TE-17 TRANSMISSION

DESCRIPTION & OPERATION,

H25-32XM-12, H28XM-16CH,
H32XM-16CH, H25-32XMS-9
(H550-700HD, H550-700HDS) [F008];
H25-32XM-12, H25-30XMS-9
(H550-700HD, H550-700HDS) [G008]

PART NO. 1703704 1300 SRM 1392

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Upda-
ted technical service information may be available from your local authorized Hyster® dealer. Service Manuals pro-
vide general guidelines for maintenance and service and are intended for use by trained and experienced technicians.
Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in dam-
age to the products, personal injury, property damage or death.
• 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. Dis-
connect 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 specifi-
cations 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.
TE-17 Transmission Table of Contents

TABLE OF CONTENTS

General ......................................................................................................................................................................................... 1
Description ................................................................................................................................................................................... 1
General .....................................................................................................................................................................................1
Operation ...................................................................................................................................................................................... 3
Hydraulic Operation ................................................................................................................................................................ 3
Variable Force Solenoids .........................................................................................................................................................5
Speed Engagement ...................................................................................................................................................................6
Cooling and Lubrication .......................................................................................................................................................... 6
Control System ............................................................................................................................................................................. 7
General .....................................................................................................................................................................................7
APC200 Controller .................................................................................................................................................................. 7
Self Test .............................................................................................................................................................................. 7
Protection Modes ................................................................................................................................................................ 7
Limp Home Mode .......................................................................................................................................................... 7
Shut Down Mode ........................................................................................................................................................... 8
Transmission Exceed Codes .......................................................................................................................................... 8
Fault Codes ......................................................................................................................................................................... 8
Description ..................................................................................................................................................................... 8
Fault Log Mode ...................................................................................................................................................................8
Access ............................................................................................................................................................................ 8
Exit ................................................................................................................................................................................. 9
Clear ............................................................................................................................................................................... 9
Fault Identification ..............................................................................................................................................................9
Transmission Control Valve .................................................................................................................................................... 9
Transmission Control Valve Repair ..................................................................................................................................12
Pressure Check ..................................................................................................................................................................12
Pressure Specifications ..................................................................................................................................................... 13
Pressure, Speed, and Temperature Sensors ........................................................................................................................... 14
Pressure Switch .................................................................................................................................................................16
Test ...............................................................................................................................................................................16
Speed Sensor .....................................................................................................................................................................16
Test ...............................................................................................................................................................................18
Temperature Sensors .........................................................................................................................................................18
Test ...............................................................................................................................................................................19
Dana Dashboard Software ..........................................................................................................................................................19
Description .............................................................................................................................................................................19
Connection .............................................................................................................................................................................19
Transmission Test and Calibration .............................................................................................................................................19
Precautions .............................................................................................................................................................................19
Stall Test ................................................................................................................................................................................ 20
Description ........................................................................................................................................................................20
Stall Test Procedure .......................................................................................................................................................... 20
Inching Calibration ................................................................................................................................................................ 20
Description ........................................................................................................................................................................20
Brake and Inching Pedal Adjustment ............................................................................................................................... 21
Inching Pedal Sensor Adjustment .....................................................................................................................................21
Inching Pedal Sensor Calibration ......................................................................................................................................22
Electrical Specifications ............................................................................................................................................................. 22
APC200 Display Information .....................................................................................................................................................23
General ...................................................................................................................................................................................23

©2013 HYSTER COMPANY i

Table of Contents TE-17 Transmission

TABLE OF CONTENTS (Continued)

General Information Group ................................................................................................................................................... 24

Fault Codes ............................................................................................................................................................................ 25
Indication of Protection Modes ............................................................................................................................................. 25
Test Function Group .............................................................................................................................................................. 25
Digital Input Test ...................................................................................................................................................................26
Analog Input Test .................................................................................................................................................................. 27
Speed Sensor Test ..................................................................................................................................................................28
Output Test ............................................................................................................................................................................ 29
Voltage Test ...........................................................................................................................................................................30
Calibration Group .................................................................................................................................................................. 32
Calibration Mode .............................................................................................................................................................. 32
Clutch Filling Calibration ................................................................................................................................................. 32
Heat Up Mode ...................................................................................................................................................................33
Inching Pedal Sensor Calibration ......................................................................................................................................33
Inching Pedal Sensor Adjustment ................................................................................................................................ 33
Inching Pedal Sensor Calibration .................................................................................................................................34
Diagrams, Schematics or Arrangements..................................................................................................................................... 34
Figure 1. Transmission Wiring Diagram................................................................................................................................ 36

This section is for the following models:

H25-32XM-12, H28XM-16CH,H32XM-16CH, H25-32XMS-9 (H550-700HD,

H550-700HDS) [F008];
H25-32XM-12, H25-30XMS-9 (H550-700HD, H550-700HDS) [G008]

ii
1300 SRM 1392
General
This manual provides information on the operation and
diagnostics of the TE17 transmission as equipped on the
F008 and G008 series lift trucks.
Note that for F008 and G008 trucks the indication 'Forward'
and 'Reverse' needs to be considered for the transmission
and for the truck separately.
The reason is that the F008 and G008 drive axle input shaft
requires an opposite direction of rotation compared with the
normal rotation of the transmission output shaft.
To achieve that the truck moves according the position of
the shift lever or MONOTROL pedal, the APC200
software for F008 and G008 has been changed. The
changed programming causes the APC200 to send an
output signal to the solenoid which has the opposite
direction compared with the input signal for forward or
reverse.
The indication 'forward' and 'reverse' has been retained for
pressure ports, clutches, solenoids, electrical connections
and fault codes.
Description
GENERAL
The transmission transfers engine power from the engine
flywheel to the drive wheels, and to the hydraulic pumps
that are attached to the transmission.
The engine flywheel is connected to the torque converter
through drive plates. See Figure 1.
The flexing properties of the drive plate reduce transfer of
axial forces between the engine crankshaft and the torque
converter. A gear on the torque converter housing drives
the transmission pump and the attached pumps for the lift
truck hydraulic system. The torque converter housing,
transmission, and attached pumps turn at proportional en-
gine 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.
General
When doing repairs or ordering spare parts, remember that
activating the forward clutch on F008 and G008 trucks
causes the lift truck to move in reverse direction, and
activating the reverse clutch causes the F008 and G008
truck to move in forward direction.
The repair procedures for the transmission and the control
valve are shown in TE-17 Transmission Repair
1300SRM1393.
For electrical system diagrams, see the Diagrams manual
for your lift truck.
For electrical connectors, see the Electrical System manual
for your lift truck.
The torque converter hydraulically connects the engine fly-
wheel 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 transmis-
sion. The heat generated in this process is removed by the
transmission lubrication oil, which flows through the torque
converter.
The different speed ratios between the input shaft and the
drive shaft are obtained by engaging and disengaging the
different clutches. The engagement and disengagement of
the clutches are controlled by the transmission hydraulic
system.
Three groups of gears are continuously engaged with each
other: the input gears, the interconnecting gears, and the
output gears. See Figure 2.
1
Description 1300 SRM 1392

A. INPUT GEARS
B. INTERCONNECTING GEARS
C. OUTPUT GEARS

Figure 2. Gear Engagement

If clutches belonging to one group would be engagedsimul-

taneously, the transmission would lock. Erroneous clutch
engagement is prevented by the transmission control sys-
tem.

1. DRIVE PLATE Different speeds are obtained by engaging either the for-
2. TORQUE CONVERTER ward or the reverse clutch, and by engaging the 1st, 2nd, or
3. PUMP DRIVE GEAR 3rd speed clutch.
4. TRANSMISSION PUMP
5. INPUT GEAR
6. INTERCONNECTING GEAR When the transmission is in NEUTRAL, the forward
7. CLUTCH clutch and the reverse clutch are disengaged, while one of
8. TRANSMISSION FILTER the speed clutches remains engaged.
9. TRANSMISSION INPUT SHAFT
The clutches consist of a hub which carries friction discs
Figure 1. Transmission Input Section
with internal splines, and a drum which carries steel discs
with external splines. See Figure 3.

The friction discs and the steel discs are alternately instal-
led. By pressurizing the clutch piston, the friction 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 return springs force the piston back against
the clutch housing and allows the hub and drum to rotate
independently. The drum, steel discs, piston, spacer, and re-
turn springs rotate at the same speed. The hub and friction
discs rotate at the same speed.

2
1300 SRM 1392 Operation

1. INTERCONNECTING GEAR 9. CLUTCH HUB, FWD GEAR

2. CLUTCH DRUM, 3RD GEAR 10. FRICTION DISCS, FWD GEAR
3. PISTON SEALS 11. PISTON
4. CLUTCH DRUM, FWD GEAR 12. PISTON SPRING SPACER
5. INTERCONNECTING GEAR 13. CLUTCH END PLATE
6. OIL SEALS 14. CLUTCH HUB, 3RD GEAR
7. PRESSURE SUPPLY, 3RD CLUTCH 15. PISTON SPRING SET
8. PRESSURE SUPPLY, FWD CLUTCH 16. STEEL DISC

Figure 3. Clutch Components

Operation
HYDRAULIC OPERATION
The transmission sump is the main reservoir for the trans-
mission oil. The transmission pump is driven by gears that
connect with the torque converter housing. The pump trans-
fers the oil from the sump through the transmission filter, to
the 10 bar (145 psi) pilot pressure regulator valve, and to
the 25 to 30 bar (363 to 435 psi) main pressure regulator
valve. See Figure 4.
The 25 to 30 bar (363 to 435 psi) system pressure regulator
valve regulates system pressure by relieving excess oil
through the torque converter, oil cooler, and lubrication
system. See Cooling and Lubrication. System pressure is
used to fill and pressurize the clutches.
The 10 bar (145 psi) pilot pressure regulator valve provides
pilot pressure to the total neutral valve and to the modula-
tion solenoids. The function of the total neutral valve is to
activate or deactivate the clutch supply valve when required
by the control system. The 25 to 30 bar (363 to 435 psi)
activated clutch supply valve transfers system pressure to
each of the clutch intensifier valves.
If the APC200 controller does NOT receive the proper sig-
nals, the total neutral valve will be deactivated, causing the
clutch supply valve to close. All clutches release immedi-
ately when the clutch supply valve closes.

3
Operation 1300 SRM 1392

Figure 4. Hydraulic Diagram

4
1300 SRM 1392 Operation

Legend for Figure 4

NOTE: THE CIRCLED NUMBERS IN THE HYDRAULIC DIAGRAM REFERENCE THE PRESSURE CHECK
PORTS IN TABLE 2, TABLE 3, ANDTABLE 4.

NOTE: THE VARIABLE FORCE SOLENOIDS ARE SHOWN IN THE ACTIVATED POSITION, CUTTING OFF
THE OIL SUPPLY TO THE INTENSIFIER VALVES.

A. COOLING AND LUBRICATION C. SYSTEM PRESSURE (HIGH PRESSURE) 0 TO

B. PILOT PRESSURE (LOW PRESSURE) 0 TO 30 bar (0 TO 435 psi)
10 bar (0 TO 145 psi) D. CLUTCH PRESSURE
1. SUMP 16. VFS SPOOL, FORWARD
2. SCREEN 17. VFS SPOOL, SECOND
3. PUMP 18. VFS SPOOL, REVERSE
4. FILTER 19. VFS SPOOL, FIRST/THIRD
5. BYPASS VALVE 20. INTENSIFIER VALVE, FORWARD
6. 25 TO 30 bar (363 TO 435 psi) SYSTEM PRES- 21. INTENSIFIER VALVE, SECOND
SURE REGULATOR VALVE 22. INTENSIFIER VALVE, REVERSE
7. 9 bar (131 psi) SAFETY VALVE 23. INTENSIFIER VALVE, FIRST/THIRD
8. TORQUE CONVERTER 24. SELECTOR SPOOL, FIRST/THIRD
9. OIL COOLER 25. THIRD SPEED CLUTCH
10. LUBRICATION OF SHAFTS AND CLUTCHES 26. FIRST SPEED CLUTCH
11. PRESSURE GAUGE 27. REVERSE CLUTCH
12. TEMPERATURE GAUGE 28. SECOND SPEED CLUTCH
13. 10 bar (145 psi) PILOT PRESSURE REGULA- 29. FORWARD CLUTCH
TOR VALVE 30. PRESSURE SWITCH
14. TOTAL NEUTRAL VALVE
15. CLUTCH SUPPLY VALVE

VARIABLE FORCE SOLENOIDS
The Variable Force Solenoids (VFS) transfer proportional
oil pressure to the clutch intensifier valves, according to a
PWM signal from the APC200 controller.
Neutral selection is obtained by disengaging both the for-
ward 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.

When the PWM signal from the APC200 controller reaches • Park brake engagement.
100 mA, oil supply from the VFS is cut off. With a de- • Fully depressed inching pedal.
creasing PWM signal, the VFS increases oil pressure to the • Seat NOT occupied.
clutch intensifier valve. When there is NO PWM signal
from the APC200 controller, the VFS allows full pilot pres- • Sensor inputs causing the APC200 controller to en-
sure to the clutch intensifier valve. gage neutral.

As oil pressure from the VFS increases, the clutch intensi- NOTE: Trucks equipped with a MONOTROL® pedal do
fier valve increasingly allows system pressure to reach the not have a shift lever with a neutral position.
relevant clutch. When the clutch is fully engaged, full sys-
NOTE: The transmission will automatically shift to neu-
tem pressure remains applied until the VFS closes, causing
tral a few seconds after the operator has left the seat.
the intensifier valve to also close, which drains clutch pres-
sure to the sump and releases the clutch. NOTE: The speed clutch will remain engaged according
to the position of the gear shift lever, or will engage accord-
The spool of the VFS moves in a cavity to dampen hy- ing to the gear selection made by the automatic drive mode.
draulic vibration between the VFS and the clutch intensi-
fier.

For an overview of the activated solenoids and clutches for

the different transmission speeds, refer to Table 1.

5
Operation 1300 SRM 1392

Table 1. Activated Solenoids and Gear Selection

Transmission Clutch Activated ON/OFF Solenoids Deactivated Activated

Direction Speed Clutches Clutches
Activated VFS Deactivated VFS
Full Current Full Current No Current
Forward 3rd Total Neutral Reverse, 2nd Forward, 3rd
Forward 2nd Total Neutral Reverse, 1st/3rd Forward, 2nd
Forward 1st Total Neutral 1st/3rd Range Reverse, 2nd Forward, 1st
Neutral 1st Total Neutral 1st/3rd Range Forward + Reverse + 2nd 1st
Reverse 3rd Total Neutral Forward, 2nd Reverse, 3rd
Reverse 2nd Total Neutral Forward, 1st/3rd Reverse, 2nd
Reverse 1st Total Neutral 1st/3rd Range Forward, 2nd Reverse, 1st

SPEED ENGAGEMENT
Engagement of the forward, reverse, and 2nd speed
clutches is through separate VFSs and intensifier valves.
Engagement of the clutches for 1st speed and 3rd speed is
through a common VFS and intensifier valve and an addi-
tional selector valve. The transferred system oil pressure
connects with the 1st/3rd selector valve, which transfers oil
pressure to either the 1st clutch or the 3rd clutch, depending
on the electrical signal from the APC200 controller. When
the 1st speed selection solenoid is activated, the 1st/3rd se-
lector valve transfers system oil pressure to the 1st speed
clutch. When the 1st speed selection solenoid is NOT acti-
vated, the 1st/3rd selector valve will transfer system oil
pressure to the 3rd speed clutch.
COOLING AND LUBRICATION
Heat is primarily generated at the torque converter and at
the clutch plates during transmission operation. The heat
generated by mechanical friction at gears, shafts and bear-
ings is relatively low.
Heat generated in the torque converter relates directly 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 because 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.
tion, the transmission control system determines the dura-
tion of clutch engagement. 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 cer-
tain amount of generated heat has been exceeded.
Only a minor portion of the total transmission pump supply
is used for clutch filling. The majority of transmission oil
supply is used for the cooling and lubrication circuit that
functions at a pressure that is lower than system pressure.
See Hydraulic Diagram. The pressure regulator valve ad-
mits oil that is not required for clutch filling. The safety
valve reduces oil pressure to 9 bar (131 psi) to protect the
torque converter and oil cooler. The normal oil flow is
through the torque converter, the transmission oil cooler
and to the transmission lubrication port. The volume of oil
and the oil flow resistance causes that the initial
9 bar (131 psi) supply pressure is reduced to 0.4 to
0.85 bar (5.8 to 12.3 psi) at the transmission lubrication
port. Flow resistance increases during torque converter stall
or when oil temperature is low. When the transmission is at
operating temperature and no load is applied, the volume of
lubrication oil is 64 liter (17 gal) at 1800 rev/min.
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.

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 opera-

6
1300 SRM 1392
To speed the warming-up process, a thermostat valve is in-
stalled between the torque converter outlet port and the
transmission radiator. The thermostat starts opening at
87°C (188.6°F) and is completely opened at
102°C (188.6°F). At temperatures below 87°C (215.6°F),
Control System
GENERAL
The control system of the transmission consists of the
APC200 controller, several switches, and sensors. The sen-
sors provide information to the APC200 controller and to
the hydraulic control valve, which regulates pressures ac-
cording to signals from the APC200 controller.
Note that for F008 and G008 trucks the indication 'Forward'
and 'Reverse' needs to be considered for the transmission
and for the truck separately.
The truck moves according the position of the shift lever or
MONOTROL pedal, but the signals forward and reverse
have been swopped with the transmission functions for-
ward and reverse. The indication 'forward' and 'reverse' for
transmission components is still identical to the original no-
menclature of the manufacturer.
When doing repairs or ordering spare parts, remember that
activating the forward clutch on F008 and G008 trucks cau-
ses the lift truck to move in reverse direction, and activat-
ing the reverse clutch causes the F008 and G008 truck to
move in forward direction.
APC200 CONTROLLER
The APC200 controller has software that controls the oper-
ation of the transmission and performs the following func-
tions:
• 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.
Control System
oil flow is directly returned to the transmission. At temper-
atures 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.
• Allowing diagnostics and calibration with a laptop
(Dana Dashboard software).
Depending on the signals of the shift lever and various
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.
Protection modes and self tests are part of the APC200 pro-
gramming 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 informa-
tion. Normally, the gauges and displays on the instrument
panel are used to read transmission-related information. For
diagnostics and settings, it is recommended to use the Dana
Dashboard software system. Refer to APC200 Display In-
formation 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 con-
troller fails these checks, it will shut off all outputs. The
transmission cannot be operated until the problem is re-
solved 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
7
Control System
• Two out of three transmission speed sensors (tur-
bine, drum, or output speed sensor).
To continue driving, place the shift lever in NEUTRAL,
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.
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 sol-
enoid, cutting off pressure to the clutches. Intolerable faults
are also referred to as Redundant Shutdown Path (RSP) er-
rors.
Transmission Exceed Codes
During operation of the lift truck, the APC200 controller
may display transmission exceed codes on the hourmeter/
fault code display. These exceed codes show that the re-
quest made by the operator will not be executed because of
certain circumstances. APC200 Fault Code Guide
1300SRM1435 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 running hours. The
maximum hours that can be displayed 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 in-
stead of the engine running hours.
Fault codes starting with E’ refer to engine fault codes.
• Fault code number(s)
8
1300 SRM 1392
Fault codes starting with t’ refer to transmission exceed and
fault codes, which are listed in APC200 Fault Code Guide
1300SRM1435.
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 communication
problem.
Display fault code E-CON is shown when the following oc-
curs:
• The engine controller does not reply to the engine
identification request or request for fault codes.
• The engine controller stops sending one of the regu-
lar messages, such as engine RPM or engine coolant
temperature.
Display fault code t-CON is shown when the instrument
cluster does not receive a cyclic message or receives incor-
rect 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, switch-
ing 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’.
1300 SRM 1392
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 a letter and four
numbers for each fault code. For engine fault codes, the let-
ter is E’. For transmission fault codes, the letter is t’.
After the fault code, three numbers are shown which repre-
sent 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 recor-
ded 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 sec-
onds. 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 repetition of the proce-
dure 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 proce-
dure to clear fault codes.
Control System
Fault Identification
Fault codes are listed in APC200 Fault Code Guide
1300SRM1435, which provides an explanation of the fault,
the resulting action of the APC200 controller, and checks
for troubleshooting. Each fault code represents a specific
defect or malfunction.
In most cases, the suggested solution is to check electrical
functionality between the APC200, the wiring and sensors,
solenoids, or switches.
Before disassembling components for test purposes, con-
nect the Dana Dashboard software. The screen Dashboard-
Monitor’ allows verification of the functionality of speed
sensors, the pressure switch, and the shift lever. If several
possible defects are indicated, Dana Dashboard software
may narrow down the number of possible defects, prevent-
ing unnecessary removal of components that function cor-
rectly.
To repair problems with switches, solenoids, and sensors,
look up their actual location, and test the component. The
location of the solenoids are shown in the section Trans-
mission Control Valve. The location of sensors and
switches are shown in the section Pressure, Speed, and
Temperature Sensors. Test values of solenoids and sensors
are shown in the section Temperature Sensor (In Speed
Sensor) Resistance Versus Temperature.
Note that the Dana Dashboard software and the APC200
Fault Code Guide 1300SRM1435 have wire references
and input references that relate to the APC200.
Refer to Table 13 for the conversion from APC200 wire
numbers to Hyster wire numbers.
To determine the exact location of a harness problem, refer
to the APC200 Fault Code Guide 1300SRM1435.
TRANSMISSION CONTROL VALVE
Note that for F008 and G008 trucks the indication 'Forward'
and 'Reverse' needs to be considered for the transmission
and for the truck separately.
The truck moves according the position of the shift lever or
MONOTROL pedal, but the signals forward and reverse
have been swapped with the transmission functions forward
and reverse. The indication 'forward' and 'reverse' for trans-
mission components is still identical to the original nomen-
clature of the manufacturer.
9
Control System 1300 SRM 1392

When doing repairs or ordering spare parts, remember that
activating the forward clutch on F008 and G008 trucks cau-
ses the lift truck to move in reverse direction, and activat-
ing the reverse clutch causes the F008 and G008 truck to
move in forward direction.
The functioning of the transmission control valve depends
on the available pump supply pressure and the activation of
the electrical solenoids. The activation of the electrical sol-
enoids is controlled by the APC200 controller. For the hy-
draulic control valve schematic, see Figure 4.

The transmission control valve is a hydraulically operated
valve and is located at the front of the transmission. The
transmission control valve consists of a modulator valve, a
regulator valve, and a distribution plate. See Figure 5.
Some of the pressure check ports are located at the front of
the modulator valve. The VFS solenoids and the pressure
switch are located under the two side covers of the modula-
tor valve. The location of the check ports is shown in Fig-
ure 9. The location of the solenoids and the pressure switch
is shown in Figure 6.

1. DISTRIBUTION PLATE
2. GASKET
3. REGULATOR VALVE
4. GASKET
5. SEPARATOR PLATE
6. MODULATOR VALVE
Figure 5. Control Valve Components

10
1300 SRM 1392 Control System

1. SCREW 14. SELECTOR VALVE SPRING AND CLUTCH

2. LOCKWASHER SUPPLY SPRING
3. LEFT CONTROL VALVE COVER 15. SCREW
4. CONTROL VALVE COVER GASKET 16. PRESSURE SWITCH CLAMP
5. VFS REVERSE SOLENOID 17. PRESSURE SWITCH
6. ACCUMULATOR SPOOL 18. PRESSURE SWITCH STOP
7. ACCUMULATOR SPRING 19. O-RING
8. MODULATOR VALVE BODY 20. PRESSURE REDUCER SPRING
9. VFS FORWARD SOLENOID 21. 10 bar (145 psi) PILOT PRESSURE REDUCER
10. RIGHT CONTROL VALVE COVER SPOOL
11. WIRE HARNESS 22. 1ST/3RD SELECTOR SPOOL
12. TOTAL NEUTRAL SOLENOID 23. 1ST/3RD SOLENOID
13. CLUTCH SUPPLY SPOOL 24. VFS 1ST/3RD SOLENOID
25. VFS 2ND SOLENOID

Figure 6. Modulator Valve Components

The regulator valve includes the modulation spools and the The function of the distribution plate is to provide the
pressure intensifier spools that regulate pressure to the proper connection between the transmission housing and
clutches. Several pressure regulator valves are also incorpo- the control valve.
rated in this housing. See Figure 7.

11
Control System 1300 SRM 1392

1. PLUG 9. 9 bar (131 psi) SAFETY VALVE SPOOL

2. O-RING 10. SAFETY VALVE SPRING
3. PRESSURE INTENSIFIER REVERSE SPOOL 11. REGULATOR VALVE BODY
4. PRESSURE INTENSIFIER SPRING 12. 25 TO 30 bar (363 TO 435 psi) PRESSURE
5. PRESSURE INTENSIFIER PISTON REGULATOR SPOOL
6. PRESSURE INTENSIFIER FORWARD SPOOL 13. PRESSURE REGULATOR SPRING
7. CONVERTER BYPASS SPRING 14. PLUG
8. 5 bar (73 psi) CONVERTER BYPASS SPOOL 15. PRESSURE INTENSIFIER 1ST/3RD GEAR
SPOOL
16. PRESSURE INTENSIFIER 2ND GEAR SPOOL
Figure 7. Regulator Valve Components

Transmission Control Valve Repair
Repairs to the control valve are limited to replacing sole-
noids and gaskets. Hydraulic components of the control
valve may be inspected, but cannot be adjusted and are not
available for replacement.
For details on control valve repairs or replacement, refer to
the manual TE-17 Transmission Repair 1300SRM1393.
Pressure Check
locations on the transmission. See Figure 10 and Figure 11,
Figure 12, and Figure 13. The port numbers mentioned at
each check port correspond with the port numbers as shown
in Figure 4. Figure 4 also shows the nominal pressure val-
ues.
The oil pressures are not adjustable. If a pressure is out of
specification, the cause must be established. If a pressure
reducing valve causes the problem, the entire assembly that
includes this valve must be replaced.

Most of the transmission oil pressures can be measured at

the side of the control valve. See Figure 9, which lists the
check port numbers and their descriptions. Additional
check ports for transmission oil pressures are at different

12
1300 SRM 1392 Control System

With the transmission control valve removed, oil ports

leading to the various clutches can be pressurized with air.
The amount of air pressure applied should be approxi-
mately 14 bar (200 psi). When applying air pressure to the
control valve ports, clutch engagement and obvious leaks
can be determined. This test will not work using the trans-
mission pressure test ports, as the air will escape through
the intensifier valve. For the location of the ports see Fig-
ure 8.

Port Number Description

31 Regulator Pressure
33 Lubrication Pressure
36 Pilot Pressure
41 Clutch Pressure, 1st
42 Clutch Pressure, 2nd
43 Clutch Pressure, 3rd
51 Pressure Intensifier, 2nd
1. REGULATOR 4. 2ND CLUTCH 52/50 Pressure Intensifier, 1st - 3rd
2. 3RD CLUTCH 5. REVERSE
3. FORWARD 6. 1ST CLUTCH 54 Pressure Intensifier, Forward
55 Pressure Intensifier, Reverse
Figure 8. Transmission Control Valve Ports
Figure 9. Check Ports, Control Valve

The filter bypass valve is incorporated in the filter element.

NOTE: Check port fitting size: M10×1 - O-ring.
The modulator valve includes the 10 bar (145 psi) pilot
pressure reducing valve. Pressure Specifications

The regulator valve includes the 30 bar (435 psi) pressure
regulator valve, the converter bypass, and the
9 bar (131 psi) safety valve.
The relief pressures in the transmission are influenced by
the volume and viscosity of the oil passing through the re-
lief valves. Smaller supply volumes and lower viscosity re-
sult in lower system pressures. Larger supply volumes and
higher viscosity result in higher system pressures. The vol-
ume of oil flowing through the relief valves depends on en-
gine speed. Viscosity depends on the oil quality, and de-
creases with higher temperatures. Make sure the oil quality
meets the required specification and has been replaced at
the correct interval. Temperature of the oil must be 82 to
93°C (180 to 200°F) for correct pressure measurement. See
Table 2 for pressure specifications.

13
Control System 1300 SRM 1392

In the cooling and lubrication circuit, the torque converter

causes additional flow resistance with increasing speed dif-
ference between the engine and the transmission input
shaft.

Table 2. Pressure Specifications

Description Port Pressure Specification

Filter Bypass Valve --- 4.5 bar (65 psi)
Regulator Pressure 31 25 bar (363 psi) minimum at 600 rpm.
Regulator Pressure 31 30 bar (435 psi) maximum at 2200 rpm.
Clutch Pressure 41, 42, 43, 45, and 46 25 bar (363 psi) minimum at 600 rpm.
Clutch Pressure 30 bar (435 psi) maximum at 2200 rpm.
Torque Converter Out - Minimum Pressure 32 3 bar (44 psi) at stall speed.
Torque Converter Out - Maximum Pressure 32 6.5 bar (94 psi) at 2200 no load.
Lubrication Pressure - Minimum 33 0.4 bar (5.8 psi)
Lubrication Pressure - Maximum 33 0.85 bar (12.3 psi)

PRESSURE, SPEED, AND

TEMPERATURE SENSORS
Before disassembling components for test purposes, con-
nect the Dana Dashboard software. The screen Dashboard-
Monitor’ allows verification of the functionality of several
components, preventing unnecessary removal of compo-
nents that function correctly.

The location of the speed and temperature sensors are

shown in Figure 10. The engine speed sensor is located at
the pump drive gear. The schematic location of the turbine,
output, and drum speed sensors is shown in Figure 14.

NOTE: FOR LEGEND, SEE TABLE 3 AND TABLE 4.

Figure 10. Check Ports and Senders, Left Side

View

14
1300 SRM 1392 Control System

NOTE: FOR LEGEND, SEE TABLE 3 AND TABLE 4.

Figure 11. Check Ports, Front and Rear View

NOTE: FOR LEGEND, SEE TABLE 3 AND TABLE 4.

Figure 12. Check Ports, Right View

NOTE: FOR LEGEND, SEE TABLE 3 AND TABLE 4.

Figure 13. Check Ports, Front View

Table 3. Transmission Housing Check Ports

Port Number Description Figure Fitting

32 Torque Converter Out - To Cooler Figure 10 and Figure 13 M12 × 1.5 O-ring
33 Lubrication Pressure Figure 10, Figure 11, Fig- M12 × 1.5 O-ring
ure 12, and Figure 13

15
Control System 1300 SRM 1392

Table 3. Transmission Housing Check Ports (Continued)

Port Number Description Figure Fitting

35 Pump Pressure Figure 10 and Figure 13 M12 × 1.5 O-ring
37 Safety Valve Pressure Figure 12 M22 × 1.5 O-ring
45 Clutch Pressure Forward Figure 10, Table 4, and Fig- M12 × 1.5 O-ring
ure 13
46 Clutch Pressure Reverse Figure 10, Table 4, and Fig- M12 × 1.5 O-ring
ure 12,

Table 4. Sensors and Switches

Item Sensor or Switch Figure

A Turbine Speed Sensor Figure 10 and Figure 12
B Output Speed Sensor Figure 10, Figure 12, and Figure 13
C Drum Speed Sensor Figure 10, Figure 11, and Figure 13
D Engine Speed and Temperature Sensor Figure 10, Figure 11, and Figure 13
E Torque Convertor Out Temperature Switch Figure 10, Figure 12, and Figure 13

Pressure Switch Speed Sensor

The pressure switch signals if system pressure is applied by
the clutch supply valve to the intensifier valves.
Test
When system pressure is above 16.5 bar (239 psi), the in-
ternal 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.
The speed sensors determine the rotation speed of the dif-
ferent 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 gener-
ates a fault code and eventually enters a protection mode.
See Figure 14. The following are a few examples of speed
inputs and ratios that are monitored by the APC200 con-
troller:
• Converter Speed Ratio

Verify the pressure circuit resistance by opening the Moni-

tor screen in the Dana Dashboard software. View either the
Pressure Switch Resistance Gauge or the Analog Input Sig-
nal for the pressure switch (Analog input 0). The location
of the pressure switch is shown in Figure 6.

16
1300 SRM 1392
- 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 con-
verter. This ratio is a major factor for the
APC200 controller to determine if a higher
or lower gear is to be selected during the au-
tomatic 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 clamping.
• Transmission Ratio
- Each selected transmission gear has a spe-
cific transmission ratio. When one of the di-
rection clutches is closed and the output
speed has reached a certain value for check-
ing, the actual ratio is compared with the
specified ratio. If deviation exceeds 5%, one
of the clutches is assumed to be slipping. A
fault is flagged and the APC200 controller
enters the Shut Down Mode.
• Gear Ratio
A. TURBINE SPEED B. DRUM SPEED
Figure 14. Schematic Speed Sensor Locations
Control System
- If the turbine, drum, or output speed sensor
fails, the APC200 controller calculates the
actual ratio’ based on the value of the re-
maining sensors. This allows continued op-
eration of the transmission. Speed sensor
failure is indicated by a fault code. If the en-
gine 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 in-
ching pedal position as the required pressure
for the inching clutch. The heat generated in
the inching clutch is proportional to the
power transferred 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 pressure in the clutch
and flag a fault.
C. OUTPUT SPEED
17
Control System
Test
Dana Dashboard software shows functionality of each of
the speed sensors under Speed Monitor’. Electrical func-
tionality can be tested by using the schematic shown in Fig-
ure 15. 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 connec-
ted to 12 Volt+. Pin C must be connected to 12 Volt-. Fig-
Figure 15. Speed Sensor Test
Table 5. Speed Sensor Test Values
Voltage Reading Current Level
Gear tooth sensed 1.2 volt 6 to 8 mA
No gear tooth sensed 2.6 to 3.0 volt 13 to 15 mA
Temperature Sensors
There are two temperature sensors which measure the tem-
perature at two different locations:
• Pump Supply
- This temperature sensor is combined with
the engine speed sensor in one unit and is
connected with the APC200 controller
through pin B of the sensor connector. The
temperature measured is from the oil return-
ing from filter 1, close to port 31. The signal
18
1300 SRM 1392
ure 15 shows the connectors which are used to connect to
the speed sensors. Connecting the sensor with an incorrect
polarity will destroy the sensor. Table 5 shows the accepta-
ble test values. Replace the sensor if it fails the test.
Speed sensors should be installed as close as possible to the
gear. The speed signal will fail if the distance exceeds
1.8 mm (0.07 in.). The sensor mounting bracket normally
ensures correct sensor installation.
to the APC200 controller is translated into a
CANbus signal to the instrument cluster and
represents the transmission sump tempera-
ture. Dana Dashboard software indicates
functionality of this temperature sensor un-
der Transmission sump temperature.’
• Torque Converter Out, Port 32
- This temperature sensor is a switch that con-
nects to ground when the temperature has
exceeded 120°C (248°F). The function of
this temperature switch is to trigger a protec-
tion mode. Functionality can only be tested
by immersing the temperature switch in hot
oil, and measuring if it switches at
120°C (248°F).
1300 SRM 1392 Dana Dashboard Software

Test

shows the electrical resistance values of the sump tempera-

ture sensor for different temperatures. Resistance can be
measured with a normal ohmmeter, if correct polarity is ob-
served.

Dana Dashboard Software

DESCRIPTION
A system called Dashboard can be used to access diagnos-
tics and execute software settings.

The Dana Dashboard system consists of a laptop computer,

diagnostic software, and a USB (Universal Serial Bus) in-
terface cable. To obtain these items, order the following
part numbers:
• 1550633 - Dana Dashboard software, including
software for the USB interface cable.
• 1534010 - USB interface cable (standard ifac cable)

CONNECTION
Install the Dana Dashboard software and USB interface
drivers on a laptop per instructions delivered with the Dana
Dashboard software and USB interface cable. The help text
contains all information required to work with the diagnos-
tic software and also provides the necessary education and
guidance.

NOTE: Make sure the key switch is in the OFF position

before connecting the Dana Dashboard system to the lift
truck.

Connect the Dana Dashboard software to the lift truck us-

ing the USB interface cable (Hyster P/N 1534010). The lift 1. APC200 CONTROLLER
2. DIAGNOSTIC PLUG
truck connector is located in the side console of the cab.
See Figure 16. Figure 16. APC200 Connector Location

Transmission Test and Calibration

PRECAUTIONS • Check the transmission fluid level. Add transmis-
sion fluid as needed.
Before testing or calibrating the transmission, verify the • Make sure the transmission oil temperature is at
following: least 60°C (140°F).
• Check the engine coolant level. Add coolant as nee-
ded. Refer to the Operating Manual for instructions on how to
• Make sure the parking brake and service brakes op- add coolant and transmission oil.
erate correctly.

19
Transmission Test and Calibration
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 transmission 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 converter. The
stall test is performed with the transmission engaged and
the engine operating at full throttle, 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
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 engine
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.
20
1300 SRM 1392
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 manual
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 specification,
the engine is not operating at full power. Check if engine
fault codes are present and repair or correct any indicated
problems.
If the stall speed is higher than the specification, the en-
gaged clutch(es) may not be holding, or the torque con-
verter may be damaged. Check if transmission fault codes
are present and repair or correct any indicated problems.
If no transmission fault codes are present and the stall
speed is considerably higher than the specification, remove
the torque converter for inspection.
If the stall speed is only slightly higher than the specifica-
tion, consider the service life of the torque converter and
decide whether to replace the torque converter immediately
or at a later point in time.
INCHING CALIBRATION
Description
Inching is a controlled traction and braking mode. It ena-
bles 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 in-
ching pedal position to clutch pressure. The relation be-
tween pedal position and clutch pressure results in the natu-
ral reaction of the operator to depress the inching pedal fur-
ther when the actual lift truck speed is too high. A further-
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.
1300 SRM 1392 Transmission Test and Calibration

The inching pedal sensor must be calibrated for two pedal 3. Adjust the adjustment bolt for the inching/brake pedal
positions: inching pedal completely depressed, and inching coupling so that the inching pedal has no play. Both
pedal released. Calibration is required when the inching pedals should move together when the inching pedal is
sensor has been replaced, or when it becomes loose. Cali- applied. The additional spring installed under the in-
bration is also required annually, due to wear and creep of ching pedal provides flexibility when adjusting the
pedals and linkages. Before calibrating the inching sensor, brake/inching overlap. See Figure 17 and Figure 18.
verify the adjustment of the brake pedal and the inching
sensor. Incorrect sensor calibration triggers fault codes dur-
ing operation. By slightly varying the free travel of the
brake pedal, it is possible to vary the moment when brakes
are applied. An early brake application will result in exces-
sive 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 adjustments in the free travel of the brake pedal
and make sure there is adequate distance between the ped-
als and the floor plate when the pedals are in the fully-ap-
plied/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 17.

Figure 18. 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 in-
ching pedal sensor should be between 600 and 700 mV.

NOTE: A slight preload of the potentiometer arm is re-

quired to achieve the output voltage for the inching pedal in
1. BRAKE PEDAL the released (pedal up) position. Use Dana Dashboard soft-
2. INCHING PEDAL ware to check the output voltage.
3. ADJUSTMENT BOLT FOR BRAKE PEDAL
4. ADJUSTMENT BOLT FOR BRAKE PEDAL COU- 1. Connect a laptop computer to the diagnostic plug in the
PLING side console. See APC200 Connector Location .
5. ADJUSTMENT BOLT FOR INCHING PEDAL
2. Turn the key switch to the ON position.
Figure 17. Brake Pedal Assembly
3. Select Inching Pedal Calibration Mode’.
2. Adjust the adjustment bolt located behind the inching
4. Make sure the analog input of the inching pedal sensor
pedal on the inching pedal assembly so that the inching
is between 600 and 700 mV when the pedal is in the
pedal is at the same level as the brake pedal when both
pedal up position.
pedals are in the released (pedal up) position. See Fig-
ure 17.

21
Electrical Specifications
5. If the analog input is not within specifications, proceed
as follows:
a. Raise the cab until the latch locks in the partially
open position. Refer to the manual Operator's Cab
0100SRM1390.
b. Loosen the two inching pedal sensor-mounting cap-
screws. See Figure 19.
c. Rotate the inching pedal sensor in the slotted 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 inching 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 diagnostic
plug. See APC200 Connector Location.
1. SENSOR-MOUNTING CAPSCREW
2. INCHING PEDAL SENSOR
Figure 19. Sensor Adjustment
Electrical Specifications
Electronically controlled modulation valves:
Fwd/Rev/2nd/1st - 3rd
Coil resistance : 4.35 ±0.35Ω at 25°C (77°F)
ON/OFF solenoids:
22
1300 SRM 1392
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 Location.
3. Turn the key switch to the ON position.
4. Use the Automatic Calibration’ mode of the Dana
Dashboard program.
5. Select the Inching Pedal Calibration’ mode of the Dana
Dashboard program and follow the instructions.
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)
7. Check the inching percentage of the transmission by
using the Dana Dashboard program. When the pedal is
released, the inching percentage 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.
10. Disconnect the laptop computer from the diagnostic
plug.
Total neutral and 1st/3rd range solenoids
Coil resistance : 28 ±2Ω at 20°C (68°F)
1300 SRM 1392 APC200 Display Information

Speed sensor: Table 6. Temperature Sensor (In Speed Sensor)

Type - Magneto resistive sensor. Resistance Versus Temperature (Continued)
Sensing distance : 0 to 1.8 mm (0 to 0.07 in.) Ambient Temperature Resistance
Sensor signal - Generates a square current with a Ω
fixed amplitude changing between 7 and 14 mA. 40°C (104°F) 2245
50°C (122°F) 2417
Table 6. Temperature Sensor (In Speed Sensor)
Resistance Versus Temperature 60°C (140°F) 2597
70°C (158°F) 2785
Ambient Temperature Resistance
Ω 80°C (176°F) 2980
−30°C (−22°F) 1247 90°C (194°F) 3182
−20°C (−4°F) 1367 100°C (212°F) 3392
−10°C (14°F) 1496 110°C (230°F) 3607
0°C (32°F) 1630 120°C (248°F) 3817
10°C (50°F) 1772 125°C (257°F) 3915
20°C (68°F) 1922
25°C (77°F) 2000
30°C (86°F) 2080

APC200 Display Information

GENERAL • Test
• Calibration
Note that for F008 and G008 trucks the indication 'Forward'
and 'Reverse' needs to be considered for the transmission These display modes provide an alternative method to cali-
and for the truck separately. brate or obtain information if the Dana Dashboard software
is not available.
The truck moves according the position of the shift lever or
MONOTROL pedal, but the signals forward and reverse
have been swopped with the transmission functions for-
ward and reverse. The indication 'forward' and 'reverse' for
transmission components is still identical to the original no-
menclature of the manufacturer.

When doing repairs or ordering spare parts, remember that

activating the forward clutch on F008 and G008 trucks cau-
ses the lift truck to move in reverse direction, and activat-
ing the reverse clutch causes the F008 and G008 truck to Figure 20. APC200 Front Panel
move in forward direction.

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 20.
The information is provided by means of codes. The inter-
pretation of these codes depends on the display mode being
activated. The following display modes are available:
• General Information
The LED lamp labeled D’ is yellow and will be ON to indi-
cate diagnostic modes.
The LED lamp labeled E’ is yellow and blinks to indicate
faults.
The LED lamp labeled F’ is red and is ON when the
APC200 is in the reset condition.

23
APC200 Display Information 1300 SRM 1392

The push button marked M’ is used to scroll to one of the After startup, the display will show the sub group that was
three display groups. selected when the APC200 was switched OFF.

The push button marked S’ is used to scroll to the next sub

group within a display group. See Table 7.

GENERAL INFORMATION GROUP

Table 7 shows the structure of the General Information
Group. Figure 21 schematically shows that by pressing the
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 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 positioned 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 dis-
play group by pressing the M button by starting in the
GPoS, cPoS, or Err display group. Figure 21. APC200 Display Groups

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 actual measured value.
See Table 7 for sequence and explanation of the sub
groups.

Table 7. General Information Group

Display Description Explanation Example

Gear, Vehicle Speed, Distance
GPoS Gear Position Shows the actual engaged gear direction (F, R) and range (1, 2, 3). F3
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 resolution, and has 12.3.4.
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 Position Shows the current shift lever position (F, R) (1, 2, 3). F3

24
1300 SRM 1392 APC200 Display Information

Table 7. General Information Group (Continued)

Display Description Explanation Example

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 side in N•m. 125
ttnP Transmission Temper- Shows the transmission temperature in °C. 65
ature
ctnP Cooler in Temperature Shows the cooler input temperature in °C. 75
Fault Codes
Err Fault Code Shows the transmission fault code number. 31.01

FAULT CODES
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. Figure 22. Indication of Protection Mode

If more than one fault has been detected, the most severe
fault will be shown first. Push and release the S button once TEST FUNCTION GROUP
to display the next fault code.
To enter the Test Function Group, press the S button while
After the last code has been displayed, the display will turning the key switch to ON. Release the S button when
show - - - -’. the display shows: 8.8.8.8.’. After releasing the S button the
display will show: diSP’. See Figure 23.
Displayed fault codes either appear blinking, or are shown
uninterrupted. When shown uninterrupted, the fault code is
active. When blinking, the fault has occurred but is cur-
rently 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 dash-
board display retains all fault codes until its memory has
been cleared.
INDICATION OF PROTECTION MODES
The Limp Home Mode and Shutdown Mode as described
under Control System’ are only made visible on the
APC200 display when it is in the GPoS- or 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 22.
Figure 23. Test Function Group Mode
The only way to leave the test function group is by switch-
ing the key switch to OFF.
Figure 24 schematically shows that by pressing the M but-
ton 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 display group list (diSP, dinP, etc.). Start-
ing 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 after hav-
ing reached the lowest positioned sub group.

25
APC200 Display Information 1300 SRM 1392

To scroll to the next display group, first scroll to the sub Instructions for how to call off information for each test
group (diSP, dinP, etc.) that is highest on the display group group are described separately.
list. Only when starting at diSP, dinP, etc., will it be possi-
ble to scroll to the next display group by pressing the M
button.

Figure 24. Test Function Group Schematic

DIGITAL INPUT TEST

The APC200 has 10 digital inputs which measure connec-
tivity of the wires listed in Table 8. After the display has
shown dinP’ (see Figure 25), push and release the S button.
The display indicates the active inputs by switching ON Figure 25. Digital Input Test
certain segments of the display (see Figure 26). The num-
bered segments 0-9 represent the digital inputs DIGIN0
through DIGIN9.
In the example shown in Figure 27, 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.

26
1300 SRM 1392 APC200 Display Information

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 26. Display Segment Numbers

Press and hold the S button to scroll to the individual digi- Figure 27. Active Digital Inputs
tal inputs. The display will show the logic input number
with the matching APC200 wire number. The example in
Figure 28 shows that DIGIN0 relates to APC200 wire A12.
Table 8 provides the conversion from APC200 wire num-
bers to Hyster wire numbers.

Table 8. Digital Input Test

Code Wire APC200 Wire Hyster Wire APC200 Pin Wire Description Output
Name Nr 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 Re- hi/lo
lay
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 Mode hi/lo
8.45 DIGIN8 B15 938-c N3 Park Brake ON/OFF hi/lo
9.46 DIGIN9 B16 OPEN P3 OPEN lo

After the display has shown AinP’ (see Figure 29), push
and release the S button. The display will show the value in
kilo Ohm in sequence of each of the four inputs. Values be-
low 1 kOhm are shown as 0’. Each input value is separated
by a dot. See Figure 30.
Figure 28. Digital Input Code

ANALOG INPUT TEST

The APC200 has seven analog resistance inputs, which
measure the actual resistance of the sensors listed in Ta- Figure 29. Analog Input Test
ble 9.

27
APC200 Display Information 1300 SRM 1392

shows ANI0 and APC200 wire A11. Table 9 provides the

conversion from APC200 wire numbers to Hyster wire
numbers.

When releasing the S button, the display shows the resist-

Figure 30. Analog Resistance Values ance value in Ohms. Pressing the S button after 6.36 returns
the display to AinP.’ See Figure 29.
Press and hold the S button to scroll to the individual ana-
log inputs. The display will show the logic input number
with the matching APC200 wire number. The first input

Table 9. Analog Input Test

Code Wire APC200 Wire Hyster Wire APC200 Pin Wire Description Output
Name Nr Nr 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 represent
the number of teeth that pass the sensor per second (see Ta-
ble 10). After the display has shown SPd’ (see Figure 31),
push and release the S button. The display will show the
value in kilo-Ohms in sequence of each input. Each value is
separated by a dot.
indicated by 0.22,’ meaning that sensor SS0 relates to
APC200 wire A22. Table 10 provides the conversion of
APC200 wire numbers to Hyster wire numbers.
When releasing the S button, the display shows a c’ to indi-
cate a current type sensor, and a dot and three digits to indi-
cate the frequency in kHz. Figure 32 shows a frequency of
0.933 kHz. Pressing the S button after 3.41 returns the dis-
play to SPd’.

Figure 31. Speed Sensor Test

Figure 32. Measured Frequency
Press and hold the S button to scroll to the individual ana-
log inputs. The display will show the logic input number
with the matching APC200 wire number. The first sensor is

Table 10. Speed Sensor Test

Code Wire Name APC200 Wire Hyster Wire APC200 Pin Wire Description Output
Nr Nr Nr
Speed Sensor Test

28
1300 SRM 1392 APC200 Display Information

Table 10. Speed Sensor Test (Continued)

Code Wire Name APC200 Wire Hyster Wire APC200 Pin Wire Description Output
Nr Nr Nr
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

OUTPUT TEST indicated by 0.2’, meaning that VFS0 relates to APC200

The Output Test Group shows the outputs to the VFS sole-
noids and to the ON/OFF solenoids. After the display has
shown outP’ (see Figure 33), push and release the S button.
The display indicates the active outputs by switching ON
certain segments of the display. The numbered segments 0 -
3 represent the outputs for VFS0 - VFS3. Segments 4 - 6
are not used. Segments 7 - 10 represent the outputs for DO0
- DO3.
wire A02. Table 11 provides the conversion of APC200
wire numbers to Hyster wire numbers.
When releasing the S button, the display shows either 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 segment 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 33. Output Test Pressing the S button after 10.20 returns the display to
SPd’.
Press and hold the S button to scroll to the individual out-
puts. The display will show the logic reference number
with the matching APC200 wire number. The first output is

Table 11. Output Test

Code Wire Name APC200 Wire Hyster Wire APC200 Pin Wire Description Output
Nr Nr Nr
Output Test Variable Force Solenoids
0.2 VFSO+ A02 871-a B1 VFS Forward Hi Side Out mA
1.4 VFS1+ A04 873-a D1 VFS 2nd VFS Hi Side Out mA
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 Solenoid hi/lo

29
APC200 Display Information 1300 SRM 1392

Table 11. Output Test (Continued)

Code Wire Name APC200 Wire Hyster Wire APC200 Pin Wire Description Output
Nr Nr Nr
10.20 DO3 A20 766-a K2 Total Neutral Solenoid − hi/lo

VOLTAGE TEST
After the display has shown Volt’ (see Figure 34), push and
release the S button to scroll to one of the three measured
voltages:
• VP’ - Permanent Voltage as measured on APC200 Figure 34. Voltage Test
wire A01.
• VS’ - Switched Voltage as measured on APC200
wire B12. Table 12 provides the conversion of APC200 wire numbers
to Hyster wire numbers.
• VSEn’ - Sensor Voltage as measured at any analog
input.

Pressing the S button after VSEn’ returns the display to

Volt’.

Table 12. Voltage Test

Code Wire Name APC200 Wire Hyster Wire APC200 Pin Wire Description Output
Nr Nr 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 13 provides the conversion of APC200 wire numbers

to Hyster wire numbers.

Table 13. APC200 Wire Number to Hyster Wire Number Conversion

APC200 Wire Wire Hyster Wire Color APC200 Pin Wire Description Output
Nr Name Nr 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

30
1300 SRM 1392 APC200 Display Information

Table 13. APC200 Wire Number to Hyster Wire Number Conversion (Continued)

APC200 Wire Wire Hyster Wire Color APC200 Pin Wire Description Output
Nr Name Nr Nr
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
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

31
APC200 Display Information 1300 SRM 1392

Table 13. APC200 Wire Number to Hyster Wire Number Conversion (Continued)

APC200 Wire Wire Hyster Wire Color APC200 Pin Wire Description Output
Nr Name Nr Nr
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

CALIBRATION GROUP
Calibration Mode

Figure 35 schematically shows the procedure to enter the

calibration mode. The only relevant modes are under trAn Figure 36. Entering Calibration Mode
(clutch filling calibration), hEAt (heating the transmission),
and brAH (inching sensor calibration). See Figure 36. To
enter the calibration mode, press and hold the S button, and
turn the key switch to ON. During the first 15 seconds, the
Clutch Filling Calibration
display will show 8888’. Release the S button after 15 sec- NOTE: DO NOT interfere with the calibration. Activat-
onds when the display shows trAn’. ing any controls or components will stop the calibration
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 REVERSE

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 dis-
play 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 conditions are

met, the APC200 display will show:
Figure 35. Calibration Mode

32
1300 SRM 1392 APC200 Display Information

9. The automatic calibration starts when the forward/ 5. Apply the service brakes.
reverse lever or the MONOTROL® pedal is moved
6. Place the MONOTROL® pedal or the shift lever in the
into the FORWARD position. The screen will display:
FORWARD position.

7. Push the throttle for approximately 15 seconds.

8. Place the shift lever in NEUTRAL or the MONO-

TROL® pedal in REVERSE.
10. When the calibration has been completed, the APC200
display will show donE’: 9. Run the engine at 1300 rpm for approximately 15 sec-
onds in NEUTRAL.

10. Decelerate the engine to idle.

11. Repeat Step 6 through Step 10 until the APC200 dis-

11. Switch the key switch OFF when the APC200 display
indicates that the calibration has been completed. Ob-
serve the display and wait until no segments are illumi-
nated. When the display remains OFF, the new cali-
bration has been entered into the APC200 memory.
The new calibration 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 calibration purposes. Dur-
ing the heat up mode, only the highest gear is selected and
the inputs from the parking brake and the brake pedal posi-
tion are ignored.
play shows a temperature above 60°C (140°F).
12. Push the M button to scroll to the desired calibration
mode. For a clutch calibration, scroll until 'tRan' is dis-
played.
Inching Pedal Sensor Calibration
Inching Pedal Sensor Adjustment
NOTE: Before calibrating the inching pedal sensor, the in-
ching pedal must be adjusted correctly. See Transmission
Test and CalibrationBrake and Inching 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:

1. Press and hold the S button, and turn the key switch to
the ON position. During the first 15 seconds, the dis-
play will show 8888’. Release the S button after 15
seconds when the display shows trAn’.
2. Release the "S" button after 15 seconds when the dis-
2. Start the engine.
play shows:
3. Press the M button once and release. The word hEAt’
will show:

3. Push the M button until the APC200 display shows an-

alog input:
4. Press the S button again and release. The actual trans-
mission sump temperature will be shown:

33
Diagrams, Schematics or Arrangements 1300 SRM 1392

3. Push the M button several times until the APC200 dis-

play shows brAH’:

4. Push the S button three times. The display will show

0.11, 1.28, 2.29, and a value. Pushing the S button an-
other time changes the display to 03.47. Releasing the
button shows the value in Ohms for the inching pedal 4. Push the S button once to start the inching pedal sensor
sensor (for example: 0.652). calibration. The APC200 display will show:

NOTE: The voltage reading of the inching pedal sensor 5. Push the S button in the pedal up position. The
will be shown after a 1-2 second delay. APC200 display will show:

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 position.

6. If the reading is not between 0.600 and 0.700 mV, ad-
just 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.
6. Fully depress the inching pedal and press the S button
again.
7. When the calibration is complete, the APC200 display
will show donE’:

Inching Pedal Sensor Calibration

NOTE: Calibration will fail under the following circum-
stances:
• Inching sensor adjustment is below 450 mV.
• During calibration, the voltage at the inching pedal
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:
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 remains OFF, the
new calibration has been entered into the APC200 mem-
ory. The new calibration settings will be lost if the key
switch is turned ON too early.

2. Release the "S" button after 15 seconds when the dis-

play shows:

34
1300 SRM 1392 Diagrams, Schematics or Arrangements

Diagrams, Schematics, or Arrangements

35
Diagrams, Schematics or Arrangements 1300 SRM 1392

Figure 37. Transmission Wiring Diagram

36
1300 SRM 1392 Diagrams, Schematics or Arrangements

Legend for Figure 37

Item Description Code Location

No.
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 19, 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 Figure 6, Item 11
9 Turbine Speed Sensor CPS 26 Figure 10 and Figure 12, Item A
10 Drum Speed Sensor CPS 25 Figure 10,Figure 11, and Figure 13, Item C
11 Output Speed Sensor CPS 24 Figure 10 , Figure 12, and Figure 13, Item B
12 Engine Speed Sensor CPS 23 Figure 10,Figure 11, and Figure 13, Item D
13 Transmission Temperature Switch TS 27 Figure 10,Figure 11, and Figure 13, Item D

37
 NOTES

38
 TECHNICAL PUBLICATIONS

1300 SRM 1392 9/12 (3/11)(5/10)(3/10)