Description

Hirschmann QUY260 2009 User Manual

If you are working on a Zoomlion QUY260 crane and need the correct load moment indicator setup, stop guessing. I have been turning wrenches for 28 years, and I can tell you that a crane’s LMI is not something to fudge. The Hirschmann QUY260 2009 User Manual is the only document Hirschmann released for this system. It is 27 pages of factory data. No aftermarket reprint. No rewritten fluff. Just the specs Hirschmann wrote for the QUY260. You need the torque values? Wait, this is an LMI – no head bolts here. But you need the angle sensor calibration procedure, the KMD force sensor wiring check, and the CAN-bus diagnostic routine. That is what this manual gives you. Page 19 has the troubleshooting flowchart. Page 2 spells out the warnings. If you ignore those warnings, you risk load swing, sensor drift, or worse. I don’t want your name in a crane accident report.

Warnings and Safety – Not Optional

Section 3 of this Hirschmann manual is labeled “Warnings”. It is two full pages. Hirschmann does not waste space. They tell you exactly what can go wrong if you bypass a limit switch or miswire the console. I have seen techs skip reading warnings because they think it is CYA language. On a load moment indicator, the warnings are the procedure. If you ever worked on a crane, you know that a 0.5° angle error can change the rated capacity by tons. This manual forces you to acknowledge those limits. Keep page 2 visible while you work.

3 Reasons to Choose the OEM Manual

First, the OEM document contains the exact controller model used – Hirschmann’s own controller board. Second, the connector pinouts for the KMD force sensor and angle sensor are only in this version. Third, the CAN-bus checking procedure on page 16 is written by the engineers who designed the CAN network. Aftermarket manuals often rephrase the troubleshooting steps incorrectly. I have fixed three cranes where a previous tech followed a generic wiring diagram and shorted the CAN bus. Do not be that guy. Stick with the factory print.

System Configuration Breakdown

The QUY260 LMI consists of a controller, a console, a KMD force sensor, and an angle sensor. Chapter 4 diagrams each component. The controller sits inside the cab; the console mounts on the dashboard. You need the 12-pin connector layout for the force sensor – that is on page 4. The angle sensor uses a 4-wire connection. If you are retrofitting a used LMI, you must verify that the cable colors match the factory schematic. This manual lists every wire. I have used it to rebuild a salvaged QUY260 console. It works.

Troubleshooting – Factory Procedure on Page 19

Page 19 walks you through six fault scenarios: no display, inaccurate load, angle error, force sensor fault, CAN-bus failure, and system lockout. Each step tells you which I/O port to check, what voltage to expect, and how to re-zero the sensor. The manual also covers the OM icon and reeving settings in section 5.3.1. You can change the reeving configuration from the function key menu. If you skip that step and the crane hoists with the wrong reeving, the load chart is useless. I saw a guy lift 30 tons with a 2-part line set for 4-part – the boom bent. The manual prevents that.

Does This Manual Cover Load Chart Calibration?

It covers the system settings (section 5.3.3) and angle limitation (section 5.3.5). You can adjust the angle limits and set the time. The actual load chart values are stored in the controller memory and not user-changeable. What the manual gives you is the procedure to verify that the LMI reads correctly. If the displayed load does not match the crane’s rated capacity, the manual tells you to check the KMD force sensor and the angle sensor. You will need a multimeter and a test weight. Page 12 shows the I/O port checking – you can measure the analog voltage from the force sensor directly.

Audience Fit – Who Needs This 27-Page Manual

If you own or service a Zoomlion QUY260 crane, this manual is your baseline. Crane operators who want to understand the LMI interface will benefit from the main interface explanation on page 7 and the function key map on page 8. Shop mechanics who replace sensors need the wiring diagram on page 25. Beginners? Yes, if you can read a multimeter and follow step-by-step checks. But do not attempt calibration without understanding the warnings. The manual assumes you have basic electrical knowledge. If you are completely new to cranes, pair this with the crane’s operator manual. I also recommend the Hirschmann HC4900 Load Moment Indicator User Manual if you work on older rigs. For the iVISOR Mentor QVGA display, see Hirschmann iVISOR Mentor QVGA User Manual 2009. And if you need the PRS 40 EZ nest system, grab Hirschmann PRS 40 EZ 2010 Operators Manual – Factory Specs.

One more thing – do not confuse this LMI manual with a Manual Transmission repair guide. The diagnostic approach is different. An LMI uses sensors and CAN bus, not meshing gears. If you are coming from automotive, read the warnings twice. The same goes for any Manual Transmission technician – shifting a gearbox does not prepare you for a crane’s load chart. Trust the factory process.

Why OEM Documentation Beats Aftermarket

I have seen aftermarket manuals for the QUY260 that substitute a generic load cell schematic. They omit the specific CAN-bus ID settings. Hirschmann’s manual includes the CAN-bus checking routine (section 5.3.4) that shows exactly which bytes to monitor. Without that, you cannot confirm the controller is receiving the force sensor data. The OEM manual also has the copyright page that lists Hirschmann Electronics (Shanghai) Co., Ltd. as the source. That means every torque spec (not applicable here, but the principle holds) or sensor voltage tolerance came from the manufacturer’s test lab. Aftermarket copies often misprint the pin numbers. I have seen a pinout that swapped pin 2 and pin 5 on the KMD sensor – that would backfeed 12V into the signal wire. Hirschmann’s manual does not make that mistake.

Is this manual a factory original?

Yes. It is the exact PDF of the 2009 first edition published by Hirschmann Electronics (Shanghai) Co., Ltd.

How many pages and what format?

27 pages in English. The file is a high-resolution scan of the printed user manual. Includes all pages from cover to back, including the index and wiring diagram on page 25. No missing sections.

Does it include the torque values for the sensor mounting bolts?

No. This manual covers the electrical and software setup. For mechanical mounting torque specifications, you need the crane’s service manual. However, the manual does list the acceptable voltage range for the force sensor (0-10V typical) and the angle sensor resistance values. That data is on page 12 under I/O Port checking.

Can I use this manual to program the LMI for a different boom length?

You can adjust the reeving and angle limits through the function key menu (section 5.3.1 and 5.3.5). The load chart itself is fixed in the controller. If you change the boom length beyond the programmed configurations, you must replace the controller or get a new load chart from Zoomlion. The manual explains how to verify that the current configuration matches the crane’s physical setup.

If you work on the QUY260 crane or any crane using Hirschmann’s LMI, you need this 27-page document on your bench. Access the Factory Manual – it is the only source for the correct CAN-bus IDs, sensor pinouts, and troubleshooting steps. I keep a copy in my shop for every Hirschmann-equipped crane that comes through. You should too.