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Service manual

(20
Wheel loader
(10 points)
L550 - L586 2plus2
(10
en
PRELIMINARY
Address
Address: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Dr. Hans Liebherr Strae 4
A 5500 BISCHOFSHOFEN, AUSTRIA
Product identification
Manufacturer: LIEBHERR-WERK BISCHOFSHOFEN GMBH
Product group: Wheel loader
Type: L 550 L 556 L 566 L 576 L 580 L586
Construction number: 456 454 460 457 459 461
Serial number: 99999 99999 14171 14171 14171 99999
Document identification
Order number: xxxxxxxxx
Author: LBH / T-DOK department
Document version: 01
Manual number:
Owner:
Service manual
(20
Wheel loader
(10 points)
L550 - L586 2plus2
(10
en
Foreword
Target group This Service Manual has been written for those whose job it is to make sure
that the machines remain operational on a daily basis. This specifically
includes the mechanics and workshop specialists at Liebherr dealers and
Liebherr branch offices.
Contents In the first chapter you will find information about safety regulations as well
as specifications of the special tools needed for maintenance and repair.
Chapter 2 provides an overview of all important technical data for the entire
machine and the individual assemblies.
The following chapter, entitled Maintenance, contains the maintenance and
inspection schedule, inspection and setting logs, lubrication schedules and
filling quantity tables, a description of maintenance procedures and speci-
fications for prescribed lubricants and fuels.
The technical description of the machine in the following chapters is divided
into 15 functional groups. The design, function, and technical data for each
group, component and part are explained.
Chapter 19 is new. In it, you will find a list of available repair manuals,
troubleshooting hints, the service code table and a description of the
BODEM service software.
How to use this manual This manual describes a variety of types and finished forms. In general, this
information applies to the types and serial number groups specified in the
footnotes. One exception is that specific type and serial number data are
indicated at the beginning of each section (e.g. the technical specifications of
the components).
Whenever possible, parts and components are supplemented by indication
of the identification number in the heading.
This manual is available in German, English, French, Spanish and Italian.
Working instructions It is imperative that safety regulations be observed with all tasks done on the
machine. You will find information on this in the General Information
chapter.
A complete set of tools in perfect condition is required for work on the
machine, along with any special tools that might be needed. Absolute
cleanliness must be observed with all tasks!
Sealing material such as O-rings and surface seals should be replaced
whenever repairs are carried out.
DVD edition We would particularly like to draw your attention to the fact that this book is
available not only in printed form, but also as an electronic document on
DVD (Lidos).
General information 1
Product description 2
Maintenance 3
Diesel engine, pump distributor gear 4
Cooling system 5
Travel hydraulics 6
Working hydraulics 7
Steering system 8
Brake system 9
Electrical system 10
Transfer gear 11
Axles, drive shafts 12
Machine frame, ballast weight 13
Central lubrication system 14
Covering, cab access 15
Cab, heating, air-conditioning 16
Lift arm, quick-change device 17
Attachments, accessories 18
Repair work, troubleshooting 19
Options 20
L550 - 456 / from 99999 L576 - 457 / from 14171 1. 0- 1 of 2
L556 - 454 / from 99999 L580 - 459 / from 14171
L566 - 460 / from 14171 L586 - 461 / from 99999
MJFCIFSS
1 General Information
1.0
Chapter contents
1 General Information ............................................................ 1.0-1
1.1 Safety regulations...........................................................................1.1-1
1.1.1 Introduction...........................................................................1.1-1
1.1.2 Overview of the safety regulations .......................................1.1-2
1.2 Special tools for maintenance and repair work...............................1.2-1
1.2.1 Special tools in general ........................................................1.2-1
1.2.2 Special tools for Liebherr diesel engines..............................1.2-2
1.2.3 Special tools for hydraulic cylinders .....................................1.2-3
1.2.4 Special tools for electronics..................................................1.2-3
1.2.5 Special tools for axles...........................................................1.2-4
1.2.6 Special tools for the transmission.........................................1.2-5
1.2.7 Central lubrication system....................................................1.2-5
1.2.8 Special tools for the air conditioning system........................1.2-5
1.2.9 Special tools for cab windows ..............................................1.2-6
Service Manual General Information
Special tools for maintenance and repair work
L550 - 456 / from 99999 L576 - 457 / from 14171 1. 1- 1 of 2
L556 - 454 / from 99999 L580 - 459 / from 14171
L566 - 460 / from 14171 L586 - 461 / from 99999
MJFCIFSS
1.1 Safety regulations
Working on the machine poses safety risks to the operator, driver or
maintenance engineers. You can prevent risks and accidents by regularly
reading and observing the various safety instructions.
This is especially important for personnel who only occasionally work on the
machine, for example, carrying out rigging or maintenance work. The safety
regulations listed below, if conscientiously followed, will ensure your own
safety and that of others, and will prevent the machine from being damaged.
Whenever tasks which could cause danger to personnel or damage to the
machine are described, the necessary safety precautions are explained in
this manual.
These are indicated by the headings Danger, Warning or Caution.
1.1.1 Introduction
1. The symbols below have the following meanings:
Danger
Warning that without appropriate precautions, certain procedures could
result in fatal accidents.
Warning
Warning that without appropriate precautions, certain procedures could
result in severe physical injuries.
Caution
Warning that without appropriate precautions, certain procedures could
result in minor physical injuries or damage to the machine.
2. Observance of these instructions does not exempt you from following
any additional rules and guidelines that may apply
The following should also be observed:
The safety rules in force at the operating site
Legally enforceable road traffic regulations
Guidelines issued by trade associations
Danger
Warning
Caution
General Information Service Manual
Safety regulations
1. 1- 2 of 2 L550 - 456 / from 99999 L576 - 457 / from 14171
L556 - 454 / from 99999 L580 - 459 / from 14171
L566 - 460 / from 14171 L586 - 461 / from 99999
MJFCIFSS
1.1.2 Overview of the safety regulations
A detailed description of these can be read in the relevant section of the
safety regulations chapter in the operating manual.
The following sections are included in the operating manual:
1 Introduction
2 General safety regulations
3 Proper use
4 Decals on the machine
5 Instructions on preventing crushing injuries and burns
6 Instructions on preventing fires and explosions
7 Safety instructions for start-up
8 Safety precautions during start-up
9 Instructions for safe working
10 Safety instructions for driving on slopes
11 Parking safely
12 Transporting the machine safely
13 Towing the machine safely
14 Measures for ensuring safe maintenance
15 Safety instructions for working on machines with hydro accumulators
16 Safety instructions for welding work on the machine
17 Instructions for working safely on the working attachment
18 Safety instructions for transporting the machine by crane
19 Safe maintenance of hydraulic hoses and hose lines
20 Attachments and accessories
21 Protection against vibrations
Service Manual General Information
Special tools for maintenance and repair work
L550 - 456 / from 99999 L576 - 457 / from 14171 1. 2- 1 of 6
L556 - 454 / from 99999 L580 - 459 / from 14171
L566 - 460 / from 14171 L586 - 461 / from 99999
MJFCIFSS
1.2 Special tools for maintenance and
repair work
1.2.1 Special tools in general
Description ID no. Use Remarks
Anti-freeze and battery tester 7408922 All wheel loaders
For checking the acid concentration
(battery charging state) and anti-freeze
24 volt vacuum pump 7408148 All wheel loaders For preventing oil loss
Filling and testing device with
case
8145359 All wheel loaders For checking the hydro accumulator
Manometer 0-40 bar 7361288 All wheel loaders For checking the hydraulic pressure
Manometer 0-250 bar 5002932 All wheel loaders For checking the hydraulic pressure
Manometer 0-600 bar 5002866 All wheel loaders For checking the hydraulic pressure
Manometer connection 7002436 All wheel loaders Connection for the manometer
High pressure hose 1500 mm 7002475 All wheel loaders High pressure hose for manometer
High pressure hose 4000 mm 7009134 All wheel loaders High pressure hose for manometer
Screw connection M 10 x 1 5005180 All wheel loaders For checking the hydraulic pressure
Draining hose 7005660 All wheel loaders For draining oil via a drain valve
Drain piece 7402657 All wheel loaders For the drain hose
Safety cap SW 10 7009315 All wheel loaders
For securing the valves on the variable
adjustment motor
Safety cap SW 13 7615515 All wheel loaders For securing the valves on the pumps
Safety cap SW 17 7615589 All wheel loaders For securing the valves on the pumps
Safety cap SW 19 7009317 All wheel loaders For securing the valves on the pumps
Safety cap SW 17 7622068 All wheel loaders
For securing the valves on the control
block
USB dongle 10333608 L550 - L586 With SERVICE authorisation
Diagnostic data cable 10035410 L550 - L586
For adjusting the travel hydraulics, and
testing the electrical system and options
Adapter cable RS232<>USB 693190714 All wheel loaders
For communicating with the wheel
loader electronics if there is an error
with the RS232 interface on the
notebook.
Extraction tool size 20 for pin
and bushing
8503630 All wheel loaders For DEUTSCH connectors
SDCF 03 memory card
adapter
10223098 L550 - L586 For writing to the compact flash card
Compact flash card 10223095 L550 - L586
Blank compact flash card.
Data medium for application software
General Information Service Manual
Special tools for maintenance and repair work
1. 2- 2 of 6 L550 - 456 / from 99999 L576 - 457 / from 14171
L556 - 454 / from 99999 L580 - 459 / from 14171
L566 - 460 / from 14171 L586 - 461 / from 99999
MJFCIFSS
1.2.2 Special tools for Liebherr diesel engines
Description ID no. Use Remarks
Mandrel 9078118 L550 - L556 engine
For installing the mass equalisation
shafts (D 934)
Mandrel 9078119 L550 - L556 engine
For installing the mass equalisation
shafts (D 934)
Rotary angle device 0524062 L550 - L586 engine
For installing and removing the cylinder
head
Holder 0528464 L550 - L586 engine
For checking projection of the cylinder
bushings
Dial gauge holder 10023885 L550 - L586 engine
For checking projection of the cylinder
bushings
Compression tester 8008782 L550 - L586 engine For checking the compression
Compression tester insert 10012817 L550 - L586 engine For checking the compression
Adapter 10297211 L550 - L586 engine For checking the compression
Claw 10117612 L550 - L586 engine For checking the compression
Engine turner 0524045 L550 - L586 engine
For installing and removing the pistons
and rods
Holder 0528464 L550 - L586 engine
For installing and removing the pistons
and rods
Piston strap 8000592 L550 - L586 engine
For installing and removing the pistons
and rods
Rotary angle device 0524062 L550 - L586 engine
For installing and removing the pistons
and rods
Piston ring tongs 7009319 L550 - L586 engine
For installing and removing the piston
rings
Extractor tool 0526855 L550 - L586 engine
For installing and removing the cylinder
bushing
Extractor tool 0528462 L550 - L586 engine
For installing and removing the cylinder
bushing
Mounting pin 0528470 L550 - L586 engine
For installing and removing crankshaft
attachments
Hook and lever 7019858 L550 - L586 engine
For installing and removing the front
crankshaft seal
Inserter 10116249 L550 - L586 engine
For installing and removing the front
crankshaft seal
Mounting pin 0528470 L550 - L586 engine For installing and removing the flywheel
Inserter 10116250 L550 - L586 engine
For installing and removing the rear
crankshaft seal
Special spanner 10020852 L550 - L586 engine
For installing and removing the injection
line
Adapter 0524029 L550 - L586 engine
For installing and removing the
pressure pipe port and injection nozzles
Adapter 10220689 L550 - L586 engine
For installing and removing the
pressure pipe port and injection nozzles
Hammer puller 0524072 L550 - L586 engine
For installing and removing the
pressure pipe port and injection nozzles
Pusher tube 10289319 L550 - L586 engine
For installing and removing the injection
pump and roller tappet
Pusher tube 10289320 L550 - L586 engine
For installing and removing the injection
pump and roller tappet
Mounting pin 0528472 L550 - L586 engine
For installing and removing the exhaust
pipe
Service Manual General Information
Special tools for maintenance and repair work
L550 - 456 / from 99999 L576 - 457 / from 14171 1. 2- 3 of 6
L556 - 454 / from 99999 L580 - 459 / from 14171
L566 - 460 / from 14171 L586 - 461 / from 99999
MJFCIFSS
1.2.3 Special tools for hydraulic cylinders
Description ID no. Use Remarks
Assembly sleeve 80 mm 9227165
L550, L556 steering
cylinder
For fitting the seals
Assembly sleeve 90 mm 9227161
L566, L576, L580
steering cylinder
For fitting the seals
Assembly sleeve 130 mm 9998624 L550, L556 lift cylinder For fitting the seals
Assembly sleeve 150 mm 9998622
L550, L556 tilt cylinder
L566, L576, L580 lift
cylinder
For fitting the seals
Assembly sleeve 170 mm 9107931
L566, L576, L580 tilt
cylinder
For fitting the seals
Expansion sleeve 80 mm 9227166
L550, L556 steering
cylinder
For fitting the seals
Expansion sleeve 90 mm 9227162
L566, L576, L580
steering cylinder
For fitting the seals
Expansion sleeve 130 mm 9110408 L550, L556 lift cylinder For fitting the seals
Expansion sleeve 150 mm 9110410
L550, L556 tilt cylinder
L566, L576, L580 lift
cylinder
For fitting the seals
Expansion sleeve 170 mm 9110412
L566, L576, L580 tilt
cylinder
For fitting the seals
Bearing head assembly
spanner 70/8 mm
9210219
L550, L556 steering
cylinder
For fitting the piston rod bearing
Bearing head assembly
spanner 75/12 mm
9239572
L566, L576, L580
steering cylinder
For fitting the piston rod bearing
1.2.4 Special tools for electronics
Description ID no. Use Remarks
Digital multimeter 8502956 All wheel loaders
For measuring voltage, current,
resistance and frequency
Test probe, red 884191214 All wheel loaders For testing DEUTSCH connectors
Test probe, black 884191114 All wheel loaders For testing DEUTSCH connectors
Magnet tester 8145743 All wheel loaders For checking solenoid valves
Stripping and crimping pliers
0.5 - 6.0 mm
2 8460263 All wheel loaders For MATE-N-LOK connectors
Crimping pliers 8503647 All wheel loaders For DEUTSCH connectors
Wedge extractor tool 7026267 All wheel loaders For DEUTSCH connectors
Extraction tool size 12 for pin
and bushing
8145674 All wheel loaders For DEUTSCH connectors
Extraction tool size 16 for pin
and bushing
8145673 All wheel loaders For DEUTSCH connectors
General Information Service Manual
Special tools for maintenance and repair work
1. 2- 4 of 6 L550 - 456 / from 99999 L576 - 457 / from 14171
L556 - 454 / from 99999 L580 - 459 / from 14171
L566 - 460 / from 14171 L586 - 461 / from 99999
MJFCIFSS
1.2.5 Special tools for axles
Description ID no. Use Remarks
Hand pump 8145835 L550 - L586 axles For testing disc brakes for leaks
Collet 7009536 L550 - L586 axles
For installing and removing the snap
ring in the planetary drive
Spring hook 8145767 L550 - L586 axles
For attaching and detaching the return
springs
Slip bushing 260 mm 7017559
L556 front axle
L556 rear axle
For fitting the brake piston
Slip bushing 315 mm 7017556
L566, L576 front axle
L566, L576, L580 rear
axle
For fitting the brake piston
Slip bushing
M 90 x 1.5 mm
7017558 L556 rear axle For fitting ring gear carriers
Slip bushing
M 110 x 1.5 mm
7017557
L556 front axle
L566, L576 rear axle
For fitting ring gear carriers
Slip bushing
M 130 x 1.5 mm
7017555
L566, L576, L580 front
axle; L580 rear axle
For fitting ring gear carriers
Handle 7017566 L550 - L580 axles Handle for mounting tool
Handle 7011518 L550 - L580 axles Handle for various mounting tools
Mounting tool 7017563 L556 rear axle For fitting cartridge seal ring
Mounting tool 7017560
L556, L566, L576, 580
front axle; L566, L576,
L580 rear axle
For fitting cartridge seal ring
Centring bracket 7013775 L556 - L580 axles For groove nut spanner
Groove nut spanner 111 mm 7009537 L556 rear axle For fitting the grooved nuts
Groove nut spanner 140 mm 7011251
L556 front axle
L566, L576 rear axle
For fitting the grooved nuts
Groove nut spanner 169 mm 7013774
L566, L576, L580 front
axle; L580 rear axle
For fitting the grooved nuts
Measuring screw
M 16 x 1.5
7019556
L556 front axle
L556, L566, L576 rear
axle
For measuring wear on the brake discs
Measuring screw
M 16 x 1.5
8145771
L566, L576, L580 front
axle; L580 rear axle
For measuring wear on the brake discs
Clamp fork 7011522 L556 - L580 axles For fitting the drive flange
Mounting tool 7013922 L556 - L580 axles For fitting the shaft seal ring
Slotted nut spanner
81 mm
10017840 L550 - L580 axles
For fitting the grooved nuts on the axle
drive
Mounting tool (used with
grip 7011518)
7624271 L550 axles, MT-L 3085 For fitting the dust protection axle insert
Mounting tool 7624272 L550 axles, MT-L 3085 For fitting the shaft seal ring axle insert
Centring bracket 10008138
L550 - L576 axles
MT-L 3085-3105
For detaching the output
Socket wrench 10008139
L550 MT-L 3085 axles
L556 rear axle
For detaching the output
Socket wrench 10218794
L550 MT-L 3085 front
axle L556 - L576 axles
For detaching the output
Clamp fork 10008140 L550 MT-L 3085 axles For removing and fitting the drive pinion
Special tool kit for Hercules
axles
10286181 L580 Hercules axles
Contains the following items: 10286183
-10286198
Driver for lubrication and oil
seal
10286183 L580 Hercules axles
For fitting the lubrication and oil seal, to
be used with grip 10286788
Service Manual General Information
Special tools for maintenance and repair work
L550 - 456 / from 99999 L576 - 457 / from 14171 1. 2- 5 of 6
L556 - 454 / from 99999 L580 - 459 / from 14171
L566 - 460 / from 14171 L586 - 461 / from 99999
MJFCIFSS
Description ID no. Use Remarks
3 bushing driver with guide
and grip
10286186 L580 Hercules axles
For installing bushing, including grip
10286788
Grip for seal driver and shell 10286788 L580 Hercules axles
For fitting the outer lip seal, to be used
with appropriate driver
Driver for inner lip seal 10286189 L580 Hercules axles
For fitting the inner lip seal, to be used
with grip 10286788
Driver for wear bushing with
guide
10286190 L580 Hercules axles For installing the wear bushing
Grooved nut socket 10286192 L580 Hercules axles
For removing and fitting the grooved
nuts
Seal holder installation tool 10286193 L580 Hercules axles For fitting the seal holder
Driver for oil bearing casings,
bevel gear
10286194 L580 Hercules axles
For installing the bearing casings, bevel
gear
Driver for grease seal and
disc
10286195 L580 Hercules axles
For fitting the grease seal and disc, to
be used with grip 10286788
Rolling apparatus 10286196 L580 Hercules axles
For testing the rolling torque of the
wheel hubs
Lifting tackle 10286197 L580 Hercules axles For removing the wheel hub
Installation tool for Lifetime
seal
10286198 L580 Hercules axles For fitting the Lifetime seal
1.2.6 Special tools for the transmission
Description ID no. Use Remarks
Fixing spanner 10016179 L550 - L586
For loosening and tightening the
grooved nut on the coupling 1
Special socket 10016180 L550 - L586
For loosening and tightening the
grooved nut on the coupling 1
Mounting tool 10016181 L550 - L586
For removing and attaching the snap
ring on the couplings
1.2.7 Central lubrication system
Description ID no. Use Remarks
BEKA MAX filling press 10009239 All wheel loaders
For quickly filling the BEKA Max
reservoir
Groeneveld filling press 10333342 All wheel loaders
For quickly filling the Groeneveld
reservoir
Filling connection 7029283 All wheel loaders For filling the reservoir
Grneveld central lubrication
data cable
7624289 All wheel loaders
For inspecting the central lubrication
system
Grneveld central lubrication
plug adapter
7624290 All wheel loaders
For inspecting the central lubrication
system
1.2.8 Special tools for the air conditioning system
Description ID no. Use Remarks
Vacuum pump 7027552 All wheel loaders
For evacuating the air conditioning
system
4-valve test fitting 7027558 All wheel loaders
For testing, evacuating and filling the air
conditioning system
Filling hose, blue 1500 mm 7027553 All wheel loaders For the test fitting
Filling hose, yellow 1500 mm 7027554 All wheel loaders For the test fitting
General Information Service Manual
Special tools for maintenance and repair work
1. 2- 6 of 6 L550 - 456 / from 99999 L576 - 457 / from 14171
L556 - 454 / from 99999 L580 - 459 / from 14171
L566 - 460 / from 14171 L586 - 461 / from 99999
MJFCIFSS
Filling hose, red 1500 mm 7027555 All wheel loaders For the test fitting
Car coupling 253a 7027556 All wheel loaders For the test fitting
Car coupling 254a 7027557 All wheel loaders For the test fitting
1.2.9 Special tools for cab windows
Description ID no. Use Remarks
Complete tool box with
suction pads
10021147 All wheel loaders For installing and removing windows
L566 - 460 / ab 14171 3.3
L576 - 456 / ab 14171
L580 - 459 / ab 14171 MJFCIFSS
Customer:
Job site:
L566, L576, L580 Ser. Nr. /
Operating hours:
Type of application:
Checked by:
Checked on date:
Check / Adjustment
Unit
Adjust.
values
Value
before
adjust.
Value
after
adjust.
Adjust.
point
Test
point
Operating temperature
Operating temperature
(Temperature sensor hydraulic oil)
C 58
5
Cooling system
Cooling System (fan control)
Fan at high Diesel engine RPM /
Sensor unplugged
Fan at high Diesel engine RPM /
Prop. solenoid valve current less
bar
bar
165
5
220
10
1
P
P
Diesel engine
Adjustment - pedals
Gas pedal angle sensor
Inching pedal angle sensor
S
C
U
L
I
Diesel engine RPM
Low idle RPM
High idle RPM
min
-1
min
-1
900
10
2065
10
Travel hydraulic
Replenishing pressure
At high idle RPM bar 34
1
3 G
High pressure relief valves
Forward
Reverse
bar
bar
470
10
470
10
2
4
MA
MB
Pressure cut off
High pressure
Engine speed drop, max. difference
to high idle RPM
bar
min
-1
430
5
30
1 MA (MB)
Display
Block curve at 930 min
-1
Diesel engine RPM
High pressure
min
-1
bar
930
50
10
930 930
S
C
U
L
I
MA (MB)
Block curve at 1200 min
-1
Diesel engine RPM
High pressure
min
-1
bar
1200
230
10
1200 1200
S
C
U
L
I
MA (MB)
Block curve at 1400 min
-1
Diesel engine RPM
High pressure
min
-1
bar
1400
330
10
1400 1400
S
C
U
L
I
MA (MB)
Adjustment var. displ. motor
Automatically adjustment of the
variable displacement motors
S
C
U
L
I
High pressure L566
High pressure L576, L580
Diesel engine RPM
bar
bar
min
-1
340
10
350
10
1980
30
MA
MA
= Blocked Machine
3.3 L566 - 460 / ab 14171
L576 - 457 / ab 14171
L580 - 459 / ab 14171 MJFCIFSS
Check and adjust only if required
Check / Adjustment
Unit
Adjust.
values
Value
before
adjust.
Value
after
adjust.
Adjust.
point
Test
point
Working hydraulic
Control valve block
Secondary pressure relief valve, lift
Secondary pressure rel. valve, tilt in
Secondary pressure rel. valve, tilt out
Primary pressure relief valve
bar
bar
bar
bar
420
5
400
5
400
5
380
5
3
4
6
5
P
P
P
P
Control valve block
LS-Pressure cut off bar 350
5
7 P
Working hydraulic pump
Power regulator bar 180
10
1 M / M1
Working hydraulic pump
Flow regulator-Pressure difference bar 22
2
2 M / LS
Stabilization module
Shut off pressure (LFD turned off) bar 120
20
MX
Hydro accumulator LFD
Pretension pressure (nitrogen filling)
bar 25
2
9 9
Steering system
Variable displacement pump
Pressure cut off bar 210
5
2 P
Variable displacement pump
Flow regulator Pressure difference bar 22
2
1 P / LS
Brake system
Compact brake valve
Cut in pressure
Cut out pressure
Brake pressure in axles L566, L576
Brake pressure in axles L580
bar
bar
bar
bar
180
5
210
5
95
5
70
5
1
1
2
2
M3
M3
M4 / M5
M4 / M5
Accumulator
After 9 braking actions bar > 50 M4 / M5
Pressure switch - brake system
Switching point bar 120
5
M3
Transfer gear
Transfer gear
Switching pressure bar 20
3
P
Preload pressure (nitrogen filling) bar 12
2
1
Remarks: Signature:
Service Manual Maintenance
Tests and adjustments
L550 - 456 / from XXXXX L580 - 459 / from 14171 1 of 3
L556 - 454 / from XXXXX L586 - 461 / from XXXXX
L566 - 460 / from 14171
L576 - 457 / from 14171
MJFCIFSS
Brief description of adjustment work, L566 - L580
Bringing the machine up to operating temperature
The operating temperature is 58
5
C . The temperature is measured by the
hydraulic oil sensor and can be seen in Sculi.
Procedure
Cover the hydraulic oil cooler 1 with a box 2 or something similar.
Bring the machine up to operating temperature using the working hydraulics
and the travel hydraulics.
Warming up using the working hydraulics creates a good mixture in the
hydraulic tank so that the temperature can be accurately measured.
Checking the fan motor and the fan control
Procedure
Unplug the hydraulic oil temperature sensor.
At upper idling speed, check that the pressure is 165
5
bar.
If it is correct, there is no need for the second test (220
10
bar).
If it is not correct:
Select the parameter Cooling system solenoid valve output current
and set the current to 0 mA.
At upper idling speed, check that the pressure is 220
10
bar.
If it is not correct:
Adjust the proportional pressure relief valve
When you switch off the ignition after testing or adjusting, the parameter
Cooling system solenoid valve output current is automatically reset to
the previous value.
Checking the diesel engine speed
The diesel engine speed is set by fixed parameters in the master electronics.
It only needs to be checked.
Procedure
Check that the top and bottom engine speeds are correct.
If they are not correct:
Calibrate the gas pedal angle sensor and check the speed again.
Calibrating the gas pedal angle sensor
The teaching curve no longer has to be recorded. The master electronics
only have to detect the end positions of the angle sensor.
Procedure
Set the parameter Gas pedal - start calibration to 1.
Push the gas pedal all the way down.
The master electronics detect the position of the angle sensor. The para-
meter Gas pedal start calibration automatically switches back to 0 after
15 seconds, or you can do it manually.
Then select Gas pedal set value and check that 0 % and 100 %
are attained.
Maintenance Service Manual
Battery installation
2 of 3 L550 - 456 / from XXXXX L566 - 460 / from 14171
L556 - 454 / from XXXXX L576 - 457 / from 14171
L580 - 459 / from 14171
L586 - 461 / from XXXXX
MJFCIFSS
Calibrating the inch pedal angle sensor
Procedure
Set the parameter Inch pedal start calibration to 1.
Push the inch pedal all the way down.
The master electronics detect the position of the angle sensor. The para-
meter Inch pedal start calibration automatically switches back to 0 after
15 seconds, or you can do it manually.
Then select Inch pedal set value and check that 0 % and 100 %
are attained.
Calibrating the block curve
Procedure
Set the parameter Inch pedal function OFF to 1 (inching is deactivated).
Select fixed gear 2 and forward travel, and hold the machine in the
blocked condition using the service brake.
Increase the engine speed to 930 min
-1
, 1200 min
-1
and 1400 min
-1
and
check the high pressure according to the adjustment checklist.
If it is not correct:
Adjust the parameter Travel pump current at 900 / 1200 / 1400 1/min
until the high pressure is correct.
Set the parameter Inch pedal function OFF back to 0.
Calibrating the variable displacement motors
The variable displacement motors are calibrated automatically by the
master electronics.
Procedure
Start up the engine.
The parking brake must be activated.
Set the parameter Travel motors start calibration to 1.
The master electronics raise the engine speed to 1000 min
-1
and adjust the cur-
rent to the variable displacement motors until they reach the required speed.
When the calibration is completed, you must switch the ignition off and
on again.
Checking the diesel engine power
Before you check the power of the engine, you must carry out the follow-
ing tasks:
Tasks in maintenance schedule (air filter, fuel filter etc.)
Check the operating pressures according to the adjustment checklist
The machine must be at operating temperature
Procedure
Connect a manometer (600 bar) to the test connection MA.
Set the parameter Inch pedal function OFF to 1.
Start the machine, select fixed gear 2 and forward travel direction.
Hold the machine with the service brake and run it at full throttle.
Slowly release the service brake until the machine moves at a speed
13 km/h. Check that the set values for pressure and engine speed
are reached.
Service Manual Maintenance
Tests and adjustments
L550 - 456 / from XXXXX L580 - 459 / from 14171 3 of 3
L556 - 454 / from XXXXX L586 - 461 / from XXXXX
L566 - 460 / from 14171
L576 - 457 / from 14171
MJFCIFSS
If they are not correct:
Troubleshoot the engine: air filter, fuel filter etc.
Troubleshoot the travel hydraulics: check the operating pressure etc.
Then set the parameter Inch pedal function OFF back to 0.
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Malfunctions Operating Manual
L580-459/11780 0-)&,)66
4.2 EIiminating maIfunctions
4.2.1 RepIacing fuses
Caution There is a risk of damaging the electrical system.
! n order to prevent damage to the electrical system, only use fuses with
the correct rating.
Make sure that:
The electrical circuit has been checked before changing the fuse.
For safety reasons, after checking the circuit, that the machine's elec-
trical system has been switched off.
Caution Danger of electrocution
f you touch live parts you can be electrocuted.
! Switch off the machine's electrical system before working on live compo-
nents.
! For safety reasons, turn off the battery main switch.
Mega fuses
f you need to access the fuses:
Open the rear hatch.
Remove the cover of the fuse boxes 6.
Main fuse
1 Fuse F07
2 Fuse F010
3 Fuse F03
4 Fuse F01
5 Fuse F08
6 Fuse box cover (removed)
Eliminating malfunctions
4 - 17
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Fuse VaIue Unit Designation/function Location
F07 10 A Hazard warning system Rear left of engine compartment
F010 5 A nfo. heating flange Rear left of engine compartment
F03 60 A Preglow Rear left of engine compartment
F01 100 A Main fuse Rear left of engine compartment
F08 200 A Emergency steering pump Rear left of engine compartment
Fuses in the engine compartment
Use the table above to identify the defective fuse.
Take out the defective fuse and replace it with a new one with the
same rating.
PIug-in fuses on the reIay and fuse board
Fuse box
1 Fuse box
2 Cover
3 Screw
Eliminating malfunctions
4 - 18
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
The circuit board and the relay as well as the plug-in fuses are located
behind the driver's seat.
Relay and fuse board
Fuse VaIue Unit Designation/function Location
F1 10 A Spare in the fuse box
F2 7.5 A Left high beam
F3 7.5 A Right high beam
F4 7.5 A Left low beam
F5 7.5 A Right low beam
F6 3 A Left profile light/parking light
F7 3 A Right profile light/parking light
F07b 10 A Hazard warning lights
F8 10 A nterior illumination, radio, cigarette lighter (X70)
F8a 15 A Seat compressor (optional), seat heating (op-
tional)

F9 10 A LH control lever button, air conditioning system,
optional keyboard

F10 5 A Display unit
F11 10 A Pressure switches B32, B28, B3. B3a
F12 20 A Spare
F13 20 A Spare
F14 30 A Separ engine prewarming system
F15 10 A LH control lever V (forward) - N - R (reverse)
excitation G3. simulation D+

F16 40 A Terminal 15 (MAX fuse)
Eliminating malfunctions
4 - 19
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Fuse VaIue Unit Designation/function Location
F17 40 A Terminal 15 (MAX fuse)
F18 10 A Brake light, rear windscreen wiper and washer
pump

F19 10 A Heater, air conditioning system, terminal 15
F19A 20 A Heater, air conditioning system, terminal 30
F20 15 A Front windshield wiper/washer pump, horn
F21 10 A Low beam, high beam
F22 7.5 A Switch lighting
F23 15 A Spare
F24 10 A gnition ON, engine ECU
F25 10 A Flashing beacon
F26 10 A Diagnostic plug
F27 10 A Profile light, parking light
F28 10 A Spare
F29 25 A gnition start lock relief
F30 15 A Vcc voltage converter, radio, 12 V socket
F31a 10 A Front left working floodlight
F31b 10 A Front right working floodlight
F32a 10 A Left working floodlight, rear hatch
F32b 10 A Right working floodlight, rear hatch
F33a 10 A Left working floodlight, rear cab roof (optional)
F33b 10 A Right working floodlight, rear cab roof (optional)
F34 20 A Refuelling pump (optional)
F35 10 A Vcc master terminal 30
F36 40 A A14.B1 LH-ECU-UP/CR
A14.B2 LH-ECU-UP/CR (MAX fuse) terminal 30
F37 40 A Reserve (MAX fuse) terminal 30
F38 5 A LH-ECU-UP/CR Vcc Controller
F39 10 A Clock, auxiliary heater
F40 20 A Vcc auxiliary heater terminal 30
F41 20 A Spare
F42 20 A Spare
F43 5 A Logic nput 1+2, Logic nput 1+2
F44 10 A nput module 1 Vcc
F45 10 A nput module 2 Vcc
F46 10 A nput module 3 Vcc
F47 10 A Output module 1 Bank 1 Y10, Y14, Y9, Y17
F48 10 A Output module 1 Bank 2 Y18, Y13. H40, Y57
F49 10 A Spare
F50 10 A Spare
F51 10 A Output module 1 DO 1 output module 2 Y51.
Y52

F52 10 A Output module 1 DO 1 output module 2 Y2a,
Y3a, Y11. Y12

F53 10 A Output module 1 DO 3 Y62 central lubrication
system

F54 5 A Terminal 15 master
F55 10 A Output module 2 Bank 1 Y16. Y53. Y15. Y15a
F56 10 A Output module 2 Bank 2 K11/50, Y50, Y20,
Y21

F57 10 A Spare
F58 10 A Spare
F59 10 A Output module 2 DO 1 output module 1
YEP1. YEP2, Y2, Y3

F60 10 A Output module 2 DO 2 output module 1 MO1.
Y6.1.2.3

F61 10 A Output module 2 DO 3 E1. E5 reversing light
F62 10 A Output module 2 DO 4 B16 back-up alarm
Eliminating malfunctions
4 - 20
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Fuse VaIue Unit Designation/function Location
F63 10 A Output module 3 Vcc Bank 1
F64 10 A Output module 3 Vcc Bank 2
F65 10 A Output module 3 Vcc Bank 3
F66 10 A Output module 3 Vcc Bank 4
F67 10 A Output module 3 Vcc DO 1
F68 10 A Output module 3 Vcc DO 2
F69 10 A Output module 3 Vcc DO 3
F70 10 A Output module 3 Vcc DO 4
F71 10 A Vcc keyboards terminal 15
F72 30 A Spare
F73 10 A Spare
F74 15 A Rear window heating, mirror heating (optional)
F75 10 A Radio terminal 58, 12 V socket
F76 10 A Radio terminal 30
Fuses in the driver's cab
Remove the cover 2.
Use the table above to identify the defective fuse.
Take out the defective fuse and replace it with a new one with the
same rating.
LED test for checking the pIug-in fuses
There is an LED next to every plug-in fuse.
The LEDs glow to show that the fuse is intact during the LED test.
Procedure for checking the pIug-in fuses
The following LED test is possible:
With the ignition OFF:
All plug-in fuses (terminal 30) are tested.
With the ignition OFF:
All plug-in fuses (terminal 15 terminal 30 and terminal 58) are tested.
With the ignition ON and a function switched on:
All plug-in fuses affected by the corresponding function are tested.
1 Button LED test
2 Fuse (example)
3 LED (example)
With the ignition ON and a function switched on:
The button LED test 1 checks the fuse(s) function is switched on.
f the fuse is intact, the corresponding LED lights up.
Eliminating malfunctions
4 - 21
L580-459/11780 0-)&,)66
4 MaIfunctions
Warning and error messages
Various faults are indicated by the corresponding symbol fields (visu-
ally) or by display instruments on the instrument panel.
See the section on the display unit in chapter 3.
Some warning functions are accompanied by audible warning signals.
Finding and eIiminating errors and maIfunctions
Faults can often be traced back to incorrect operation or servicing of
the machine.
Therefore, carefuIIy read the appropriate section of the operating
manuaI each time a fauIt occurs.
AnaIyse the cause of the fauIt and correct it immediateIy.
Describe the fault and all related circumstances as accurately as
possible if you contact LIEBHERR CUSTOMER SERVICE.
Precise information helps to locate and eliminate the cause of the fault.
This means that the exact type and serial number of the machine need
to be stated.
Never perform any work for which you have not been trained or
instructed.
Note f you cannot recognise the cause of the fault using the service code
tables or cannot rectify the fault:
! Contact LEBHERR CUSTOMER SERVCE.
4 - 1
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
4.1 Service Code TabIe
4.1.1 Service code indication on the dispIay
The control system monitors many of the machine's functions.
t monitors for short circuits, cable rupture, external voltage and incorrect
input and output signals.
n addition, the controller continuously checks the program sequence and
communication with the control modules.
Display unit
1 Service code(s) display 2 STOP display
f a fault occurs while you are setting up or operating the machine, it is
shown on the display unit and stored in the service code memory of the
main electronics (MASTER).
Service code display
The foIIowing must be taken into account:
The service code is shown in the segment display 1 (see segment
display).
All service codes are stored in the service code memory of the main
electronics (MASTER).
All service codes can be read out with the LEBHERR diagnosis
software.
The occurrence of all service codes is accompanied by a single beep.
Service Code Table
4 - 2
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
MaIfunctions and their effects
Every malfunction has a defined effect.
See the Effects column in the service code table.
Depending on the cause of the fault, restriced driving may still be possible.
f malfunctions occur which can seriously damage the machine:
The machine is shut down.
Neutral travel direction is automatically selected and the machine
coasts to a halt.
This is indicated by the STOP display 2 on the display unit.
Note Note the service code.
! After switching off the ignition, the sevice code in the segment display
(see display unit) is deleted.
Have LEBHERR CUSTOMER SERVCE rectify the fault.
Service-Code Symptom Cause SoIution
E 2000 No emergency steer-
ing function.
Emergency steering pump:
Pressure switch B3 is closed
even though the engine is not
running
Contact LEBHERR CUSTOM-
ER SERVCE
E 2001 No emergency steer-
ing function.
Emergency steering pump:
Pressure switch B3 does not
switch after the engine starts
Contact LEBHERR CUSTOM-
ER SERVCE
E 2002 No emergency steer-
ing function.
Emergency steering pump:
Test failed (B3a emergency
stering pump check pressure
switch did not switch)
Contact LEBHERR CUSTOM-
ER SERVCE
E 2003 No emergency steer-
ing function.
Emergency steering pump:
Emergency steering pump
pressure switch check B3a
closed without check
Contact LEBHERR CUSTOM-
ER SERVCE
E 2013 The output of the trav-
el pump is reduced
The hydraulic oil (B8) has
overheated to more than
95 C
Clean the cooling system, con-
tact LEBHERR CUSTOMER
SERVCE
E 2016 Symbol field H19
glows, after 2 mins the
warning beep sounds
constantly, travel di-
rection cannot be se-
lected
Brake accumulator pressure:
pressure too low
Contact LEBHERR CUSTOM-
ER SERVCE
E 2017 All three LEDs on the
control unit switch
light up, central lubri-
cation system does
not work
Central lubrication system:
Electrical fault at output (cable
rupture) of grease supply line
fault
Check the distributor, grease
supply lines and lubrication
points, contact LEBHERR
CUSTOMER SERVCE
Service Code Table
4 - 3
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 2018 Gerotor steering (2 in
1 steering) is deacti-
vated
Gerotor steering (2 in 1 steer-
ing): Signal at output does not
correspond to the activation
Contact LEBHERR CUSTOM-
ER SERVCE
E A005 Display unit (A13)
does not work
CAN: Display unit (A13) time
out, display unit (A13) hard-
ware defective, error in CAN
wiring
Contact LEBHERR CUSTOM-
ER SERVCE
E A006 Air conditioning does
not work
CAN: Air conditioning module
timeout, air conditioning hard-
ware defective, error in CAN
wiring
Contact LEBHERR CUSTOM-
ER SERVCE
E A007 Option output module
does not work
CAN: Option output module
timeout, hardware defective,
error in CAN wiring
Contact LEBHERR CUSTOM-
ER SERVCE
E A008 Option input module
does not work
CAN: Option input module
timeout, hardware defective,
error in CAN wiring
Contact LEBHERR CUSTOM-
ER SERVCE
E A020 Depends on the fault Calculation error options, input
module 1. module has sent an
internal error code
Contact LEBHERR CUSTOM-
ER SERVCE
E A021 Depends on the fault Calculation error options, out-
put module 1. module has sent
an internal error code
Contact LEBHERR CUSTOM-
ER SERVCE
E A023 Depends on the fault Caclulation error, optional
keypad module has sent an
internal error code
Contact LEBHERR CUSTOM-
ER SERVCE
E A024 Depends on the fault Calculation error, main keypad
(A11) module has sent an in-
ternal error code
Contact LEBHERR CUSTOM-
ER SERVCE
E A025 Depends on the fault Calculation error, display unit
(A13) module has sent an in-
ternal error code.
Contact LEBHERR CUSTOM-
ER SERVCE
E A026 Depends on the fault Calculation error, output
module 2 (A17b), module has
sent an internal error code
Contact LEBHERR CUSTOM-
ER SERVCE
E A027 Depends on the fault Calculation error, output mod-
ule 1 (A17a), module has sent
an internal error code
Contact LEBHERR CUSTOM-
ER SERVCE
E A028 Depends on the fault Calculation error, input module
2, module has sent an internal
error code.
Contact LEBHERR CUSTOM-
ER SERVCE
Service Code Table
4 - 4
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E A029 Depends on the fault Calculation error, input module
1. module has sent an internal
error code.
Contact LEBHERR CUSTOM-
ER SERVCE
E A02A Depends on the fault Calculation error, A 15 master
unit module has sent an inter-
nal error code.
Contact LEBHERR CUSTOM-
ER SERVCE
E 3000 STOP symbol field
H24 flashes, no emer-
gency steering func-
tion available
Emergency steering pump:
Pressure switch B3a check -
shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3001 STOP symbol field H8
flashes, no emergen-
cy steering function
available
Emergency steering pump:
Pressure switch B3 - shorted
to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3002 Symbol field H19
lights up, condition of
the parking brake can-
not be detected
Brake accumulator pressure:
Pressure switch B19 - shorted
to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3003 No float position avail-
able
Float position: Pressure switch
B32 - shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3004 No inching function
available
nching angle sensor: Channel
1 electrical fault (overcurrent
>20mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 3005 No inching function
available
nching angle sensor: Channel
1 electrical fault (undercurrent
<4mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 3006 Travel direction can-
not be selected
Control lever S2, forwards
travel direction signal: Channel
1 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3007 Travel direction can-
not be selected
Control lever S2, reverse
travel direction signal: Channel
1 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3008 No lift kick-out avail-
able
Lift kick-out: nductive switch
B17 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3009 No bucket return-to-
dig available
Bucket return-to-dig: nductive
switch B15 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 300A Gear oil symbol field
(H14) lights up
Gear oil: Overheated, over-
heating switch B14 shorted to
earth
Clean the cooler, contact
LEBHERR CUSTOMER SER-
VCE
Service Code Table
4 - 5
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 300B Fuel filling level not
detected - minimum
filling level displayed
Tank sensor B25: Electrical
fault (undervoltage <1V)
Contact LEBHERR CUSTOM-
ER SERVCE
E 300C Fuel filling level not
detected - minimum
filling level displayed
Tank sensor B25: Electrical
fault (overvoltage >4V)
Contact LEBHERR CUSTOM-
ER SERVCE
E 300D Engine cannot be
started
S1 ignition switch: Start signal
K 50a shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 300E Engine speed cannot
be changed, driving
not possible
Gas pedal angle sensor R5:
Channel 1. current too high at
the input of the input module
(>20mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 300F Engine speed cannot
be changed, driving
not possible
Gas pedal angle sensor R5:
Channel 1. current too low at
the input of the input module
(<4mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 3010 Symbol field H23
lights up, incorrect fan
speed calculated, driv-
ing only possible in
fixed gear 1 or 2
Hydraulic oil: Temperature
sensor B8 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3011 Symbol field H23
lights up, incorrect fan
speed calculated, driv-
ing only possible in
fixed gear 1 or 2
Hydraulic oil: Temperature
sensor B8 cable rupture
Contact LEBHERR CUSTOM-
ER SERVCE
E 3012 Continued driving is
only possible in fixed
gear 2
Variable displacement motor
1: nductive sensor B2 shorted
to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3013 Continued driving is
only possible in fixed
gear 2
Variable displacement motor
1: nductive sensor B2 cable
rupture
Contact LEBHERR CUSTOM-
ER SERVCE
E 3014 No speed display (out-
put speed) available.
Output speed: nductive
sensor B1 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3015 No speed display (out-
put speed) available.
Output speed: nductive
sensor B1 cable rupture
Contact LEBHERR CUSTOM-
ER SERVCE
E 3016 None Driving light: Wiring shorted to
earth at input of the input mod-
ule
Contact LEBHERR CUSTOM-
ER SERVCE
Service Code Table
4 - 6
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 3017 Symbol field H12
flashes, high beam
symbol not triggered
on monitor
High beam: Wiring shorted to
earth at input of the input mod-
ule
Contact LEBHERR CUSTOM-
ER SERVCE
E 3018 Symbol field H10
lights up, indicator
symbol not triggered
on monitor
ndicator signal: Wiring shorted
to earth at input of the input
module
Contact LEBHERR CUSTOM-
ER SERVCE
E 3019 LFD not available Ride control: Pressure switch
B28 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 301A Travel direction can-
not be selected
Control lever S2: Forwards
travel direction signal channel
2 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 301B Travel direction can-
not be selected
Control lever S2: Reverse
travel direction signal channel
2 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 301C No inching function
available
nching angle sensor R1:
Channel 2 electrical fault
(overcurrent >20mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 301D No inching function
available
nching angle sensor R1:
Channel 2 electrical fault (un-
dercurrent <4mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 301E Engine speed cannot
be changed, driving
not possible
Gas pedal angle sensor R6:
Channel 2 electrical fault
(overcurrent >20mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 301F Engine speed cannot
be changed, driving
not possible
Gas pedal angle sensor R6:
Channel 2 electrical fault (un-
dercurrent <4mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 3020 Kick-down function
not available
Control lever kick-down button
S12: shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3021 Option 2 function not
available
Control lever option 2 button
S12a: shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3022 Option 3 function not
available
Control lever option 3 button
S12b: shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3023 No audible warning
signals, H40 beeper
cannot be triggered by
an external function
H40 beeper: nput shorted to
earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3024 Central lubrication
system not available
Central lubrication system fill-
ing level: nductive switch B44
shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
Service Code Table
4 - 7
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 3025 Particle filter cannot
be monitored
Particle filter: nput 1 electrical
fault (shorted to earth)
Contact LEBHERR CUSTOM-
ER SERVCE
E 3026 Particle filter cannot
be monitored
Particle filter input 2 electrical
fault (shorted to earth)
Contact LEBHERR CUSTOM-
ER SERVCE
E 3027 Joystick steering not
available
Joystick steering: Left input
signal electrical fault (overcur-
rent >20mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 3028 Joystick steering not
available
Joystick steering: Left input
signal electrical fault (under-
current <4mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 3029 No driving function
available
Variable displacement motor
2: nductive sensor B2a short-
ed to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 302A No driving function
available
Variable displacement motor
2: nductive sensor B2a cable
rupture
Contact LEBHERR CUSTOM-
ER SERVCE
E 302B Central lubrication
system not available
Central lubrication cycle: n-
ductive sensor B43 shorted to
earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 302C Central lubrication
system not available
Central lubrication cycle: n-
ductive sensor B43 cable rup-
ture
Contact LEBHERR
CUSTOMER SERVCE
E 302D Joystick steering not
available
Joystick steering: Right input
signal electrical fault (overcur-
rent >20mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 302E Joystick steering not
available
Joystick steering: Right input
signal electrical fault (under-
current <4mA)
Contact LEBHERR CUSTOM-
ER SERVCE
E 302F Joystick steering not
available
Joystick steering: Pressure
switch 1 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3030 Joystick steering not
available
Joystick steering: Pressure
switch 2 shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3031 Basket mode - emer-
gency off function not
available
Emergency off: nput signal 1
shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3032 Basket mode - emer-
gency off function not
available
Emergency off: nput signal 2
shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3033 Basket mode function
not available
Basket mode: nput signal 1
shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
Service Code Table
4 - 8
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 3034 Basket mode function
not available
Basket mode: nput signal 2
shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3035 Joystick steering not
available
Joystick steering: Activation
button shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 3036 Joystick steering not
available
Joystick steering: Arm rest in-
ductive switch shorted to earth
Contact LEBHERR CUSTOM-
ER SERVCE
E 4000 Symbol field H11
flashes, parking brake
cannot be released,
driving not possible
Parking brake: Electrical fault
at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4002 Working hydraulics
lockout cannot be lift-
ed
Working hydraulics lockout:
Fault at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4004 No bucket return-to-
dig available
Bucket return-to-dig: Fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4006 No lift kick-out avail-
able
Lift kick-out: Fault at output
(short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4008 No float position avail-
able
Float position: Fault at output
(short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 400A Fan does not work
(full speed)
Fan: Fault at output (short cir-
cuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 400B Fan does not work
(full speed)
Fan: Fault at output (short cir-
cuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 400C Fan does not work
(full speed)
Fan: Fault at output (fault cur-
rent)
Contact LEBHERR CUSTOM-
ER SERVCE
E 400D Fan does not work
(full speed)
Fan: Fault at output (deviation)
The measured return current
does not match the output cur-
rent
Contact LEBHERR CUSTOM-
ER SERVCE
E 400E Buzzer cannot be
activated
Buzzer: Fault at output (short
circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4010 Possible gearbox
damage, coupling
damage during longer
trips
Swivel angle restriction: Elec-
trical fault at output (short cir-
cuit)
Contact LEBHERR
CUSTOMER SERVCE
E 4012 Range A2-3 activated,
kick-down not possi-
ble
1st gear solenoid: Fault at out-
put (short circuit)
Contact LEBHERR
CUSTOMER SERVCE
Service Code Table
4 - 9
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 4014 Fixed gear 1 is en-
gaged and variable
displacement motor 1
is set to a wide angle
to prevent overspeed
2nd gear solenoid: Fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4016 Fixed gear 2 is en-
gaged
3rd gear solenoid: Fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4018 Coupling damage Modulation solenoid: Fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 401A Fixed gear 2 engaged,
kick-down not possi-
ble
Variable displacement motor
1: Fault at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 401B Fixed gear 2 engaged,
kick-down not possi-
ble
Variable displacement motor
1: Fault at output (interruption)
Contact LEBHERR CUSTOM-
ER SERVCE
E 401C Fixed gear 2 engaged,
kick-down not possi-
ble
Variable displacement motor
1: Fault at output (fault current)
Contact LEBHERR CUSTOM-
ER SERVCE
E 401D Fixed gear 2 engaged,
kick-down not possi-
ble
Variable displacement motor
1: Electrical fault at output (de-
viation) The measured return
current does not match the
output current
Contact LEBHERR CUSTOM-
ER SERVCE
E 401E Fixed gear 1 is en-
gaged and variable
displacement motor 1
is set to a wide angle
to prevent overspeed
Variable displacement motor
2: Fault at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 401F Fixed gear 1 is en-
gaged and variable
displacement motor 1
is set to a wide angle
to prevent overspeed
Variable displacement motor
2: Electrical fault at output (in-
terruption)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4020 Fixed gear 1 is
engaged and variable
displacement motor 1
is set to a wide angle
to prevent overspeed
Variable displacement motor
2: Electrical fault at output
(fault current)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4021 Fixed gear 1 is en-
gaged and variable
displacement motor 1
is set to a wide angle
to prevent overspeed
Variable displacement motor
2: Electrical fault at output (de-
viation) The measured return
current does not match the
output current
Contact LEBHERR CUSTOM-
ER SERVCE
Service Code Table
4 - 10
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 4022 Only reverse travel
possible
Travel pump 1 forward direc-
tion valve: Electrical fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4024 Only forward travel
possible
Travel pump 1 reverse direc-
tion valve, electrical fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4026 No rear axle brake
available at overspeed
Overspeed protection: Fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4028 Quick change device
not available
Quick-change device: Fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 402A Driving is not possible Proportional valve control
pressure travel pump 1: Fault
at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 402B Driving is not possible Proportional valve control
pressure travel pump 1: Fault
at output (interruption)
Contact LEBHERR CUSTOM-
ER SERVCE
E 402C Driving is not possible Proportional valve control
pressure travel pump 1: Fault
at output (fault current)
Contact LEBHERR CUSTOM-
ER SERVCE
E 402D Driving is not possible Proportional valve control
pressure travel pump 1: Fault
at output (deviation) The mea-
sured return current does not
match the output current
Contact LEBHERR CUSTOM-
ER SERVCE
E 402E Driving is not possible (L584 only) proportional valve
control pressure travel pump
2: Fault at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 402F Driving is not possible (L584 only) proportional valve
control pressure travel pump
2: Fault at output (interruption)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4030 Driving is not possible (L584 only) proportional valve
control pressure travel pump
2: Fault at output (fault current)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4031 Driving is not possible (L584 only) proportional valve
control pressure travel pump
2: Fault at output (deviation)
The measured return current
does not match the output cur-
rent
Contact LEBHERR CUSTOM-
ER SERVCE
E 4032 No emergency
steering
Emergency steering pump:
Fault at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
Service Code Table
4 - 11
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 4034 No fan reversal avail-
able
Fan reversal: Fault at output
(short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4036 No ride control avail-
able
Ride control: Fault at output
(short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4038 No ride control, float
position function avail-
able
Ride control / float position:
Fault at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 403A Only reverse travel
possible
(L584 only) travel direction
valve travel pump 2 forwards:
Fault at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 403C Only forward travel
possible
(L584 only) travel direction
valve travel pump 2 reverse,
fault at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 403E Additional equipment
1 cannot be activated
Additional equipment 1: Fault
at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4040 Additional equipment
2 cannot be activated
Additional equipment 2: Fault
at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4042 No joystick steering
available
Joystick steering, left: Fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4044 No joystick steering
available
Joystick steering, right: Fault
at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4046 No 2in1 steering
(Gerotor steering)
available
Gerotor steering: Fault at out-
put (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4048 Joystick steering not
available
2. Joystick steering lockout 2
deactivated: Fault at output
(short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 404A Travel pump 2 not
available
2. Travel pump 2 lockout 2
deactivated: Fault at output
(short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 404C Central lubrication
system does not work
Central lubrication system mo-
tor: Fault at output (short cir-
cuit)
Contact LEBHERR
CUSTOMER SERVCE
E 404E Flashing back-up
alarm does not work
Flashing back-up alarm: Fault
at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4050 Travel pump 1 not
available
2. Deactivation stage travel
pump 1: Fault at output (short
circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
Service Code Table
4 - 12
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 4052 Gearbox not available 2. Gearbox lockout: Fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4054 Reversing light does
not work
Reversing light E1. E5: Fault
at output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 4056 Back-up alarm does
not work
Back-up alarm B16: Fault at
output (short circuit)
Contact LEBHERR CUSTOM-
ER SERVCE
E 502A Driving only possible
in 1st gear
mplausible signal of B1 output
speed sensor, output speed
does not correspond to
hydromotor speed (monitoring
only in 1st gear)
Contact LEBHERR CUSTOM-
ER SERVCE
E 502B No kick-down function
available
Kick-down button is pressed
longer than 10 secs. (or
jammed) after igntion or
pressed longer than 2 minutes
(or jammed) in normal opera-
tion
Check kick-down button, con-
tact LEBHERR CUSTOMER
SERVCE
E 502C No inching function
available
nching angle sensor below
100%, inch pedal constantly
less than 100% for longer than
2 minutes (inch pedal dirty)
Clean the inch pedal so that it
moves properly
E 5023 Enging does not take
up fuel
Gas pedal angle sensor R5:
Balance not ended or not con-
cluded with parameter
Contact LEBHERR CUSTOM-
ER SERVCE
E 5024 nching function not
available
nch pedal angle sensor R1:
Balance not ended or not con-
cluded with parameter
Contact LEBHERR CUSTOM-
ER SERVCE
E 5025 Couplings open -->
driving is not possible,
no hydrostatic brake
effect
Variable displacement motor
current balance not ended or
not concluded with parameter
Contact LEBHERR CUSTOM-
ER SERVCE
E 5026 Engine speed cannot
be changed, driving
not possible
Error in angle sensor R5 gas
pedal, values of sensor 1 and
sensor 2 differ
Contact LEBHERR CUSTOM-
ER SERVCE
E 5027 No inching function
available
Error in angle sensor R1 inch
pedal, values of sensor 1 and
sensor 2 differ
Contact LEBHERR CUSTOM-
ER SERVCE
E 5028 Limits the speed to
20 km/h , driving only
possible in 1st or 2nd
gear
Gear oil thermo switch B14
has triggered, gear tempera-
ture above 120 C , oil level
too high, temperature switch
defective
Clean cooling system, check
oil level, contact LEBHERR
CUSTOMER SERVCE
Service Code Table
4 - 13
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Service-Code Symptom Cause SoIution
E 5029 None Rear axle brake error: rear
axle brake activated for longer
than 3 seconds at a time or for
more than 16% intermittently
Contact LEBHERR CUSTOM-
ER SERVCE
E 5034 Engine damage Engine oil pressure too low:
Fault in pressure sensor B701
or the wiring
Check engine oil level, contact
LEBHERR CUSTOMER SER-
VCE
E 5035 Travel direction selec-
tion cannot be clearly
detected
LH control lever S2: nvalid
switching condition
Contact LEBHERR CUSTOM-
ER SERVCE
E 6012 Emergency shutdown
imminent. Engine can-
not be started
The emergency shutdown can
be triggered by the following
service codes: E 500C, E
500D, E 500E, E 500F
Contact LEBHERR CUSTOM-
ER SERVCE
E 6017 Depends on the fault Caclulation error, diesel en-
gine module has sent an
internal error code. This is
shown in the display unit in-
stead of the engine service
code.
Contact LEBHERR CUSTOM-
ER SERVCE
4.1.2 VisibIe and audibIe warning signaIs
The following table contains the warning signals which have an additional
audible tone or which are only displayed visually, along with their causes
and remedies.
There are four different audibIe warning signaIs:
Continuous tone
nterval tone (1 second tone followed by 10 second pause)
nterval tone (2 second tone followed by 3 second pause)
Single 1 second beep
Service Code Table
4 - 14
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Warning signaI Cause Remedy
Service code E 6017, coolant tem-
perature symbol field (H13) flashes
Coolant temperature above 100 C
(B708)
Clean the cooling system
and STOP symbol field lights up, Check the fan speed
Continuous warning buzzer Error in the cooling or electrical system Check the temperature sensor
B708
Compare the temperature be-
tween B708 and B21. f the tem-
perature at B21 is too low, check
the diesel engine thermostat
Service code E 6017, coolant tem-
perature symbol field (H13)
Coolant level too low (B710) Check the coolant level
and STOP symbol field light up, con-
tinuous warning buzzer
Fault in the electrical system Check the coolant level
transmitter B710
Service code E 2013 Hydraulic oil temperature above 95 C
(B8)
Clean the cooling system
Hydraulic oil overheating symbol
field (H23) lights up
Check the fan speed
Warning buzzer with interval tone Fault in the cooling / hydraulic / elec-
trical system
Check the temperature sensor
B8
Tone sequence: Check the wiring
1 second tone followed by 10 sec-
onds pause
Check the working hydraulics
pressure relief valves (control
valve block)
The output of the travel pump is
reduced
Check the travel hydraulics pres-
sure relief valves (variable ad-
justment pump)
Warning buzzer with interval tone Coolant temperature above 97 C
(B21)
Clean the cooling system
Tone sequence: 1 second tone Check the fan speed
followed by 10 seconds pause Fault in the electrical system Check the temperature sensor
B21
The output of the travel pump is
reduced
Check the wiring
Service code E 2002 Emergency steering pump check not
successfully completed (B3a)
Check the emergency steering
pump
Emergency steering check symbol
field (H24) lights up
Error in the electrical / hydraulic system Check the pressure switch B3a
Check the wiring
Check the emergency steering
pump pressure
Service code E 2001 Emergency steering function activated
due to failure of steering pump (B3)
Check the steering pump
Emergency steering symbol field
(H8) lights up, warning buzzer with
constant tone
Error in the electrical / hydraulic system Check the pressure switch B3
Stop symbol field (H36) lights up,
travel direction fails
Check the steering pump stan-
dby pressure
Service code E 6017 Engine oil pressure too low (sensor is
monitored by engine ECU)
Check the oil level
Engine oil pressure symbol field
(H4) flashes
Error in the diesel engine lubricating oil
supply
Check the pressure relief valve
Stop symbol field (H36) lights up Fault in the electrical system Check the pressure switch B701
After 10 seconds continual warning
buzzer
Check the wiring
Service Code Table
4 - 15
Malfunctions Operating Manual
L580-459/11780 0-)&,)66
Warning signaI Cause Remedy
Service code E 5028 Gearbox oil temperature above 120
C (B14)
Clean the gear oil cooler
Gear oil overheating symbol field
(H14) lights up
Oil level too high Correct the oil level
Driving only possible in 1st or 2nd
gear
Fault in the electrical system Check the thermo switch B14
Check the wiring to the gear
electronics A2
Service code E 2016 Brake accumulator pressure too low
(B19)
Start the engine: the brake accu-
mulators are filled while the en-
gine runs
Accumulator pressure symbol field
(H19) lights up
Error in the electrical / hydraulic system Check the pressure switch B19
No travel direction can be selected, Check the wiring
after 2 minutes continual warning
buzzer
Check the accumulator charge
valve
Check the gear pump
Service code E 6017 Torn V-belt Fit a new V-belt
Battery charge symbol field (H6)
lights up
Defective alternator Service the alternator
The parking brake cannot be re-
leased
Check the wiring
Service code segment display (P7)
shows the service code, single
1-second beep
Refer to the service code ta-
bles
Service Code Table
4 - 16
SCULI operating manual
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MJFCIFSS
SCULI operating manual
1. Creating a data connection to the machine
Procedure
Connect the EMT data cable to the machine and the laptop (use an adapter if
you have a USB port).
Connect the dongle to the USB port.
Turn the ignition switch on the machine to position 1.
Start SCULI.
Make the data connection to the machine.
- Click the New button.
- Select the appropriate COM port.
- Click Connect the message Status: Dongle OK briefly appears. The blue
progress bar Gathering variables should then appear.
The variable editor 5 opens. The variables 6 are shown in a table. The entry
7 Active and the green flashing lamp 8 show that data is being loaded from
the master board.
1
5
6
7
8
2
3
Gathering variables from Master4 4
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MJFCIFSS
2. Modifying the view in SCULI
The first time you open SCULI, the view will still be unclear. You can customise the
settings to improve the view.
Procedure
Open the hierarchy 1 Standard English Wheel Loader Series 6.
Adjust the column width 2 for the hierarchy structure.
Hide any columns 3 which are not needed. Right-click the column header and
uncheck Address, Name and Forced.
Adjust all the columns 4 to the right width.
When the view is as you want it, click the Options button 5.
Click Save Column Layout 6 and then click OK 7 to save the settings.
All settings are stored and remain in place the next time you open SCULI.
Even if you reinstall the program, the settings are retained.

1
2
3
5
4
6
7
3
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MJFCIFSS
3. Information on the variables
The first time you open SCULI, the view will still be unclear. You can customise the
settings to improve the view.
Column functions
Click the column headers to sort the columns in ascending or descending order.
This view shows the Category column in ascending order.
1. Status: shows the status of the variables.
The variable is being loaded by the master electronics.
The value of the variable has not been updated.
If the field is white, the current value is present.
2. Description: shows the name of the variable in German, English
and French.
3. Category: the category assigns the variables to groups.
Output: output signal from the master electronics to the output
module. The output module attempts to adjust to the specified value.
You can alter the value manually. After the ignition is turned off/on,
the original value is used again.
Input: input signal to the master electronics from the CAN modules
(input module, sensors).
You can alter the value manually. After the ignition is turned off/on,
the original value is used again.
Persistent: configurable value which is retained after the ignition is
switched off/on.
Retain: value calculated by the master electronics, which can also
be changed. The value is retained after the ignition is switched
off/on.
Initialized: value calculated by the master electronics.
You can alter the value manually. After the ignition is turned off/on,
the originally calculated value is used again.
4. Value: the value is refreshed in SCULI every 1000 ms. If a line is marked
with the cursor, the value is refreshed every 200 ms. You can
change these settings under Options. SCULI refreshes the value internally
every 100 ms.
There are two ways to change a value manually:
Click the line twice. The value is highlighted in blue and the cursor
flashes. You can change the value by entering a different number or
using the up/down cursor keys. Press the Enter key to accept and
save the altered value.
Click the line once and press the space bar. The line is highlighted
pink. Now you can alter the value using either the up/down cursor
keys (slow) or the page up/down keys (fast). These altered values are
applied immediately. Press the Enter key to save them.
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MJFCIFSS
This method is recommended for setting the block curve, because
the display on the manometer changes at the same time the value
is adjusted.
5. Unit: if a value has a unit, this is shown in the Unit column.
6. Range: the range stated the possible adjustment range where
applicable. Only values which correspond to a machine type can be
entered as the Machine type variable.
7. Default: default values are normally specified for variables in the category
Correction. The defaults are already set on new master electronics.

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