KINSHOFER EuroRail Manual

©2022 Prolec Limited
EuroRail operator guide
Document Reference: 562600-100
V1.4 March 2023

562600-100, Issue 1.4 March 2023
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This guide describes operation of the
PROLEC LIFTING AND MACHINE ENVELOPE SAFETY SYSTEM FOR
RAIL CONSTRUCTION PLANT
Model covered:
PART No.
MODEL Ref
EuroRail
EuroRail –RCI / RCC / MEC SYSTEM
Prolec supports a nationwide dealer network. Warranty claims, service work, technical information and
spare parts are available by contacting:
Prolec Ltd
25 Benson Road
Nuffield Industrial Estate
Poole Dorset BH17 0GB
United Kingdom
Telephone [phone]
E-mail [e-mail]
DURING NORMAL OPERATION THE DISPLAYED SAFE WORKING LOAD OF A MACHINE USED FOR
LIFTING PURPOSES SHOULD NOT BE EXCEEDED.
THEREFORE THE WARNING OF OVERLOAD SHOULD NOT BE USED AS A NORMAL OPERATING
FACILITY. IT SHOULD BE NOTED THAT CERTAIN STATUTORY REQUIREMENTS DO NOT PERMIT
THE SAFE WORKING LOAD TO BE EXCEEDED EXCEPT FOR THE PURPOSE OF TESTING.
THIS EuroRail SYSTEM IS NOT SUITABLE FOR USE IN EXPLOSIVE ATMOSPHERES.
ADJUSTMENT BY UNAUTHORISED PERSONS WILL INVALIDATE ANY WARRANTY OR
CERTIFICATION SUPPLIED. IF A PROBLEM ARISES WHICH CANNOT BE RECTIFIED USING THIS
GUIDE, AUTHORISED SERVICE SHOULD BE SOUGHT.
THIS DEVICE IS CERTIFIED TO MEET CURRENT UK & EC SAFETY REGULATIONS FOR LIFTING
OPERATIONS.
Any alterations or modifications to machine components which affect this system, and any system
component failure, must be reported directly to Prolec Ltd, or via the machine converter or service
agreement holder. This manual must be kept with the product and be passed on to any subsequent user
of the product.
Whilst every effort has been made to ensure the accuracy of the information supplied in this manual,
Prolec Ltd cannot be held responsible for any errors or omissions.
Manufacturers original instructions.

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Contents
1. Use of this Document.................................................................................................................5
2. Notices........................................................................................................................................5
3. System Identification .................................................................................................................6
4. Operating, and Hazard Situation, Recommendations..............................................................7
4.1. RCC - MEC Override.........................................................................................................7
5. Operating Instructions...............................................................................................................8
5.1. Power Up...........................................................................................................................8
5.2. User Login.........................................................................................................................9
5.2.1. Supervisor Key Switch.......................................................................................................9
5.3. Using the Display.............................................................................................................10
5.4. User Logout.....................................................................................................................11
6. Top Menu..................................................................................................................................11
7. Rated Capacity Indicator and Controller ................................................................................12
7.1. Introduction......................................................................................................................12
7.2. Operation within the Safe Working Load..........................................................................13
7.3. Barred Duties, warnings and Interlocks............................................................................13
7.4. Approach to Overload......................................................................................................13
7.5. Stability Overload Indication ............................................................................................14
7.5.1. Hydraulic Limitation Indication.........................................................................................14
7.6. Stability Overload Control................................................................................................15
7.6.1. Hydraulic Limitation Control.............................................................................................15
7.7. Overload Alarm Mute.......................................................................................................16
7.8. SWL Increase to 110%....................................................................................................17
7.9. Overload / Hydraulic Limitation Control Override .............................................................18
7.9.1. Soft Override...................................................................................................................18
7.9.2. Master Override Key Switch............................................................................................18
7.10. Lift Mode Menu ............................................................................................................19
7.10.1.Lifting Point Selection......................................................................................................19
7.10.2.Lifting Mode - Automatic Up Cant SWL Capacity Increase..............................................20
7.10.3.Lifting Mode - Non Lifting Mode.......................................................................................21
7.10.4.Tandem Lifting Mode.......................................................................................................22
7.11. Load Chart Menu .........................................................................................................23
7.12. Duty Numbering...........................................................................................................24
7.13. Axle Interlocks..............................................................................................................25

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7.14. In Gauge Indicator........................................................................................................26
8. Envelope Monitoring................................................................................................................27
8.1.1. Height Limit Menu ...........................................................................................................28
8.1.2. Height Limit Setting - Known Height................................................................................29
8.1.3. Height Limit Setting - Using Current Highest Point ..........................................................30
8.1.4. Machine Envelope Controller (MEC) - Height..................................................................31
8.2. Slew Limit........................................................................................................................32
8.2.1. Slew Limits Menu............................................................................................................32
8.2.2. Virtual Wall Limit Setting - Using the keypad...................................................................33
8.2.3. Virtual Wall Limit Setting - Using the Arrow Buttons ........................................................35
8.2.4. Angular Slew Limit Setting...............................................................................................37
8.3. Equipment Position Measurement...................................................................................40
9. System Messages ....................................................................................................................41
9.1. On Screen Safety Messages...........................................................................................41
9.2. On Screen Component Error Messages..........................................................................43
9.2.1. On Screen Component Error Message List.....................................................................43
9.3. LED and Internal Alarm Warnings....................................................................................44
10. Maintenance..........................................................................................................................44
11. Test / Diagnostics.................................................................................................................45
11.1. Relay Function Test .....................................................................................................46
11.2. Sensor Information.......................................................................................................47
11.3. Blue/amber lamp, Alarm and Display LED Function.....................................................48
12. System Information ..............................................................................................................48
13. Display Settings Information ...............................................................................................49
13.1. Day / Night Mode .........................................................................................................49
13.2. Select Display Machine................................................................................................50
13.3. Select Language..........................................................................................................50
13.4. Select Screen background colour.................................................................................50
14. Taking Product out of Operation.........................................................................................51
15. Service and Repair................................................................................................................51
15.1. Maintenance Review....................................................................................................51
16. Data Logger...........................................................................................................................52
16.1. The Event Logger.........................................................................................................52
16.2. The Periodic Logger.....................................................................................................52
17. Definitions / Glossary...........................................................................................................53
18. Amendment / Revision Record............................................................................................54

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1. Use of this Document
This user guide is intended for persons familiar with the use of construction plant undertaking lifting
operations.
WARNING denotes information about particular risks which may be generated
by certain applications, by using certain fittings, and about additional protective
measures which are necessary for such applications.
HAZARD Actions that can lead to serious injury or death
2. Notices
Adjustment by unauthorised persons will invalidate any warranty or certification
supplied. If an error condition is displayed which cannot be rectified using this
guide, STOP any operation, seek authorised service immediately, and do not
continue the operation until the fault has been remedied.

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3. System Identification
The EuroRail system provides three primary safety functions
1. Lifting Stability indication
2. Lifting Stability overload control
3. Machine Envelope Control
All safety functions are achieved through real time monitoring of some or all of
the machine’s moving parts (booms, other articulations, turret etc) and its
environment (track condition, load etc) and actively determining the safety of the
current operation where appropriate limits have been set.
The Lifting Stability function falls into two classes
•Rated Capacity Controllers (RCC) prevent instability when the machine
is involved in lifting operations
This is achieved by hydraulically controlling unsafe movements of the
machine which could cause the machine to become unstable.
•Rated Capacity Indicator (RCI) warns of instability when the machine is
involved in lifting operations.
This protection is achieved with internal and external alarms fitted to the
machine. An external beacon may also be installed.
The Machine Envelope Monitoring function has a single class
•Machine Envelope Controllers (MEC) prevent movements that would
bring parts of the machine into hazardous areas, for example, height
restrictions when working under overhead wires.
This is achieved by hydraulically controlling unsafe movements of the
machine.
•MEC equipped systems may include Height Limiting and or Slew
Limiting.

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4. Operating, and Hazard Situation, Recommendations
Operating Recommendations
When using envelope monitoring:
•When setting height or slew restrictions,
make sure any implement/tool attached is
in its least favourable position
•Check for correct operation once the
restriction has been set
•Reduce operating speed
•Do not move the equipment quickly when
close to a restriction
•Do not operate the machine in a reckless
manner
•Do not travel with a restriction set
•Reset the slew restriction if the machine is
relocated
Hazard Situation Recommendations
In a limit hazard state:
•Return the control levers to neutral once a
limit has been reached, if appropriate
•Operate the machine at a slow speed
•Do not travel
When operating the machine as a crane:
•Ensure Lift Mode is selected during lifting
operations
•Operate the machine at a sensible speed
•Take extra care when travelling with a load
attached
•Do not operate the machine in a reckless
manner
4.1.RCC - MEC Override
The system is fitted with a key operated master override switch. To access the master
override switch, a tamper detection device must be broken and the operation of this
switch will be automatically logged. Turning the switch to the override position will
allow normal operation of any of the hydraulic services controlled by EuroRail
regardless of safety status. When the system is in override, the external alarms will
stay active, the amber and blue lamps will be off and the red MMI LED will flash and
an ‘In Override’ message will be displayed. The override state will automatically return
to normal operating mode after 30 minutes (default value), regardless of the system
status. The master override key switch must be cycled to put the system back into
override. The override key switch should only be used if the system is not operational
due to a fault and the machine needs to be moved due to its location presenting a
hazard.

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5. Operating Instructions
5.1.Power Up
EuroRail automatically powers up when the
machine ignition is switched on. The in-cab display
incorporates a 4.3” high resolution LCD display
and is controlled with three buttons at each side.
Three status LEDs and an internal alarm provide
further information. The display is secured to the
machine using a flexible ball mounting allowing
easy adjustment for personal viewing preference.
On starting up:
1. All LEDs will flash, the internal display alarm and the external alarm will sound momentarily.
2. A safety warning message will be displayed as shown above, acknowledge its contents by
pressing any button.
3. The system can be configured to only allow access via a User Login code and will prompt for a
code to be entered before use (see section 5.2 for further Details).
If the RED LED is lit, a fault has been detected, halt any operation, seek
authorised service immediately and do not continue operation until the fault
has been remedied.

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5.2.User Login
If EuroRail has been configured to work with the User Login Code, the system will prompt for a user login
code upon start-up or if the logout function has been used.
Using the arrow buttons enter a valid pass code. The previous pass code digits will be replaced with a star
as the code is entered. Press the GREEN TICK button to confirm the login pass code. If a valid pass code
is entered the system will commence normal operation.
If an incorrect login code is entered, a failure screen will be displayed. Press the GREEN TICK button to
return to the Select User screen.
5.2.1.Supervisor Key Switch
The supervisor keyswitch must be in the SET position to access the
lift mode functions (see section 7), and envelope limiting functions
(see section 8). Wherever the supervisor icon is seen in this guide,
the supervisor keyswitch must be operated to gain entry to that
function.
Supervisor SET position is intended for set-up of lift mode functions
and envelope limiting functions only. The keyswitch must be
returned to the LIMIT position for normal operation.
The EuroRail system does not offer full rated capacity control or machine envelope
control whilst the supervisor keyswitch is in the SET position.
Increases highlighted
digit
Decreases highlighted
digit
Accept displayed
value
Cancel without
change
Moves highlighter to right
Moves highlighter to left
/ Hold to delete digit

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5.3.Using the Display
The display is operated by using the buttons adjacent to a function icon. The buttons can open a sub
menu, turn a function ON or OFF, set a value and toggle through multiple screens. No one button has a
single function. The button icon will turn black/purple when the button has been activated. Note that the
image of the machine on the left is fixed and does not follow the movement of the machine. Functions may
be restricted to a supervisor level, see section 5.2.1.
A secondary symbol can appear in the top left corner of an icon, these mean:
The plus symbol indicates a sub menu will be opened if selected.
The cycle symbol indicates that multiple features are available.
The on/off symbols indicate if a feature is ON or OFF. Red is ON and grey is OFF.
Help is available for each button. To access help, push and
hold the relevant button for three seconds. The help screen
can be cleared by pressing any button. EuroRail is still active
when displaying help messages, alarms or warning conditions
will be indicated, as appropriate.
Multifunction buttons:
The action of the button is
indicated by the adjacent icon.

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5.4.User Logout
If a user is logged in, they can select the logout screen by holding an exit key button down for three
seconds.
Once log off has been confirmed, the login screen will be automatically displayed.
Press the RED CROSS button to stay logged in, the screen will return to that previously shown.
6. Top Menu
The Top Menu screen allows access to all the system functions. If the icons are hidden, press any button
to reveal. To return to the Top Menu from a sub menu press the EXIT button.
Top Menu button functions:
•Limits menu
•Lifting menu
•Test Diagnostics
•Hide icons
Confirm logout
Cancel to stay
logged in
Limits Menu
Test Diagnostics
Exit / Hide icons
Lifting Menu
Menu level indicator

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7. Rated Capacity Indicator and Controller
7.1.Introduction
EuroRail has been designed to meet Rail requirements for the provision of rated capacity indicators and
ensures that the maximum lifting capacity over the range of a machine working envelope can be utilised.
1
Duty Indicator
Section 7.12
Lifting point
Section 7
Login name
Section 5
2
Sector Indicator
Section 7.12
3
Slew Angle Indicator
Section 8
4
Safe Direction Indicator
Section 8
5
Maximum Safe Working Load
Section 7
6
SWL percentage
Section 7
7
Load On Hook
Section 7
8
Logging Indicator
Section 16
9
Gradient Indicator
Section 7.12
10
Level, Up and Down Cant Indicator
Section 7
Cant Indicator
Section 7.12
In Gauge Indicator
Section 7
11
Rail Bogie Indicator
Section 7.12
12
Axle Lock Inhibit Status
Section 7.12
13
Lifting point Height/Radius
Section 7, 8
6
5
7
1
3
13
4
8
12
4
11
10
9
2

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7.2.Operation within the Safe Working Load
With Lifting Mode active, the Load on Hook, current lifting point, current duty, lifting point radius and the
maximum safe working load for that radius are shown.
When the load is less than 95% of the maximum
safe working load:
•The load capacity indicator will be green
•The green LED will be lit
7.3.Barred Duties, warnings and Interlocks
A duty can be denied entry by locking certain machine hydraulic services if there is insufficient lifting
capacity in that duty. Travel and axle lock outputs can operate automatically to ensure the stability of the
machine during use, see Axle Interlocks 7.13. Use with an offset boom: if a slew limit is active and the
offset boom is moved from straight ahead, full motion control will be asserted.
7.4.Approach to Overload
With Lifting Mode active, if the load is greater than 95% of the maximum safe working load, the system will
warn the machine is approaching the lifting capacity at the current height and radius.
If the load is greater than 95% of the maximum safe
working load:
•The load capacity indicator will be amber
•The amber LED will be lit
•The internal alarm will sound
•A warning message will be shown
In the event of an approach to overload or an overload condition, the lifting point
should only be moved in a direction that increases the safe working load. See
section 4 for further information.

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7.5.Stability Overload Indication
With the Lifting Mode active, if the load is greater than 105% of the maximum safe working load the
system will warn the machine has exceeded the lifting capacity at the current height and radius. The
system indicates an overload condition via internal and external alarms in conjunction with visual
indicators on the display. No equipment motions will be prevented.
If the load is greater than 105% of the maximum safe
working load:
•The load capacity indicator will be red
•The red LED will flash
•The internal and external alarm will sound
•A warning message will be shown
•Unsafe motion is indicated by RED arrows, safe
motion is indicated by GREEN arrows
7.5.1.Hydraulic Limitation Indication
The system will indicate the appropriate articulation in a hydraulic limit state via internal and external
alarms in conjunction with visual indicators on the display. If a particular lift is limited by hydraulic capacity
rather than stability, the maximum safe working load will be shown in RED. Hydraulic limitation is more
likely to occur at short radii.
In the event of an approach to overload or an overload condition, the lifting point
should only be moved in a direction that increases the safe working load. See
section 4 for further information.

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7.6.Stability Overload Control
Where an overload condition occurs the machine hydraulics will be locked to prevent any further
dangerous movements. If this option is activated only those movements that allow safer operation remain
active, all slewing is prevented. The radius cannot be increased and the load cannot be raised. The
internal and external alarms will sound in conjunction with visual indicators on the display.
If the load is greater than 105% of the maximum safe
working load:
•The load capacity indicator will be red
•The red LED will flash
•The internal and external alarm will sound
•A warning message will be shown
•Unsafe motion is indicated by RED arrows, safe
motion is indicated by GREEN arrows
7.6.1.Hydraulic Limitation Control
The system may cut motion to the appropriate
articulation in a hydraulic limit state via internal and
external alarms in conjunction with visual indicators on
the display. If a particular lift is limited by hydraulic
capacity rather than stability, the maximum safe working
load will be shown in RED. Hydraulic limitation is more
likely to occur at short radii.
When an overload condition occurs the machine
hydraulics will be locked to prevent any further
dangerous movements. Only those movements that
allow safer operation remain active. The radius cannot be
increased and the load cannot be raised.
After three seconds a soft override will become available. To access this function move
the supervisor keyswitch to the SET position, see section 5.2.1.
In the event of an approach to overload or an overload condition, the lifting point
should only be moved in a direction that increases the safe working load. See
section 4 for further information.

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7.7.Overload Alarm Mute
When the system is in overload a mute feature will become available after 5 seconds. This will allow the
user to mute both internal and external alarms while the system is in overload. Once the system is out of
overload this feature will self reset. If the system is in the top screen it will auto switch to top menu 1
showing the mute icon on middle left button.
In the event of an approach to overload or an overload condition, the lifting point
should only be moved in a direction that increases the safe working load. See
section 4 for further information.
Alarm mute button icon that is
available after system has been
in alarm for 5 seconds.

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7.8.SWL Increase to 110%
A soft override is provided that will temporarily increase the SWL to 110% to allow the operator to escape
from deadlock. This will reset once the load is within normal limits. Speed in this mode to be restricted to
25% of maximum.
In the event of an approach to overload or an overload condition, the lifting point
should only be moved in a direction that increases the safe working load. See
section 4 for further information.
Soft SWL Increase when
system reaches 106%. Using
this will allow increase to
110%.
Note that the 110% button
icon has now been removed
and the warning banner has
changed from overload to
close to SWL.
The percentage bar is
showing 108%. Motions may
be slowed during the use of
this feature.
Once the system has gone
above 110%, the warning
banner reverts back to
overload and unsafe motions
will be controlled.

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7.9.Overload / Hydraulic Limitation Control Override
7.9.1.Soft Override
Three seconds after overload has occurred, a soft override button will
become available in the top menu. To access this function move the
supervisor keyswitch to the SET position, see section 5.2.1.
If the soft override function is utilised, the machine hydraulics will be re-enabled. However, the external
alarm will stay active, the internal red LED will flash, the blue/amber lamp will be switched off and an ‘In
Override’ message will appear on the display. Once the alarm condition has been corrected and the
supervisor keyswitch is returned to the LIMIT position the system will automatically revert to normal
operation.
7.9.2.Master Override Key Switch
The system is fitted with a key operated Master Override Switch.
Turning the switch to the override position will allow normal operation of
the hydraulic services controlled by EuroRail regardless of safety
status. When the system is in override, the external alarms will stay
active, the internal red LED will flash, the blue/amber lamp will be
switched off, and an ‘In Override’ message will appear on the display.
The system will automatically return to normal operation after 30
minutes (default value), See section 4.1 for further details.
Soft override

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7.10. Lift Mode Menu
The Lifting Mode menu has various features which may be available if configured at
installation. If only one lifting point has been calibrated, the lifting point button will not
be displayed.
7.10.1. Lifting Point Selection
EuroRail can be configured for more than one lifting point. If more than one lifting point has been
calibrated, they can be manually selected via the lifting point selection screen shown below. Use the arrow
buttons to select the required lifting point and confirm using the GREEN TICK button. To access this
function move the supervisor keyswitch to the SET position, see section 5.2.1 for further information.
Example lifting points are shown in the list. Always refer to the manufacturer/convertor instructions
regarding positioning of the lifting point during lifting operations. Altering the lifting point will not affect the
current duty selected, see Section 7.12.
Exit to previous screen
Displays load chart(s)
Lifting point selection
Lift Mode selection
Moves highlighter UP
Moves highlighter
DOWN
Accept highlighted
lifting point
Exit without change
Lifting point Height
and Radius
Lifting point Name

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7.10.2. Lifting Mode - Automatic Up Cant SWL Capacity Increase
EuroRail replaces the lifting capacity of Duty set 3 (See Section 7.12) with Duty Set 2 when the machine is
facing Up Cant.
The system will display one of the following icons above the Cant Value indicator on the main RCI screen.
Level Rail
Actual Level Rail Duties and
SWL values are being
displayed (Duty set 2)
Up Cant
Level Rail Duties and SWL
values are being displayed
(Duty set 2) in lieu of the actual
Canted Rail Duties and their
SWL values
Down Cant
Canted Rail Duties and SWL
values are being displayed
(Duty set 3)