TRANSMISSION

OPERATION AND
DIAGNOSTICS
(TE27 AND TE32)
H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH,
RS46-41S CH, RS46-41L CH, RS46-41LS CH,
RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27,
HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L,
HR45-41LS) [B222]; HR45-27, HR45-31, HR45-40S,
HR45-36L, HR45-40LS, HR45-45LSX [C227];
H40.00-52.00XM-16CH (H1050HD-CH,
1150HD-CH) [F117]

PART NO. 1616703 1300 SRM 1220

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Transmission operation and diagnostics Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description of Operation.................................................................................................................................... 1
General ........................................................................................................................................................... 1
Operation............................................................................................................................................................ 4
Hydraulic Operation...................................................................................................................................... 4
Variable Force Solenoids ............................................................................................................................... 6
Speed Engagement ........................................................................................................................................ 7
Cooling and Lubrication................................................................................................................................ 7
Control System................................................................................................................................................... 8
General ........................................................................................................................................................... 8
APC200 Controller......................................................................................................................................... 8
Self Test ..................................................................................................................................................... 8
Protection Modes ....................................................................................................................................... 8
Limp Home Mode .................................................................................................................................. 8
Shut Down Mode ................................................................................................................................... 9
Transmission Exceed Codes ................................................................................................................. 9
Fault Codes ................................................................................................................................................ 9
Description ............................................................................................................................................ 9
Fault Log Mode.......................................................................................................................................... 9
Access..................................................................................................................................................... 9
Exit ........................................................................................................................................................ 10
Clear ...................................................................................................................................................... 10
Fault Identification ................................................................................................................................... 10
Transmission Control Valve.......................................................................................................................... 10
Hydraulic Control Valve Repair ............................................................................................................... 14
Pressure Check .......................................................................................................................................... 14
Pressure Specifications ................................................................................................................................. 15
Pressure, Speed, and Temperature Sensors................................................................................................. 15
Pressure Switch......................................................................................................................................... 16
Test ........................................................................................................................................................ 16
Speed Sensor.............................................................................................................................................. 16
Test ........................................................................................................................................................ 18
Temperature Sensors ................................................................................................................................ 18
Test ........................................................................................................................................................ 19
Transmission Test and Calibration................................................................................................................... 19
Precautions .................................................................................................................................................... 19
Stall Test ........................................................................................................................................................ 19
Description................................................................................................................................................. 19
Stall Test Procedure .................................................................................................................................. 19
Clutch Filling Calibration ............................................................................................................................. 20
Description................................................................................................................................................. 20
Procedure ................................................................................................................................................... 20
Inching Calibration ....................................................................................................................................... 21
Description................................................................................................................................................. 21
Brake and Inching Pedal Adjustment ...................................................................................................... 21
Inching Pedal Sensor Adjustment ............................................................................................................ 22
Inching Pedal Sensor Calibration............................................................................................................. 22
Electrical Specifications..................................................................................................................................... 23
APC200 Display Information ............................................................................................................................ 24
General ........................................................................................................................................................... 24
General Information Group .......................................................................................................................... 24

©2010 HYSTER COMPANY i

Table of Contents Transmission operation and diagnostics

TABLE OF CONTENTS (Continued)

Fault Codes .................................................................................................................................................... 25
Indication of Protection Modes ..................................................................................................................... 25
Test Function Group...................................................................................................................................... 26
Digital Input Test .......................................................................................................................................... 27
Analog Input Test .......................................................................................................................................... 28
Speed Sensor Test.......................................................................................................................................... 29
Output Test .................................................................................................................................................... 30
Voltage Test.................................................................................................................................................... 31
Calibration Group.......................................................................................................................................... 33
Calibration Mode....................................................................................................................................... 33
Clutch Filling Calibration......................................................................................................................... 33
Heat Up Mode............................................................................................................................................ 34
Inching Pedal Sensor Calibration............................................................................................................. 34
Inching Pedal Sensor Adjustment........................................................................................................ 34
Inching Pedal Sensor Calibration ........................................................................................................ 35
Diagrams, Schematics, or Arrangements ......................................................................................................... 36
Figure 35. Transmission Wiring Diagram............................................................................................... 36
Torque Specifications ......................................................................................................................................... 38
Torque Specifications for Lubricated or Plated Screw Threads .................................................................. 38
Troubleshooting ................................................................................................................................................. 40

This section is for the following models:

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];

RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222];
HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX [C227];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]

ii
1300 SRM 1220 Description of Operation

General
This manual provides information on the operation The repair procedures for the transmission and the
and diagnostics of the TE-27 and TE-32 transmission control valve are shown in Transmission Repair,
as fitted on B222, A917 and F117 series lift trucks. (TE27 and TE32) 1300 SRM 1445.
The difference between models TE-27 and TE-32 is
in the torque converter and the number of discs in Electrical system diagrams are shown in Diagrams
the clutches. Model TE-27 is fitted on trucks with 8000 SRM 1153 for A917 and F117, and in Dia-
the 224 kW engine option, model TE-32 is fitted on grams 8000 SRM 1261 for B222.
trucks with the 250 kW engine option.

Description of Operation
GENERAL Three groups of gears are continuously engaged
with each other: the input gears, the interconnect-
The transmission transfers engine power from the ing gears, and the output gears. See Figure 2 and
engine flywheel to the drive wheels, and to the hy- Figure 3.
draulic pumps that are attached to the transmission.

The engine flywheel is connected to the torque con-

verter through drive plates. See Figure 1.

The flexing properties of the drive plate reduce

transfer of axial forces between the engine crank-
shaft and the torque converter. A gear on the torque
converter housing drives the transmission pump and
the attached pumps for the lift truck hydraulic sys-
tem. The torque converter housing, transmission,
and attached pumps turn at proportional engine
speed.

The oil pressure generated by the transmission

pump is used for lubrication, internal cooling, and
hydraulic control of the transmission. Without oil
pressure, the transmission cannot function.

The torque converter hydraulically connects the

engine flywheel to the transmission input shaft. The
torque converter functions as a torque multiplier,
and as a fluid clutch to smoothly transfer power from
the engine to the transmission. The heat generated
1. DRIVE PLATE
in this process is removed by the transmission lubri- 2. TORQUE CONVERTER
cation oil, which flows through the torque converter. 3. PUMP DRIVE GEAR
4. INPUT GEAR
The different speed ratios between the input shaft 5. PUMP 1. SYSTEM PRESSURE
and the drive shaft are obtained by engaging and 6. PUMP 2. LUBRICATION
disengaging the different clutches. The engagement 7. CLUTCH FORWARD
and disengagement of the clutches are controlled by 8. TRANSMISSION INPUT SHAFT
the transmission hydraulic system. Figure 1. Transmission Input Section

1
Description of Operation
A. INPUT GEARS B. INTERCONNECTING GEARS
Figure 2. Gear Engagement
If clutches belonging to one group would be engaged
simultaneously, the transmission would lock. Erro-
neous clutch engagement is prevented by the trans-
mission control system.
Different speeds are obtained by engaging either the
forward or the reverse clutch, and by engaging the
1st, 2nd, 3rd or 4th speed clutch.
When the transmission is in NEUTRAL, the forward
clutch and the reverse clutch are disengaged, while
one of the speed clutches remains engaged.
The clutches consist of a hub which carries friction
discs with internal splines, and a drum which carries
steel discs with external splines.
2
1300 SRM 1220
C. OUTPUT GEARS
The friction discs and the steel discs are alternately
installed. By pressurizing the clutch piston, the fric-
tion discs and the steel discs are clamped together,
which causes the hub and the drum to rotate as one
unit. When hydraulic pressure is released, the re-
turn springs force the piston back against the clutch
housing and allows the hub and drum to rotate inde-
pendently. The drum, steel discs, piston, spacer, and
return springs rotate at the same speed. The hub and
friction discs rotate at the same speed. See Figure 4.
1300 SRM 1220 Description of Operation

1. CLUTCH PRESSURE OIL SUPPLY

2. LUBRICATION OIL SUPPLY
3. SHAFT SEALS
4. INTERCONNECTING GEAR
5. CLUTCH HUB
6. CLUTCH DRUM
7. PISTON SEALS
8. OUTPUT GEAR
1. INPUT GEARS 9. PISTON SPRINGS
2. INTERCONNECTING GEARS 10. WEAR SLEEVE
3. OUTPUT GEARS 11. PISTON
12. CLUTCH PLATES
Figure 3. Gear Engagement 13. CLUTCH END PLATE

Figure 4. Clutch Components

3
Operation 1300 SRM 1220

Operation
HYDRAULIC OPERATION
The transmission sump is the main reservoir for
transmission oil. The transmission pumps are
driven by gears that connect with the torque con-
verter housing. The pumps transfer the oil from
the sump through the transmission filters into the
hydraulic system. Each filter has a bypass valve
that opens when pressure difference between filter
entry and filter outlet exceeds 0.45 MPa (65.2 psi).
The smaller pump (pump 2) provides oil supply for lu-
brication and internal cooling only. The bigger pump
(pump 1) provides oil supply to the 12 bar (174 psi)
pilot regulator valve, and to the 22 bar (319 psi) main
regulator valve. The 22 bar (319 psi) main regulator
valve maintains system pressure by relieving excess
oil through the torque converter, oil cooler and lubri-
cation system. System pressure is used to fill and
pressurize the clutches.
VFS solenoids. The function of the total neutral so-
lenoid is to activate or de-activate the clutch supply
valve as required by the control system. When acti-
vated, the clutch supply valve transfers system pres-
sure to each of the clutch intensifier valves.
If the APC200 controller does NOT receive the proper
signals, the total neutral valve will be deactivated,
causing the clutch supply valve to close. All clutches
release immediately when the clutch supply valve
closes.
Note that on Figure 5 the total neutral solenoid and
the total neutral valve are shown as being de-ener-
gized. This means that the transmission is in shut-
down mode. The VFS solenoids are shown in the ac-
tivated position, cutting off oil supply to the intensi-
fier valves. The numbers in circles refer to check port
numbers.

The 12 bar (174 psi) pilot regulator valve provides pi-

lot pressure to the total neutral solenoid and to the

Legend for Figure 5

NOTE: THE VARIABLE FORCE SOLENOIDS ARE SHOWN IN THE ACTIVATED POSITION, CUTTING OFF THE
OIL SUPPLY TO THE INTENSIFIER VALVES.
A. LUBRICATION C. SYSTEM PRESSURE
B. PILOT PRESSURE D. DRAIN
1. OPERATOR COMPARTMENT 19. HOSE
2. TEMPERATURE GAUGE 20. FILTER 1
3. PRESSURE GAUGE 21. PUMP 1
4. PRESSURE REDUCER VALVE 22. SCREEN
5. TOTAL NEUTRAL 23. AIR BREATHER
6. VFS FWD 24. OIL SUMP
7. VFS 2ND/4TH 25. PUMP 2
8. VFS REV 26. FILTER 2
9. VFS 1ST/3RD 27. LUBRICATION RANGE CLUTCHES
10. 3RD/1ST SELECTOR VALVE 28. COOLER
11. 4TH/2ND SELECTOR VALVE 29. SAFETY VALVE
12. 3RD CLUTCH 30. PRESSURE REGULATOR VALVE
13. 1ST CLUTCH 31. TORQUE CONVERTER
14. REV CLUTCH 32. PRESSURE SWITCH
15. 4TH CLUTCH 33. FWD INTENSIFIER VALVE
16. 2ND CLUTCH 34. 4TH/2ND INTENSIFIER VALVE
17. FWD CLUTCH 35. REV INTENSIFIER VALVE
18. BYPASS VALVE 36. 3RD/1ST INTENSIFIER VALVE

4
1300 SRM 1220 Operation

Figure 5. Hydraulic Diagram

5
Operation 1300 SRM 1220

VARIABLE FORCE SOLENOIDS For an overview of the activated solenoids and

The Variable Force Solenoids (VFS) transfer propor-
tional oil pressure to the clutch intensifier valves, ac-
cording to a PWM signal from the APC200 controller.
When the PWM signal from the APC200 controller
reaches 100 mA, oil supply from the VFS is cut off.
With a decreasing PWM signal, the VFS increases oil
pressure to the clutch intensifier valve. When there
is NO PWM signal from the APC200 controller, the
VFS allows full pilot pressure to the clutch intensifier
valve.
As oil pressure from the VFS increases, the clutch
intensifier valve increasingly allows system pressure
to reach the relevant clutch. When the clutch is fully
engaged, full system pressure remains applied until
the VFS closes, causing the intensifier valve to also
close, which drains clutch pressure to the sump and
releases the clutch.
clutches for the different transmission speeds, refer
to Table 1.
Neutral selection is obtained by disengaging both the
forward clutch and reverse clutch. The signal from
the APC200 controller to select neutral is generated
by each of the following inputs:
• Neutral position of the gear shift selector.
• Park brake engagement.
• Fully depressed inching pedal.
• Seat NOT occupied.
• Sensor inputs causing the APC200 controller to en-
gage neutral.
NOTE: Trucks equipped with a Monotrol® pedal do
not have a shift lever with a neutral position.
NOTE: The transmission will automatically shift to
neutral a few seconds after the operator has left the
seat.

The spool of the VFS moves in a cavity to dampen NOTE: The speed clutch will remain engaged accord-
hydraulic vibration between the VFS and the clutch ing to the position of the gear shift lever, or will en-
intensifier. gage according to the gear selection made by the au-
tomatic drive mode.

Table 1. Activated Solenoids and Gear Selection

Transmission Activated On/Off Activated VFSs Activated

Gear Solenoids (Full Current) Clutches
Forward 4 Neutral Reverse, 1st/3rd Forward, 4th
Forward 3 Neutral Reverse, 2nd/4th Forward, 3rd
Forward 2 Neutral, 2nd/4th Reverse, 1st/3rd Forward, 2nd
Forward 1 Neutral, 1st/3rd, Reverse, 2nd/4th Forward, 1st
2nd/4th
Neutral 4 Neutral Forward, Reverse, 1st/3rd 4th
Neutral 3 Neutral Forward, Reverse, 2nd/4th 3rd
Neutral 2 Neutral, 2nd/4th Forward, Reverse, 1st/3rd 2nd
Neutral 1 Neutral, 1st/3rd Forward, Reverse, 2nd/4th 1st
Reverse 4 Neutral Forward, 1st/3rd Reverse 4th
Reverse 3 Neutral Forward, 2nd/4th Reverse 3rd
Reverse 2 Neutral, 2nd/4th Forward, 1st/3rd Reverse 2nd
Reverse 1 Neutral, 1st/3rd, Forward, 2nd/4th Reverse 1st
2nd/4th

6
1300 SRM 1220 Operation

SPEED ENGAGEMENT
Engagement of the forward and reverse clutch is
through a separate VFS and intensifier valve. En-
gagement of the speed clutches is through a common
VFS and common intensifier valve for 3rd/1st speed
and for 4th/2nd speed.

To engage 1st speed respectively 2nd speed, also

the selector valve for 3rd/1st respectively 4th/2nd
has to be activated. When these selector valves are
NOT activated, 3rd gear respectively 4th gear will
be engaged when the VFS and intensifier valve are
opened.

COOLING AND LUBRICATION

Heat is primarily generated at the torque converter
and at the clutch plates during transmission opera-
tion. The heat generated by mechanical friction at
gears, shafts and bearings is relatively low.

Heat generated in the torque converter relates di-

rectly to the degree of stall, i.e. the speed difference
between engine and turbine. In a stall situation most
of the supplied engine power is transferred into heat.
This heat accumulates in the torque converter be-
cause of the reduced oil flow during a stall situation.
With increasing turbine speed, the volume of added
heat reduces, while simultaneously the increased oil
flow more rapidly transfers the accumulated heat.

Heat generated at the clutch plates varies with the

actually available engine power at time of clutch
engagement and the duration of clutch engagement.
During normal operation, the transmission control
system determines the duration of clutch engage-
ment. During inching it is the driver who controls
the added heat in the clutch by varying engine power
and clutch engagement. The transmission control
system will close the forward or reverse clutch when
a certain amount of generated heat has been ex-
ceeded.
Only a minor portion of pump oil supply is used for
clutch filling. The majority of transmission oil sup-
ply is used for the cooling and lubrication circuit that
functions at a pressure that is lower than system
pressure. See Hydraulic Diagram.
The smaller transmission pump directly provides oil
to the lubrication circuit through the oil filter. See
Figure 6.
1. FILTER
2. OIL COOLER
3. THERMOSTAT VALVE
Figure 6. Port Connections Cooling and
Filtration
The bigger transmission pump provides oil to the lu-
brication circuit through the torque converter and
transmission oil cooler. The pressure regulator valve
admits oil that is not required for clutch filling. The
safety valve reduces oil pressure to 9 bar (130.5 psi)
to protect the torque converter and oil cooler.
With increasing stall of the torque converter, flow re-
sistance increases, causing a reduced oil flow through
the torque converter and causing the 9 bar (130.5 psi)
safety valve to relieve more oil. In a stall situation
most of the lubrication oil is provided by the smaller
transmission pump.

7
Control System
From the transmission lubrication port the oil flows
into channels in the different shafts, which lead to
the shaft bearings for lubrication, and to the inside of
the clutch packs where the oil absorbs the heat that
is generated at the clutch plates.
To speed the warming-up process, a thermostat valve
is installed between the torque converter outlet port
and the transmission radiator. The thermostat
Control System
GENERAL
The control system of the transmission consists of
the APC200 controller, several switches and sensors
and the hydraulic control valve. The sensors and
switches provide information to the APC200 con-
troller, which sends signals to the control valve to
operate the solenoids.
APC200 CONTROLLER
The APC200 controller has software that controls the
operation of the transmission and performs the fol-
lowing functions:
• Self-testing and troubleshooting.
• Functional control of the transmission.
– Automatic shifting gear selection.
– Inching.
• Entering a protection mode when required:
– Improper pressures, temperatures, and speeds.
– No operator present.
– Parking brake applied.
– Gear or direction change at improper speeds.
• Logging a fault code when circumstances have ex-
ceeded certain values.
• Allowing diagnostics and calibration with a laptop
(Dana Dashboard software).
Depending on the signals of the shift lever and var-
ious switches and sensors, the APC200 controller
activates or deactivates the solenoids and VFS in the
control valve, which transfer hydraulic oil pressure
to the clutches in the transmission. If an input
signal does not comply with the programming of
the APC200, the APC200 controller will record the
fault and react by activating a protection mode. All
recorded events are stored as fault codes and are
shown on the hourmeter/fault code display when the
fault occurs. Faults can also be retrieved and read at
a later time, making it possible to trace intermittent
problems.
8
1300 SRM 1220
starts opening at 87°C (188.6°F) and is completely
opened at 102°C (188.6°F). At temperatures be-
low 87°C (215.6°F), oil flow is directly returned to
the transmission. At temperatures above 102°C
(215.6°F), the entire oil flow from the outlet port
passes through the transmission radiator before it is
returned to the transmission.
Protection modes and self tests are part of the
APC200 programming and cannot be influenced.
The APC200 controller is located in the side console
of the cab and has a display and push buttons to call
off information. Normally, the gauges and displays
on the instrument panel are used to read transmis-
sion-related information. For diagnostics and set-
tings, it is recommended to use the Dana Dashboard
software system. Refer to APC200 Display Informa-
tion for the instructions on how to access and retrieve
information from the APC200 controller when the
Dana Dashboard software is not available.
Self Test
A series of checks is done at power-up. If the APC200
controller fails these checks, it will shut off all out-
puts. The transmission cannot be operated until the
problem is resolved or repaired. A fault code will be
displayed.
Protection Modes
Limp Home Mode
The transmission shifts to NEUTRAL if a fault is
detected on the following:
• Outputs for solenoids, VFS, or pressure switch
• Engine speed sensor
• Two out of three transmission speed sensors (tur-
bine, drum, or output speed sensor).
To continue driving, place the shift lever in NEU-
TRAL, and reengage a direction. When Limp Home
Mode has been entered, the user can operate the
transmission in either direction in 1st and 2nd gear
only, and inching is disabled.
1300 SRM 1220
Shut Down Mode
If an intolerable combination of faults is detected,
the Shut Down Mode will be entered. The APC200
controller puts the transmission in NEUTRAL by
putting all VFS signals at zero pressure and by
switching OFF the total neutral solenoid, cutting
off pressure to the clutches. Intolerable faults are
also referred to as Redundant Shutdown Path (RSP)
errors.
Transmission Exceed Codes
During operation of the lift truck, the APC200 con-
troller may display transmission exceed codes on the
hourmeter/fault code display. These exceed codes
show that the request made by the operator will
not be executed because of certain circumstances.
APC200 Fault Code Guide 1300 SRM 1435 lists
the transmission exceed codes with a description of
the encountered circumstances.
Fault Codes
Description
Under normal conditions, the hour meter/fault code
display on the instrument cluster shows engine run-
ning hours. The maximum hours that can be dis-
played is 9999.9 hours.
• Hourmeter reading
If the engine and/or transmission controller detects
a fault, the hourmeter/fault code display will show a
fault code instead of the engine running hours.
Fault codes starting with ‘E’ refer to engine fault
codes.
• Fault code number(s)
Fault codes starting with ‘t’ refer to transmission ex-
ceed and fault codes, which are listed in APC200
Fault Code Guide 1300 SRM 1435.
Control System
When more than one fault occurs at the same time,
the fault codes will be displayed in succession. When
circumstances have changed and all faults have
ceased to exist, the hour meter/fault code display
will show engine running hours again.
Fault code E-CON and t-CON indicate a communica-
tion problem.
Display fault code E-CON is shown when the follow-
ing occurs:
• The engine controller does not reply to the engine
identification request or request for fault codes.
• The engine controller stops sending one of the
regular messages, such as engine RPM or engine
coolant temperature.
Display fault code t-CON is shown when the instru-
ment cluster does not receive a cyclic message or
receives incorrect error messages from the APC200
controller.
Fault codes that appear as tE123 are for faults that
occur during calibration of the transmission.
Fault Log Mode
Access
The instrument cluster has a memory that records
each fault as it occurs. The faults that have occurred
can be reviewed at a later point in time by entering
into the fault log mode. Proceed as follows to enter
into the fault log mode:
1. Apply the parking brake.
2. Turn the key switch to ON, but do not start the
lift truck.
3. Turn the key switch OFF and ON three times,
switching one time per second. After the first
OFF and ON cycle, the display will show a ‘1’.
After the second OFF and ON cycle, the display
will show a ‘2’. After the third OFF and ON cycle,
the display will show a ‘3’.
The display is now in fault log mode. When no faults
have been recorded, the LCD display shows ‘clear’.
When faults have been recorded, the display shows
9
Control System
a letter and four numbers for each fault code. For
engine fault codes, the letter is ‘E’. For transmission
fault codes, the letter is ‘t’.
After the fault code, three numbers are shown which
represent the following:
• Fault code
• Hourmeter reading at last occurrence
• Hourmeter reading at first occurrence
• Number of occurrences of current fault
Each number is shown for three seconds, after which
the following number is shown. The faults will be
shown in the opposite sequence of occurrence: the
most recent fault first and the initial fault last. When
all recorded fault codes have been shown, the display
will continue to repeat the recorded fault codes until
the user exits the fault log mode.
Exit
To exit the fault log mode, turn the key switch OFF
and then ON, leaving the key switch ON for more
than two seconds. The cluster will also exit to normal
mode when the parking brake is released or when the
engine is started.
Clear
To clear the fault codes logged in the display, proceed
as follows:
1. Access the fault log mode. See Access.
2. Clear the fault log by cycling the ignition key
OFF and ON three more times. This is a repeti-
tion of the procedure to access the fault log mode.
See Access.
If the data-erasing process is successful, the display
will show ’clear’. If the data-erasing process is not
successful, the display will show the fault codes in
the memory, shown in the order by the time of the
occurrence. To return to the normal mode, follow
the procedure as described in Exit. To retry erasing
stored fault codes, follow Step 2 of the procedure to
clear fault codes.
Fault Identification
Fault codes are listed in APC200 Fault Code Guide
1300 SRM 1435, which provides an explanation of
the fault, the resulting action of the APC200 con-
troller, and checks for troubleshooting. Each fault
code represents a specific defect or malfunction.
10
1300 SRM 1220
In most cases, the suggested solution is to check elec-
trical functionality between the APC200, the wiring
and sensors, solenoids, or switches.
Before disassembling components for test purposes,
connect the Dana Dashboard software. The screen
‘Dashboard-Monitor’ allows verification of the func-
tionality of speed sensors, the pressure switch, and
the shift lever. If several possible defects are indi-
cated, Dana Dashboard software may narrow down
the number of possible defects, preventing unneces-
sary removal of components that function correctly.
To repair problems with switches, solenoids, and sen-
sors, look up their actual location, and test the com-
ponent. The location of the solenoids are shown in
the section Transmission Control Valve. The loca-
tion of sensors and switches are shown in the section
Pressure, Speed, and Temperature Sensors. Test val-
ues of solenoids and sensors are shown in the sec-
tion Temperature Sensor (In Speed Sensor) Resis-
tance Versus Temperature.
Note that the Dana Dashboard software and the
APC200 Fault Code Guide 1300 SRM 1435 have
wire references and input references that relate to
the APC200.
Refer to Table 11 for the conversion from APC200
wire numbers to Hyster wire numbers.
To determine the exact location of a harness problem,
refer to the Electrical System SRM.
TRANSMISSION CONTROL VALVE
The hydraulic control valve is located at the right-
hand side of the transmission and contains the pres-
sure switch, all solenoids, most of the valves and sev-
eral check ports. Functioning of the hydraulic control
valve depends on available pump supply pressure
and the activation of the electrical solenoids. Acti-
vation of these solenoids is controlled by the APC200
controller. Hydraulic functioning of the control valve
is schematically shown on the hydraulic diagram on
Figure 5.
Note that on Figure 5 the total neutral solenoid and
the total neutral valve are shown as being de-ener-
gized. This means that the transmission is in shut-
down mode. The VFS solenoids are shown in the acti-
vated position, cutting off oil supply to the intensifier
valves.
1300 SRM 1220 Control System

The numbers in circles refer to check port numbers. The locations of the main components of the control
Table 2 lists the check port numbers, description, fig- valve are shown on Figure 8. The location of the
ure and item number that show the location of these solenoids and the pressure switch is shown in Fig-
ports ure 7.

Table 2. Port Numbers

Port Port Pressure Figure Item

Number Description
Port 31 System Pressure 2.15 - 2.55 MPa @ 2200 rpm See Figure 11 3
Port 32 Torque Converter Out 0.2 - 0.5 MPa @ 2000 rpm See Figure 11 1
Port 34 Lubrication Supply 0.18 - 0.26 Mpa @ 1450 rpm See Figure 12 4
Port 37 Torque Converter In 0.9 MPa See Figure 11 2
Port 41 Clutch 1st 2.15 - 2.55 MPa @ 2200 rpm See Figure 12 7
Port 42 Clutch 2nd 2.15 - 2.55 MPa @ 2200 rpm See Figure 12 1
Port 43 Clutch 3rd 2.15 - 2.55 MPa @ 2200 rpm See Figure 12 6
Port 44 Clutch 4th 2.15 - 2.55 MPa @ 2200 rpm See Figure 12 3
Port 45 Clutch Forward 2.15 - 2.55 MPa @ 2200 rpm See Figure 11 6
Port 46 Clutch Reverse 2.15 - 2.55 MPa @ 2200 rpm See Figure 12 2
Port 49/51 VFS 4th/2nd 1.0 MPa See Figure 9 13
Port 50/52 VFS 3rd/1st 1.0 MPa See Figure 9 10
Port 54 VFS Forward 1.0 MPa See Figure 9 12
Port 55 VFS Reverse 1.0 MPa See Figure 9 8
Port 56 Intensifier pressure 2.15 - 2.55 MPa @ 2200 rpm See Figure 9 9
Port 57 Pilot Pressure 1.0 MPa See Figure 9 4
Port 58 Intensifier pressure 2.15 - 2.55 MPa @ 2200 rpm See Figure 9 6
Port 59 Intensifier pressure 2.15 - 2.55 MPa @ 2200 rpm See Figure 9 3
Port 60/62 Intensifier Pressure 2.15 - 2.55 MPa @ 2200 rpm See Figure 9 11
3rd/1st
Port 61/66 Intensifier Pressure 2.15 - 2.55 MPa @ 2200 rpm See Figure 9 1
4th/2nd
Port 64 Clutch Forward 2.15 - 2.55 MPa @ 2200 rpm See Figure 9 2
Port 65 Clutch Reverse 2.15 - 2.55 MPa @ 2200 rpm See Figure 9 7

11
Control System 1300 SRM 1220

Legend for Figure 7

1. VFS 4TH/2ND
2. VFS FORWARD
3. VFS 3RD/1ST
4. VFS REVERSE
5. TOTAL NEUTRAL
6. 4TH/2ND SELECTOR SOLENOID
7. 3RD/1ST SELECTOR SOLENOID
8. PRESSURE FEEDBACK SWITCH

Figure 7. Solenoid Locations

Legend for Figure 8

1. SPACER PLATE 20. PRESSURE REDUCER SPOOL
2. ADAPTER PLATE 21. PRESSURE REDUCER SPRING
3. SPACER PLATE GASKET 22. PRESSURE CHECK SPOOL
4. PLUG 23. PRESSURE CHECK SPRING
5. SPOOL BODY 24. SEPARATOR PLATE
6. VFS SOLENOID 25. STOP
7. 24V SOLENOID 26. SPOOL INTENSIFIER
8. VFS CLAMP 27. SPRING
9. CLAMP ON/OFF 28. O-RING
10. PRESSURE SWITCH CLAMP 29. RESTRICTOR PLUG
11. PRESSURE SWITCH 30. STOP SPOOL
12. SCREW 31. ACCUMULATOR SPOOL
13. WIRING HARNESS 32. ACCUMULATOR SPRING
14. SOLENOID COVERS 33. PLUG
15. SPOOL 34. LOCKWASHER
16. SPOOL 35. CAPSCREW
17. PILOT VALVE SPRING 36. LOCKWASHER
18. SWITCH PILOT SPOOL 37. SCREW
19. SEPARATOR PLATE 38. PROTECTION COVER GASKET.

12
1300 SRM 1220 Control System

Figure 8. Control Valve Components

13
Control System 1300 SRM 1220

Hydraulic Control Valve Repair

Repairs to the control valve are limited to replacing
solenoids and gaskets. Hydraulic components of the
control valve may be inspected, but cannot be ad-
justed and are not separately available for replace-
ment.

Pressure Check
Check ports for transmission oil pressures are at dif-
ferent locations on the outside of the transmission
housing and on the control valve. See Figure 9, Fig-
ure 11, and Figure 12. An overview of port numbers,
pressure specifications and port locations is in Ta-
ble 2.

None of the oil pressures are adjustable. If a pressure

is out of specification, the cause has to be established
by further checking. Not all component parts of the
control valve are being serviced. This implies that
the entire assembly must be replaced if certain com-
ponents are beyond repair.

With the transmission control valve removed, oil

ports leading to the various clutches can be pressur-
ized with air. The amount of air pressure applied
should be approximately 14 bar (200 psi). When ap-
plying air pressure to the control valve ports, clutch
engagement and obvious leaks can be established.
This test will not work using the transmission pres-
sure test ports, as the air would escape through the
intensifier valve. For the location of the ports see
Figure 10.
1. PORT 66/61 - INTENSIFIER PRESSURE
4TH/2ND
2. PORT 64 - CLUTCH FORWARD
3. PORT 59 - INTENSIFIER PRESSURE
4. PORT 57 - PILOT PRESSURE
5. PORT 31 - SYSTEM PRESSURE
6. PORT 58 - INTENSIFIER PRESSURE
7. PORT 65 - CLUTCH REVERSE
8. PORT 55 - VFS REVERSE
9. PORT 56 - INTENSIFIER PRESSURE
10. PORT 52/50 - VFS 3RD/1ST
11. PORT 62/60 - INTENSIFIER PRESSURE
3RD/1ST
12. PORT 54 - VFS FORWARD
13. PORT 49/51 - VFS 4TH/2ND

Figure 9. Check Ports, Control Valve

14
1300 SRM 1220 Control System

PRESSURE, SPEED, AND TEMPERATURE

SENSORS
Before disassembling components for test purposes,
connect the Dana Dashboard software. The screen
‘Dashboard-Monitor’ allows verification of the func-
tionality of several components, preventing unneces-
sary removal of components that function correctly.

The location of the speed and temperature sensors

are shown in Figure 11. The engine speed sensor is
located at the pump drive gear. The schematic loca-
tion of the turbine, output, and drum speed sensors
is shown in Figure 13.

A. TOP
1. REGULATOR
2. 4TH CLUTCH
3. 1ST CLUTCH
4. REVERSE CLUTCH
5. 2ND GEAR
6. 3RD GEAR CLUTCH
7. FORWARD CLUTCH

Figure 10. Transmission Control Valve Ports

PRESSURE SPECIFICATIONS
The relief pressures in this transmission are influ- 1. PORT 32 - TORQUE CONVERTER OUT
enced by the volume and viscosity of the oil passing 2. PORT 37 - TORQUE CONVERTER IN
3. PORT 31 - SYSTEM PRESSURE
through the relief valves. Smaller supply volumes 4. TEMPERATURE SWITCH
and lower viscosity result in lower system pressures. 5. ENGINE SPEED SENSOR
Bigger supply volumes and higher viscosity result in 6. PORT 45 - CLUTCH FORWARD
higher system pressures. The volume of oil through 7. TURBINE SPEED SENSOR
the relief valves depends on engine speed. Viscos- 8. OUTPUT SPEED SENSOR
9. DRUM SPEED SENSOR
ity depends on oil quality and decreases with higher
temperatures. Make sure that oil quality meets the Figure 11. Check Ports and Senders, Left Side
required specification and that oil has been replaced View
in time. Temperature of the oil must be 82 to 93°C
(180 to 199°F) for correct pressure measurement.

In the cooling and lubrication circuit the torque con-

verter causes additional flow resistance with increas-
ing speed difference between engine and transmis-
sion input shaft.

15
Control System 1300 SRM 1220

A. FRONT VIEW B. REAR VIEW

1. PORT 42 - CLUTCH 2ND 5. PORT 32 - TORQUE CONVERTER OUT
2. PORT 46 - CLUTCH REVERSE 6. PORT 43 - CLUTCH 3RD
3. PORT 44 - CLUTCH 4TH 7. PORT 41 - CLUTCH 1ST
4. PORT 34 - LUBRICATION SUPPLY

Figure 12. Check Ports, Front and Rear View

Pressure Switch
The pressure switch signals if system pressure is ap-
plied by the clutch supply valve to the intensifier
valves.
Test
When system pressure is above 16.5 bar (239 psi), the
internal resistance of the pressure switch is 1 kOhm.
When no pressure is applied, the internal resistance
is 2 kOhms. The APC200 controller measures the
actual resistance and determines that the following
conditions exist:
• 0 to 500 Ohms - Short circuit.
• 500 to 1,500 Ohms - System pressure applied.
• 1,500 to 4,000 Ohms - No system pressure.
• 4,000 Ohms or higher - Open circuit.
Verify the pressure circuit resistance by opening the
Monitor screen in the Dana Dashboard software.
View either the Pressure Switch Resistance Gauge
or the Analog Input Signal for the pressure switch
(Analog input 0). The location of the pressure switch
is shown in Figure 7.
Speed Sensor
The speed sensors determine the rotation speed of
the different gear groups. The APC200 controller
calculates the speed ratios between the different
groups and compares the calculated values with
the programmed values. If deviation exceeds an
allowable value, the APC200 controller generates a
fault code and eventually enters a protection mode.
See Figure 13. The following are a few examples of
speed inputs and ratios that are monitored by the
APC200 controller:
• Converter Speed Ratio
– The ratio between engine speed and turbine
speed is called the converter speed ratio. The
converter speed ratio is a measure of the power
being transferred through the converter. This
ratio is a major factor for the APC200 controller
to determine if a higher or lower gear is to be

16
1300 SRM 1220
selected during the automatic selection mode.
During calibration, a sudden change in converter
speed ratio is used to determine the clutch piston
position at the moment the clutch starts clamp-
ing.
• Transmission Ratio
– Each selected transmission gear has a specific
transmission ratio. When one of the direction
clutches is closed and the output speed has
reached a certain value for checking, the actual
ratio is compared with the specified ratio. If
deviation exceeds 5%, one of the clutches is as-
sumed to be slipping. A fault is flagged and the
APC200 controller enters the Shut Down Mode.
• Gear Ratio
– If the turbine, drum, or output speed sensor fails,
the APC200 controller calculates the ‘actual ra-
tio’ based on the value of the remaining sensors.
A. TURBINE SPEED B. DRUM SPEED
Figure 13. Schematic Speed Sensor Locations
Control System
This allows continued operation of the trans-
mission. Speed sensor failure is indicated by a
fault code. If the engine speed sensor fails, or if
more than one speed sensor fails, the APC200
controller will enter the Limp Home Mode and
flag a fault.
• Maximum Torque During Inching
– The APC200 programming interprets the inch-
ing pedal position as the required pressure for
the inching clutch. The heat generated in the
inching clutch is proportional to the power trans-
ferred by the torque converter (converter speed
ratio). When the power is transferred at an
excessively high level for an extended period of
time, the APC200 controller will release pres-
sure in the clutch and flag a fault.
C. OUTPUT SPEED
17
Control System 1300 SRM 1220

Test the speed sensors. Connecting the sensor with an

Dana Dashboard software shows functionality of
each of the speed sensors under ‘Speed Monitor’.
Electrical functionality can be tested by using the
schematic shown in Figure 14. Observe the correct
sensor polarity. Pin 1 must be connected to 12 Volt+.
Pin 2 must be connected to 12 Volt . For the engine
speed sensor, pin A must be connected to 12 Volt+.
Pin C must be connected to 12 Volt . Figure 14
shows the connectors which are used to connect to
incorrect polarity will destroy the sensor. Table 3
shows the acceptable test values. Replace the sensor
if it fails the test.
Speed sensors should be installed as close as possi-
ble to the gear. The speed signal will fail if the dis-
tance exceeds 1.8 mm (0.07 in.). The sensor mount-
ing bracket normally ensures correct sensor installa-
tion.

Figure 14. Speed Sensor Test

Table 3. Speed Sensor Test Values sensor connector. The temperature measured is
from the oil returning from filter 1, close to port
Voltage Current 31. The signal to the APC200 controller is trans-
Reading Level lated into a CANbus signal to the instrument
cluster and represents the transmission sump
Gear tooth sensed 1.2 volt 6 to 8 mA
temperature. Dana Dashboard software indi-
No gear tooth 2.6 to 3.0 volt 13 to 15 mA cates functionality of this temperature sensor
sensed under ‘Transmission sump temperature.’
• Torque Converter Out, Port 32
Temperature Sensors – This temperature sensor is a switch that con-
nects to ground when the temperature has ex-
There are two temperature sensors which measure ceeded 120°C (248°F). The function of this tem-
the temperature at two different locations: perature switch is to trigger a protection mode.
• Pump Supply Functionality can only be tested by immersing
– This temperature sensor is combined with the the temperature switch in hot oil, and measur-
engine speed sensor in one unit and is connected ing if it switches at 120°C (248°F).
with the APC200 controller through pin B of the

18
1300 SRM 1220
Test
Temperature Sensor (In Speed Sensor) Resistance
Versus Temperature shows the electrical resistance
Transmission Test and Calibration
PRECAUTIONS
Before testing or calibrating the transmission, verify
the following:
• Check the engine coolant level. Add coolant as
needed.
• Make sure the parking brake and service brakes
operate correctly.
• Check the transmission fluid level. Add transmis-
sion fluid as needed.
• Make sure the transmission oil temperature is at
least 60°C (140°F).
Refer to the Operating Manual for instructions on
how to add coolant and transmission oil.
To raise the oil temperature, run the engine while
stalling the torque converter as follows:
1. Place the lift truck against an object that cannot
move.
2. Apply the brake pedal and release the parking
brake.
3. Select the 3rd gear in manual mode.
4. Run the engine at half throttle until the trans-
mission oil temperature gauge indicates 60°C
(140°F).
NOTE: The transmission will shift to NEUTRAL
when the parking brake is applied.
STALL TEST
Description
The stall test provides indications for the condition
of the engine, transmission clutches, and torque con-
verter. The stall test is performed with the transmis-
sion engaged and the engine operating at full throt-
tle, while the drive wheels are being blocked. The
stall speeds for the engines are as follows:
• 224 kw engine - 1,860 to 1,950 rpm
• 250 kw engine - 1,860 to 1,950 rpm
Transmission Test and Calibration
values of the sump temperature sensor for different
temperatures. Resistance can be measured with a
normal ohmmeter, if correct polarity is observed.
Stall Test Procedure
CAUTION
DO NOT hold the throttle open for more than 15
seconds at a time. Permit the engine to operate
at idle speed for 2 minutes between tests.
CAUTION
Release the accelerator immediately if the en-
gine speed increases to its governed speed of
2,130 rpm.
CAUTION
Performing a stall test in 1st or 2nd gear may
damage the internal parts of the drive axle.
Perform the stall test in 4th gear only.
1. Connect a laptop computer to the diagnostic plug
in the side console. Select the screen to read the
engine speed.
2. Place a capacity load on the forks to prevent the
wheels from turning.
3. Place the lift truck against an object that cannot
move.
4. Apply the brake pedal and release the parking
brake.
5. Start the engine and select the 3rd gear in man-
ual mode.
6. Push the accelerator pedal to full throttle.
7. Read the stall speed and release the throttle
pedal.
If the stall speed is 50 to 200 rpm below the specifica-
tion, the engine is not operating at full power. Check
if engine fault codes are present and repair or correct
any indicated problems.
19
Transmission Test and Calibration
If the stall speed is higher than the specification, the
engaged clutch(es) may not be holding, or the torque
converter may be damaged. Check if transmission
fault codes are present and repair or correct any in-
dicated problems.
If no transmission fault codes are present and the
stall speed is considerably higher than the specifica-
tion, remove the torque converter for inspection.
If the stall speed is only slightly higher than the spec-
ification, consider the service life of the torque con-
verter and decide whether to replace the torque con-
verter immediately or at a later point in time.
CLUTCH FILLING CALIBRATION
Description
The APC200 controller is programmed to quickly fill
the clutch area until the piston starts clamping the
discs, and only then raise clutch pressure further
within a certain period of time until full engagement
has been reached.
When shifting up, the clutch to be released will start
relieving its pressure at the same moment when the
engaging clutch starts clamping. For a short period
of time, the two clutches are both partially engaged.
This feature allows shifting up smoothly under full
traction.
As the clutch plates wear, they will get slightly thin-
ner. As the clutch plates get thinner, the piston will
have longer travel until the piston starts clamping
the discs. This causes the transmission to shift less
smoothly until it has been recalibrated.
The APC200 has a calibration program to readjust
the clutch filling time and the time to reach full en-
gagement. Clutch filling time is determined by the
elapsed time between clutch fill start and the mo-
ment when the turbine speed sensor detects a change
in speed (touch detection). The time to reach full
engagement is determined by the elapsed time be-
tween touch detection and full clutch engagement.
An automatic warning to recalibrate the transmis-
sion appears on the instrument cluster every 2000
hours (tE501). See Transmission Exceed Codes.
The automatic clutch filling calibration requires that
the pumps connected to the transmission take off a
constant load from the system. The automatically
triggered command to recharge the brake accumula-
tor will cause an unacceptable load increase that will
20
1300 SRM 1220
stop the automatic clutch calibration. For this rea-
son, a calibration switch, located in the side console,
has been installed to disable the accumulator charg-
ing function to prevent interference of the automatic
clutch calibration. Also, any inadvertent operation of
a hydraulic function will cause an unacceptable load
increase and will stop the automatic clutch calibra-
tion.
During clutch calibration, codes may be displayed
that indicate incorrect conditions for proper clutch
calibration. The explanation of these codes is in
APC200 Fault Code Guide 1300 SRM 1435.
During clutch calibration, fault codes with a preced-
ing ‘E’ may be displayed (for example: E1.25). The
first digit after the ‘E’ can be a ‘1’ or a ‘2’. ‘1’ re-
lates to faults during clutch filling time. ‘2’ relates to
faults during clutch engagement. The last two digits
indicate calibration faults, which are listed and ex-
plained in APC200 Fault Code Guide 1300 SRM
1435.
Procedure
1. Apply the parking brake.
2. Connect a laptop computer to the diagnostic plug
in the side console. See APC200 Connector Loca-
tion.
3. Place the calibration switch in the down position.
4. Make sure the shift lever is in NEUTRAL or RE-
VERSE for lift trucks with a shift lever.
5. Make sure the MONOTROL® pedal is in RE-
VERSE for lift trucks with a MONOTROL®
pedal.
6. Start the engine.
7. Make sure the transmission oil temperature is at
least 60°C (140°F).
8. Select the ‘Settings’ icon from the side tool bar,
next select the ‘Automatic Calibration’ icon, then
select the ‘Transmission Calibration’ icon.
9. The automatic calibration starts when the shift
lever or MONOTROL® is moved into the FOR-
WARD position and the transmission oil temper-
ature is at least 60°C (140°F).
10. When transmission oil temperature is below
60°C (140°F), the automatic calibration program
1300 SRM 1220
will first heat the transmission before proceed-
ing with the calibration. This feature is part
of the calibration program process. DO NOT
interfere with the calibration program process,
as interference will stop the calibration.
11. The complete automatic calibration process
takes 12 to 15 minutes. The screen will show
when the calibration has been completed. The
engine speed will remain at idle during calibra-
tion.
12. Switch the key switch OFF after the laptop
screen indicates that the calibration is complete.
13. Place the calibration switch in the up position.
NOTE: DO NOT interfere with the calibration. Acti-
vating any controls or components will stop the cal-
ibration mode before completion. The screen will
show when the calibration is complete.
During calibration, the APC200 display may show
calibration condition messages or error codes. See
APC200 Fault Code Guide 1300 SRM 1435.
INCHING CALIBRATION
Description
Inching is a controlled traction and braking mode. It
enables higher engine speeds, resulting in increased
hydraulic function speeds, while the lift truck travel
speed remains low. The inching function is obtained
by relating the inching pedal position to clutch
pressure. The relation between pedal position and
clutch pressure results in the natural reaction of
the operator to depress the inching pedal further
when the actual lift truck speed is too high. A fur-
ther-depressed inching pedal causes the pressure in
the slipping clutch to lower, which reduces lift truck
speed regardless of engine speed. If excessive heat is
generated during inching, the APC200 will release
all pressure and show fault code 46.05.
The inching pedal sensor must be calibrated for two
pedal positions: inching pedal completely depressed,
and inching pedal released. Calibration is required
when the inching sensor has been replaced, or when
it becomes loose. Calibration is also required annu-
ally, due to wear and creep of pedals and linkages.
Before calibrating the inching sensor, verify the ad-
justment of the brake pedal and the inching sensor.
Incorrect sensor calibration triggers fault codes dur-
ing operation. By slightly varying the free travel of
Transmission Test and Calibration
the brake pedal, it is possible to vary the moment
when brakes are applied. An early brake application
will result in excessive heat being generated in the
inching clutch and in the brakes. A delayed brake
application results in longer pedal travel time before
the brakes are fully applied. Always make small ad-
justments in the free travel of the brake pedal and
make sure there is adequate distance between the
pedals and the floor plate when the pedals are in the
fully-applied/depressed position.
Brake and Inching Pedal Adjustment
1. Adjust the adjustment bolt located behind the
pedal on the brake pedal assembly so that the
roller has contact with the capscrew on the valve
and there is no play. See Figure 15.
1. BRAKE PEDAL
2. INCHING PEDAL
3. ADJUSTMENT BOLT FOR BRAKE PEDAL
4. ADJUSTMENT BOLT FOR BRAKE PEDAL
COUPLING
5. ADJUSTMENT BOLT FOR INCHING PEDAL
Figure 15. Brake Pedal Assembly
2. Adjust the adjustment bolt located behind the
inching pedal on the inching pedal assembly so
that the inching pedal is at the same level as the
brake pedal when both pedals are in the released
(pedal up) position. See Figure 15.
3. Adjust the adjustment bolt for the inching/brake
pedal coupling so that the inching pedal has no
play. Both pedals should move together when the
inching pedal is applied. The additional spring
installed under the inching pedal provides flexi-
bility when adjusting the brake/inching overlap.
See Figure 15 and Figure 16.
21
Transmission Test and Calibration
Figure 16. Brake Inching Pedal Adjustment
Inching Pedal Sensor Adjustment
NOTE: When the inching pedal is not activated and
in the released (pedal up) position, the analog output
of the inching pedal sensor should be between 600
and 700 mV.
NOTE: A slight preload of the potentiometer arm is
required to achieve the output voltage for the inching
pedal in the released (pedal up) position. Use Dana
Dashboard software to check the output voltage.
1. Connect a laptop computer to the diagnostic plug
in the side console. See APC200 Connector Loca-
tion.
2. Turn the key switch to the ON position.
3. Select ‘Inching Pedal Calibration Mode’.
4. Make sure the analog input of the inching pedal
sensor is between 600 and 700 mV when the
pedal is in the pedal up position.
5. If the analog input is not within specifications,
proceed as follows:
a. Raise the cab until the latch locks in the par-
tially open position. Refer to the manual Op-
erator’s Cab 100 SRM 1390.
22
1300 SRM 1220
b. Loosen the two inching pedal sensor-mount-
ing capscrews. See Figure 17.
c. Rotate the inching pedal sensor in the slot-
ted holes located beneath the inching pedal
until the output voltage of the released (pedal
up) position inching pedal is between 600 and
700 mV.
d. Tighten the two sensor-mounting capscrews
and make sure the output voltage of the inch-
ing pedal sensor is between 600 and 700 mV,
with the inching pedal in the released (pedal
up) position.
6. Turn the key switch to the OFF position.
7. Disconnect the laptop computer from the diag-
nostic plug. See APC200 Connector Location.
1. SENSOR-MOUNTING CAPSCREW
2. INCHING PEDAL SENSOR
Figure 17. Sensor Adjustment
Inching Pedal Sensor Calibration
1. Make sure the pedals and the inching sensor
have been correctly adjusted.
2. Connect a laptop computer to the diagnostic plug
in the side console. See APC200 Connector Loca-
tion.
3. Turn the key switch to the ON position.
4. Use the ‘Automatic Calibration’ mode of the Dana
Dashboard program.
1300 SRM 1220 Electrical Specifications

5. Select the ‘Inching Pedal Calibration’ mode of the
Dana Dashboard program and follow the instruc-
tions.
6. The following must be calibrated with the key
switch in the ON position:
• Fully released pedal (600- 700 mV)
• Fully depressed pedal (2500-4000 mV)
When the pedal is released, the inching percent-
age should be at 0%. If the value deviates from
0%, the ‘Inching Pedal Calibration’ process must
be repeated.
8. Exit the Dashboard program.
9. Turn the key switch to the OFF position.

7. Check the inching percentage of the transmis- 10. Disconnect the laptop computer from the diag-
sion by using the Dana Dashboard program. nostic plug.

Electrical Specifications
Electronic controlled modulation solenoids Table 4. Temperature Sensor (In Speed Sensor)
VFS 2nd/4th - VFS 1st/3rd - VFS Fwd - VFS Rev: Resistance Versus Temperature (Continued)
Coil resistance - 4.35 ±0.35 at 25°C (77°F)

ON/OFF solenoids Ambient Resistance

Total neutral, 1st/3rd and 2nd/4th range solenoid: Temperature
Coil resistance - 12V - 28 ±2 at 20°C (68°F) 20°C (68°F) 1922
Coil resistance - 24V - 87 ±2 at 20°C (68°F)
25°C (77°F) 2000
Speed sensor 30°C (86°F) 2080
Type - Magneto resistive sensor.
Sensing distance - 0 to 1.8 mm (0 to 0.07 in.) 40°C (104°F) 2245
Sensor signal - Generates a square current with a 50°C (122°F) 2417
fixed amplitude changing between 7 and 14 mA.
60°C (140°F) 2597
Table 4. Temperature Sensor (In Speed Sensor)
70°C (158°F) 2785
Resistance Versus Temperature
80°C (176°F) 2980
Ambient Resistance
90°C (194°F) 3182
Temperature
100°C (212°F) 3392
30°C ( 22°F) 1247
110°C (230°F) 3607
20°C ( 4°F) 1367
120°C (248°F) 3817
10°C (14°F) 1496
125°C (257°F) 3915
0°C (32°F) 1630
10°C (50°F) 1772

23
APC200 Display Information 1300 SRM 1220

APC200 Display Information

GENERAL
The APC200 controller is located in the side console
of the cab. The APC200 controller has a display and
push buttons to call off information. See Figure 18.
The information is provided by means of codes. The
interpretation of these codes depends on the display
mode being activated. The following display modes
are available:
• General Information
• Test
• Calibration
These display modes provide an alternative method
to calibrate or obtain information if the Dana Dash-
board software is not available.
is pressed to scroll to the next display group, the dis-
play will first show the sub group that is highest on
the display group list (GPoS, or cPoS, or Err). From
the sub group that is highest on the display group
list, it is possible to scroll to sub groups that are lower
on the sub group list. To return to the highest po-
sitioned sub group, press the S button after having
reached the lowest positioned sub group.
To scroll to the next display group, first scroll to the
sub group (GPoS, or cPoS, or Err) that is highest on
the display group list. It will only be possible to scroll
to the next display group by pressing the M button by
starting in the GPoS, cPoS, or Err display group.
To read the value of a sub group, press and release
the S button. After half a second, the display will
show the code of the sub group, followed by the ac-
tual measured value. See Table 5 for sequence and
explanation of the sub groups.

After startup, the display will show the sub group

that was selected when the APC200 was switched
OFF.

Figure 18. APC200 Front Panel

The LED lamp labeled ‘D’ is yellow and will be ON

to indicate diagnostic modes.

The LED lamp labeled ‘E’ is yellow and blinks to in-

dicate faults.

The LED lamp labeled ‘F’ is red and is ON when the

APC200 is in the reset condition.

The push button marked ‘M’ is used to scroll to one

of the three display groups.

The push button marked ‘S’ is used to scroll to the

next sub group within a display group. See Table 5.

GENERAL INFORMATION GROUP

Table 5 shows the structure of the General Informa-
tion Group. Figure 19 schematically shows that by
pressing the M button, the display scrolls to the next
display group, and by pressing the S button the dis- Figure 19. APC200 Display Groups
play scrolls to the next sub group. When the M button

24
1300 SRM 1220 APC200 Display Information

Table 5. General Information Group

Display Description Explanation Example

Gear, Vehicle Speed, Distance
GPoS Gear Position Shows the actual engaged gear direction (F, R) and range F3
(1, 2, 3).
USPd Vehicle Speed Shows the lift truck speed in 0.1 km/hr resolution. 167
diSt Travel Distance Shows the travelled distance in 0.1 km resolution. 1258
Press the S button within 3 seconds to reset to zero.
oPEr Operating Hours Shows the total lift truck running hours in one hour 12.3.4.
resolution, and has a range of 0 to 49999 hours. The
number digits show the hours, the number of dots in
between show the number of times 10000 hours needs to
be added to the number shown.
Lever Position, Transmission Speed, Temperature
cPoS Shift Lever Shows the current shift lever position (F, R) (1, 2, 3). F3
Position
ESPd Engine Speed Shows the measured engine speed. 1580
tSPd Turbine Speed Shows the measured turbine speed. 885
oSPd Output Speed Shows the measured output speed. 600
SrAt Speed Ratio Shows the speed ratio, and turbine/engine speed. 0.56
tq i Turbine Torque Shows the measured turbine torque at transmission input 125
side in N•m.
ttnP Transmission Shows the transmission temperature in °C. 65
Temperature
ctnP Cooler in Shows the cooler input temperature in °C. 75
Temperature
Fault Codes
Err Fault Code Shows the transmission fault code number. 31.01

FAULT CODES Displayed fault codes either appear blinking, or are

When the M button is pushed to scroll to the fault
code group (Err), the display normally shows ‘- - - -’,
to indicate that no faults are active. When the E-LED
is blinking, a fault is active and will be shown on the
display.
If more than one fault has been detected, the most
severe fault will be shown first. Push and release
the S button once to display the next fault code.
After the last code has been displayed, the display
will show ‘- - - -’.
shown uninterrupted. When shown uninterrupted,
the fault code is active. When blinking, the fault has
occurred but is currently inactive.
Once an inactive fault code has been displayed, it will
not be shown again. Write down the codes of inactive
faults, or refer to the dashboard display. The memory
of the dashboard display retains all fault codes until
its memory has been cleared.
INDICATION OF PROTECTION MODES
The Limp Home Mode and Shutdown Mode as de-
scribed under ‘Control System’ are only made visi-
ble on the APC200 display when it is in the GPoS- or

25
APC200 Display Information 1300 SRM 1220

cPoS-mode. The display shows ‘LH’ for Limp Home,

or ‘Sd’ for Shut Down, and also the direction and
the gear selected at that moment. Once in the Shut
Down mode, the APC200 will already have selected
NEUTRAL. The E-LED on the APC200 front panel
will be blinking. See Figure 20. Figure 21. Test Function Group Mode

The only way to leave the test function group is by

switching the key switch to OFF.

Figure 22 schematically shows that by pressing the

Figure 20. Indication of Protection Mode
TEST FUNCTION GROUP
To enter the Test Function Group, press the S button
while turning the key switch to ON. Release the S
button when the display shows: ‘8.8.8.8.’. After re-
leasing the S button the display will show: ‘diSP’.
See Figure 21.
M button the display scrolls to the next display group,
and by pressing the S button the display scrolls to
the next sub group. When the M button is pressed
to scroll to the next display group, the display will
first show the sub group that is highest on the dis-
play group list (diSP, dinP, etc.). Starting from these
positions, it will be possible to scroll to sub groups
that are lower on the sub group list. To return to the
highest positioned sub group, press the S button af-
ter having reached the lowest positioned sub group.

Figure 22. Test Function Group Schematic

26
1300 SRM 1220
To scroll to the next display group, first scroll to the
sub group (diSP, dinP, etc.) that is highest on the
display group list. Only when starting at diSP, dinP,
etc., will it be possible to scroll to the next display
group by pressing the M button.
Instructions for how to call off information for each
test group are described separately.
DIGITAL INPUT TEST
The APC200 has 10 digital inputs which measure
connectivity of the wires listed in Table 6. After
the display has shown ‘dinP’ (see Figure 23), push
and release the S button. The display indicates the
active inputs by switching ON certain segments of
the display (see Figure 24). The numbered segments
0-9 represent the digital inputs DIGIN0 through
DIGIN9.
Figure 23. Digital Input Test
In the example shown in Figure 25, the segments 1,
4, and 5 are ON, indicating that DIGIN1, DIGIN4,
and DIGIN5 are active. By moving the selector lever,
different segments will be switched ON.
APC200 Display Information
Figure 24. Display Segment Numbers
Press and hold the S button to scroll to the individ-
ual digital inputs. The display will show the logic in-
put number with the matching APC200 wire number.
The example in Figure 26 shows that DIGIN0 relates
to APC200 wire A12. Table 6 provides the conversion
from APC200 wire numbers to wire numbers.
When releasing the S button, the display shows
either ‘hi’ or ‘lo’. When the lever switch is making a
connection or has a short circuit, ‘hi’ is shown. When
the lever switch does not connect or has an open
circuit, ‘lo’ is shown. Unsupported connections will
show ‘lo’.
Pressing the S button after 9.46 returns the display
to ‘dinP’.
Figure 25. Active Digital Inputs
27
APC200 Display Information 1300 SRM 1220

Table 6. Digital Input Test

Code Wire APC200 Hyster APC200 Pin Wire Description Output

Name Wire Nr Wire Nr Nr
Digital Input Test
0.12 DIGIN0 A12 549-c B2 Shift Lever 1st hi/lo
1.13 DIGIN1 A13 590-1 C2 Shift Lever 2nd hi/lo
2.14 DIGIN2 A14 551-a D2 Seat Occupied, Switch hi/lo
Relay
3.17 DIGIN3 A17 OPEN G2 OPEN lo
4.18 DIGIN4 A18 553-e H2 Shift Lever Forward hi/lo
5.19 DIGIN5 A19 554-f J2 Shift Lever Reverse hi/lo
6.43 DIGIN6 B13 555-c L3 Start in 2nd Gear hi/lo
7.44 DIGIN7 B14 556-c M3 Automatic/Manual hi/lo
Mode
8.45 DIGIN8 B15 938-c N3 Park Brake ON/OFF hi/lo
9.46 DIGIN9 B16 OPEN P3 OPEN lo

Figure 26. Digital Input Code Figure 28. Analog Resistance Values

ANALOG INPUT TEST
The APC200 has seven analog resistance inputs,
which measure the actual resistance of the sensors
listed in Table 7.
After the display has shown ‘AinP’ (see Figure 27),
push and release the S button. The display will show
the value in kilo Ohm in sequence of each of the four
inputs. Values below 1 kOhm are shown as ‘0’. Each
input value is separated by a dot. See Figure 28.
Press and hold the S button to scroll to the individ-
ual analog inputs. The display will show the logic
input number with the matching APC200 wire num-
ber. The first input shows ANI0 and APC200 wire
A11. Table 7 provides the conversion from APC200
wire numbers to wire numbers.
When releasing the S button, the display shows the
resistance value in Ohms. Pressing the S button af-
ter 6.36 returns the display to ‘AinP.’ See Figure 27.

Figure 27. Analog Input Test

28
1300 SRM 1220 APC200 Display Information

Table 7. Analog Input Test

Code Wire APC200 Hyster APC200 Wire Description Output

Name Wire Nr Wire Nr Pin Nr
Analog Input Test
0.11 ANI0 A11 569-a A2 Pressure Feedback Switch + Ohm
1.28 ANI1 A28 396-a H3 Transmission Temperature Ohm
2.29 ANI2 A29 386-a J3 Converter Out Temperature Ohm
3.47 ANI3 B17 387-a R3 Inching Pedal Signal Ohm
4.32 ANI4 B02 251-a M1 Inching Pedal Ohm
5.34 ANI5 B04 open P1 open
6.36 ANI6 B06 open S1 open

SPEED SENSOR TEST
The APC200 has four speed sensor inputs which rep-
resent the number of teeth that pass the sensor per
second (see Table 8). After the display has shown
‘SPd’ (see Figure 29), push and release the S button.
The display will show the value in kilo-Ohms in se-
quence of each input. Each value is separated by a
dot.
input number with the matching APC200 wire num-
ber. The first sensor is indicated by ‘0.22,’ meaning
that sensor SS0 relates to APC200 wire A22. Table 8
provides the conversion of APC200 wire numbers to
wire numbers.
When releasing the S button, the display shows a ‘c’
to indicate a current type sensor, and a dot and three
digits to indicate the frequency in kHz. Figure 30
shows a frequency of 0.933 kHz. Pressing the S but-
ton after 3.41 returns the display to ‘SPd’.

Figure 29. Speed Sensor Test

Press and hold the S button to scroll to the individ- Figure 30. Measured Frequency
ual analog inputs. The display will show the logic

Table 8. Speed Sensor Test

Code Wire APC200 Hyster APC200 Wire Description Output

Name Wire Nr Wire Nr Pin Nr
Speed Sensor Test
0.22 SSO+ A22 391-a B3 Drum Speed Sensor + kHerz
1.24 SS1+ A24 393-a D3 Output Speed Sensor + kHerz
2.26 SS2+ A26 395-a F3 Engine Speed Sensor + kHerz
3.41 SS3+ B11 398-a R2 Turbine Speed Sensor kHerz
+

29
APC200 Display Information 1300 SRM 1220

OUTPUT TEST
The Output Test Group shows the outputs to the VFS
solenoids and to the ON/OFF solenoids. After the
display has shown ‘outP’ (see Figure 31), push and
release the S button. The display indicates the active
outputs by switching ON certain segments of the dis-
play. The numbered segments 0 - 3 represent the out-
puts for VFS0 - VFS3. Segments 4 - 6 are not used.
Segments 7 - 10 represent the outputs for DO0 - DO3.
that VFS0 relates to APC200 wire A02. Table 9 pro-
vides the conversion of APC200 wire numbers to wire
numbers.
When releasing the S button, the display shows ei-
ther a value for VFS solenoids, or ‘hi’/‘lo’ for ON/OFF
solenoids. The value shown for VFS solenoids is in
mA. When the solenoid is activated, ‘hi’ is shown.
When the solenoid is NOT activated, ‘lo’ is shown.
If an output is currently at fault, the respective seg-
ment in the overview screen blinks slowly. On the
output specific screen the display alternates between
mA or ‘hi’/‘lo’, and a fault type. Fault types used are
Open, Short, Curr, or Oor (out of range).

Figure 31. Output Test Pressing the S button after 10.20 returns the display
to ‘SPd’.
Press and hold the S button to scroll to the individ-
ual outputs. The display will show the logic refer-
ence number with the matching APC200 wire num-
ber. The first output is indicated by ‘0.2’, meaning

Table 9. Output Test

Code Wire APC200 Hyster APC200 Wire Description Output

Name Wire Nr Wire Nr Pin Nr
Output Test Variable Force Solenoids
0.2 VFSO+ A02 871-a B1 VFS Forward Hi Side mA
Out
1.4 VFS1+ A04 873-a D1 VFS 2nd VFS Hi Side mA
Out
2.6 VFS2+ A06 875-a F1 VFS Rev Hi Side Out mA
3.8 VFS3+ A08 877-a H1 VFS 1st/3rd Hi Side Out mA
4.31 VFS4+ B01 OPEN L1 OPEN ---
5.33 VFS5+ B03 OPEN N1 OPEN ---
6.35 VFS6+ B05 OPEN R1 OPEN ---
Output Test ON/OFF Solenoids
7.10 DO0 A10 763-a K1 Total Neutral Solenoid hi/lo
+
8.15 DO1 A15 OPEN E2 OPEN lo
9.16 DO2 A16 765-a F2 1st/3rd Selector hi/lo
Solenoid
10.20 DO3 A20 766-a K2 Total Neutral Solenoid hi/lo

30
1300 SRM 1220 APC200 Display Information

VOLTAGE TEST Pressing the S button after ‘VSEn’ returns the dis-
play to ‘Volt’.
After the display has shown ‘Volt’ (see Figure 32),
push and release the S button to scroll to one of the
three measured voltages:
• ‘VP’ - Permanent Voltage as measured on APC200
wire A01.
• ‘VS’ - Switched Voltage as measured on APC200
wire B12. Figure 32. Voltage Test
• ‘VSEn’ - Sensor Voltage as measured at any analog
input. Table 10 provides the conversion of APC200 wire
numbers to Hyster wire numbers.

Table 10. Voltage Test

Code Wire APC200 Hyster APC200 Wire Description Output

Name Wire Nr Wire Nr Pin Nr
Voltage Test
VP PPWR A01 950-b A1 Permanent Battery + 24.0 Volt
VS SPWR B12 992-b S2 Switched Battery + 24.0 Volt

Table 11 provides the conversion of APC200 wire

numbers to Hyster wire numbers.

Table 11. APC200 Wire Number to Hyster Wire Number Conversion

APC200 Wire Hyster Color APC200 Wire Description Output

Wire Nr Name Wire Nr Pin Nr
A01 PPWR 950-b red A1 Permanent Battery + 24.0 Volt
A02 VFS0+ 871-a white B1 VFS Forward Hi Side Out mA
A03 VFS0 872-a green C1 VFS Forward Lo Side Out mA
A04 VFS1+ 873-a white D1 VFS 2nd VFS Hi Side Out mA
A05 VFS1 874-a green E1 VFS 2nd VFS Lo Side Out mA
A06 VFS2+ 875-a white F1 VFS Rev Hi Side Out mA
A07 VFS2 876-a green G1 VFS Rev Lo Side Out mA
A08 VFS3+ 877-a white H1 VFS 1st/3rd Hi Side Out mA
A09 VFS3 878-a green J1 VFS 1st/3rd Lo Side Out mA
A10 DO0 763-a white K1 Total Neutral Solenoid + hi/lo
A11 ANI0 569-a white A2 Pressure Feedback Switch + Ohm
A12 DIGIN0 549-c white B2 Shift Lever 1st hi/lo
A13 DIGIN1 550-1 white C2 Shift Lever 2nd hi/lo
A14 DIGIN2 551-a white D2 Seat Occupied, Switch Relay hi/lo
A15 DO1 Open E2 Open
A16 DO2 765-a white F2 1st/3rd Selector Solenoid hi/lo

31
APC200 Display Information 1300 SRM 1220

Table 11. APC200 Wire Number to Hyster Wire Number Conversion (Continued)

APC200 Wire Hyster Color APC200 Wire Description Output

Wire Nr Name Wire Nr Pin Nr
A17 DIGIN3 Open G2 Open
A18 DIGIN4 553-e white H2 Shift Lever Forward hi/lo
A19 DIGIN5 554-f white J2 Shift Lever Reverse hi/lo
A20 DO3 766-a white K2 Total Neutral Solenoid - hi/lo
A21 GND 13-fh black A3 APC200 Ground Volt
A22 SS0+ 391-a white B3 Drum Speed Sensor + kHerz
A23 SS0- 392-a green C3 Drum Speed Sensor - kHerz
A24 SS1+ 393-a white D3 Output Speed Sensor + kHerz
A25 SS1- 394-a green E3 Output Speed Sensor - kHerz
A26 SS2+ 395-a white F3 Engine Speed Sensor + kHerz
A27 SS2- 397-a green G3 Engine Speed Sensor - kHerz
A28 ANI1 396-a white H3 Transmission Temperature Ohm
A29 ANI2 386-a white J3 Converter Out Temperature Ohm
A30 GND 582-a black K3 Ground Ohm
B01 VFS4+ Open L1 Open
B02 ANI4 251-a orange M1 Inching Pedal Ohm
B03 VFS5+ Open N1 Open
B04 ANI5 Open P1 Open
B05 VFS6+ Open R1 Open
B06 ANI6 Open S1 Open
B07 CAN L 900-k green L2 CAN Low
B08 CAN H 901-k yellow M2 CAN High
B09 RXD Open N2 Open
B10 TXD Open P2 Open
B11 SS3+ 398-a white R2 Turbine Speed Sensor + kHerz
B12 SPWR 992-b red S2 Switched Battery + 24.0 Volt
B13 DIGIN6 555-c white L3 Start in 2nd Gear hi/lo
B14 DIGIN7 556-c white M3 Automatic/Manual Mode hi/lo
B15 DIGIN8 938-c white N3 Park Brake ON/OFF hi/lo
B16 DIGIN9 Open P3 Open
B17 ANI3 387-a white R3 Inching Pedal Signal Ohm
B18 GND 13-fm black S3 Ground Volt

32
1300 SRM 1220
CALIBRATION GROUP
Calibration Mode
Figure 33 schematically shows the procedure to enter
the calibration mode. The only relevant modes are
under trAn (clutch filling calibration), hEAt (heating
the transmission), and brAH (inching sensor calibra-
tion). See Figure 34. To enter the calibration mode,
press and hold the S button, and turn the key switch
to ON. During the first 15 seconds, the display will
show ‘8888’. Release the S button after 15 seconds
when the display shows ‘trAn’.
Figure 33. Calibration Mode
Figure 34. Entering Calibration Mode
APC200 Display Information
Clutch Filling Calibration
NOTE: DO NOT interfere with the calibration. Acti-
vating any controls or components will stop the cali-
bration mode before completion.
1. Apply the parking brake.
2. Block the drive tires.
3. Make sure the transmission temperature is at
least 60°C (140°F).
4. Make sure the shift lever is in NEUTRAL or RE-
VERSE for lift trucks with a shift lever.
5. Make sure the MONOTROL® pedal is in RE-
VERSE for lift trucks with a MONOTROL®
pedal.
6. Press and hold the S button, and turn the key
switch to the ON position. During the first 15
seconds, the display will show ‘8888’. Release the
S button after 15 seconds when the display shows
‘trAn’:
NOTE: Keep engine speed at idle.
7. Start the engine.
8. Push the S button once. When all above condi-
tions are met, the APC200 display will show:
9. The automatic calibration starts when the for-
ward/reverse lever or the pedal is moved into the
FORWARD position. The screen will display:
33
APC200 Display Information
10. When the calibration has been completed, the
APC200 display will show ‘donE’:
11. Switch the key switch OFF when the APC200
display indicates that the calibration has been
completed. Observe the display and wait until
no segments are illuminated. When the display
remains OFF, the new calibration has been en-
tered into the APC200 memory. The new calibra-
tion settings will be lost if the key is switched ON
too early.
Heat Up Mode
The heat up mode provides a convenient way to
quickly heat the transmission for test and calibra-
tion purposes. During the heat up mode, only the
highest gear is selected and the inputs from the
parking brake and the brake pedal position are
ignored.
1. Press and hold the S button, and turn the key
switch to the ON position. During the first 15
seconds, the display will show ‘8888’. Release the
S button after 15 seconds when the display shows
‘trAn’.
2. Start the engine.
3. Press the M button once and release. The word
‘hEAt’ will show:
4. Press the S button again and release. The actual
transmission sump temperature will be shown:
34
1300 SRM 1220
5. Apply the service brakes.
6. Place the pedal or the shift lever in the FOR-
WARD position.
7. Push the throttle for approximately 15 seconds.
8. Place the shift lever in NEUTRAL or the pedal
in REVERSE.
9. Run the engine at 1300 rpm for approximately 15
seconds in NEUTRAL.
10. Decelerate the engine to idle.
11. Repeat Step 6 through Step 10 until the APC200
display shows a temperature above 60°C (140°F).
12. Push the M button to scroll to the desired cali-
bration mode. For a clutch calibration, scroll un-
til ’tRan’ is displayed.
Inching Pedal Sensor Calibration
Inching Pedal Sensor Adjustment
NOTE: Before calibrating the inching pedal sensor,
the inching pedal must be adjusted correctly. See
Transmission Test and Calibration, Brake and Inch-
ing Pedal Adjustment.
1. Press and hold the "S" button, and turn the key
switch to the ON position. During the first 15
seconds, the display will show:
2. Release the "S" button after 15 seconds when the
display shows:
1300 SRM 1220 APC200 Display Information

3. Push the M button until the APC200 display 2. Release the "S" button after 15 seconds when the
shows analog input: display shows:

4. Push the S button three times. The display will 3. Push the M button several times until the
show 0.11, 1.28, 2.29, and a value. Pushing the S APC200 display shows ‘brAH’:
button another time changes the display to 03.47.
Releasing the button shows the value in Ohms
for the inching pedal sensor (for example: 0.652).

4. Push the S button once to start the inching pedal

sensor calibration. The APC200 display will
show:
NOTE: The voltage reading of the inching pedal sen-
sor will be shown after a 1-2 second delay.

5. Check the voltage reading of the inching pedal

sensor. The reading must be between 0.600 and
0.700 mV when the pedal is in the pedal up posi-
tion.
5. Push the S button in the pedal up position. The
6. If the reading is not between 0.600 and 0.700 mV, APC200 display will show:
adjust the inching pedal sensor until the reading
is within specifications.

7. Turn the key switch to the OFF position to exit

the APC200 test function group.

Inching Pedal Sensor Calibration

6. Fully depress the inching pedal and press the S
NOTE: Calibration will fail under the following cir- button again.
cumstances:
• Inching sensor adjustment is below 450 mV. 7. When the calibration is complete, the APC200
• During calibration, the voltage at the inching pedal display will show ‘donE’:
sensor does not reach 2,500 mV or exceeds 4,000
mV.

1. Press and hold the "S" button, and turn the key
switch to the ON position. During the first 15
seconds, the display will show:

35
Diagrams, Schematics, or Arrangements 1300 SRM 1220

NOTE: The calibration procedure must be repeated if
the key switch is turned ON too early.
8. Turn the key switch to the OFF position to save
the calibration settings.
Observe the APC200 display and wait until no
segments are illuminated. When the display re-
mains OFF, the new calibration has been en-
tered into the APC200 memory. The new cali-
bration settings will be lost if the key switch is
turned ON too early.

Legend for Figure 35

Item No. Description Code Location

1 APC200 J2 CPS 27 APC200 Connector Location,
Item 1
2 Transmission Lever CPS 29 Located in the steering column
3 MONOTROL® Pedal CPS 31 Located underneath the
operator cab
4 Inching Pedal CPS 32 Figure 17, Item 2
5 Transmission Resistors CPS 34 Behind the relays panel
6 APC200 J1 CPS 21 APC200 Connector Location,
Item 1
7 Diagnostic Plug CPS 20 APC200 Connector Location,
Item 2
8 Transmission Control Valve CPS 22 Control Valve Components
9 Turbine Speed Sensor CPS 26 Figure 11
10 Drum Speed Sensor CPS 25 Figure 11,Figure 12
11 Output Speed Sensor CPS 24 Figure 11
12 Engine Speed Sensor CPS 23 Figure 11,Figure 12
13 Transmission Temperature Switch TS 27 Figure 11,Figure 12

36
1300 SRM 1220 Diagrams, Schematics, or Arrangements

Figure 35. Transmission Wiring Diagram

37
Torque Specifications 1300 SRM 1220

Torque Specifications
TORQUE SPECIFICATIONS FOR LUBRICATED OR PLATED SCREW THREADS
Table 12. Grade 5

Nom. Size Fine Thread Coarse Thread

0.2500 12.2 to 14.9 N•m (9 to 11 lbf ft) 10.8 to 13.6 N•m (8 to 10 lbf ft)
0.3125 21.7 to 27.1 N•m (16 to 20 lbf ft) 16.3 to 21.7 N•m (12 to 16 lbf ft)
0.3750 35.2 to 39.3 N•m (26 to 29 lbf ft) 31.2 to 33.9 N•m (23 to 25 lbf ft)
0.4375 55.6 to 61 N•m (41 to 45 lbf ft) 50.2 to 55.6 N•m (37 to 41 lbf ft)
0.5000 86.8 to 94.9 N•m (64 to 70 lbf ft) 77.3 to 85.4 N•m (57 to 63 lbf ft)
0.5625 123.4 to 135.6 N•m (91 to 100 lbf ft) 111.2 to 122 N•m (82 to 90 lbf ft)
0.6250 173.5 to 191.1 N•m (128 to 141 lbf ft) 153.2 to 168.1 N•m (113 to 124 lbf ft)
0.7500 302.3 to 332.1 N•m (223 to 245 lbf ft) 271.1 to 298.2 N•m (200 to 220 lbf ft)

Table 13. Grade 8

Nom. Size Fine Thread Coarse Thread

0.2500 14.9 to 17.6 N•m (11 to 13 lbf ft) 12.2 to 14.9 N•m (9 to 11 lbf ft)
0.3125 38 to 43.4 N•m (28 to 32 lbf ft) 35.2 to 40.7 N•m (26 to 30 lbf ft)
0.3750 50.2 to 55.6 N•m (37 to 41 lbf ft) 44.7 to 48.8 N•m (33 to 36 lbf ft)
0.4375 78.6 to 86.8 N•m (58 to 64 lbf ft) 70.5 to 77.3 N•m (52 to 57 lbf ft)
0.5000 122 to 134.2 N•m (90 to 99 lbf ft) 108.4 to 119.3 N•m (80 to 88 lbf ft)
0.5625 173.5 to 191.1 N•m (128 to 141 lbf ft) 155.9 to 172.2 N•m (115 to 127 lbf ft)
0.6250 244 to 268.4 N•m (180 to 198 lbf ft) 215.5 to 237.2 N•m (159 to 175 lbf ft)
0.7500 427 to 470.4 N•m (315 to 347 lbf ft) 382.3 to 420.2 N•m (282 to 310 lbf ft)

Table 14. Grades 8.8, 10.9, and 12.9

Nom. Grade 8.8 Grade 10.9 Grade 12.9

Size
Coarse Thread Coarse Thread Coarse Thread
M5 5 to 6 N•m 7 to 8 N•m 8 to 10 N•m
(3.7 to 4.4 lbf ft) (5.2 to 5.9 lbf ft) (5.9 to 7.4 lbf ft)
M6 8 to 10 N•m 12 to 15 N•m 13 to 16 N•m
(5.9 to 7.4 lbf ft) (8.9 to 11.1 lbf ft) (9.6 to 11.8 lbf ft)
M8 20 to 25 N•m 30 to 35 N•m 35 to 40 N•m
(14.8 to 18.4 lbf ft) (22.1 to 25.8 lbf ft) (25.8 to 29.5 lbf ft)
M10 40 to 50 N•m 60 to 65 N•m 65 to 75 N•m
(29.5 to 36.9 lbf ft) (44.3 to 47.9 lbf ft) (47.9 to 55.3 lbf ft)

38
1300 SRM 1220 Torque Specifications

Table 14. Grades 8.8, 10.9, and 12.9 (Continued)

Nom. Grade 8.8 Grade 10.9 Grade 12.9

Size
Coarse Thread Coarse Thread Coarse Thread
M12 68 to 75 N•m 100 to 110 N•m 115 to 130 N•m
(50.2 to 55.3 lbf ft) (73.8 to 81.1 lbf ft) (84.8 to 95.9 lbf ft)
M14 110 to 125 N•m 150 to 175 N•m 180 to 210 N•m
(81.1 to 92.2 lbf ft) (110.6 to 129.1 lbf ft) (132.8 to 154.9 lbf ft)
M16 170 to 190 N•m 240 to 275 N•m 280 to 320 N•m
(125.4 to 140.1 lbf ft) (177 to 202.8 lbf ft) (206.5 to 236 lbf ft)
M20 320 to 360 N•m 450 to 500 N•m 525 to 600 N•m
(236 to 265.5 lbf ft) (331.9 to 368.8 lbf ft) (387.2 to 442.5 lbf ft)
M24 570 to 650 N•m 800 to 900 N•m 900 to 1050 N•m
(420.4 to 479.4 lbf ft) (590.1 to 663.8 lbf ft) (663.8 to 774.4 lbf ft)
M30 1150 to 1300 N•m 1600 to 1800 N•m 1850 to 2100 N•m
(848.2 to 958.8 lbf ft) (1180.1 to 1327.6 lbf ft) (1364.5 to 1548.9 lbf ft)
M36 2000 to 2250 N•m 2749 to 3149 N•m 3249 to 3699 N•m
(1475.1 to 1659.5 lbf ft) (2027.6 to 2322.6 lbf ft) (2396.3 to 2728.2 lbf ft)

Table 15. Elastic Stop Nut Torque Table 17. Pipe Plug Torque Chart

Thread Size Torque Thread Size

Torque
NPTF
M10 × 1 8 to 10 N•m
(6 to 7 lbf ft) 1/16 × 27 7 to 9 N•m (5 to 7 lbf ft)
M14 × 1.5 10 to 12 N•m 1/8 × 27 9 to 14 N•m (7 to 10 lbf ft)
(7 to 9 lbf ft)
1/4 × 18 20 to 27 N•m (15 to 20 lbf ft)
M18 × 1.5 34 to 41 N•m
3/8 × 18 34 to 41 N•m (25 to 30 lbf ft)
(25 to 30 lbf ft)
M22 × 1.5 48 to 60 N•m 1/2 × 14 41 to 47 N•m (30 to 35 lbf ft)
(35 to 44 lbf ft) 3/4 × 10 or 14 54 to 61 N•m (40 to 45 lbf ft)
M33 × 2 112 to 140 N•m 1 × 11 1/2 68 to 75 N•m (50 to 55 lbf ft)
(83 to 103 lbf ft)
1 1/4 × 11 1/2 81 to 88 N•m (60 to 65 lbf ft)

Table 16. O-ring Port Plug Torque Chart Table 18. Pipe Plug Torque Chart

Thread Size Nominal Plugs (Permanent Plugs)

Torque
NPTF Size Torque
16 to 20 N•m M18 × 1.5 6H 34 to 41 N•m (25 to 30 lbf ft)
9/16 × 18
(12 to 15 lbf ft)
M26 × 1.5 6H 61 to 68 N•m (45 to 50 lbf ft)
27 to 34 N•m
3/4 × 16
(20 to 25 lbf ft)

39
Troubleshooting 1300 SRM 1220

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Low clutch pressure. Low oil level. Fill to proper level.

Clutch pressure regulating valve Clean valve spool and housing.

stuck open.

Faulty charging pump. Replace pump.

Broken or worn clutch shaft or piston Replace piston rings.

rings.

Clutch piston bleed valve stuck open. Clean bleed valves thoroughly.

Low charging pump output. Low oil level. Fill to proper level.

Suction screen plugged. Clean suction pump.

Defective charging pump. Replace pump.

Overheating Worn oil sealing rings. Remove, disassemble, and rebuild

convertor assembly.

Worn charging pump. Replace charging pump.

Low oil level. Fill to proper level.

Dirty oil cooler. Clean cooler.

Restriction in cooler lines. Change cooler lines.

Noisy convertor. Worn charging pump. Replace charging pump.

Worn or damaged bearings. A complete disassembly will be nec-

essary to determine which bearing is
faulty.

Lack of power. Low engine RPM at convertor stall. Tune engine, check governor.

See Overheating and make same Make corrections as explained in

checks. Overheating.

40
 TECHNICAL PUBLICATIONS

1300 SRM 1220 10/10 (12/09)(7/07)(11/06)(8/06)(7/06)(5/06)(8/05) Printed in United Kingdom