20

10 points)

10


20

10 points)

10

15 Restrictor
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 (opti-
cally) or by display instruments on the instrument panel.
Some warning functions are accompanied by acoustic warning sig-
nals.

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 opera-
tor's manual each time a fault occurs.
Analyse the cause of the fault and correct it immediately.

L544 - 442 / from 0101! ! 19.2 - 1 of 10

L554 - 452 / from 0101
L564 - 462 / from 0101
L574 - 472 / from 0101
MJFCIFSS
L580 - 475 / from 0522
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 with the display unit.

Display unit
1 Service code type display 3 STOP display
2 Service code number display
If an error arises when the machine is started or when in use, this is indi-
cated 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 sec-
onds in the segment field 2.
Service codes 21 to 30 are not indicated by the display unit.
Service code 31 is indicated byEE 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 addi-
tional data (service hours, date and time) using the special
INTERFACE tool and the HYPERTERMINAL software.

19.2 - 2 of 10 L544 - 442 / from 0101

L554 - 452 / from 0101
MJFCIFSS L564 - 462 / from 0101
L574 - 472 / from 0101
L580 - 475 / from 0522
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.
Service
Effect Cause Remedy
code
Communication problem be- Check the wiring harness, the con-
STOP - the machine is shut
*EE tween display unity and control nectors on the control unit and the
down
unit. control unit.
Incorrect RAM information for
Service hours display not operating hours
E 11 Replace the control unit
working
(Fault in the control unit)
Incorrect EEPROM information
Service hours display not for operating hours
E 12 Replace the control unit
working
(Fault in the control unit)
Incorrect EEPROM information
Additional button function
E 13 for stored buttons (error in the Replace the control unit
inactive
control unit)
Engine oil pressure symbol Engine oil pressure too low or Check the engine oil level, pressure
E 21
field lights up sensor (B7) defective and sensor (10 184 )
Coolant temperature symbol Coolant level too low or sensor
E 22 Top up coolant and check sensor
field lights up (B13) defective
Clean the cooler, check the fan
Hydraulic oil temperature Excessive hydraulic oil tempera-
E 23 speed and check the switching point
symbol field is illuminated ture or defective switch (B6)
(1063 C)
Brake accumulator pressure too
Brake accumulator pressure Check the accumulator pressure
E 24 low or defective pressure switch
symbol field lights up and the switching point (905 bar)
(B19)
Gearbox oil temperature sym- Excessive gear oil temperature Check the gearbox for errors and
E 25
bol field lights up or defective switch (B14) check the switching point (1203 C)
Check the cooler for dirt, check the
Engine overheating and cool- Coolant temperature too high or temperature, check the sensor,
E 26
ant level symbol field lights up sensor (B20) defective (switching point 1003 C / sensor at
90C 515 )
Engine oil pressure symbol Engine oil pressure too low or Check the engine oil level and the
E 27
field lights up switch (B7) defective switch (0.50.15 bar)
The emergency steering Check the steering pump pressure
Steering pump pressure too low.
pump is activated and the and the cable connection to the
E 28 Pressure switch B3 defective or
emergency steering symbol pressure switch (switching point 18
cable broken
field lights up bar)
L564 L580 from Ser. Nr.
0847 Diesel engine speed exceeded
E 29 Brake while driving downhill
The automatic brake is acti- (above 2500 rpm)
vated.
Diesel engine speed too low Check the speed sensor
E 30 No effect (resistance 540 / frequency at
(below 500 rpm) 2000 rpm 4900 Hz)

L544 - 442 / from 0101! ! 19.2 - 3 of 10

L554 - 452 / from 0101
L564 - 462 / from 0101
L574 - 472 / from 0101
MJFCIFSS
L580 - 475 / from 0522
Repairs, Troubleshooting Service Manual
Service codes and warning signals

Service
Effect Cause Remedy
code
Communication problem be- Check the wiring harness, the con-
STOP - the machine is shut
E*31 tween the gearbox control unit nectors on the control unit and the
down
and the control unit MC6
EMERGENCY - the gears can Short circuit at one of the gear- Check the wiring harness
only be shifted manually box control unit outputs when the Check the solenoid valve spread
E 61 ignition is switched on (70 7 ) and the gear solenoids
(115 10 )
Interruption at one of the gearbox Check the wiring harness and the
STOP - the machine is shut
E 62 control unit outputs when the connectors on control board A12,
down
ignition is switched on replace the electronics
Check the wiring harness, the
STOP - the machine is shut Incorrect input combination of
E 64 Ka and Kb relays and the
down Ka, Kb relay or V/R button
travel direction switch
STOP - the machine is shut On-board circuit over / undervolt- Check the wiring harness, generator
E 65
down age (<13 V or >39 V) Check the battery
STOP - the machine is shut Incorrect RAM information Replace the gearbox control unit
E 66
down (memory test failed)
STOP - the machine is shut Incorrect drive program (data Replace the gearbox control unit
E 67
down comparison failed)
STOP - the machine is shut Incorrect program run (software Switch the on-board circuit on and
E 68
down test for all program sections) off, replace the gearbox control unit
EMERGENCY - the gears can Speed sensor input failure (B1) Check the wiring harness and speed
E69
only be shifted manually (gearbox) sensor (1050100 )
EMERGENCY - the gears can Speed sensor input failure (B2) Check the wiring harness and speed
E 70
only be shifted manually (variable displacement motor) sensor (2000200 )
EMERGENCY - the gears can Interface error (on display unit)
E 71 Check the wiring harness
only be shifted manually
STOP - the machine is shut Input and output speed sensor Check the wiring harness
E 72 down failure Check the speed sensor
STOP - the machine is shut Slip identified between input and Check the shift pressure on the cou-
E 73
down output pling (17+3 bar)
EMERGENCY - the gears can Short circuit at solenoid valve Check the wiring harness
E 74 only be shifted manually Y6.1 (1st gear) Check the solenoid valve (11510 )
EMERGENCY - the gears can Interruption at Y6.1, or pressure Check the wiring harness and the
only be shifted manually K1 too low, or disengaged park- solenoid valve (115
10
)
E 75 ing brake and travel range se-
lected while diesel engine is shut Check the shift pressure on the cou-
down pling (17+3 bar)
STOP - the machine is shut External power supply Y6.1
E 76 Check the wiring harness.
down
EMERGENCY - the gears can Short circuit at solenoid valve Check the wiring harness
E 77 only be shifted manually Y6.2 (2nd gear) Check the solenoid valve (11510 )
EMERGENCY - the gears can Interruption or external power Check the wiring harness. Check
only be shifted manually supply at Y6.2 or pressure K2 too the solenoid valve (11510 )
E 78 low Check the shift pressure on the cou-
pling (17+3 bar)
EMERGENCY - the gears can Short circuit at solenoid valve Check the wiring harness and the
E 80
only be shifted manually Y6.3 (3rd gear) solenoid valve (11510 )

19.2 - 4 of 10 L544 - 442 / from 0101

L554 - 452 / from 0101
MJFCIFSS L564 - 462 / from 0101
L574 - 472 / from 0101
L580 - 475 / from 0522
Service Manual Repairs, Troubleshooting
Service codes and warning signals

Service
Effect Cause Remedy
code
EMERGENCY - the gears can Interruption or external power Check the wiring harness and the
only be shifted manually supply at Y6.3 or pressure K3 too solenoid valve (11510 )
E 81 low Check the shift pressure on the cou-
pling (17+3 bar)
EMERGENCY - the gears can Short circuit at the replenishing Check the wiring harness and sole-
E83
only be shifted manually pressure solenoid valve (Y7) noid valve (313 )
STOP - the machine is shutInterruption or external voltage at Check the wiring harness and sole-
E 84 down the replenishing pressure sole- noid valve (313 )
noid valve (Y7)
EMERGENCY - the gears can Short circuit at the forward sole- Check the wiring harness and the
E 85
only be shifted manually noid valve (Y2) solenoid valve (222 )
STOP - the machine is shutInterruption or external voltage at Check the wiring harness and the
E 86
down the forward solenoid valve (Y2) solenoid valve (222 )
EMERGENCY - the gears can Short circuit at the reverse sole- Check the wiring harness and the
E 87
only be shifted manually noid valve (Y3) solenoid valve (222 )
STOP - the machine is shutInterruption or external voltage at Check the wiring harness and the
E 88
down the reverse solenoid valve (Y3) solenoid valve (222 )
EMERGENCY - the gears can Short circuit at the spreader so- Check the wiring harness and the
E 89
only be shifted manually lenoid valve (Y8) solenoid valve (222 )
EMERGENCY - the gears can Short circuit at the spreader so- Check the wiring harness
E 90 only be shifted manually lenoid valve (Y8) Check the solenoid valve (656 )
+3
EMERGENCY - the gears can Gearbox shit pressure is too high Check the shift pressure (17 bar)
E 91 only be shifted manually >22 bar Check the pressure sensor
(1 bar = 0.13 V)
STOP - the machine is shut Coupling K1 blocked (K1 >1 bar) Check the solenoid valve Y6.1
E 92 down Check the pressure sensor
(1 bar = 0.13 V)
EMERGENCY - the gears can Short circuit at creeper valve Check the wiring harness and sole-
E 93
only be shifted manually (Y19) noid valve (222 )
STOP - the machine is shut Pressure in the selected coupling Check the solenoid valve Y6.1
E95 down K1 is too low (K1 <11 bar) Check the pressure sensor
(1 bar = 0.13 V)
EMERGENCY - the gears can Fault in pressure sensor K1 Check the wiring harness
E98 only be shifted manually (B22)
(Voltage <0.25 / >4.5 V)
EMERGENCY - the gears can Fault in pressure sensor (B23) Check the wiring harness
E99 only be shifted manually control pressure (cut-in block)
(Voltage <0.25 / >4.5 V)
EMERGENCY - the gears can Fault in the gas pedal angle sen- Check the wiring harness
E9A
only be shifted manually sor (R5) (voltage <0.25 / >4.5 V)
EMERGENCY - the gears can Interruption or external voltage at Check the wiring harness and sole-
E9C
only be shifted manually the creeper solenoid valve (Y19) noid valve (222 )
STOP - the machine is shut Short circuit or external power Check the wiring harness
E9E
down supply on supply voltage 5 V
No effect Short circuit at output for tractive Check the wiring harness
E9F
force limitation
EMERGENCY - the gears can Error on Kick-down button Check the wiring harness
A0 only be shifted manually Replace the kick-down button

L544 - 442 / from 0101! ! 19.2 - 5 of 10

L554 - 452 / from 0101
L564 - 462 / from 0101
L574 - 472 / from 0101
MJFCIFSS
L580 - 475 / from 0522
Repairs, Troubleshooting Service Manual
Service codes and warning signals

19.2.2 Reading service codes

Valid for: L544 442 / from 0393 onwards; L554 - 452 / from 0287 onwards
L564 - 462 /from 0606 onwards; L574 - 472 / from 0609 onwards;
L580 - 475 /from 0617 onwards
The service codes are stored in the control unit A11 and can be read or de-
leted using the special Interface tool and the Hyperterminal software.

Hyperterminal is part of the Windows software and can be opened as fol-

lows, depending on the operating system:
On Windows 3.11, 95 and 98 open the program by selecting Start,
Programs, Accessories, Hyperterminal.
On Windows 2000, XP, NT and 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 software.

In the Name field, enter the Ser. no. Of the device or type in a Name
under which the file will be stored.
Click OK to confirm.

19.2 - 6 of 10 L544 - 442 / from 0101

L554 - 452 / from 0101
MJFCIFSS L564 - 462 / from 0101
L574 - 472 / from 0101
L580 - 475 / from 0522
Service Manual Repairs, Troubleshooting
Service codes and warning signals

In the Connect via field, enter the interface COM1.

Click OK to confirm.

Then enter the following data to set the connection:

Bits per second: 9600

Data bits: 8
Parity: None
Stop bits: 1
Protocol: None
Click OK to confirm.

L544 - 442 / from 0101! ! 19.2 - 7 of 10

L554 - 452 / from 0101
L564 - 462 / from 0101
L574 - 472 / from 0101
MJFCIFSS
L580 - 475 / from 0522
Repairs, Troubleshooting Service Manual
Service codes and warning signals

An empty field with a flashing cursor then appears.

Turn the ignition key to position 1 and then back to position 0.

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 laptop is complete.
During the data transfer, a list of all service codes runs through on the lap-
top, and a white field 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 set-
ting)
Error memory read (the last time the service codes were read)
Error memory plot out (the last time the service codes were deleted)

19.2 - 8 of 10 L544 - 442 / from 0101

L554 - 452 / from 0101
MJFCIFSS L564 - 462 / from 0101
L574 - 472 / from 0101
L580 - 475 / from 0522
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: You can save the list of service codes on a data medium.

19.2.3 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 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! ! 19.2 - 9 of 10

L554 - 452 / from 0101
L564 - 462 / from 0101
L574 - 472 / from 0101
MJFCIFSS
L580 - 475 / from 0522
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 table 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 Cause Remedy

Coolant temperature over 95 C Clean the cooling system
Coolant temperature segment (B20) Check the fan speed
field indicates high tempera- Check the temperature sensor B20
ture and interval tone sounds. Compare the temperature between
Tone sequence: 5 tones fol- Error in the cooling or electrical system B20 and B21.
lowed by 5 second pauses If the temperature at B21 is too low,
check the diesel engine thermostat
Hydraulic oil temperature over 95C Clean the cooling system
(B8) Check the fan speed
Interval tone sounds tone
Check the hydraulic oil cooling circuit
sequence: 5 tones followed
Fault in the cooling , hydraulic or elec- Check the variable displacement
by 5 second pauses
trical system pump hydraulic valves
Check the temperature sensor B8
The emergency steering sym- The emergency steering function is acti-
Check the steering pump
bol field (H8) lights up, and vated when the steering pump fails
the warning buzzer sounds an Check the pressure switch B3
Fault in the electrical or hydraulic sys-
interval tone with no break Check the steering pump standby
tem
pressure
Coolant temperature above 100 C Clean the cooling system
Engine overheating and cool- (B20) Check the diesel engine thermostat
ant level symbol field (10) Coolant level too low (B13) Top up with coolant
flashes with a continuous tone Check the thermo switch B20
after 10 seconds. Error in the electrical system Check the coolant level transmitter
B13
Check the oil level and top up with
Too little engine oil
Engine oil pressure symbol engine oil if necessary
field (H4) flashes with a con- Error in the diesel engine lubricating oil
Check the oil level
tinuous tone after 10 seconds. supply
Error in the electrical system Check the pressure switch B7
Hydraulic oil overheating Clean the cooling system
Hydraulic oil temperature over 100 C
symbol (H23) field lights up Check the hydraulic oil cooling circuit
with a continuous tone after Fault in the cooling , hydraulic or elec- Check the fan system pressure
10 seconds trical system Check the temperature switch B6
Gear oil overheating symbol Gear oil temperature over 120 C Check the oil level
field lights up with a continu- fault in gearbox Check the temperature switch B14
ous tone after 10 seconds Error in the cooling or electrical system Check the electrical system
Brake accumulator pressure too low Start the engine when the diesel
Brake system accumulator due to the machine having been shut engine runs, the brake accumulators
pressure symbol field lights down for a long time will be filled
up with a continuous tone Check the brake accumulator pres-
after 10 seconds Error in the brake or electrical system sure
Check the pressure switch B19
Service code segment display Refer to the service code tables Rectify the error using the service code
shows service code and con- tables
tinuous tone is sounded.

19.2 - 10 of 10 L544 - 442 / from 0101

L554 - 452 / from 0101
MJFCIFSS L564 - 462 / from 0101
L574 - 472 / from 0101
L580 - 475 / from 0522