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Related Manuals for KINSHOFER EuroRail
Summary of Contents for KINSHOFER EuroRail
- Page 1 EuroRail operator guide Document Reference: 562600-100 V1.4 March 2023 © 2022 Prolec Limited...
- Page 2 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.
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Page 3: Table Of Contents
562600-100, Issue 1.4 March 2023 Contents Use of this Document......................... 5 Notices ............................5 System Identification ......................... 6 Operating, and Hazard Situation, Recommendations .............. 7 4.1. RCC - MEC Override ......................7 Operating Instructions ....................... 8 5.1. Power Up ........................... 8 5.2. - Page 4 562600-100, Issue 1.4 March 2023 7.14. In Gauge Indicator ......................26 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.
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Page 5: Use Of This Document
562600-100, Issue 1.4 March 2023 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. -
Page 6: System Identification
562600-100, Issue 1.4 March 2023 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... -
Page 7: Operating, And Hazard Situation, Recommendations
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’... -
Page 8: Operating Instructions
562600-100, Issue 1.4 March 2023 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. -
Page 9: User Login
562600-100, Issue 1.4 March 2023 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. Cancel without... -
Page 10: Using The Display
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. -
Page 11: User Logout
562600-100, Issue 1.4 March 2023 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. Cancel to stay Confirm logout logged in 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. -
Page 12: Rated Capacity Indicator And Controller
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. -
Page 13: Operation Within The Safe Working Load
562600-100, Issue 1.4 March 2023 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: •... -
Page 14: Stability Overload Indication
562600-100, Issue 1.4 March 2023 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. -
Page 15: Stability Overload Control
562600-100, Issue 1.4 March 2023 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. -
Page 16: Overload Alarm Mute
562600-100, Issue 1.4 March 2023 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. -
Page 17: Swl Increase To 110
562600-100, Issue 1.4 March 2023 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. -
Page 18: Overload / Hydraulic Limitation Control Override
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’... -
Page 19: Lift Mode Menu
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. -
Page 20: Lifting Mode - Automatic Up Cant Swl Capacity Increase
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. -
Page 21: Lifting Mode - Non Lifting Mode
562600-100, Issue 1.4 March 2023 7.10.3. Lifting Mode - Non Lifting Mode When the machine is not being used for lifting operations it can be put into ‘Non Lifting Mode’. This is available from the Lifting Mode screen. When in Non Lifting Mode, the system still monitors all machine activity and safety status but will NOT warn of overload or impose any form of overload hydraulic control, the system will continue to monitor backward stability... -
Page 22: Tandem Lifting Mode
Moves highlighter DOWN Tandem Lifting symbol The EuroRail system does not offer full rated capacity control or machine envelope control whilst the supervisor keyswitch is in the SET position. The keyswitch must be returned to the LIMIT position for normal operation. -
Page 23: Load Chart Menu
7.11. Load Chart Menu EuroRail can display the load chart for the currently selected lifting duty and lifting point. *If the machine is equipped with a hydraulically adjustable boom, both maximum and minimum charts will be available via this button. -
Page 24: Duty Numbering
562600-100, Issue 1.4 March 2023 7.12. Duty Numbering The duty number is made up of three values: Road/rail cant - active sector - Axle lock status e.g. 2BL will be rail (0-50mm cant), sector B, Axles Locked. Road/Rail Cant Levels Road Rail between 0-50mm cant The cant levels shown here are... -
Page 25: Axle Interlocks
When the oscillating rail axle is locked, EuroRail will start to monitor the equivalent UNLOCKED duty. If either the lift capacity or the backward stability level of the UNLOCKED duty is unsafe, the YELLOW ‘padlocks’... -
Page 26: In Gauge Indicator
562600-100, Issue 1.4 March 2023 7.14. In Gauge Indicator If the machine is on-rail, within the W6a Gauge and the oscillating axle is unlocked, the In Gauge icon will turn from a RED CROSS to a GREEN TICK and the In Gauge button will appear in the top menu, press to motion cut all services for safe travel. -
Page 27: Envelope Monitoring
8.3 for monitored points on the machine. EuroRail is NOT aware of any attachment fitted, therefore where an attachment is in use, limits should be determined and set in accordance with the safe system of work. -
Page 28: Height Limit Menu
562600-100, Issue 1.4 March 2023 8.1.1. Height Limit Menu A height limit can be set by entering a known height on the keypad or by manually moving the machine to the desired limit. Current height limit and highest point. Only displayed if a height limit is set. Turns Monitoring and OFF Enter a value... -
Page 29: Height Limit Setting - Known Height
562600-100, Issue 1.4 March 2023 8.1.2. Height Limit Setting - Known Height A known limit can be entered into the display: Enter a limit value Exit to previous menu Step One Press the ’Enter a limit value’ button Cancel without change Increases highlighted digit Moves highlighter to left... -
Page 30: Height Limit Setting - Using Current Highest Point
562600-100, Issue 1.4 March 2023 8.1.3. Height Limit Setting - Using Current Highest Point The highest point of the machine can be used to create a height limit. Step One Move the equipment to the required height limit and press the ‘Set using highest point of equipment’ button Move equipment to required height limit... -
Page 31: Machine Envelope Controller (Mec) - Height
562600-100, Issue 1.4 March 2023 8.1.4. Machine Envelope Controller (MEC) - Height If any of the equipment enters the approach limit* • The amber LED will be lit • The internal alarm will sound • The message shown here will be displayed. -
Page 32: Slew Limit
562600-100, Issue 1.4 March 2023 8.2. Slew Limit 8.2.1. Slew Limits Menu A virtual wall slew limit can be set by entering a known distance on the keypad or by moving the virtual wall on the screen using the arrow buttons. With a slew limit set, the screen will display a hatched area on the plan view. -
Page 33: Virtual Wall Limit Setting - Using The Keypad
562600-100, Issue 1.4 March 2023 8.2.2. Virtual Wall Limit Setting - Using the keypad A virtual wall can be set on either side of the machine to a desired distance by entering an exact value. The value displayed is measured from the centre of the machine. Do not travel once a slew limit has been set. - Page 34 562600-100, Issue 1.4 March 2023 Step four Use the UP and DOWN arrows to increase and decrease the highlighted number. Use the LEFT and RIGHT arrows to move the highlighter to the left and to the right. Press the GREEN TICK to accept the displayed value.
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Page 35: Virtual Wall Limit Setting - Using The Arrow Buttons
562600-100, Issue 1.4 March 2023 8.2.3. Virtual Wall Limit Setting - Using the Arrow Buttons A virtual wall can be set on either side of the machine to a desired distance by using the directional arrows to manually move the limit. The limit displayed is measured from the centre of the machine. - Page 36 4. Do not travel once a slew limit has been set. The EuroRail system does not offer full rated capacity control or machine envelope control whilst the supervisor keyswitch is in the SET position. The keyswitch must be returned to the LIMIT position for normal operation.
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Page 37: Angular Slew Limit Setting
562600-100, Issue 1.4 March 2023 8.2.4. Angular Slew Limit Setting Select angular slew limiting, follow the on screen instructions. Do not travel once a slew limit has been set. Set to angular slew Press this button to start the setup procedure Step by step instructional banner Step One Extend equipment to appropriate... - Page 38 562600-100, Issue 1.4 March 2023 Step three Move to right slew limit, press any button to set the right slew limit. Another marker will be placed here Left slew restriction marker Step four Move to safe zone and press any button to complete operation.
- Page 39 4. Do not travel once a slew limit has been set. The EuroRail system does not offer full rated capacity control or machine envelope control whilst the supervisor keyswitch is in the SET position. The keyswitch must be returned to the LIMIT position for normal operation.
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Page 40: Equipment Position Measurement
562600-100, Issue 1.4 March 2023 8.3. Equipment Position Measurement EuroRail measures equipment pin positions using equipment mounted angle sensors. All positions are corrected for chassis pitch (rail gradient), roll (rail cant) and slew angle. The radius displayed on the operators screen represents the current lifting point and the height represents the tool pin height. Shown without hitch. -
Page 41: System Messages
562600-100, Issue 1.4 March 2023 9. System Messages 9.1. On Screen Safety Messages Close to max height Highest point of equipment within *0.5m of set limit Max height reached Equipment has reached set limit Close to slew right limit Equipment within *10 degrees or 0.5m of slew limit Close to Slew left limit Equipment within *10 degrees or 0.5m of slew limit Slew left limit reached... - Page 42 562600-100, Issue 1.4 March 2023 In Override Override is active (Soft override or Master Key) In Gauge Lock Active In Gauge mode has been activated Backward Stability Backward Stability angle reached System Not Calibrated Calibration verification required Maximum speed exceeded Maximum permissible travel speed exceeded Front bogie not deployed Front Rail axle safety interlock in unsafe state...
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Page 43: On Screen Component Error Messages
562600-100, Issue 1.4 March 2023 9.2. On Screen Component Error Messages EuroRail continuously monitors the presence and condition of all system components. If any sensor, input, output, or other component fails, an error message will appear along the bottom of the display. In the event of a failure, ALL motion control relays will be operated, the cab mounted blue lamp will indicate that the RCC is NOT active, the display red LED will flash and the internal and external alarms will sound. -
Page 44: Led And Internal Alarm Warnings
8 Hz Maintenance To be carried out on a daily basis. Full maintenance schedules are available in the EuroRail Maintenance Manual - Prolec Part Number 562010-000. The maintenance instructions for the Rated Capacity Indicator fitted in your RRV are to be carried out in conjunction with the vehicle manufactures instruction handbook. -
Page 45: Test / Diagnostics
562600-100, Issue 1.4 March 2023 Job Code Job Description Test slew limiter controls and stops machine before the limit, see section 8 of the EuroRail Operator Manual - Prolec Part Number SFC1 Check road axle icon shows correct state on display when operated... -
Page 46: Relay Function Test
562600-100, Issue 1.4 March 2023 11.1. Relay Function Test Select the I/O module unit required from the list displayed. Use the Blue Arrow Icon button to select each connector in turn. *Any amber LED lamps indicate an input/output is active. Green LEDs indicate OK and Red LEDs indicate failure. CAN S and CAN D Communication Link to Function Inputs. -
Page 47: Sensor Information
562600-100, Issue 1.4 March 2023 11.2. Sensor Information Displays the system’s sensor information. Use the Actual column for direct comparison. The status column shows the health of each sensor. Base Pitch Pitch Angle Base Roll Roll Angle Boom Base Piston Piston Pressure Boom Base Rod Rod Pressure Boom AS7/10... -
Page 48: Blue/Amber Lamp, Alarm And Display Led Function
562600-100, Issue 1.4 March 2023 11.3. Blue/amber lamp, Alarm and Display LED Function Press to activate the function in turn. Press the Beacon icon button to activate the beacon (if fitted) Press the Beacon icon button to activate the external alarm (if fitted) Press the Alarm icon button to activate the internal alarm and display LEDs... -
Page 49: Display Settings Information
562600-100, Issue 1.4 March 2023 Display Settings Information The display brightness, button click volume, background colour and the displayed machine can be adjusted from this menu. Adjust button click volume Select day/night mode Language selection Select machine Exit to previous menu colour/type and background colour 13.1. -
Page 50: Select Display Machine
562600-100, Issue 1.4 March 2023 13.2. Select Display Machine An appropriate machine type for the display can be selected from this list. Moves highlighter UP Accept highlighted item Exit without change Moves highlighter DOWN 13.3. Select Language The appropriate language can be selected from this list. Moves highlighter UP Accept highlighted item Exit without change... -
Page 51: Taking Product Out Of Operation
Any alterations or modifications to machine components which affect the system must be reported to Prolec Ltd or via the service agreement holder. To aid in the use of EuroRail, all appropriate technical bulletins relating to EuroRail must be assessed and implemented as appropriate. This information is available from Prolec Ltd. -
Page 52: Data Logger
562600-100, Issue 1.4 March 2023 Data Logger EuroRail has two data-logging functions. The data logging icon appears in the bottom left of the screen. The data can only be viewed by extracting it from the system, contact your service agreement holder or Prolec Ltd for further assistance. -
Page 53: Definitions / Glossary
562600-100, Issue 1.4 March 2023 Definitions / Glossary Definitions of words used to ensure understanding: Second or third articulation (dipper, stick) Second articulation of a hydraulically adjustable boom (luffing boom, knuckle boom, Artic two piece boom) Attachment Tool fixed to the arm other than a bucket Angle sensor Sensor detecting current equipment angle First articulation attached to turret... -
Page 54: Amendment / Revision Record
562600-100, Issue 1.4 March 2023 Amendment / Revision Record Issue Section / Page Amendment / Revision Description Number Description of new features Use of supervisor keyswitch—section 5.2.1 added. 17, 23, 24. 29, References to 5.2.1 added. 38,41 Section 7.9.1 use of supervisor keyswitch detail Section 8.1.1 use of supervisor keyswitch detail Section 8.2 use of supervisor keyswitch detail Simplified image for ‘in gauge’... - Page 55 562600-100, Issue 1.4 March 2023 Prolec Ltd 25 Benson Road Nuffield Industrial Estate Poole England BH17 0GB Tel: +44 (0)1202 441000 E-mail: service@prolec.co.uk Prolec Ltd® is a member of the Kinshofer Group of Companies Page 55 of 55...
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