vos8.082008 5 i Service Manual Repair work, troubleshooting MaFunctons 19.1 Malfunctions Warning and fault messages = Various faults are indicated by the corresponding symbol fields (optically) or by display instruments on the instrument panel = Some warming 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. — Analyse the cause of the fault and correct it immediately. 19.1.1 Service code indication on the display ‘The microcontroller MC8 monitors many of the machine's functions. It monitors for short circuits, 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 =F Display unit 1 Service code display 2 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. 1 2 Error display sea 443 / from 7477 554-453 /from 7477. 564-463 / ftom 747 L574 = 473 ftom 7477 580-458 /from 7477 copyrintby 19.1-1 of 6 LEBHERRRepair work, troubleshooting Service Manual ‘Malfunctions Keep in mind the following: The service codes are displayed in the segment field 4 Service codes E11 to E 31 are not indicated by the display unit. The service codes are stored in the service code memory (starting with the service code E 60) and can be read by using the BODEM software. All service codes are accompanied by a single beep. Symptoms of an error Every error has a defined symptom. This is specified in the Effect” column of the service code table, Limited driving mode is usually sill 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 2 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 oft Analyse and rectify the fault Service Sonace | effect Cause Remedy Operating hours display _| Incorrect RAM information for Replace the control board (CPU) em | geeraing operating hours i (Fault in the main electronics) Fan rotating at high speed Check the wiring hamess £18 | Tracive force reduction |C@B/@ rupture orshortcrcutin | Check the temperature sensor active yaraulic oll temperature sensor BS | ‘resistance at 20° C1112 0) Fan rotating at high speed | Cable rupture or short eircultin heck the wiring hamess E19 | Tractive force reduction _| cooling water temperature sensor _| Check the temperature sensor active B21 (resistance at 20° C_1112)0 Coolant temperature symbol | Cable rupture or short circuit in Check the wiring hamess E20 |field H13 flashes cooling water temperature sensor _| Check the temperature sensor continuous warning buzzer_| B20 (resistance at 20°C 11120) E21 [Engine oll pressure symbol | Engine oil pressure too low or Check the engine oil level. field lights up sensor defective pressure and sensor (10 - 184 0) Engine overheating and £22 coolant level H13 symbol | Coolant level oo low Check tha coolant evel ad the field lights up level sw! E24 | Brake accumulator pressure | Brake accumulator pressure too low | Check the accumulator pressure symbol field lights up or defective pressure switch (B19) _| (switching point 90" bar) Eas |Nodisplay or (display MC- nat sending data fo the control | Check the MC-6 master power frozen) electronics A1 (CPU) supph Engine overheating and Check the temperature sensor £25 feootanttevel #13 symbol | Coolant temperature too high (220) | Check he temperature senso field flashes esistanee 2 E27 [Engine oil pressure symbol | Engine oll pressure too low or switch | Check the engine oll level and the field lights up. (B7) defective switch (0.5*° bar) Check the speed sensor E30 | Noeffect Diese! engine speed too low (Resistance 640 0 / Frequency at (below 500 rpm) 2000 min’ 4800 Hz) ‘Communication problem between — | Check the connectors on the E31 f oepley or (display the display unit A13 and the control_| display unit A13 and the control ozer electronics A1 (CPU) electronics At ma ' Check the wiring hamess, speed E60 | Outputs remain de- Starting condition not fuflled (ouput | Censor and output (Resistance energised speed below 1 km/h) 1050.) 19.1-2 of 6 copyaht by Used - 443 tom 7477 L554 = 453! rom 747 LIEBHERR L864 = 463! om 7477 574 580 473 ftom 7477 458 fom 747Service Manual Repair work, troubleshooting MaFunctons ene? | Effect Cause Remedy ‘Communication problem between | Check the connectors on the E61 [STOP the machine is shut | ie MCB master board and the control electronics A1 (CPU) and control electronics A1 (CPU) the MCB Check the wiring hamess, he Communication problem between . E62 _|STOP. the machine is shut | FoTmumication problem between, [connectors on the main down ben electronics and the MC6 Replace the electronics E65 | Noeffect Battery voltage below 17 V Wiring hamess, battery, E66 | Noeffect Battery voltage below 17 V Greek ee hares | Fis No signal from the angle sensor ar__| Check the angle and set it to 235, E67 | Noinching function the inching parameters set to 255 _| using the BODEM software " Set to 200 mA using BODEM £68 | Pump does otrevact | Cuentmin Vmax’ parameter at | Sotvare a. rom MCS onwards) vaclh Tach pedal wil not retum To the O- [Check the Inch pedal 0 position, E69 | Reduced tractive force position Check the angle Check the wiring hamess STOP, the machine is shut | Faulty current at the control E70 | down pressure proportional valve vis __ | Qheck the proportional valve V18 Check the wining harness Winer oe forward travel solenoid | Check the forward solenoid valve E71 | Only reverse travel possible | To e iencrihrs inne (Y2 Resistance: approx. 220, digital voltage at the digital output Haan ornenen ‘g Check the wiring hamess Wien ne reverse Mayet solenoid | Check the reverse solenoid valve E72 _ | Only forward travel possible Y3 rnd is flowing or there is no voltage | Resistance: approx. 22 0, digital at the digital output terminal defective 7 ‘ck. | Faulty current at the proportional | Check the wiring hamess E73 |Fixed gsar 2 engaged. kick” | valves Y27 on variable displacement | Check the proportional valve Y27 i motor 4 (Resistance: approx. 22 1) Fixed gear 1 is engaged jand Faulty current at the proportional __| Check the wiring hamess E74 P valves Y28 on variable displacement | Check the proportional valve Y28 is set to awide angle 0 | motor 2 (Resistance: approx. 22 0) prevent overspeed PP Travel range A2-3 is uy ou “a1 | Oneck the wiring hamess E75 |engaged, kick-down is not | Faully current atthe gear solenoid 1 | creck the gear magnet Y6 1 possible (Resistance 90 - 110.0) Fixed gear 1 is engaged and Check the wiring harness variable displacement motor | Faulty current at the gear solenoid 2 E76 | tissettoawide angleto |¥6.2 Check the gear magnet 62 prevent overspeed Check the wiring hamess E77 |Fixedgear2is engaged | au currentat the gear solenoid 3 | creck the gear magnet Y6 3 (Resistance 90 - 110.0) ‘Automatic rear axle brake | Faully current at the rear axle brake | Check the wiring hamess E7e nee eet Check the brake magnet Y16 (Resistance approx. 22 9) Check the wiring hamess E80 |Fixed gear tis engages, | Voltage at gas potentiometer 0.3.V. | Cheek ine ts Sata arse sensor travel only via diesel speed | outside the set limits Re voltage meseurement Check the wiring hamess E81 _| Inching function switched off | Voltage at inching potentiometer | EPEC the mcning pedal angle over a 20 second ramp 0.3 V outside the set limits sensor R1 (voltage measurement) sea 443 from 7477 554-453 /from 7477. 564-463 / ftom 747 L574 = 473 ftom 7477 580° 458 /from 7477 conyrigtby 19.1-3 of 6Repair work, troubleshooting Service Manual ‘Malfunctions Service sonee® | ettect Cause Remedy There is an implausible input Cheek the wiring hamess £83 |STOP, the machine is shut | combination from the travel direction | Check the travel direction switch switch and the relays Ka and Kb The kick-down button has been 24 | The kick-down function isnot] Tre Rekcdown Button has beet | Free the kick-down button or active replace it starting Driving only POSSiBTeTA TSE 5 7 Check the wiring hamess E85 | gearwith the motors at the | ,he diesel engine Speed is Oafer | Check the diesel engine speed maximum swivel angle 9 ld sensor B24 (5400) Engine speed of variable Driving is only possible in 1st | displacement motor 1 does not | Check the wiring hamess £87 — | gearwith the motors at the | match output speed and engine _| Check the motor 1 speed sensor maximum swivel angle | speed of variable displacement _| 2 (Resistance 1050 0) motor 2 Engine speed of variable Driving is only possible in 1st | displacement motor 2 does not | Check the wiring hamess 88 | gearwith the motors at the | match output speed and engine _| Check the motor speed 2 sensor maximum swivel angle | speed of variable displacement _| 82a (Resistance 1050 0) motor 1 Driving is only possible in Tst| The speed of he variable Check te wiring hares 89 |gearwith the motors at the | displacement motor is greater than | Check the output speed sensor maximum swivel angle _| the output speed 81 (resistance 1050 0) Excessive engine speed difference | Measure the coupling pressure es [STOP themachineis shut | veen ott ane varade (19 ban, Check he gar displacement motors, ete 90-110.0) ‘The machine switches to E91 |Meutral. The driver can select| The speed of one or both variable | The driver has criven downhill too the travel direction after the | displacement motors is too high _| fast speed drops “The power ouput atthe travel pump is reduced, | Current limited on the control Check the cooling system, check 92 |waring sound every 10 _| presure proportional valve due to _| the temperature sensor 88 seconds, each lasting 1 excess hydraulic oiltemperature_| (Resistance at 20° C = 1112.0) second con | italy no oflects ater Variable displacement motor 1 Repair the variable displacement overspeed rotates with couplings 1 and 3 open | motor 1 or the coupling 1 E95 italy no ofects tater Variable displacement motor 2 Repair the variable displacement overspeed | rotates with coupling 2 open motor 2 or the coupling 2 “The machine switches fo | Automatic braking due fo excess eae _ | neutral. The driver can select | diesel engine or variable The driver has driven downhill too the travel direction after the | displacement motor speed for more | fast speed drops than 3 seconds ‘The output ofthe travel Current limited on the control Check the cooling system, check pump is reduced, There is a E97 presure proportional valve due to _| the temperature sensor 621 1 second beep every excess coolant temperature (Resistance at 20°C = 1112 0) 40 seconds Shift to neutral, afer the 9g [ensine speed drops the | evcessive diesel engine speed _| The driver has driven downhill too travel direction can be fast engaged again Continued driving is only , EB0 | Drivingis not possible, no | Engine current comparison mode _| Fomplete the correction and set hydrostatic brake effect Pi 19.1.2 Horm and headlight flasher Waring messages accompanied by an acoustic tone or those only displayed optically, are listed in the table below along with their causes and remedies, There are four various types of audible warning signals: = Continuous tone — Interval tone (1 second tone followed by 10 second pause) — Interval tone (2 second tone followed by 3 second pause) = Single 1 second beep Error signal Cause Remedy Coolant temperature over 102°C | Cleaning the cooling system (620) Check the fan speed Coolant temperature symbol field (H13) flashes and symbol field STOP js illuminated, continuous warning buzzer Error in the cooling or electrical system Check the temperature sensor B20 Compare the temperature between 820 and B21. Ifthe temperature at B21 is too low, Check the diesel engine thermostat Coolant temperature symbol field (H13) flashes and symbol field Coolant level too low (813) Check the coolant level STOP is illuminated continuous warning buzzer Error in the electrical system Check the coolant level transmitter B13 Service code E 92 Hydraulic oil temperature over 85°C. (88) Cleaning the cooling system Check the fan speed Hydraulic oil overheating symbol field (H23) lights up, Warning buzzer with interval tone Tone sequence: 1 second tone followed by 10 seconds pause, The output of the travel pump is reduced Fault in the cooling / hydraulic / electrical system Check the temperature sensor BB. Check the wiring to the main electronics. Check the working hydraulics pressure relief valves (control vaive block). Check the travel hydraulics pressure relief valves (variable adjustment pump) sea 443 from 7477 554-453 /from 7477. 564-463 / ftom 747 L574 = 473 ftom 7477 580° 458 /from 7477 conyrigtby 19.1-5 of 6Repair work, troubleshooting Service Manual ‘Malfunctions Error signal Cause Remedy Service code E 97 Warning buzzer with interval tone Tone sequence: 1 second tone followed by 10 seconds pause, The output of the travel pump is reduced Coolant temperature over 87 °C (B21) Cleaning the cooling system Check the fan speed Error in the electrical system Check the temperature sensor B21 Check the wiring to the main electronics Emergency steering check symbol field (H24) lights up Emergency steering pump check not successfully completed (B3a) Check the emergency steering pump Error in the electrical / hydraulic system Check the pressure switch B3a. Check the wiring to the main electronics. Check the emergency steering pump pressure The emergency steering symbol field (H8) lights up ‘Warning buzzer with interval tone Tone sequence: 2 second tone followed by 3 seconds pause. After 1 minute: The stop symbol field (H36) lights up, Travel direction is deactivated ‘The emergency steering function is activated when the steering pump falls (83) Error in the electrical / hydraulic system Check the steering pump Check the pressure switch BS Check the steering pump standby pressure ‘The engine oil pressure symbol field (Ha) flashes, The stop symbol field (H36) lights up, After 10 seconds continual warming buzzer Insufficient engine oil pressure (87) Check the oil level Error in the diesel engine oil supply Check the pressure relief valve Error in the electrical system Check the pressure switch B7 Check the wiring to the main electronics Service code E 99 The gear oil overheating symbol field (H14) lights up, Driving is only possible at a low speed (approx. 20km/h) Gear oll temperature over 120°C (B14) Clean the gear oil cooler Oil level too high Error in the electrical system Correct the oil level Check the thermo switch B14 Check the wiring to the gear electronics A2 ‘The accumulator pressure symbol field (H1) lights up, No travel direction can be selected, After 2 minutes continual warning buzzer Brake accumulator pressure too low (B19) Start the engine — when the diesel ‘engine runs, the brake accumulators willbe filled Error in the electrical / hydraulic system Check the pressure switch B19 Check the wiring to the main electronics Check the accumulator charge valve Check the gear pump The battery charge indicator symbol field (H) lights up, The parking brake cannot be released Tom V-belt Fita new V-belt Defective alternator Repair the alternator Check the wiring to the main electronics The service code segment display (P7) indicates the service code Single 1 second beep Refer to the service code tables 19.1-6 of 6 copyritby sea 554 L564 574 580 443 from 747 453 from 747 4463 fom 747 473 ftom 7477 458 fom 747