TRAINING CENTER

Road / Rail Excavator Erstellt: J. Pape

Datum: 02.07

ROAD / RAIL EXCAVATOR

TRAINING COURSE

1404 Serie 241

1604 Serie 168

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 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

CONTENTS

1-5 Displays and Controls

6 - 10 Description of Functions
11 - 12 Electronic slewing limiter
13 - 26 Hand - held programmer
27 - 31 Adjusting procedure
32 Hydraulic Circuit Diagram - Road / Rail Equipment
33 Foult Indication on the Display
34 - 36 Valve Location / Undercarriage
37 - 39 Valve Block
40 Locking Valve / Track Roller Ram
40.1 Emergency valve
41 Hydraulic Diagram / Stabilizers
42 Reversing Valve
43 Preload Valve
44 Check Valve, Pilot – controlled
44.1 Triple stop valve
45 Slew angle transmitter
46 Compressed - Air System
47 Relay Valve
48 Rotary Air Distributor
48.1 Air dryer
49 - 56 Height Limiter
56.1 Pilot relier / hight limiter
57 Rail Track Packing System Adjustments
58 - 61 Pressure balance - Electronically controlled
62 - 65 Oil volume and Pressure regulation
66 - 68 Pressure Adjustment Table 1404
72 – 73.2 Hydraulic Diagram 1404 / 1604
74 - 76 Circuit Board Chart
77 - 79 Computer Circuit Board / Eprom

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Road / Rail Excavator Erstellt: J. Pape
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1 Multi - function lever, left

Inching speed, intermittent wipers, pre-selection for
direction of travel
2 Multi - function lever, right
Dimmet light, drive light, horn, directional indicator
3 Accelerator pedal
4 Brake pedal
5 Pedal for luffing boom
6 Brake pedal - slewing
7 Warning - signal switch for accompanying person
8 Height limit indicator

Note on item 3
Pre-selection of the travel direction can also be carried out at the switches ( 9 and 10 ) on the left pilot
control lever:
Place the multi-function lever (1) in the central positon. Set the pre-selection switches
( 11 and 12 ) to position 4. Briefly press switch ( 9 ) and the excavator will move forward when the
accelerator is operated. To change direction ( reverse ), briefly press switch ( 10 ). The pre-selected
direction is shown in the display field. If the switch is pressed twice, neutral selected.

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1. Cylinder head temperature and hydraulic oil temperature

2. Hydraulic oil level
3. Engine oil level
4. Engine stop - Engine oil pressure too low
- Coolant overheating
- Coolant level too low
5. Fuse monitor
6. Alternator charge control
7.
8. Coolant overheating / flashes
Coolant level / comes on
9. Track roller pressure, rear
10. Track roller pressure, front
11. Parking brake
12. Engine oil pressure warning light
13. Low fuel level
14. Caution - Computer malfunction ( comes on )
- Bulb faulty ( flashes )
15. Hazard warning flashers
16. Hydraulic oil filter
17. Central lubrication
18. Auxiliary heater
19. Air cleaner contamination / comes on
Mesh strainer fuel filter / flashes
20. Load limit control faulty
21. Engine pre-heating
22. Preselector for stabilizers
23. Inching speed
24. Preselection direction of travel
V - Forward
R - Reverse
25. Swing axle lock
26. Warning lights 1 to 5
27. Road/rail excavator - fault, REC 2.2
- electric rotary distributor
- zero point outside tolerance
28. Swing axle lock ( when brake pedal is operated )
29. Work-area light
30. High-beam headlights
31. Rear fog light
32. Parking lights and driving lights
33. Hydraulic hammer
34. Pressure cut - in stage / Boosting lifting force ( road / rail excavator )
35. Flashing direction indicators
36. Heigt / depth limiter
37. Overload warning device
38. Tiller
39. Rotating beacon
40. Engine oil pressure
41. Fuel level
42. Engine oil temperature / Coolant temperature

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Road / Rail Excavator Erstellt: J. Pape
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1 Key-operated switch for rail operation

2 Control light for lowering track roller axles (yellow)
3 Control light for rail operation (white)
4 Switch for lifting/lowering track roller axles
5 Switch for preselecting track roller axles front/rear
6.a Switch for locking ( working position )
6.b Switch for automatic mode ( traveling position )
6.c Button for lifting out the excavator ( indusi )
7 Switch for slewing limit
8 Control light for slewing limit (green)
9 Switch for interruption of slewing limit
10 Warning light for interruption of slewing limit (red)
11 Switch for interruption of height limit
12 Warning light for interruption of height limit (red)
13 Switch for height limit
14 Control light for height limit (green)

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Road / Rail Excavator Erstellt: J. Pape
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15 Switch for swing axle lock

16 Switch for stabilizers
17 Switch for boosting lifting force
18 Spare, for optional extra
19 Switch for rail lamp, rear (tail signal)
20 Switch for rail lamp, front (three lamp apex signal)
21 Ignition key
22 Spare, for optional extra
23 Continuously variable potentiometer for precision control
24 Interior lights switch
25 Spare, for optional extra
26 Switch for overload warning device
27 Switch for windshield wiper
28 Switch for parking and driving lights
29 Switch for hazard warning flasher
30 Speed indicator
31 Air tank pressure gauge

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Road / Rail Excavator Erstellt: J. Pape
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32 Left pushbutton for special functions and

preselecting travel direction-forward
33 Right pushbutton for special functions and
preselecting travel direction-reverse
34 Pushbutton for: Horn / Fanfare (megaphone)
35 Blower switch ( speeds 1 and 2 )
36 Preselector switch for left pushbutton (32), (positions 0 to 4)
37 Preselector switch for right pushbutton (33), (positions 0 to 4)
38 Parking brake lever
39 Gear shift switch to select either on-road or off-road ratio
40 Pull switch for heating
41 Spare, for optional extra
42 Knob for fanfare (megaphone)
43 Lever for pilot control
44 Lever for waggon braking system
II - Driving position
III - End positon ( neutral position for brake holding pressure )
V - Quick brake position

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1. Track rollers
2. Automatic operation - track roller axles
3. Working position - track roller axles
4. Travel over switch device (Indusi)
5. Increasing lifting power
6. Lifting the track rollers
7 Switching to emergency operation
8. Emergency towing operation
9. Electronics - Main battery switch - Jump starting

NOTE: The positions and valve information refer to pages 4, 5, 6 and 33.

1. Track rollers
1.1 Lowering the track rollers - without pre-selection
Press button (4) with the track roller symbol. Solenoid valves (Y220, Y213, Y206, Y209, Y212, Y216,
Y219, Y210) are energized through the electronics. The oil flows through the plate valve (1) to the track
roller rams. The track rollers are lowered. Continue to hold the button down until the appropriate
amount of pressure has built up. Release the button. The automatic system then begins to control the
track roller ram based on the position of the superstructure.

1.2 Lowering the track rollers - with pre-selection

Activate switch (5), steering axle (F) preselection. Press button (4) with the track roller symbol.
Solenoid valves (Y220, Y213, Y216, Y219, Y211) are energized. The “front” track roller rams move
down. Continue to hold the button down until the appropriate amount of pressure has built up.

1.3 Lowering the track rollers – with pre-selection

Activate switch (5), rigid axle (R) pre-selection. Press button (4) with the track roller symbol. Solenoid
valves (Y220, Y206, Y209, Y212, Y218) are energized. The “rear” track roller rams move down.
Continue to hold the button down until the appropriate pressure has built up.

NOTE: The indicator light and buzzer do not turn off until the switch (6b) for the track roller axles is on
“automatic” and the adhesion pressure has been reached.

2. Automatic operation - track roller axles

2.1 Slew the boom to the middle of the track in the direction of travel. Activate switch (4) for the track
rollers . The solenoid valves (Y209, Y210, Y212, Y216, Y219, Y215, Y207) are supplied with electricity.
The adhesion pressure of the “front” track rollers (steering axle) is determined by pressure relief valve
(3+), and the adhesion pressure of the “rear” track rollers (rigid axle) is determined by pressure relief
valve (1-). The pressure switches (B124 and B121) monitor the adhesion pressure. If the “front”
adhesion pressure goes down, it is registered by the pressure switch (B124) and reported to the
electronics. The electronic equipment sends electricity to solenoid valves (Y220, Y213). The plate valve
(1) switches and supplies the front rams with the appropriate amount of pressure until the pressure
switch is reached. Solenoid valve (Y210) is energized and the rams are connected on the B-side with
the tank.

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2.2 During slewing from the middle of the track (approx. 5 degrees), solenoid valves (Y209, Y212,
Y216, Y219) are de-energized by the angle transmitters via the electronics. The rams are locked. The
B-side of the ram remains connected with the tank so that the track rollers stay in contact with the track
on the side from which the weight has been removed. The center-pivot axle is locked simultaneously.

2.3 Automatic replenishment of the track roller rams

If the pilot-control locking lever (43) is switched forward (working position), the replenishment is
accomplished proportionally in accordance with the electronic setting,
If the pilot-control locking lever (43) is switched upwards (traveling position), a "black and white circuit"
results. The replenishment corresponds to this.

3. Working position - track roller ram lock

3.1 Slew the boom to the middle of the track in the direction of travel. Activate switch (6a). Solenoid
valves (Y216, Y219) are de-energized, thus locking the rams. The adhesion pressure of the track
rollers on the side that the weight has been removed from are monitored by pressure switch (B121) and
controlled by the electronics. Solenoid valves (Y207, Y209, Y212, Y210) are supplied with electricity.
The B-sides of the rams are connected with the tank.

3.2 During slewing from the middle of the track (approx. 5 degrees), the same switching occurs as
described under 2.2.

4. Lifting the excavator out for travel over the switching device (Indusi)
4.1 Travel-over when coasting
Let the excavator coast. Press and hold down button (6c). The excavator first lifts itself out with the
steering axle and then with the rigid axle. Solenoid valves (Y220, Y206, Y213, Y216, Y219, Y209,
Y212) are supplied with electricity. Release the button once the excavator has traveled over the switch
device. The excavator first sinks down with the rigid axle, and then with the steering axle. The
automatic system then begins to function again.

4.2 Powered travel-over

Actuate switch (5) for pre-selection of track roller axle (“front” axle or “rear axle”). Press and hold down
button (6c). Solenoid valves (Y220, Y206 or Y213, Y216, Y219, Y209, Y212) are energized. The
center-pivot axle is locked simultaneously. The excavator lifts out the corresponding axle. Travel slowly
over the switch device with this axle. The automatic system then begins to function again.

4.3 Activate the other track roller axle.

5. Increasing the lifting power

5.1 Activate switch (17) for increasing the lifting power. The switch for the track roller axles (6a) must
be in the “working” position. The increase in lifting power does not begin to function until the
superstructure is slewed approx. 5 degrees from the middle of the tracks. Solenoid valves (Y211, Y218)
are supplied with electricity and the B-side of the ram is locked. When a load is lifted, the track roller
axles act as an additional counterbalance.

6 Lifting the track rollers

6.1 Press Button (4) the track roller axles move up until the stop position is reached.
Switch off the key (1) for rail/road operation.
Note: It is only possiable to move the track roller axles up when the switch (6b) is on „automatic -
operation“, and the parking brake is released.

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7. Switching to emergency operation.

7.1 If the electronics should fail to operate, it is
essential to ensure that the following functions still
work:
- Raising the track roller axles
- Travel off-road
- Slewing the superstructure
- Raising or lowering the boom.
- Release swing axle interlock

7.2 If necessary, the vehicle can be switched to

emergency operation as follows:
Turn off key switch (1) for road/ rail operation. Press
and hold down button (4) for “lifting” the track rollers.
The required functions can be performed (off road
travel not possible).
If this does not work, switch to the expanded
emergency operations mode. The following parts are
required for this and are included in the excavator’s
accessories:
– a distributor with a connector for the
cigarette lighter socket
– two connecting cables for the
electronics box.
When switching to emergency operations, you must
proceed in the following order:
1. Attach connecting cable (1) to the
electronics box.
2. Plug the connecting cable into the
distributor (2).
3. Start the engine and plug the
distributor into the socket for the cigarette lighter.
The track wheels move up automatically and the
functions listed under 7.1 can be performed.

7.3 Switch over the block ball-valve to release the

center-pivot axle.

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 8. Operation for emergency towing
8.1 If the engine should fail, it is possible to use a manual hydraulic pump to: lift the boom,
release the slewing brake, manually turn the excavator’s superstructure, lift the stabilizers and
extend the track roller rams.
Hand pump (A) is used to accomplish this. Valve (B) must be closed.

Lifting the boom

– Attach connectors (1 and 8) with the 2000 mm hose
– Attach connectors (9 and 7) with the 1000 mm hose
– Open (10) - and close (11) block ball-valve
– Lift the boom to the appropriate height
– Unscrew the hoses beginning with position (8).

Releasing the slewing brake

Road / Rail Excavator

– Attach connectors (2 and 6) with the 2000 mm hose.
– Close (10) - and open (11) block ball-valve.
– Turn the ignition key to position I.
– Release the slewing brake.
– Manually move the superstructure to the position required.
– Set the slewing brake in the cab.
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– Unscrew the hoses.

Lifting the stabilizers

– Attach connectors (1 and 5) with the 4000 mm hose.
– Open (10) - and close (11) block ball-valve.
– Lift the stabilizers to the appropriate height.
– Unscrew the hoses.

Lifting out the excavator

– Secure the excavator so that it cannot roll away.
– Attach connectors (1 and 3) with 4000 mm, 200 mm and 1000 mm hoses.
– Attach connectors (4 and 9) with 4000 mm hose.
– Open (10) - and close (11) block ball-valve.
– Lift the front of the excavator to the appropriate height.
– Attach the hoses from the connectors (3) appropriately in the back.
– Lift the rear of the excavator to the appropriate height.

Datum: 02.07
Erstellt: J. Pape
TRAINING CENTER
Secure the excavator to the towing vehicle properly and tow to a safe location.
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

9. Electronics/ Main battery switch/ Jump start

ATTENTION: the following rules must be complied with absolutely in order to avoid damage to
the electronics installed on the excavator:

9.1 The electronics may only be tested with a measuring device that is suitable for this task.
Under no circumstances should conventional test lamps be used, since this could destroy the
electronics.

When welding work is being done, the battery master switch must never be turned off, nor
should the chassis earth (ground) connection to the batteries be interrupted. For devices with
power limit control, the plug must be removed from the electronic box. The earthing
(grounding) cable from the welder must be attached as close to the welding point as possible.

Chargers with a starting aid device (220-24 volts power supply unit), if used, must have a
controlled, stabilized output.

When jump starting from another vehicle, in order to prevent peak voltages, the engine of the
second vehicle should not run simultaneously.

When jump starting, make sure that the polarity is correct, or otherwise the excavator’s
electronics can be damaged.

Never us a power supply higher than 24 volts for jump starting.

When charging the batteries, use only chargers with a controlled, stabilized output.
Additionally, disconnect a terminal connection to the vehicle electrical system.

When rapid charging the batteries, open the cell covers, or else the batteries could explode
otherwise.

Make sure that the battery acid level stays at the prescribed level. If has to be added, use only
distilled water, not acid.

Check the charge level (acid level) if possible.

Never run the engine when the batteries have been disconnected.

Never operate the battery master switch when the engine is running, since this could cause
circuit board damage as a result of peak voltages.

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Adjusting the switch-off points for slewing ranges A and B symmetrically.

Turn off key switch (1) for rail operation. Turn the
pre-selector switch (7) for the slewing limiter to
position 0.
Press switch (9) for the slewing limiter cutout, hold
it down and turn on the key switch (1). The control
and warning lights (8 and 10) will begin to flash.
Release the switch again.
Slew the boom to the designated switch-off point.

Press switch (9) and hold down until the control

lights (8 and 10) are continuously illuminated.
Release the switch. The control lights will flash
rapidly for a short time and then go out. The
slewing areas A and B are now memorized.

Checking: switch on the slewing limiter and check

the switch-off point.

Note: If no other switches are operated within

approx. 25 seconds, the actual slewing distances /
switch- off points will not be changed and the
adjusting mode will be automatically ended.

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Road / Rail Excavator Erstellt: J. Pape
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Setting the switch-off point of slewing areas A and B individually.

Slew the cabin centrally in the direction of travel.

Turn off key switch (1) for rail operation.
Set the pre-selector switch (7) for the slewing
limiter to the designated slewing area. If the switch
is set to position I, then slewing area B is released.
Press switch (9), hold down and switch on key
switch (1). As soon as the green control light
flashes (8), release the switch. Slew the boom to
the required switch-off point.

Attention: If a buzzer sound intermittently, the

incorrect slewing area has been pre-selected at
the selector switch (7).

Press switch (9) until a continuous green light (8)

appears.
The pre-selected slewing area/switch-off point is
now temporarily memorized.
To set the other slewing area, switch (7) is moved
to Position II.
A red flashing light comes on (10). Slew the boom
to the other slewing area and the required switch-
off point. Press switch (9) until a continuous red
light (10) appears. Release the switch; brief, rapid
flashing of the light occurs. After the indicator
lights disappear, the designated slewing areas are
memorized.

Checking: switch on the slewing limiter and check

the switch-off point.

Note: If no other switches are operated within

approx. 25 seconds, the actual slewing
distances/switch-off points will not be changed and
the adjusting mode will be automatically ended.

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Road / Rail Excavator Erstellt: J. Pape
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Hand-held programmer

The PT 20 hand-held programmer is used on the computer-controlled ZW-4 road-rail excavator. It is

connected via an adapter cable to the 7-pin emergency socket on the cabin’s control panel and is
required for the following functions:

1. Adjusting: 2. Detection:

- To select the language - Current faults

- Pressure switch for controlling the guide rollers - Actual slewing angle
- Control pressure supply - Target switching status
- Setting the zero point for the slewing angle - Operating hours
- Slewing speeds - Road-rail operating hours
- Loading the factory setting - Number of faults
- Current faults
- Old faults
- Delete old faults

WPI
OYSTER
TERMIFLEX
Excavator ZW – 4
UPP V7.02
LOW V8.01
1404 ZW - 4

PT 20
Mod Cncl CR SP 0 →
↑
PT 20 hand-held programmer
1 Esc 2Nul 3 4 : 5 Complete with program and cable with
~
Voltage regulator.
6 7 8 9 A EDP No. 6001259
B C D E F Adapter cable to connect to the
Emergency socket on the cabin’s
G H I J K Control panel.
EDP No. 5442457
L M N O P

Q R S : T U

V W X . Y , Z

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Road / Rail Excavator Erstellt: J. Pape
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WPI OYSTER TERMIFLEX

Excavator ZW 4
UPP V7.04
LOW V8.01
1404 ZW 4

PT 20
Mode Cncl CR SP ← 0 →
↑ ↓
~
1 Esc 2 3 Del 4 : 5
Null
6 7 % 8 $ 9 @ A #
&
B ? C " D [ E ( F <

G ! H ' I ] J ) K
>
L + M N O / P =
- Μ
Q _ R ∧ S : T ; U \

V { W X . Y , Z }

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Language
Level 4

Language
> German
English
2 nd foreign L.

Select the corresponding language with key B or C (arrow points to pre-selected language, the plus
sign is on the confirmed language). Confirm with the CR key.
Subsequently save with the V key. The display appears:

XXXXXXXXXXXXXXXX
X OK X
X Saved X
XXXXXXXXXXXXXXXXX

Subsequently, the program switches automatically to program level 2.

Level 2

> Settings
Data display
Faults
Factory setting

Pressure setting

This program mode permits the manual correction of guide roller pressures.

Level 4
+ Arm at front
> Arm at backside
Supply to front
+ Supply to back

Choose the corresponding function with key B or C (arrow points to the pre-set position, plus sign is at
the confirmed position).
Selection of the arm and the supply positions must be confirmed separately with the CR key.

By pressing the N key, the supply is activated.

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Control pressure

Reduced guide roller pressure supply with pilot control active.

Level 4
Control pres.
Supply
25

The valve flow can be changed with key K or F. A corresponding decimal value from 12 to 30 is shown
in the display.

The new setting must be saved with the V key. The display show:

XXXXXXXXXXXXXXX
X OK X
X Saved X
XXXXXXXXXXXXXXX

The program then changes automatically to program level 2.

Level 2

> Settings
Data display
Faults
Factory setting

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Zero point

To save the zero point, the excavator has to be slewed over the steered axle and secured with the
locking pin.

Level 4
Save
Zero point
> No
Yes

Select with key B or C (arrow points to pre-selected position, the plus sign is at the confirmed position).
Confirm with CR key.
Return with the M key. The angle is automatically set to zero. Confirmation is shown on the display:

XXXXXXXXXXXXXXXXX
X OK X
X Saved X
XXXXXXXXXXXXXXXXX

If the zero point is not saved, this is shown by the display:

XXXXXXXXXXXXXXXXX
X Fault X
X Fault X
XXXXXXXXXXXXXXXXX

The program then switches automatically to program level 3.

Level 3
> Language
Pressure set.
Control pressure
Zero point >

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Slewing speed

This program item sets the slewing speeds at the slewing limiter.

Level 4
> Min. speed right
Max. speed right
Min. speed left
Max. speed left

Select the required speed with key B or C (arrow points to the pre-selected position). Subsequently,
change over to program level 5 with the L key.

Slewing speed
Right max.
X,X rpm
XX

The valve flow and thus the slewing speed can be set with keys K or F. The slewing speed together
with a corresponding decimal value from 12 to 30 is shown in the display. When the slewing speed is
set correctly, the setting can be saved separately with the V key. It is also possible to set all the slewing
speeds first and to save them all together subsequently with the V key. The following display appears:

XXXXXXXXXXXXXXXXX
X OK X
X Saved X
XXXXXXXXXXXXXXXXX

The program then switches automatically to program level 2.

Level 2

> Settings
Data display
Faults
Factory setting

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Adopting the factory setting

If necessary, the factory setting can be accessed again.

Level 4
Factory setting
load ?
> No
Yes

Select with key B or C (arrow points to the pre-selected position, the plus sign is at the confirmed
position). Confirm with the CR key, then save with the V key. The confirmation is seen on the display
as:

XXXXXXXXXXXXXXXXX
X OK X
X Saved X
XXXXXXXXXXXXXXXXX

The program subsequently switches automatically to program level 2.

Level 2
> Settings
Data display
Faults
Factory setting
Slewing data

Display of the slewing speed and the superstructure’s actual slewing angle.

Level 4
Slewing speed
X, X rpm
Slewing angle
X deg

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Target status

In this display all input and output signals for guide roller control in the superstructure (UPP) and
undercarriage (LOW) are shown. You can choose between two displays.

Level 4

> UPP symbol disp

LOW symbol disp
UPP ident. disp
LOW ident. disp

Select the corresponding display with key B or C and switch to another level with key L.

The “symbol” display is used in connection with a table (hydraulic plan). There is a position in the
display for each input and output. The symbols show the corresponding selection status.

− = Input or output is not active

* = Input or output is active
F = Fault at the output

UPP symbol disp

Display of UPP symbol ----------------
----------------
----------------

Display of LOW symbol LOW symbol disp

- - -- --
------- - - --
----- --- ---

The “identifier” display shows all input and output signals with the corresponding identifiers from the
circuit diagrams.
If the input or the output is active, this is shown as a negative display.
The displays extend over several fields, which can be run through with key B or C.
UPP identifier display UPP ident. disp.
S180 S184 S185B
S185N S186V
S186H S187U >

LOW ident. disp.

B121 B122 B123
B124
>

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 Display in menu node UPP symbol display
-- = Input or output is not active
* = Input or output is active
F = Fault at output

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Road / Rail Excavator
Datum: 02.07
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TRAINING CENTER
 Display in menu node UPP symbol display
-- = Input or output is not active
* = Input or output is active
F = Fault at output

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Road / Rail Excavator
Datum: 02.07
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TRAINING CENTER
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Datum: 02.07

Operating hours

This display shows the total number of operating hours as well as the operating hours in the ZW mode.

Level 4

Operating hours
XXXX, XX hours
Rail operating h
XXXX, XX hours

Number of faults

The number of actual and old faults in the guide roller control system is shown.

Level 4
Number of faults
Actual XX
Old XX

Current faults

In the “current faults” display, the current faults on the superstructure or undercarriage are shown with
fault number and identification of the output.
In addition, the possible cause of the fault and the number of faults are shown.

Level 4

LOW fault 19
Y 218
open - short cir.
X hours 1/3

The individual faults can be called up with key B or C.

Further information can be obtained from the fault table on page 26.

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Datum: 02.07

Old faults

In the “old faults” display, the old faults from the superstructure and undercarriage are shown with fault
number and identification of the output. In addition, the possible cause of the fault, at how many
operating hours and the number of faults are shown. Up to 10 old faults can be saved.

Level 4

LOW fault 19
Y 218
open - short cir.
X hours 1/3

The individual faults can be called up with key B or C.

Further information can be obtained from the fault table on page 13.

Deleting old faults

In this program mode, old faults can be deleted.

Level 4

Old faults
Delete ?
> No
Yes

Select with key B or C (arrow points to pre-selected position, the plus sign is at the confirmed position).
Confirm with CR key.
Subsequently return with the M key. The display appears:

XXXXXXXXXXXXXXXXX
X OK X
X X
XXXXXXXXXXXXXXXXX

The program then switches automatically to program level 3.

> Number of fault

Current faults
Old faults
Del. old faults

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Fault table

Fault Component Function Installed Possible fault

number identification location

1 Y210 Tank connection for steered axle/rigid axle LOW Wire break, short circuit
st
2 Y204 Gear change, 1 gear LOW Wire break, short circuit
3
nd
4 Y205 Gear change, 2 gear LOW Wire break, short circuit
5 Y219 Shut-off left cylinder, steered axle LOW Wire break, short circuit
6
7
8 Y216 Shut-off right cylinder, steered axle LOW Wire break, short circuit
9 Y209 Shut-off left cylinder, rigid axle LOW Wire break, short circuit
10 Y212 Shut-off right cylinder, rigid axle LOW Wire break, short circuit
11
12
13 Y207 Pressure limiting, rigid axle - LOW Wire break, short circuit
14 Y208 Pressure limiting, rigid axle + LOW Wire break, short circuit
15 Y214 Pressure limiting, steered axle - LOW Wire break, short circuit
16 Y215 Pressure limiting, steered axle + LOW Wire break, short circuit
17 Y238 Pressure accumulator LOW Wire break, short circuit
18
19 Y218 Increased lifting power on steered axle LOW Wire break, short circuit
20 Y211 Increased lifting power on rigid axle LOW Wire break, short circuit
21 Y213 Pre-selection of guide rollers, steered axle LOW Wire break, short circuit
22 Y206 Pre-selection of guide rollers, rigid axle LOW Wire break, short circuit
23
24
25 Y227 Slewing brake UPP Wire break, short circuit
26
27 Y233 Height limitation of base boom UPP Wire break, short circuit
28 Y222 Height limitation of luffing boom UPP Wire break, short circuit
29 Y233 Foot brake free if pads are up UPP Wire break, short circuit
30 Y201 Pads UPP Wire break, short circuit
31 Y221 Guide rollers up UPP Wire break, short circuit
32
33 H 46 Guide rollers down UPP Wire break, short circuit
34 H 47 Height limitation on/off UPP Wire break, short circuit
35 H 48 Height limitation connection UPP Wire break, short circuit
36 H 49 Slewing limiter on/off UPP Wire break, short circuit
37 H 50 Slewing limiter connection UPP Wire break, short circuit
38 Y220 Guide rollers down UPP Wire break, short circuit
39 Y226 Slewing limiter left UPP Wire break, short circuit
40 Y225 Slewing limiter right UPP Wire break, short circuit
41 E EPROM Memory on circuit board 2.2 UPP E EPROM defective
42 CAN – OWG CAN component in circuit board 2.2 UPP CAN component defective
43 CAN – Wg CAN connection to angle transmitter UPP CAN connection defective
44 CAN – UWG CAN connection to undercarriage UPP CAN connection defective
45 ADW – UWG Control current for fault diagnosis UPP Internal current connection
defective
46 Zero Slewing limiter UPP Zero point incorrect

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1. General
2. Track wheel cylinder
3. Reduced pilot pressure for track wheel axles
5. Pad support
6. Vehicle brake
7. Height limitation

1. General – ATLAS road-rail excavator

This generation of road-rail excavators with computer controlled rail travel gear has automatic level
control of the track wheels. In this way, the excavator handles better when travelling on rails with and
without a load.

Note:
Positions and valve details relate to pages 3, 4, 5 and 32.
The key switch for rail operation must be switched on before the adjusting procedure. The respective
setting values are to be taken from the pressure setting tables on pages 65-69. The hydraulic oil
temperature must be between 45-60°C. The hand-held programmer PT20 and an adapter cable are
necessary for the adjusting procedure.

2. Track wheel cylinder

2.1 The piston stroke limiter on the A-side (A) at
the valve section for the track wheel cylinder
must be screwed in by 6 mm, and on the B-
side (B) 7 mm, measured on the locknut.
Slew the boom over the rigid axle. Switch off
the diesel engine. Connect the hand-held
programmer to the socket (1) via the adapter
cable.

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2.2 Adjusting the pressure limiting valve (1-) and the

pressure switch (B121).
Connect a 0-400 bar pressure gauge to the
measurement connections (M1 and M2). Start the
diesel engine. A display (2.2) appears on the hand-
held programmer. The type of excavator and the
Eprom status are shown.
Set switch (6b) to automatic mode. Lower the track
wheel axles with switch (4) until the excavator begins
to rise.
Then release the switch. Tighten the pressure limiting
valve setting screw (1-) by about 4 turns. Loosen the
setting screw of pressure switch (B121) until it is flush
with the housing.
Using the B key on the programmer, level 2 is called
up (the cursor is before “settings”).By pressing the L
key, level 3 is displayed.
Using the B key, the cursor is set in the “pressure
setting” line.
By pressing the L key, level 4 appears.The cursor is at Without support
the “arm at the front” line. This is confirmed with the pads
CR key. Press the C key and the cursor is at “rear
supply”. Press the N key until the track wheel axle
pressure builds up.
Set the pressure limiting valve (1-) to the designated
value of the pressure switch (B121). Slowly tighten the
pressure switch setting screw until there is overlap with
the valve (alternate on and off switching).
Tighten the pressure limiting valve setting screw about
4 turns.
Press the N key until the track wheel axle pressure
builds up. Set the pressure limiting valve to the
designated value.

With support pads

Level 1 Level 2
Excavator ZW 4 > Settings
UPP V7.04 Data display
LOW V8.01 Faults
1404 ZW 4 Factory setting
2.3 Adjusting the pressure limiting valve (3+), the
pressure switch (B124) and the measuring union
Level 3 Level 4
M2.
> Language > Arm at front
Set the cursor to “front supply” with the C key and Pressure set. + Arm at backside
confirm with the CR key. Contr. pressure Supply to front
Set according to the procedure described in 2.2. Zero point + Supply to back

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2.4 Adjusting the pressure limiting valve (4-)

and the pressure switch (B123).
Set the cursor on the programmer to “arm at
the rear” with the C key and confirm with the
CR key. By pressing the B key, the cursor is set
to “front supply”. Confirm with the CR key.
Tighten the setting screw of the pressure
limiting valve (4-) about 4 turns. Loosen the
setting screw of the pressure switch (B123) until
it is flush with the housing.
Press the N key until the track wheel axle
pressure builds up.
Set the pressure limiting valve (4-) to the
designated value of the pressure switch (B123).
Slowly tighten the pressure switch setting screw
until there is an overlapping effect with the
valve (alternate on and off switching). Tighten
the pressure limiting valve setting screw about
4 turns. Press the N key until the track wheel
axle pressure builds up. Set the pressure
limiting valve to the designated value. Without support pads

2.5 Adjusting the pressure limiting valve (2+),

the pressure switch (B122) and the
measurement connection M1.
Set the cursor to “rear supply” with the B key
and confirm with the CR key.
Set according to the procedure described in 2.4.

With support pads

By pressing the M key, level 3 appears.

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3. Reduced pilot pressure for the track wheel

axles.
3.1 Connect a pressure gauge (0-60 bar) to the
measuring union (M3) of the pilot cap to lower the
track wheel axles. Connect the hand programmer
with the adapter cable to the socket (1) on the
electronics box. Start the diesel engine.
Using the L key, change from level 1 to level 2.
The “settings” line is called up in level 2.Press
the L key and level 3 appears. Using the B key in
this level, the cursor is set in the line for “Contr.
pressure”. Press the L key. The pressure is
shown on the pressure gauge (target value 11
bar). Using the K key, the pressure is increased
by impulses and reduced with the F key. A
decimal value of 12 - 30 is shown on the display.
The setting is saved with the V key and
confirmed in the display with “OK”.

Level 1 Level 2
Excavator ZW 4 > Settings
UPP V7.04 Data display
LOW V8.01 Faults
1404 ZW 4 Factory setting

Level 3 Level 4
> Language Control pres.
Pressure set. Supply
Contr. pressure 25
Zero point

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5.Stabilizers
5.1 Connect a manometer (0-400 bar) to the
measurement union (M4). Make sure the foot
brake is locked. Tum on switch (5) for the
stabilizers. Switch the lever on the steering-
column assembly to “forward” direction of travel.
Press the accelerator (pedal) all the way down
and hold at max. engine speed until the
excavator is stabilized. Adjust to the prescribed
pressure on the pressure relief valve (1).
Note:
When the stabilizers are moving up, the pressure
relief acts as a safety device.

6. Rail- vehicle brake

6.1 Adjusting the pilot-control brake pressure.
Connect a manometer (0-6 bar) to the
measurement union (M5). Move the lever (43) on
the driver’s brake valve to position II. The
pressure is adjusted to 5,3 bar on the adjusting
screw (1) of the pressure relief valve.

6.2 Adjusting the air pressure reservor. Move the

lever on the driver’s brake valve (43) to position
II. The pressure is shown on the manometer (2)
located on the undercarriage. The pressure is
adjusted to 5,1 bar on the adjusting screw (3) of
the pressure relief valve.

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If faults occur in the rail operation, the fault diagnosis in the circuit board 2.2’s display can be accessed as follows:
Select the switch for the track wheel axles when the rail operation is active and raise the axles. Switch off the key switch (1) for rail operation
and switch on again. After the test program has been run (about 10 seconds), the fault is shown in the display of the circuit board 2.2. The
abbreviations in the display can be correspondingly classified via the fault table.

Fault table

Letter display Fault range Assembly location LED V29 ZW control

D9 REC 2.2 display field
OK No faults out out
REC 2.2 defect UPP on flashing
ZERO Zero point UPP flashing flashing
CANO CAN data, internal memory, REC. 2.2 UPP flashing flashing
CANU CAN data, in or to the electronics box UPP / LOW flashing flashing
CANW CAN data, in or to the angle transmitter UPP flashing flashing
EEPR E-EPROM, REC. 2.2 UPP out out
ADWU Current measurement/ LOW out out
fault recognition in electronics box
F 201 Solenoid valve Y 201, pads LOW out out
F 204 Solenoid valve Y 204, gear change 1st gear LOW out out
F 205 Solenoid valve Y 205, gear change 2nd gear LOW out out
F 206 Solenoid valve Y 206, rear guide rollers LOW out out
F 207 Solenoid valve Y 207, rear pressure setting - LOW out out
F 208 Solenoid valve Y 208, rear pressure setting + LOW out out
F 209 Solenoid valve Y 209, cut-off rear right LOW out out
F 210 Solenoid valve Y 210, tank connection front and rear LOW out out
F 211 Solenoid valve Y 211, rear lifting power reinforcement LOW out out
F 212 Solenoid valve Y 212, cut-off rear left LOW out out
F 213 Solenoid valve Y 213, front guide rollers LOW out out
F 214 Solenoid valve Y 214, front pressure setting - LOW out out
F 215 Solenoid valve Y 215, front pressure setting + LOW out out
F 216 Solenoid valve Y 216, cut-off front right LOW out out
F 218 Solenoid valve Y 218, front lifting power reinforcement LOW out out
F 219 Solenoid valve Y 219, cut-off front left UPP out out
F 220 Solenoid valve Y 220, guide rollers down UPP out out
F 221 Solenoid valve Y 221, guide rollers up UPP out out
F 222 Solenoid valve Y 222, height limitation on lifting UPP out out
positioning boom
F 223 Solenoid valve Y 223, height limitation on lifting main UPP out out
arm
F 225 Solenoid valve Y 225, slewing limiter , slewing right UPP out out
F 226 Solenoid valve Y 226, slewing limiter , slewing left UPP out out
F 227 Solenoid valve Y 227, slewing limiter , slewing brake UPP out out
F∗∗ Several faults, can be accessed via switch on circuit
board 5.1

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Valve Location Withaut stabilizers

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Valve Location With stabilizers

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Valve location undercarriage

Y202 Controller bypass

Y203 Center-pivot axle lock
Y204 Gear shift - off-road travel
Y205 Gear shift - road travel
Y206 Preselection - activation of track-wheel axle, rigid axle
Y207 4/3-way directional control valve - pressure adjustment (-), rigid axle
Y208 4/3-way directional control valve - pressure adjustment (+), rigid axle
Y209 Stop valve - rigid axle, right
Y210 Stop valve - tank connection, side-B of ram
Y211 Lifting power increase, rigid axle
Y212 Stop valve - rigid axle, left
Y213 Preselection - activation of track roller axle, steering axle
Y214 4/3-way directional control valve - pressure adjustment (-), steering axle
Y215 4/3-way directional control valve - pressure adjustment (+), steering axle
Y216 Stop valve - steering axle, left
Y218 Lifting power increase, steering axle
Y219 Stop valve - steering axle, left

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Bank of valves

Y206 Preselection - activation of track roller axle, rigid axle

Y207 4/3-way directional control valve - pressure adjustment, rigid axle (-)
Y208 4/3-way directional control valve - pressure adjustment, rigid axle (+)
Y213 Preselection - activation of track-wheel axle, steering axle
Y214 4/3-way directional control valve - pressure adjustment, steering axle (-)
Y215 4/3-way directional control valve - pressure adjustment, steering axle (+)
1 Pressure limiting valve, rigid axle (-)
2 Pressure limiting valve, rigid axle (+)
3 Pressure limiting valve, steering axle (+)
4 Pressure limiting valve, steering axle (-)
5 Measurement union, rigid axle
6 Measurement union, steering axle
7 Tightening torque 6 Nm

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Valve unit For track roller axel pressure

1 Valve cone
2 Valve seat
3 Solenoid valve connection (Y207 or Y214)
4 Solenoid valve connection (Y208 or Y215)
5 Pressure switch connection
6 Valve block/ ram connection

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Valve block

1 Tightening torque: 6 Nm
Y 210 Stop valve, tank connection, side-B of ram
Y 211 Stop valve, ram side (B), rigid axle
Y 218 Stop valve, ram side (B), steering axle

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Locking valve for track roller ram

1 Solenoid
2 Pressure pin
3 Turcon Glyd ring
4 Spring
5 Spring
6 Screw for emergency discharge

Z Ram connection
A Control connection

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Emergency valve

Z1 / Z2 - Connection ram
VSt - Connection handbrake
T - Connection tank
M - Check point
1 - Non return valve
2 - Piston spool
3 - Balaner piston with prevelier
4 - Stop piston leakoil free
5 - Non return valve
6 - Pressure control valve 50 – 60 bar

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Reversing valve Travel / Stabilizers

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Reversing valve Travel / Stabilizers

1 Presure relief valve

2 Solenoid valve
3 Check valve
4 Shuttel valve
5 Check valve

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Preload valve Stabilizers

1 Guide piece
2 Spring
3 Valve unit
P Valve block connection
R Stabilizer ram connection, large side

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Check valve, pilot – controlled stabilizers

1 To check valve
2 From check valve
3 Control line from small side of ram
4 Control piston with Turcon Glyd ring,
must be fitted with installation
device
A Connection for large side of ram
B Connection for valve block

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Triple stop valve

1 Butter

2 Blocking piston

3 Balanced non return valve

4 Nozzle ø 1mm

5 Non return valve

B Connetion from reversing valve / outriggers out

ST Connetion from reversing valve / outriggers in
M Checkpoint (not installed

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Slew angle Transmitter

1 Slew angle transmitter

2 Clutch

3 Housing

4 Superstructure frame

5 Slewing gear ring (inner gear teeth)

6 Shaft

7 Gear

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Hydraulik diagram / slewing limiter

1 Solenoid valve

2 Control spool

3 Non-return valve

4 Nozzle ø 1 mm

P pilot pressure connection from lever

A Connection servo pressure cap

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Compressed-air system – Rail / road excavator

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Compressed-air system – Rail / road excavator

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RELAY VALVE
GENERAL
The relay valve makes it possible to fill or to bleed large volumes of air in the shortest possible time.
When these relay valves are used, the development of pressure in the volume that is to be supplied
corresponds to the pressure development of the pilot-control pressure. The pressure is identical in
phase at an approx. 1:1 ratio over a large compounded volume.

HOW IT WORKS
Start position: the pressure in air reservoir R is present at inlet valve seat V1; pressure spring (1)
keeps the inlet valve closed; outlet valve seat V2 is in the bleed position, i.e. the compressed air from
connection C has access to atmosphere. There is no pilot-control pressure Cv.

Release process: surface Cv of the membrane-type piston (2) is exposed to pilot-control pressure Cv,
so that outlet valve seat V2 is closed and the force of pressure spring (1) is overcome, which causes
the valve seat at inlet valve V1 to be open. The pressure present at the inlet valve seat can then flow
into the vehicle’s pressure system as C-pressure and to surface C of the membrane-type piston
simultaneously. The C-pressure that arises and the force of the pressure spring (1) cause the steering
piston to return to its middle position. This means that inlet valve V1 closes and outlet valve V2 remains
closed; pressures C and Cv are equal.

Braking process: the Cv-pressure present at the membrane-type piston is bled entirely into the
atmosphere. This causes the available C-pressure to open the outlet valve V2; the C-pressure is bled
entirely into the atmosphere via the outlet valve Outlet valve V2 remains open and the membrane
piston remains bled.

Braking and releasing in steps: In stepwise braking, the process works in essentially the same way
as in the procedure described above, with the exception that only the pressure step that is selected
takes effect. The C-pressure steps are formed in accordance with the actual Cv. During stepwise
release, Cv-pressure only increases at the prescribed pressure difference, which results in a
corresponding increase in C-pressure.

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Rotary distributor compressed air

1 Foot brake
2 Parking brake
3 Rail-vehicle brake
4 Reservoir
5 Reservoir, axel lock, gear shift, turtle speed
6 Pressure gage rail brake

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Rotary distributor compressed air

1 Foot brake
2 Parking brake
3 Rail-vehicle brake
4 Reservoir
5 Reservoir
6 Center-pivot axle

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Height limiter System ST 9

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1 Solenoid valve ( 223 ) pressure reducer

2 Solenoid valve ( 224 ) cutoff function lifting
3 Solenoid valve ( 222 ) cutoff function adjustable boom
4 Pressure reducer valve = Adjustment 12 bar
= tightening torque 50 Nm

P1 Access from joystick , function lifting

P2 Access from joystick , function adjustable boom
Vst1 Access to Solenoid , function lifting
Vst2 Access to Solenoid , function adjustable boom
T Tank
M Measuring point

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Programming the height limit with or with out pressure reducer.

By the function bypass of the height limit you have to differ between the function lifting
„with advance warning „ or the old version lifting „with out advance warning „ shut down.

In the current software is as standard version the “ with advance warning” programmed.
If a new circuit board 2.3 were built in and the machine has the old version lifting shut down
you have to switch over the software.

By pressing the switch “ INDUSI “ and switching on the rail road key switch the adjustment
mode is active. In the display the control light “ 1 “ lights up.
Now press the switch „ INDUSI „ several times until the control light „ 2 „ and „ 3“ lights up.
On the circuit board 2.2 or 2.3 on that display is “ 5 RED “ shown. That means now the
function “ with advance warning “ is active.

If you press then the switch “ Track roller down “ for 3 S. then it will be switched over to the
function “ with out advance warning “ and on the display of circuit board will be “ 5”
shown.
When you press the switch “ Track rollers up “ for 3 S. then it will be switched over to “ 5RED “
and you have then the function “ with advance warning” active.

Why the differentiation:

At the function “ with advance warning “ if you press the switch bypass only the output
X33-23 for the solenoid valve 222 and 224 will be powered.

At the function “ with out advance warning “ if you press the switch bypass the output
X33-23 and X33-26 for the solenoid valve 222 ; 223 and 224will be powered.

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Adjustments – rail-track packing system

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Pressure balance Electronically controlled

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Oil volume and pressure regulation

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Oelreg.`97
S1 S2 V6 . 04
12.04.99

Platine 8.1

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1404 road / rail excavator

* Check / adjust at max. engine speed
** Check / adjust at min. engine speed
*** Check with hand pump.
Figures shown in bar or rpm
Hydraulic fluid temp. 40-60° C.
______________________________________________________________________
ENGINE SPEEDS
Min. idle speed 1050 + 100 - 50
Max. idle speed 2250 + 50 - 100
Nominal speed 2100 - 40
______________________________________________________________________
PRIMARY VALVES
** Pump 50 - 60
* Pressure cut-off 340
* Pressure cut in stage 340
* Pilot pump 25 - 27
* Pr. lim. valve - emergency shift 22
* Steering pump 210
______________________________________________________________________
POWER-SHIFT CONTROLLER (delta p)
* Pump, 25
* Fine mode poti 8 - 25
** Load limit control valve (+ air pressure on hydraulic tank ) 8.5 +- 0.2
______________________________________________________________________
SECONDARY VALVE
** Lifting rams - raising - line rupture protection valve 385+20
** - leak - free cut off 385+20
** - raising - plate valve 385+20
** - lowering 365+20
** Folding ram 365+20
** Grab operating ram 365+20
Slewing motor (fixed setting) 80 /230
* TC plate 220
** Drive motor - wheeled 400+20
** Gripper rotary motor - plate valve 150
- motor 75
** Actuating ram - extend - plate valve 365+20
** Line rupture protection valve / Leak-free cut-off 435+20
- retract 400+35
* Stabilizer support pad ram - down 140
1404 road / rail excavator
* Stabiliter support pad ram preload valve 80
*** Steering ram 200
** Telescop ram - extend 150+20
- retract 350+20
______________________________________________________________________
SWING AXEL INTERLOCK
*** Pressure - limiting valve 45
______________________________________________________________________

Seite 74 von 74
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

REGULATED TRAVEL MOTOR

** Pressure regulator 260
_____________________________________________________________________

LEAK-FREE SHUT-OFF
** Valve for minimum reduction 3+1
______________________________________________________________________

FEED PRESSURE VALVES (without tank preload)

* Wheeled 15
Return line 2,5
* Cooler protection valve 6,3
* Restrictor cooler input ( mm ) 7
______________________________________________________________________

RETURN FLOW THROTTLES (without implements+ 15 bar)

* Lowering 50
* Folding 90 +10
* Closing grab 80 +10
______________________________________________________________________

SPEEDS
* Slewing 8,5 / 6 / 2,5
* Propeller shafts 720
______________________________________________________________________

COMPRESSED AIR VALVES

Wheeled - pressure regulator 8
- flow relief valve 5
- pressure reduction valve 0.5
- tire pressure - inside 7.75
- outside 7.75
Pressure limiting valve wagon brake 5.1
______________________________________________________________________

The right to make modifications is reserved

Seite 75 von 75
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

1604 road / rail excavator

* Check / adjust at max. engine speed

** Check / adjust at min. engine speed
*** Check with hand pump.
Figures shown in bar or rpm
Hydraulic fluid temp. 40-60° C.
______________________________________________________________________

ENGINE SPEEDS
Min. idle speed 1050 + 100 - 50
Max. idle speed 2470 + 50 - 100
Nominal speed 2300 - 40
______________________________________________________________________

PRIMARY VALVES
** Pump 50 - 60
* Pressure cut-off 320
* Pressure cut in stage 340
* Pilot pump 25 - 27
* Pr. lim. valve - emergency shift 14
* Steering pump 140
______________________________________________________________________

POWER-SHIFT CONTROLLER (delta p)

* Pump, 25
* Fine mode poti 8 - 25
** Load limit control valve (+ air pressure on hydraulic tank ) 8.5 +- 0.2
______________________________________________________________________

SECONDARY VALVE
** Lifting rams - raising - line rupture protection valve 435+20
** - leak - free cut off
** - raising - plate valve 385+20
** - lowering 365+20
** Folding ram 365+20
** Grab operating ram 365+20
Slewing motor (fixed setting) 90 /280
* TC plate 260
** Drive motor - wheeled 400+20
** Gripper rotary motor - plate valve 150
1604 road / rail excavator

- motor 75
** Actuating ram - extend - plate valve 365+20
** Line rupture protection valve / Leak-free cut-off 435+20
- retract 365+20
* Stabilizer support pad ram - down 140
* Stabiliter support pad ram preload valve 80
*** Steering ram 200
** Telescop ram - extend 150+20

Seite 76 von 76
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

- retract 350+20
SWING AXEL INTERLOCK
*** Pressure - limiting valve 45
______________________________________________________________________

REGULATED TRAVEL MOTOR

** Pressure regulator 260
_____________________________________________________________________

LEAK-FREE SHUT-OFF
** Valve for minimum reduction 3+1
______________________________________________________________________

FEED PRESSURE VALVES (without tank preload)

* Wheeled 15
Return line 4,2
* Cooler protection valve 5,5
______________________________________________________________________

RETURN FLOW THROTTLES (without implements+ 15 bar)

* Lowering 50
* Folding 75 +10
* Closing grab 90 +10
______________________________________________________________________

SPEEDS
* Slewing 9,75 / 6 / 2,5
* Propeller shafts 750
______________________________________________________________________

COMPRESSED AIR VALVES

Wheeled - pressure regulator 8
- flow relief valve 5
- pressure reduction valve 0.5
- tire pressure - inside 7.75
- outside 7.75
Pressure limiting valve wagon brake 5.1
______________________________________________________________________

The right to make modifications is reserved

Seite 77 von 77
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Pressure settings table rail / road axles

Pressure settings are based on the corresponding

Slewing radius (T). Measrements in mm
_____________________________________________________________________________________
B B1 B2
1404 1575 1750 2000
_____________________________________________________________________________________
Boom over steering axle:
Pressure relief valve (3+) 80 80 80
Pressure switch (B124) 70 +2 70 +2 70 +2
Pressure relief valve (1-) 60 60 80
Pressure switch (B121) 50 +2 50 +2 70 +2

Boom over rigid axle:

Pressure relief valve (4-) 60 60 60
Pressure switch (B123) 50 +2 50 +2 50 +2
Pressure relief valve (2+) 85 85 85
Pressure switch (B122) 75 +2 75 +2 75 +2
______________________________________________________________________________
1404 with stabilizers

Boom over steering axle:

Pressure relief valve (3+) 70 70 80
Pressure switch (B124) 60 +2 60 +2 70 +2
Pressure relief valve (1-) 60 60 60
Pressure switch (B121) 50 +2 50 +2 50 +2

Boom over rigid axle:

Pressure relief valve (4-) 60 60 60
Pressure switch (B123) 50 +2 50 +2 50 +2
Pressure relief valve (2+) 85 85 95
Pressure switch (B122) 75 +2 75 +2 85 +2

1604 Serial. Nr.:168 Z301265

_____________________________________________________________________________
Boom over steering axle:
Pressure relief valve (3+) 90 105
Pressure switch (B124) 80 +2 95 +2
Pressure relief valve (1-) 60 95
Pressure switch (B121) 50 +2 85 +2

Boom over rigid axle:

Pressure relief valve (4-) 60 105
Pressure switch (B123) 50 +2 95 +2
Pressure relief valve (2+) 100 135
Pressure switch (B122) 90 +2 125 +2

Seite 78 von 78
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Hydraulic diagram 1404

Seite 79 von 79
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

M BF4M 1012 EC
P1 Oil pressure pump HPR 105 - 02
P2 Gear pump, steering
P3 Gear pump, servo control

1 Lifting ram with line brake protection

2 Grab rotating
3 Jib ram
4 Bucket ram
5 Luffing ram
6 Leakoilfree device
7 Primary valve LS controlled
8 Pressure cut off valve
9 Slewing motor with integrated control valve
10 Slewing brake
11 Breaking shut off valve (slewing)
12 Proportional solenoid valve (slewing limit)
13 Servo control valves
14 Proportional solenoid valve (Track roller function)
15 Steering valve
16 Stabilizers
17 Change - over valve
18 Oil motor driving / Driving brake valve
19 Servo control valve block (Filter element, Servo control pressure
limiter, Emergency operation, Accumulator)
20 Hydraulic oil cooler / Thermostatic valve
21 Control valve block track roller rams
22 Swing axle interlock
23 Slewing coupling
24 Collecting ring
25 Leak oil filter element
26 Cooler protection valve
27 Hydraulic oil filter / Oil tank

Seite 80 von 80
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Hydraulic diagram 1604

Seite 81 von 81
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

M BF4M 2012 EC
P1 Oil pressure pump HPR 130
P2 Gear pump, steering
P3 Gear pump, servo control

1 Lifting ram with line brake protection

2 Grab rotating
3 Jib ram
4 Bucket ram
5 Luffing ram
6 Leakoilfree device
7 Primary valve LS controlled
8 Pressure cut off valve
9 Slewing motor with integrated control valve
10 Slewing brake
11 Breaking shut off valve (slewing)
12 Proportional solenoid valve (slewing limit)
13 Pilot reliev / hight limiter
14 Servo control valves
15 Proportional solenoid valve (Track roller function)
16 Steering valve
17 Stabilizers
18 Change - over valve
19 Oil motor driving / Driving brake valve
20 Servo control valve block (Filter element, Servo control pressure
limiter, Emergency operation, Accumulator)
21 Hydraulic oil cooler / Thermostatic valve
22 Control valve block track roller rams
23 Swing axle interlock
24 Slewing coupling
25 Leak oil fiter element
26 Cooler protection valve
27 Hydraulic oil filter / Oil tank

Seite 82 von 82
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

General discription elektronik board 1 to 4

Seite 83 von 83
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Computer circuit board 1 and 1.2

Seite 84 von 84
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Circuit board 5.1 with computer circuit board 2.2

Seite 85 von 85
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Computer circuit board

Circuit board 2, 2.1, 2.2, 2.3, 2.4 = fully assembled ( used for a short
period )

EPROM
CONTROLLER
Letter display

E-EPROM

Plug-type connector X

Circuit board 2.1 / 2.4 = partly assembled ( can be used on the excavator types
ZW 2 and ZW 3 )

EPROM
CONTRO Letter display
LLER

E-EPROM

Plug-type connector X

No components in this area

Circuit board 2.2 / 2.3 = partly assembled ( can be used on the excavator
type ZW 4 )

EPROM
CONTRO Letter display
LLER

E-EPROM

Plug-type connector X 38

No components in this area

Seite 86 von 86
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Computer circuit board 2.2 / 2.3 with display

Circuit board ( 2.2 & 2.3 )

LED V 3 yellow = 24 V Input voltage
LED V 6 yellow = 5 V Voltage
LED V 21 green = Output to circuit board REC 1 control light 10 ( steering axle)
LED V 22 green = Output to circuit board REC 1 control light 9 (rigid axle)
LED V 23 green = Output to circuit board REC 1 for adjustment mode control light 26/2
LED V 24 green = Output to circuit board REC 1 for adjustment mode control light 26/3
LED V 25 green = Output to circuit board REC 1 for adjustment mode constancy light
LED V 26 green = Output to circuit board REC 1 for adjustment mode control light 26/1
LED V 27 green = Output to circuit board REC 1 for buzzer
LED V 28 green = Output to circuit board 1 trigger signal for relays K23
( swing axle lock)
LED V 29 red = Output to circuit board REC 1 for control light 27
(flashing light ; failure)

Failure in the Can-data communication or zero-point

Beyond tolerance = Flashing LED V 29
Processor failure = constancy LED V 29
Eprom

D 5 = Eprom version V 7._ on circuit board 2.2 only together with circuit board 5.1 and a
“ IVO “ angle transmitter.

D 5 = Eprom version V 10._ on circuit board 2.2 or 2.3 (from V10.1) only together with
board 5.1 and a “ FSG “ angle transmitter ( with gear).

Seite 87 von 87
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

The Eprom

Version Program Location

V1 Track roller control for the road/rail excavator Computer circuit board on
(old version, type reference 164s the superstructure
V2 Excavator electronics control system Computer circuit board 1
(new generation)
V3 Special control system for the stationary excavator Computer circuit board 1
With electric motor
V4 Track roller control for the road/rail excavator Computer circuit board 2.1
(ZW-2 generation) in connection board 5
V5 Track roller control for the road/rail excavator Computer circuit board 2.1
(ZW 3 generation) in connection board 5.1
V6 Oil volume and pressure regulation Computer circuit board 8
V7 Track roller control for the road/rail excavator Computer circuit board 2.2
(ZW 4 generation in connection board 5.1
V8 Computer circuit board in
the Black-box undercarriage
V9 Slewing restriction over a electronic Board 8.2
Angle transmitter (IVO)

Seite 88 von 88
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Version Program Location

V 10 Track roller control for the road/rail excavator ZW 4 1604 Circuit board
With mechanical angle transmitter ( Gear FSG) 2.2 u. 2.3

V 11 Track roller control for the road/rail excavator ZW 3 excavator Circuit board 2.4
New Hard.- Software in the area data transmission in connection with
board 5.1

V 12 Track roller control for the road/rail excavator ZW 2 excavator Circuit board 2.4
New Hard.- Software in the area data transmission in connection with
board 5

V 13 Track roller control for the road/rail excavator ZW 1 excavator Circuit board
New Hard.- Software in the area data transmission CPU in driver
cabin

V 14 Slewing restriction over mechanical angle transmitter Circuit board 8.2

gear (FSG)

Seite 89 von 89
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Version/ Revisions state Revision state and program modification Notice

Date of revision
Spare part

V 7 / 02 Pressure readjustment at the INDUSI By Eprom change all working

03.01.00 operation. hours go back to zero
6001856

V7 / 03 Adjustment for France specification.

01.04.00
6002404 Unintended errors by the error By the deletion of old errors
diagnostics eliminated. also the working hours were
lost

V7 / 04 Unintended automatic operation by

29.08.00 putting the track roller on track.
6004842

The automatic operation temporarily lost The actual condition on

when turning ignition off and back on saved temporary saved
again. on the E eporm.

V7 / 05 The zero point will not be automatic By error zero point slewing
11.06.01 adjusted. speed will be reduced to
6018975 1,5U/min.

Detection of the height limit. With out reducing valve you

(with / with out reducing valve) must go over the key
combination
into Modus

V7 / 06 The function friction wheeled excavator By the fiction wheeled

15.10.01 programmed. excavator a coding link from
6034540 X32-15 to X32 17 on circuit
board 5.1 is necessary.

Seite 90 von 90
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Version/ Revisions state Revision state and program modification Notice

Date of revision
Spare part

V7 / 07 The activation of the output module V7 / 07

15.10.01 modified. Did not came into the
6034540 the production.

V7 / 08 Detection of the angle fault. Every 50mS the current

12.06.02 angle will be measured
6044123 and with the old angle
compared.

Arrangements at the Error Code Automatic will the swing axle

Detection. And track rollers locked.
Slewing will be reduced and
The control light “ ZW” is
flashing

Emergency operation by angle error Hold the switch for bypass

Slewing .
Slewing is possible again.

New zero- point adjustment Superstructure slowly slew

Over the front over the
proximity switch.
First swing over the
proximity switch from the left
then from the right the zero-point
is adjusted.

V 7 / 09 If there is a zero-point error in that

6056149 moment you turn on the rail road it will
24.06.03 be choked.
Screen before 12,7 U/min
The screen for slewing on the teach now
Pendant were changed 7,5 U/min

During quick slewing more then 9 U/min

Angle error came up. Error removed.

Seite 91 von 91
 TRAINING CENTER
Road / Rail Excavator Erstellt: J. Pape
Datum: 02.07

Version/ Revisions- state

Date of revision Revision state and program modification Notice
Spare part

Program for “ FSG “ angle transmitter Insert able for circuit board
V10 / 00 with gear transmission 2.3 with additional diode
On the backside.

V10 / 01 Program for “ FSG “ angle transmitter Insert able for circuit board
with gear transmission 2.2 and 2.3.

Interlock for gear shifting. Gear shifting only possible

If the footbrake is active.

Automatic area from 5 degree to 35 Only over a additional key switch

V10 / 03 degree over key switch.

Time delay for gear shifting reduced from 2 s. to 0,5 s reduced

Errors in the Hardware removed

Removed the error message zero-point

On “ ZW “ machines with out a angle
transmitter

Seite 92 von 92