20
10 points)
10
20
10 points)
10
15 Rest Restri rict ctor or 16 Restrictor
Service Manual
Repairs, Troubleshooting Service codes and warning signals
19.2
Service codes and warning signals Warnings and fault messages –
Various faults are indicated by the corresponding symbol fields (optically) or by display instruments on the instrument panel.
–
Some warning functions are accompanied by acoustic warning signals.
Identifying and correcting faults and errors –
Faults can often be traced back to incorrect operation or servicing of the machine. Therefore, carefully read the appropriate section of the operator's manual each time a fault occurs.
–
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Analyse the cause of the fault and correct it immediately.
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Repairs, Troubleshooting
Service Manual
Service codes and warning signals
19.2.1
Service code indication on the display The gear electronics monitor the hydrostatic travel drive and the travel gear for cable rupture, external voltage and incorrect input and output signals. In addition, the microcontroller continuously checks the program sequence and communication communication with the display unit.
Display unit 1 2
Service code type display Service code number display
3
STOP display
If an error arises when the machine is started or when in use, this is indicated in the display unit or stored in the error memory.
Display and message for service codes Keep in mind the following: –
All service codes are accompanied by a single beep. Exceptions are: E 11 – E 13 and E 29 - E 31
–
The service codes are displayed in the segment field 2
–
Service codes 11 to 13 are only shown following ignition for three seconds in the segment field 2.
–
Service codes 21 to 30 are not indicated by the display unit.
–
Service code 31 is indicated by“EE“ in the segment field 2, but stored in the memory as “E31“.
–
As of the serial numbers listed under 19.2.2, all service codes are saved in the service code memory and can be read later with additional data (service hours, date and time) using the special INTERFACE tool and the HYPERTERMINAL software.
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Service Manual
Repairs, Troubleshooting Service codes and warning signals
Effects of an error Every error has a defined effect. This is specified in the "Effect" column of the service code table. Limited driving mode is usually still possible. If errors occur which can damage the machine, the entire machine is shut down. In the process, neutral travel direction is automatically selected and the machine coasts to halt. This is indicated by the STOP display 3 in the display unit. Make a note of the service code, as it will be deleted from the segment field of the display unit when the ignition is switched off. Analyse and rectify the fault. fault. Service code
Effect
*EE
STOP STOP - the machine is shut down
E 11
Service hours display not working
E 12
Service hours display not working
Cause
Remedy
Communication problem between display unity and control unit.
Check the wiring harness, the connectors on the control unit and the control unit.
Incorrect RAM information for operating hours
Replace the control unit
(Fault in the control unit) Incorrect EEPROM information for operating hours
Replace the control unit
(Fault in the control unit)
E 13
Additional button button function inactive
Incorrect EEPROM information for stored buttons (error in the control unit)
Replace the control unit
E 21
Engine oil pressure symbol field lights up
Engine oil pressure too low or sensor (B7) defective
Check the engine oil level, pressure and sensor (10 – 184 )
E 22
Coolant temperature symbol field lights up
Coolant level too low or sensor (B13) defective
Top up coolant and check sensor
E 23
Hydraulic oil temperature temperature symbol field is illuminated
Excessive hydraulic oil temperature or defective switch (B6)
Clean the cooler, check the fan speed and check the switching point ±3 (106 °C)
E 24
Brake accumulator pressure symbol field lights up
Brake accumulator pressure too low or defective pressure switch (B19)
Check the accumulator pressure and the switching point (90 ±5 bar)
E 25
Gearbox oil temperature symbol field lights up
Excessive gear oil temperature or defective switch (B14)
Check the gearbox for errors and ±3 check the switching point (120 °C)
E 26
Engine overheating and coolant level symbol field lights up
Coolant temperature too high or sensor (B20) defective
Check the cooler for dirt, check the temperature, temperature, check the sensor, ±3 (switching point 100 °C / sensor at 90°C 51±5 )
E 27
Engine oil pressure symbol field lights up
Engine oil pressure too low or switch (B7) defective
Check the engine oil level and t he switch (0.5±0.15 bar)
E 28
The emergency steering pump is activated and the emergency steering symbol field lights up
Steering pump pressure too low. Pressure switch B3 defective or cable broken
Check the steering st eering pump pressure and the cable connection to the pressure switch (switching point 18 bar)
Diesel engine speed exceeded (above 2500 rpm)
Brake while driving downhill
E 29
E 30
L564 – L580 from Ser. Nr. 0847 The automatic brake is activated. No effect
L544 - 442 / from 0101 L554 - 452 / from 0101 L564 - 462 / from 0101 L574 - 472 / from 0101 L580 - 475 / from 0522
Diesel engine speed too low (below 500 rpm)
Check the speed sensor (resistance 540 / frequency at 2000 rpm 4900 Hz) of 10 19.2 - 3 of 10
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Service Manual
Service codes and warning signals
Service code E*31
E 61
Effect STOP STOP - the machine is shut down
Cause Communication problem between the gearbox control unit and the control unit
EMERGENCY EMERGENCY - the gears can Short circuit at one of the gearbox control unit outputs when the only be shifted manually ignition is switched on
Remedy Check the wiring harness, the connectors on the control unit and the MC6 Check the wiring harness Check the solenoid valve spread ±7 (70 ) and the gear solenoids ±10 (115 )
E 62
STOP STOP - the machine is shut down
Interruption at one of the gearbox Check the wiring harness and the control unit outputs when the connectors on control board A12, ignition is switched on replace the electronics
E 64
STOP STOP - the machine is shut down
Incorrect input combination of Ka, Kb relay or V/R button
Check the wiring harness, the Ka and Kb relays and the travel direction switch
E 65
STOP STOP - the machine is shut down
On-board circuit over / undervoltage (<13 V or >39 V)
Check the wiring harness, generator Check the battery
E 66
STOP STOP - the machine is shut down
Incorrect RAM information (memory test failed)
Replace the gearbox control unit
E 67
STOP STOP - the machine is shut down
Incorrect drive program (data comparison failed)
Replace the gearbox control unit
E 68
STOP STOP - the machine is shut down
Incorrect program run (software test for all program sections)
Switch the on-board circuit on and off, replace the gearbox control unit
E69
EMERGENCY EMERGENCY - the gears can Speed sensor input failure (B1) (gearbox) only be shifted manually
Check the wiring harness and speed sensor (1050 ±100 )
E 70
EMERGENCY EMERGENCY - the gears can Speed sensor input failure (B2) (variable displacement motor) only be shifted manually
Check the wiring harness and speed ±200 sensor (2000 )
E 71
EMERGENCY EMERGENCY - the gears can Interface error (on display unit) only be shifted manually
Check the wiring harness
E 72
STOP STOP - the machine is shut down
Input and output speed sensor failure
Check the wiring harness
E 73
STOP STOP - the machine is shut down
Slip identified between input and output
Check the shift pressure on the cou+3 pling (17 bar)
E 74
EMERGENCY EMERGENCY - the gears can Short circuit at solenoid valve Y6.1 (1st gear) only be shifted manually
Check the wiring harness
E 75
Interruption at Y6.1, or pressure EMERGENCY EMERGENCY - the gears can Interruption K1 too low, or disengaged parkonly be shifted manually ing brake and travel range selected while diesel engine is shut down
Check the wiring harness and the ±10 solenoid valve (115 )
E 76
STOP STOP - the machine is shut down
E 77
EMERGENCY EMERGENCY - the gears can Short circuit at solenoid valve Y6.2 (2nd gear) only be shifted manually
E 78
Check the wiring harness. Check EMERGENCY EMERGENCY - the gears can Interruption or external power supply at Y6.2 or pressure K2 too the solenoid valve (115 ±10 ) only be shifted manually low Check the shift pressure on the cou+3 pling (17 bar)
E 80
EMERGENCY EMERGENCY - the gears can Short circuit at solenoid valve Y6.3 (3rd gear) only be shifted manually
External power supply Y6.1
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MJFCIFSS
Check the speed sensor
Check the solenoid valve (115 ±10
)
Check the shift pressure on the cou+3 pling (17 bar) Check the wiring harness. Check the wiring harness Check the solenoid valve (115 ±10
)
Check the wiring harness and the solenoid valve (115 ±10 )
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Service Manual
Repairs, Troubleshooting Service codes and warning signals
Service code
Effect
Cause
Remedy
E 81
Check the wiring harness and the EMERGENCY EMERGENCY - the gears can Interruption or external power supply at Y6.3 or pressure K3 too solenoid valve (115 ±10 ) only be shifted manually low Check the shift pressure on the cou+3 pling (17 bar)
E83
EMERGENCY EMERGENCY - the gears can Short circuit at the replenishing pressure solenoid valve (Y7) only be shifted manually
E 84
STOP STOP - the machine is shut down
Interruption or external voltage at the replenishing pressure solenoid valve (Y7)
Check the wiring harness and sole±3 noid valve (31 ) Check the wiring harness and solenoid valve (31 ±3 )
E 85
EMERGENCY EMERGENCY - the gears can Short circuit at the forward solenoid valve (Y2) only be shifted manually
E 86
STOP - the machine is shut down
E 87
EMERGENCY EMERGENCY - the gears can Short circuit at the reverse solenoid valve (Y3) only be shifted manually
E 88
STOP STOP - the machine is shut down
E 89
EMERGENCY EMERGENCY - the gears can Short circuit at the spreader solenoid valve (Y8) only be shifted manually
Check the wiring harness and the solenoid valve (22 ±2 )
E 90
EMERGENCY EMERGENCY - the gears can Short circuit at the spreader solenoid valve (Y8) only be shifted manually
Check the wiring harness
Interruption or external voltage at the forward solenoid valve (Y2)
Interruption or external voltage at the reverse solenoid valve (Y3)
E 91
EMERGENCY EMERGENCY - the gears can Gearbox shit pressure is too high >22 bar only be shifted manually
E 92
STOP STOP - the machine is shut down
E 93
E95
Coupling K1 blocked blocked (K1 >1 bar) bar)
Check the wiring harness and the solenoid valve (22 ±2 ) Check the wiring harness and the ±2 solenoid valve (22 ) Check the wiring harness and the ±2 solenoid valve (22 )
Check the solenoid valve (65
±6
)
+3
Check the shift pressure (17 bar) Check the pressure sensor (1 bar = 0.13 V) Check the solenoid solenoid valve valve Y6.1 Check the pressure sensor (1 bar = 0.13 V)
EMERGENCY EMERGENCY - the gears can Short circuit at creeper valve (Y19) only be shifted manually STOP STOP - the machine is shut down
Check the wiring harness and the solenoid valve (22 ±2 )
Check the wiring harness and sole±2 noid valve (22 )
Pressure in the selected coupling Check the solenoid valve Y6.1 K1 is too low (K1 <11 bar) Check the pressure sensor (1 bar = 0.13 V) Check the wiring harness
E98
EMERGENCY EMERGENCY - the gears can Fault in pressure sensor K1 (B22) only be shifted manually (Voltage <0.25 / >4.5 V)
Check the wiring harness
E99
EMERGENCY EMERGENCY - the gears can Fault in pressure sensor (B23) control pressure (cut-in block) only be shifted manually (Voltage <0.25 / >4.5 V)
E9A
EMERGENCY EMERGENCY - the gears can Fault in the gas pedal angle sensor (R5) (voltage <0.25 / >4.5 V) only be shifted manually
Check the wiring harness
E9C
EMERGENCY EMERGENCY - the gears can Interruption or external voltage at the creeper solenoid valve (Y19) only be shifted manually
Check the wiring harness and sole±2 noid valve (22 )
E9E
STOP STOP - the machine is shut down
Short circuit or external power supply on supply voltage 5 V
Check the wiring harness
No effect
Short circuit at output for tractive force limitation
Check the wiring harness
E9F A0
EMERGENCY EMERGENCY - the gears can Error on Kick-down button only be shifted manually
L544 - 442 / from 0101 L554 - 452 / from 0101 L564 - 462 / from 0101 L574 - 472 / from 0101 L580 - 475 / from 0522
Check the wiring harness Replace the kick-down button
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Repairs, Troubleshooting
Service Manual
Service codes and warning signals
19.2.2 Valid for: for:
Reading service codes L544 – 442 / from 0393 0393 onwards; onwards; L554 L554 - 452 / from 0287 onwards onwards L564 - 462 /from 0606 onwards; L574 - 472 / from 0609 onw ards; L580 - 475 /from 0617 onwards
The service codes are stored in the control unit A11 and can be read or deleted using the special Interface tool and the Hyperterminal software. Hyperterminal is part of the Windows software and can be opened as follows, depending on the operating system: –
On Windows 3.11, 3.11, 95 and and 98 open 98 open the program by selecting Start, Programs, Accessories, Hyperterminal .
–
On Windows 2000, XP, NT and MI open MI open the program by selecting Start, Programs, Accessories, Communication, Hyperterminal.
Make sure that: –
The machine is in maintenance position 1
–
The Interface tool and the two connecting cables are ready.
Procedure Switch on the laptop. Using the connecting cables and Interface, connect COM1 on the laptop to the X99 socket on the control unit A11. Run the Hyperterminal Hyperterminal software.
In the Name Name field, enter the Ser. no. Of no. Of the device or type in a Name under which the file will be stored. Click OK to to confirm.
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Service Manual
Repairs, Troubleshooting Service codes and warning signals
In the Connect via field, via field, enter the interface COM1. Click OK to to confirm. c onfirm. Then enter the following data to set t he connection:
Bits per second: 9600 Data bits: 8 Parity: None Stop bits: 1 Protocol: None Click OK to to confirm. c onfirm.
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Service Manual
Service codes and warning signals
An empty field with with a flashing cursor cursor then appears. appears.
Turn the ignition key to position 1 and then back to position 0. E then E then appears in display 1, and * in display 2.
The power supply and this display remain until the data transfer from the control unit A11 to the l aptop is complete. During the data transfer, a list of all service codes runs through on the laptop, and a white fi eld appears at the end.
You can use the scroll bar to scroll to the top of the list. The following data appears at the top of the list: –
Operating hours set (the last date, service hours and clock setting)
–
Error memory read (the read (the last time the service codes were read)
–
Error memory plot out (the last time the service codes were deleted)
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Service Manual
Repairs, Troubleshooting Service codes and warning signals
This data is all saved with a date and time. Use the scroll bar to scroll to the individual service codes.
Each service code event is saved with the start time. End time and operating hours. Twenty events are saved for each service code. Following the 21st event, the list is overwritten, starting from the 11th event. This means the first ten and the last ten service codes are always stored. NOTE:
19.2.3
You can save the list of service codes on a data medium.
Deleting the service code memory Once the errors have been rectified, you can delete the service codes. Procedure Plug the connecting cable and Interface to socket X99 on the control unit A11. Press both button: „speed/clock“ and „floating position“ at the same tim and turn the ignition key to position 1 and then back to position 0. E then E then appears in display 1, and * in display 2.
The power supply and this display remain until the service codes have been deleted from the control unit A11.
L544 - 442 / from 0101 L554 - 452 / from 0101 L564 - 462 / from 0101 L574 - 472 / from 0101 L580 - 475 / from 0522
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Repairs, Troubleshooting
Service Manual
Service codes and warning signals
19.2.4
Audible and visible warning signals Warning messages accompanied by an acoustic tone or a visible signal only are listed in the t able below along with their causes and remedies. There are various types of audible warning signals: – Interval tone (5 tones followed by 5 second pauses) – Interval tone (without pause) – Continuous tone
Error signal Coolant temperature segment field indicates high temperature and interval tone sounds. Tone sequence: 5 tones followed by 5 second pauses
Interval tone sounds tone sequence: 5 tones followed by 5 second pauses
Cause Coolant temperature over 95 °C (B20)
Error in the cooling or electrical system
Hydraulic oil temperature over 95°C (B8)
Remedy – Clean the cooling system – Check the fan speed – Check the temperature sensor B20 – Compare the temperature between B20 and B21. If the temperature at B21 is too low, check the diesel engine thermostat
–
Clean the cooling system Check the fan speed Check the hydraulic oil cooling circuit Check the variable displacement pump hydraulic valves Check the temperature sensor B8
–
Check the steering pump
–
Check the pressure switch B3 Check the steering pump standby pressure
– – –
Fault in the cooling , hydraulic or electrical system
The emergency steering sym- The emergency steering function is actibol field (H8) lights up, and vated when the steering pump fails the warning buzzer sounds an Fault in the electrical or hydraulic sysinterval tone with no break tem Coolant temperature above 100 °C Engine overheating and cool- (B20) ant level symbol field (10) Coolant level too low (B13) flashes with a continuous tone after 10 seconds. Error in the electrical system
Too little engine oil
Engine oil pressure symbol field (H4) flashes with a conError in the diesel engine lubricating oil tinuous tone after 10 seconds. supply Error in the electrical system
–
–
– – – – –
–
Check the oil level and top up with engine oil if necessary
–
Check the oil level
–
Check the pressure switch B7
–
Clean the cooling system Check the hydraulic oil cooling circuit Check the fan system pressure Check the temperature switch B6
Hydraulic oil overheating symbol (H23) field lights up with a continuous tone after 10 seconds
Fault in the cooling , hydraulic or electrical system
–
Gear oil overheating symbol field lights up with a continuous tone after 10 seconds
Gear oil temperature over 120 °C fault in gearbox Error in the cooling or electrical system
–
Brake accumulator pressure too low due to the machine having been shut down for a long time
–
Brake system accumulator pressure symbol field lights up with a continuous tone after 10 seconds
Hydraulic oil temperature over 100 C
– –
– –
–
Error in the brake or electrical system –
Service code segment display Refer to the service code tables shows service code and continuous tone is sounded.
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Clean the cooling system Check the diesel engine thermostat Top up with coolant Check the thermo switch B20 Check the coolant level transmitter B13
Check the oil level Check the temperature switch B14 Check the electrical system Start the engine – when the diesel engine runs, the brake accumulators will be filled Check the brake accumulator pressure Check the pressure switch B19
Rectify the error using the service code tables
L544 - 442 / from 0101 L554 - 452 / from 0 101 L564 - 462 / from 0 101 L574 - 472 / from 0 101 L580 - 475 / from 0522
