................... 152
Initial briefing ...................................................31 Central lubricating system ..................... 153
Initial inspection ..............................................53 Lubrication, see Lubrication points ............... 152
Initial installation ..............................................31
Inside the cab ..................................................35 M
Inspection ........................................................51
Main boom
Inspection intervals .........................................51
Lifting and lowering .................................. 89
Inspection material ..........................................52
Main dimensions .......................................... 192
Inspection plan ..........................................53, 54
Main-beam headlight ...................................... 65
Inspection tasks ............................................155
Replacing filament lamps ....................... 185
Intended purpose ..............................................7
Maintaining the air filter system .................... 161
Intended use .....................................................7
Maintaining the cooling system .................... 159
Interior lights ...................................................66
Maintaining the fuel system .......................... 162
At the front ................................................66
Maintenance ........................................... 24, 150
At the rear .................................................66
Air conditioning system .......................... 187
Replacing filament lamps .......................186

208

Air filter system ...................................... 161
Chassis .................................................. 168
Cleaning ................................................ 150
Compressed air system ......................... 171
Cooling system ...................................... 159
Electrical system .................................... 178
Engine ................................................... 155
Filling quantities ....................................... 53
Fuel system ........................................... 162
Fuels, lubricants and coolants ................. 52
Heating and air conditioning system ...... 187
Hydraulic system ................................... 171
Lubrication ............................................. 152
Safety signs ..................................... 17, 151
Transmission ......................................... 166
V-belt ..................................................... 163
Wheels and tyres ................................... 169
Windshield washer ................................ 178
Maintenance and inspection tasks ............... 155
Malfunctions ................................................. 196
CARSY system ...................................... 139
Height limitation ..................................... 201
Unusual operating states ....................... 202
Manual speed adjustment .............................. 78
Maximum climbing ability ............................. 191
Maximum power ............................................. 86
Measurements, see Dimensions .................. 192
Moving the track tamping equipment ............. 89
N Filling up with transmission oil ............... 168
Noise level ................................................... 191
Notes
General safety ......................................... 10
Nozzles .......................................................... 69
At the front ............................................... 69
At the rear ................................................ 69
Windshield ............................................... 69
O Pressure differential
Oil pressure and oil level adjustment ............. 91
On public roads .............................................. 80
Rear lamps .............................................. 80
Rear reflectors ......................................... 80
Slewing locking device ............................ 81
Opening and closing
Cab doors ................................................ 56
Side window ............................................ 58
Windshield ............................................... 58
Operating pressure ...................................... 191
Operating weight .......................................... 191
Operation ....................................................... 55
Within the frame of the railway transport 107
Operation in locked state
guide roll axles ....................................... 130
Operations
On road and off-road ............................... 70
Ordering spare parts ........................................ 9
Oscillating axle locking device ....................... 83
Manual release ...................................... 139
Outrigger support ........................................... 83
Angle of the paws .................................... 83
Index 15
Moving ..................................................... 84
Pre-selecting the travel direction .............. 84
Switching on/off ........................................ 84
Outside the cab .............................................. 43
Overhead lines ......................................... 23, 29
Safety distances ....................................... 29
Overload warning device ................................ 85
Overview of assemblies
Rail-road excavator .................................. 32
Overview of engine assemblies .................... 156
Overview of the assemblies
DB extras ................................................. 33
P
Pallet forks
Mounting ................................................ 101
Removing ............................................... 101
Parking ........................................................... 78
At the place of work ............................... 128
Parking brake ................................................. 75
Performance data ......................................... 191
Permissible slope angle ................................. 21
Personal protective equipment ....................... 17
Personal safety ............................................... 17
Pilot control ..................................................... 70
Pipe connections .......................................... 176
Planetary gear .............................................. 168
Checking the level of transmission oil .... 168
Filling quantities ....................................... 53
Transmission oil replacement ................ 168
Position for recovery ..................................... 140
Powershift gearbox
Transmission oil ....................................... 52
Preserving
Before starting up again ......................... 189
In the case of a high level of humidity .... 189
Pressure activation setting ............................. 84
Maximizing ............................................... 86
Problems, see Rectifying faults .................... 195
Protective equipment ...................................... 17
Public railway crossing
Rerailing/derailing .................................. 118
Pump capacity .............................................. 191
Q
Quick attach ................................................. 105
R
Rail light ........................................................ 117
At the front ............................................. 117
At the rear .............................................. 117
Rail light/DB-lamp
Replacing filament lamps ....................... 186
Rail operation ............................................... 107
Functions ............................................... 107
Type plate ................................................ 49
Rail tong
Mounting ................................................ 102
Removing ............................................... 102
209
15 Index
Rail-road excavator Rerailing ......................................................... 28
Before operation .......................................55 Between stations ................................... 120
Bringing in a position for recovery in case Emergency brake function ..................... 119
of a break-down incident .........................140 Public railway crossing .......................... 118
Closing .....................................................55 Rerailing and derailing between stations ...... 120
Disposal of ..............................................190 Roof panel
Driving ..............................................75, 121 Sunblind ................................................... 64
Filling up with fuel ...................................162 Rotating beacon ............................................. 66
Handing over ............................................31 Replacing filament lamps ....................... 186
Lifting ......................................................133 Running over a switching device .................. 124
Lifting on the guide roll axles ..................145 Step-by-step .......................................... 125
Lifting the guide roll axle on the With momentum ..................................... 125
steering axle ...........................................145
Lifting the guide roll axles on the S
solid axle .................................................146
Safe working methods .................................... 18
Lifting with the guide roll axles ...............143
Safety belt ................................................ 59, 61
Loading ...................................................132
Safety equipment
Lowering by means of the electric
Fire extinguisher ...................................... 20
emergency pump ....................................149
First aid box ............................................. 20
Lowering by means of the hand
High-visibility vest .................................... 20
emergency pump ....................................148
Warning triangle ....................................... 20
Lubricating ..............................................152
Safety markings and information signs .......... 12
Opening ....................................................55
Safety notes
Operation ..................................................55
General safety ......................................... 10
Parking at the place of work ...................128
Rail operation ........................................... 27
Preserving ..............................................189
Road and off-road operations .................. 10
Towing ....................................136, 146, 148
Safety rail operation ....................................... 27
Type plate .................................................49
Safety signs.................................................... 12
Unloading ...............................................133
For personal safety .................................. 17
Vehicle key ...............................................55
Maintenance and replacement ........ 17, 151
Rear lamps ....................................................185
Safety warning system ..................................... 6
Installing and removing ............................80
Screwed pipe connections ........................... 177
On public roads ........................................80
Seat
Replacing filament lamps .......................185
Accompanying crew ................................. 62
Rear reflectors
Adjusting the backrest ............................. 61
Installing and removing ............................80
Adjusting the headrest ............................. 61
On public roads ........................................80
Angle of the armrests ............................... 61
Recovering ......................................................26
Comfort seat ............................................ 59
On rails .............................................30, 137
Driving position ........................................ 60
On road/off-road ...............................26, 135
Height ...................................................... 59
Rectifying faults .............................................195
Inclination angle of the armrests .............. 61
Rectifying leaks on hydraulic lines ................176
Moving forward/backward ........................ 60
Replacement of safety signs .........................151
Seat suspension ...................................... 59
Replacing a wheel
Setting ...................................................... 59
Replacing a defective wheel ...................170
Service schedule and inspection plan ...... 53, 54
Twin wheel mounting ..............................171
Servicing ......................................................... 24
Twin wheel removing ..............................170
Setting
Replacing filament lamps ..............................184
Seat ......................................................... 59
Additional floodlights and additional
Steering column ....................................... 64
lights .......................................................186
Setting the engine speed ................................ 74
Dipped beam ..........................................185
Shutdown ..................................................... 189
Front direction indicator ..........................185
Side lights ....................................................... 65
Interior lights ...........................................186
Replacing filament lamps ....................... 185
Main-beam headlight ..............................185
Side window ................................................... 58
Rail light/DB-lamp ...................................186
Slewing gear ................................................. 191
Rotating beacon .....................................186
Slewing limitation .......................................... 113
Side lights ...............................................185
Checking ................................................ 115
Replacing safety signs ....................................17
Emergency switching ............................. 139
Replacing the desiccant container of the
Individually ............................................. 115
air dryer .........................................................172
Interlock circuit ....................................... 117
Replacing the filter dryer ...............................189
Setting .................................................... 114
Replacing the main fuse ...............................183
Suspending ............................................ 114

210

Switching on/off ..................................... 113
Symmetrically ........................................ 114
Slewing locking device ................................... 81
Malfunction ............................................ 203
Special functions ............................................ 41
Specifications ............................................... 191
Speed indication ............................................ 78
Stability on sloping ground ............................. 21
Starting the engine ......................................... 72
Starting up ........................................ 76, 77, 121
Improving traction .................................. 122
With load ................................................ 122
Without load ........................................... 122
Steering column
Height ...................................................... 64
Inclination angle ....................................... 64
Setting ..................................................... 64
Steering wheel
Locking .................................................. 120
Unlocking ............................................... 120
Stopping ......................................................... 78
Stopping movements ..................................... 92
Stopping the engine ....................................... 72
Structure of the rail-road excavator ................ 32
Sunblind ......................................................... 64
Switch and display panel, front ...................... 40
Switching device e.g. INDUSI
Running over ......................................... 124
Running over step-by-step .................... 125
Running over with momentum ............... 125
Swivel ............................................................. 89
T
Tamping pick
Moving ..................................................... 90
Tank filling pump .......................................... 162
Taster ohne Fahrfunktion ............................. 139
Tear-off force ............................................... 191
Technical data
Dimensions ............................................ 192
Filling quantities ....................................... 53
Fuels, lubricants and coolants ................. 52
Performance data .................................. 191
Weights .................................................. 191
Test run .......................................................... 71
Tightening torque
Air conditioning compressor V-belt ........ 165
V-belt tension ......................................... 164
Wheel nuts ..................................... 170, 171
Tightening torques
Pipe-flange connections ........................ 176
Screwed pipe connections ..................... 177
Towing ................................................. 136, 148
If the rail-road excavator got stuck ........ 137
On rails .................................................. 137
On road/off-road .................................... 135
Towing wagons ............................................ 125
Track tamping equipment
Mounting ................................................ 104
Moving ............................................... 89, 90
Tractive power ............................................. 191
Transmission
Index 15
Changing gear ......................................... 77
Maintaining ............................................. 166
See also Differentials ............................. 167
See also Gearbox .................................. 166
See also Planetary gear ......................... 168
Transport ...................................................... 132
Lifting ..................................................... 133
Loading .................................................. 132
On a wagon ............................................ 134
Rail operation ........................................... 30
Road and off-road operations .................. 26
Unloading ............................................... 133
Transporting persons ..................................... 21
Travel speed ................................................. 191
Twin wheel
Mounting ................................................ 171
Removing ............................................... 170
Replacing a defective wheel .................. 170
Type plate ....................................................... 49
Engine ...................................................... 50
Rail operation ........................................... 49
Rail-road excavator .................................. 49
Tyre pressure ............................................... 191
Tyre size ....................................................... 191
Tyres ............................................................ 191
U
Under the maintenance bonnet ...................... 43
Underground lines .......................................... 23
Uppercarriage
Turning ..................................................... 89
Use other than intended ................................... 8
V
V-belt
Air conditioning compressor V-belt ........ 164
Checking the V-belt tension ................... 164
Fuel pump V-belt .................................... 163
Generator V-belt .................................... 163
Maintenance .......................................... 163
Replacing ............................................... 165
Tightening .............................................. 165
Vehicle identification number ......................... 49
Vehicle key ..................................................... 55
Vibration ....................................................... 191
W
Wagon brake system .................................... 128
Braking fully/wagon brake ...................... 128
Final position .......................................... 128
Running position and release position ... 128
Wagons
Connecting and disconnecting ............... 126
Towing ................................................... 125
Warning lights ................................................. 65
Warning triangle, see Safety equipment ........ 20
Warranty ..................................................... 8, 31
Weights ........................................................ 191
Wheels and tyres .......................................... 169
Checking the tyre pressure .................... 170
Checking tightness of the wheel nuts .... 170
211
15 Index
Replacing a wheel ..................................170
Window
See Windshield ........................................58
Windscreen washer ........................................67
Windshield ......................................................58
Nozzles .....................................................69
Sunblind ...................................................64
Windshield washer ..................................68, 178
Windshield wiper .............................................67
Wischanlage ...................................................67
Work attachment .............................................34
Changing ..................................................93
Lubrication points ...................................153
Mounting the dipper ..................................95
Mounting the grab ....................................98
Mounting the hydraulic hammer .............100
Mounting the load hook ............................99
Mounting the load hook onto the
trench digger ...........................................102
Mounting the pallet forks ........................101
Mounting the rail tongs ...........................102
Moving ................................................88, 89
Moving hydraulic hammer ..................89, 91
Moving the dipper .....................................89
Moving the grab ........................................89
Moving the tamping pick ...........................90
Moving the track tamping equipment .......89
Moving track tamping equipment .......89, 90
Oil pressure and oil level adjustment ........91
Quick attach ...........................................105
Removing the dipper ................................94
Removing the grab ...................................96
Removing the hydraulic hammer ............100
Removing the load hook ...........................99
Removing the load hook from the
trench digger ...........................................102
Removing the pallet forks .......................101
Removing the rail tongs ..........................102
Track tamping equipment mounting .......104
Work preparation ............................................82
Working
During road or off-road operation .............82
With the rail-road excavator .....................82
Working floodlights ..........................................67
Works
In confined spaces ...................................23
In the hazard zone of overhead/underground
lines ..........................................................23
On rails ...................................................128
Under overhead lines during rail operation 29
With a rail-road excavator ......................128
Workspace ................................................21, 22
Crane operations ......................................22
Rail operation ...........................................28
Workspace safety ...........................................18

212
Index 15

213