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TRANSMISSION

OPERATION AND
DIAGNOSTICS

PART NO. 1671895 1300 SRM 1358


SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage 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. 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 ex-
ceed 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 flamma-
ble. 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.
Table of Contents

TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................2
Description ...............................................................................................................................................................2
General ................................................................................................................................................................ 2
Operation ................................................................................................................................................................. 5
Hydraulic Operation ........................................................................................................................................... 5
1st/3rd Selector Valve ......................................................................................................................................... 8
Cooling and Lubrication ................................................................................................................................... 10
Control System ...................................................................................................................................................... 12
General .............................................................................................................................................................. 12
APC200 Controller ............................................................................................................................................12
Self Test .........................................................................................................................................................12
Protection Modes .......................................................................................................................................... 12
Limp Home Mode ..................................................................................................................................... 12
Shut Down Mode ...................................................................................................................................... 12
Transmission Exceed Codes .....................................................................................................................13
Fault Codes ................................................................................................................................................... 13
Description ................................................................................................................................................13
Fault Log Mode .............................................................................................................................................13
Access ........................................................................................................................................................ 13
Exit ............................................................................................................................................................14
Clear ..........................................................................................................................................................14
Fault Rectification ........................................................................................................................................ 14
Hydraulic Control Valve ...................................................................................................................................16
Hydraulic Control Valve Repair .................................................................................................................. 18
Solenoid Replacement .................................................................................................................................. 18
Pressure Check ............................................................................................................................................. 18
Pressure Specifications .................................................................................................................................19
Pressure, Speed, and Temperature Sensors ....................................................................................................19
Pressure Switch ............................................................................................................................................ 24
Test ............................................................................................................................................................24
Speed Sensor .................................................................................................................................................25
Test ............................................................................................................................................................25
Temperature Sensors ................................................................................................................................... 26
Test ............................................................................................................................................................26
Transmission Test and Calibration ......................................................................................................................27
Precautions ........................................................................................................................................................27
Stall Test ........................................................................................................................................................... 27
Description .................................................................................................................................................... 27
Stall Test Procedure ..................................................................................................................................... 27
Clutch Calibration ............................................................................................................................................ 28
Description .................................................................................................................................................... 28
Procedure ...................................................................................................................................................... 28
Inching Calibration ...........................................................................................................................................29
Description .................................................................................................................................................... 29
Brake and Inching Pedal Adjustment ......................................................................................................... 29
Inching Sensor Adjustment ..........................................................................................................................30
Inching Sensor Calibration .......................................................................................................................... 30
Electrical Specifications ........................................................................................................................................31
APC200 Display information ................................................................................................................................32

©2016 HYSTER COMPANY i


Table of Contents

TABLE OF CONTENTS (Continued)


General .............................................................................................................................................................. 32
General Information Group ..............................................................................................................................33
Fault Codes ........................................................................................................................................................35
Indication of Protection Modes .........................................................................................................................35
Test Function Group .........................................................................................................................................35
Digital Input Test ............................................................................................................................................. 36
Analog Input Test ............................................................................................................................................. 37
Speed Sensor Test ............................................................................................................................................. 38
Output Test ....................................................................................................................................................... 39
Voltage Test .......................................................................................................................................................40
Calibration Group ............................................................................................................................................. 43
Calibration Mode .......................................................................................................................................... 43
Clutch Filling Calibration ............................................................................................................................ 43
Heat Up Mode ............................................................................................................................................... 44
Inching Sensor Calibration ...............................................................................................................................44
Inching Pedal Sensor Adjustment ............................................................................................................... 44
Inching Sensor Calibration .......................................................................................................................... 44
TE-Userlink ........................................................................................................................................................... 45
Description ........................................................................................................................................................ 45
Connection .........................................................................................................................................................45
Diagrams, Schematics or Arrangements.............................................................................................................. 45
Figure 36. APC200 Wiring Diagram.................................................................................................................46
Figure 37. Cab Side Console Harness...............................................................................................................50
Figure 38. Resistor Converter Out Connector C105 of Wire Harness Side Console Cab.............................. 53
Figure 39. Connector C120 of Wire Harness Side Console Cab...................................................................... 54
Figure 40. APC 200 Connector C110 of Wire Harness Side Console.............................................................. 56
Figure 41. Armrest Connector C80 of Wire Harness Cab Side Console......................................................... 57
Figure 42. Cab Signals Connector C60 of Wire Harness Cab Side Console................................................... 57
Figure 43. Cab Supplies Connector C70 of Wire Harness Cab Side Console................................................. 58
Figure 44. Under Floor Connector C130 of Wire Harness Cab Side Console.................................................58
Figure 45. Transmission Diagnostic Connector (Tuning Link) C415 of Wire Harness Side Console Cab... 59
Figure 46. Diagnostic Plug C535 of Wire Harness Side Console Cab.............................................................60
Figure 47. Frame Wire Harness........................................................................................................................62
Figure 48. Drum Speed Connector C90 of Wire Harness Frame.................................................................... 65
Figure 49. Control Valve Connector C80 of Wire Harness Frame.................................................................. 66
Figure 50. Engine Speed Connector C150 of Wire Harness Frame................................................................ 67
Figure 51. Output Speed Connector C120 of Wire Harness Frame................................................................67
Figure 52. Turbine Speed Connector C340 of Wire Harness Frame...............................................................68
Figure 53. Converter Out Temperature Connector C330 of Wire Harness Frame........................................ 68
Figure 54. Cab Signals Connector C144 of Wire Harness Frame................................................................... 69
Figure 55. Cab Supplies Connector C146 of Wire Harness Frame................................................................. 69
Figure 56. Under Cab Floor Wire Harness.......................................................................................................70
Figure 57. Side Console Connector C10 of Wire Harness Under Floor.......................................................... 71
Figure 58. MONOTROL Pedal Connector C30 of Wire Harness Cab Under Floor ...................................... 72
Figure 59. Steering Column Connector C60 of Wire Harness Under Floor................................................... 72
Figure 60. Inching Pedal Connector C90 of Wire Harness Under Floor........................................................ 73
Figure 61. Steering Column Wire Harness...................................................................................................... 74
Figure 62. Cab Under Floor Connector C10 of Wire Harness Steering Column ...........................................75
Figure 63. Transmission Lever Connector C50 of Wire Harness Steering Column...................................... 76

ii
Table of Contents

This section is for the following models:

iii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1300 SRM 1358 Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table


This table consist of the following Series Codes
used in this manual.

Series European Model Americas Model


Code
F007 H170-H280HD
G007 H170-H280HD
H007 H8-12XM H170-H280HD
F019 H300-360HD, H360HD-12EC
G019 H13-14XM, H16XM-6, H10-12XM-12EC H300-360HD, H360HD-EC

1
General 1300 SRM 1358

General
This manual provides information on operation and Electrical system diagrams are shown in Dia-
diagnostics of the TE10 transmission as fitted on grams 8000SRM1346.
G019 and H007 series lift trucks.

The repair procedures for the transmission and


control valve are shown in Transmission Repair
1300SRM1356.

Description
GENERAL The engine flywheel is connected to the torque con-
verter housing through drive plates. See Figure 1.
The function of the transmission is to transfer en-
gine power from the engine flywheel to the drive
wheels and to the hydraulic pumps that are at-
tached to the transmission.

2
1300 SRM 1358 Description

1. DRIVE PLATE 6. INTERCONNECTING GEAR


2. TORQUE CONVERTER HOUSING 7. INTERCONNECTING GEAR
3. PUMP DRIVE GEAR 8. CLUTCH
4. TRANSMISSION PUMP 9. INPUT GEAR
5. TRANSMISSION FILTER 10. TRANSMISSION INPUT SHAFT

Figure 1. Transmission Input Section

3
Description 1300 SRM 1358

The flexing properties of the drive plate reduce


transfer of axial forces between engine crankshaft
and torque converter. A gear on the torque con-
verter housing drives the transmission pump and
the attached pump for the hydraulic system of the
truck. Both the torque converter housing and these
two 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 en-


gine flywheel with the transmission input shaft. It
functions as a fluid clutch to smoothly transfer
power from the engine to the transmission, and as
a torque multiplier when speed difference between
engine and transmission input shaft increases. The
torque converter has a specific torque multiplica- A. INPUT GEARS
B. INTERCONNECTING GEARS
tion factor that matches the engine power charac- C. OUTPUT GEARS
teristics. Speed difference between engine and
transmission input shaft is a measure of engine Figure 2. Gear Engagement
power being transferred. With increasing speed dif-
ference, also an increasing amount of heat is gener-
ated in the converter. The heat generated is re- When the transmission is in NEUTRAL, both the
moved by the transmission lubrication oil, which forward and reverse clutch are disengaged, while
flows through the torque converter. one of the speed clutches remains engaged.

The different speed ratios between input shaft and The clutches consist of a hub which carries friction
drive shaft are obtained by engaging and disengag- discs with internal splines, and a drum which car-
ing the different clutches. Three groups of gears are ries steel discs with external splines. See Figure 3.
continuously engaged with each other: the input
gears, the interconnecting gears, and the output Friction discs and steel discs are alternately fitted.
gears. See Figure 2. By pressurizing the clutch piston, the friction discs
and steel discs are clamped together, which cause
If clutches belonging to one group would be en- the hub and drum to rotate as one unit. When hy-
gaged simultaneously, the transmission would lock. draulic pressure is released, return springs push
The clutches Forward and Reverse should not be the piston back against the clutch housing and al-
engaged at the same time. Also, the speed clutches low hub and drum to rotate independently. The
for the 1st, 2nd, and 3rd speed should not be en- drum, steel discs, piston, spacer and return springs
gaged at the same time. Erroneous clutch engage- rotate at the same speed. The hub rotates at the
ment is prevented by the transmission control sys- same speed with the friction discs.
tem.
The transmission control system pressurizes and
The different speeds are obtained by engaging ei- depressurizes the clutches.
ther the forward or reverse clutch, and by engaging
either one of the clutches for the 1st, 2nd, and 3rd
speed.

4
1300 SRM 1358 Description

1. CLUTCH HUB 10. PISTON SPRING SPACER


2. CLUTCH END PLATE 11. FRICTION DISCS
3. CLUTCH DRUM REVERSE GEAR 12. PISTON SPRING SET
4. PISTON SEALS 13. OIL SEALS
5. INTERCONNECTING GEAR 14. OIL SUPPLY FOR LUBRICATION AND COOL-
6. CLUTCH DRUM 2ND GEAR ING
7. CLUTCH HUB 2ND GEAR 15. PRESSURE SUPPLY 2ND CLUTCH
8. SHAFT 16. PRESSURE SUPPLY REVERSE CLUTCH
9. PISTON

Figure 3. Clutch Components

Operation
HYDRAULIC OPERATION que converter housing. The pump transfers oil
through the transmission filter, and further to the
The transmission sump is the main reservoir for 10 bar (145 psi) pressure reducer valve and to the
the transmission oil. The sump screen keeps large 16.5 bar (239.3 psi) pressure regulator valve. See
particles from entering the transmission pump. The Figure 4.
pump is driven by gears that connect with the tor-

5
Operation 1300 SRM 1358

Figure 4. Hydraulic Diagram

6
1300 SRM 1358 Operation

Legend for Figure 4


NOTE: THE ENCIRCLED NUMBERS REFER TO CHECK PORT NUMBERS. SEE TABLE 2 AND TABLE 3.

A. COOLING AND LUBRICATION C. SYSTEM PRESSURE


B. PILOT PRESSURE D. DRAIN
1. SUMP 16. MODULATION SPOOL, FORWARD
2. SCREEN 17. MODULATION SPOOL, REVERSE
3. PUMP 18. MODULATION SPOOL, SECOND
4. FILTER 19. MODULATION SPOOL, FIRST/THIRD
5. BYPASS VALVE 20. INTENSIFIER SPOOL, FORWARD
6. PRESSURE REGULATOR VALVE, 21. INTENSIFIER SPOOL, REVERSE
16.5 bar (239.3 psi) 22. INTENSIFIER SPOOL, SECOND
7. SAFETY VALVE, 9 bar (130.5 psi) 23. INTENSIFIER SPOOL, 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. TEMPERATURE GAUGE 27. SECOND SPEED CLUTCH
12. PRESSURE GAUGE 28. REVERSE CLUTCH
13. PRESSURE REDUCER VALVE, 10 bar (145 psi) 29. FORWARD CLUTCH
14. TOTAL NEUTRAL VALVE 30. PRESSURE SWITCH
15. CLUTCH SUPPLY VALVE

7
Operation 1300 SRM 1358

The 16.5 bar (240 psi) pressure regulator valve reg- The actuation of the modulation solenoids (VFS) is
ulates system pressure, by relieving excess oil opposite from normal expectation. When there is
through the torque converter, oil cooler, and lubri- NO signal from the APC200, the modulation valve
cation system. See Cooling and Lubrication. System admits full pressure to the clutch intensifier valve.
pressure is used to fill and pressurize the clutches. When the signal has reached 100mA, oil supply
from the modulation valve to the clutch intensifier
The 10 bar (145 psi) pressure reducer valve pro- valve is closed.
vides pilot pressure to the total neutral valve and
to the modulation solenoids. The function of the to- 1ST/3RD SELECTOR VALVE
tal neutral valve is to activate the clutch supply
valve when the control system allows this. The acti- Actuation of the clutches for 1st speed and 3rd
vated clutch supply valve will transfer system pres- speed is through a common modulation solenoid
sure, 16.5 bar (239.3 psi), to each of the clutch in- (VFS 1st/3rd), which activates a common clutch in-
tensifier valves. tensifier valve. The transferred system oil pressure
connects with the 1st/3rd selector valve, which ei-
If the APC200 control does NOT receive the proper ther transfers to the 1st or to the 3rd clutch de-
signals, the total neutral valve will be deactivated, pending on an electric signal from the APC200.
causing the clutch supply valve to close. All When the 1st speed selection solenoid is activated,
clutches release immediately when the clutch sup- the 1st/3rd selector valve transfers system pressure
ply valve closes. to the 1st speed clutch. When the 1st speed selec-
tion valve is NOT activated, the 1st/3rd selector
The total neutral spool and the clutch supply spool valve transfers system pressure to the 3rd speed
are in reality combined on one spool. See Figure 8. clutch.

The modulation solenoids (Variable Force Sole- Table 1 provides an overview of the activated sole-
noids) transfer a proportional pressure to the clutch noids and clutches for the different transmission
intensifier valves depending on the signal from the speeds. Neutral selection is by disengagement of
APC200. With increasing pressure from the modu- both the forward and reverse clutch. Trucks with a
lation solenoid, the clutch intensifier valve increas- MONOTROL® pedal will only shift to NEUTRAL
ingly admits system pressure to the relevant by applying the hand or service brake, or when the
clutch. When the clutch is fully engaged, full sys- operator has left his seat.
tem pressure remains applied until the modulation
solenoid closes, causing the intensifier valve to
close as well, which drains clutch pressure to sump
and releases the clutch.

The modulation spool moves in a cavity to dampen


hydraulic vibration between the modulation sole-
noid and the clutch intensifier. Actuation of the
clutches forward, reverse, and 2nd speed is through
separate modulation and intensifier valves.

8
1300 SRM 1358 Operation

Table 1. Activated Solenoids and Gear Selection

Transmission Gear Activated ON/OFF Solenoids Deactivated Clutches Activated


Direction Speed Clutches
Activated VFSs 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 Reverse + 2nd Forward + 1st
1st/3rd Selector
Neutral 3rd Total Neutral Forward + Reverse + 2nd 3rd
Neutral 2nd Total Neutral Forward, Reverse, 1st/3rd 2nd
Neutral 1st Total Neutral Forward + Reverse + 2nd 1st
1st/3rd Selector
Reverse 3rd Total Neutral Forward + Reverse + 2nd Reverse + 3rd
Reverse 2nd Total Neutral Forward, Reverse, 1st/3rd Reverse + 2nd
Reverse 1st Total Neutral Forward + Reverse + 2nd Reverse + 1st
1st/3rd Selector

9
Operation 1300 SRM 1358

COOLING AND LUBRICATION that is lower than system pressure. See Figure 5.
The pressure regulator valve admits oil that is not
Heat is primarily generated at the torque converter required for clutch filling. The safety valve reduces
and at the clutch plates during transmission opera- oil pressure to 9 bar (131 psi) to protect the torque
tion. The heat generated by mechanical friction at converter and oil cooler. The normal oil flow is
gears, shafts and bearings is relatively low. through the torque converter, the transmission oil
cooler and to the transmission lubrication port. The
Heat generated in the torque converter relates di- volume of oil and the oil flow resistance causes that
rectly to the degree of stall, i.e. the speed difference the initial 9 bar (131 psi) supply pressure is re-
between engine and turbine. In a stall situation duced to 0.4 to 0.85 bar (5.8 to 12.3 psi) at the
most of the supplied engine power is transferred transmission lubrication port. Flow resistance in-
into heat. This heat accumulates in the torque con- creases during torque converter stall or when oil
verter because of the reduced oil flow during a stall temperature is low. When the transmission is at
situation. With increasing turbine speed, the vol- operating temperature and no load is applied, the
ume of added heat reduces, while simultaneously volume of lubrication oil is 64 liter (17 gal) at 1800
the increased oil flow more rapidly transfers the ac- rev/min.
cumulated heat.
From the transmission lubrication port the oil flows
Heat generated at the clutch plates varies with the into channels in the different shafts, which lead to
actually available engine power at time of clutch the shaft bearings for lubrication, and to the inside
engagement and the duration of clutch engage- of the clutch packs where the oil absorbs the heat
ment. During normal operation, the transmission that is generated at the clutch plates.
control system determines the duration of clutch
engagement. During inching it is the driver who To speed the warming-up process, a thermostat
controls the added heat in the clutch by varying en- valve is installed between the torque converter out-
gine power and clutch engagement. The transmis- let port and the transmission radiator. The thermo-
sion control system will close the forward or reverse stat starts opening at 70°C (158°F) and is com-
clutch when a certain amount of generated heat pletely opened at 85°C (185°F). At temperatures be-
has been exceeded. low 70°C (158°F), oil flow is directly returned to the
transmission. At temperatures above 85°C (185°F),
Only a minor portion of the total transmission the entire oil flow from the outlet port passes
pump supply is used for clutch filling. The majority through the transmission radiator before it is re-
of transmission oil supply is used for the cooling turned to the transmission.
and lubrication circuit that functions at a pressure

10
1300 SRM 1358 Operation

1. OIL FLOW 3. LUBRICATION PRESSURE PORT


2. OIL CHANNEL

Figure 5. Cooling and Lubrication

11
Control System 1300 SRM 1358

Control System
GENERAL The APC200 controller is located in the side console
of the cab and has a display and push buttons to
The control system of the transmission consists of call off information. Normally the gauges and dis-
the APC200 controller, several switches and send- plays on the dashboard are used to read transmis-
ers that provide information to the APC200, and sion related information. For diagnostics and set-
the hydraulic control valve that regulates pressures tings, it is more convenient to use the TE-Userlink
depending on signals from the APC200. system instead of pushing the buttons on the
APC200. The section APC200 Display information
APC200 CONTROLLER has the instructions for how to call off information
from the APC200 when TE-Userlink is not availa-
The APC200 has software to control the operation ble.
of the transmission and performs the following
functions: Self Test
• Perform self-test and troubleshooting. At power up a series of checks is done. If the
• Functional control of the transmission. APC200 fails these checks, it will shut off all out-
- Automatic shifting. puts. The transmission cannot be operated until
the problem is rectified. The relevant fault code will
- Inching. be displayed.
• Enter a protection mode when required.
- Improper pressures, temperatures, Protection Modes
and speeds.
- No operator present.
Limp Home Mode
- Parking brake applied. The transmission is put in NEUTRAL if a fault is
- Gear or direction change at improper detected on the following:
speeds. • Outputs for solenoids, VFS or Pressure
• Logging a fault code when circumstances Switch
have exceeded certain values. • Engine speed sensor
• Allow diagnostics and calibration with a lap- • Two out of three vehicle speed sensors
top (TE-Userlink).
To continue driving, first the shift lever must be
Depending on the signals of the shift lever and var- put in NEUTRAL. After that, the driver can reen-
ious switches and senders, the APC200 activates or gage a direction. When Limp Home Mode has been
deactivates the solenoids and VFS valves in the entered, the user can operate the transmission in
control valve, which transfer hydraulic pressure to either direction in 1st and 2nd only. Inching is disa-
the clutches in the transmission. If an input signal bled.
does not comply with the programming of the
APC200, the APC200 will record the fault and react Shut Down Mode
by activating a protection mode. All events recorded
are stored as a fault code and are shown on the in- If an intolerable combination of faults is detected,
strument cluster when the fault occurs. Faults can the Shut Down Mode will be entered. The APC200
also be read at a later point in time, making it pos- puts the transmission in NEUTRAL by putting all
sible to trace intermittent problems. VFS signals at zero pressure and by switching OFF
the total neutral solenoid, cutting off pressure to
Protection modes and self tests are part of the the clutches. Intolerable faults are also referred to
APC200 programming and cannot be influenced. as Redundant Shutdown Path errors (RSP).

12
1300 SRM 1358 Control System

Transmission Exceed Codes

During operation of the truck, the APC200 control-


ler may display transmission exceed codes on the
hourmeter/fault code display. These exceed codes
reflect that the request made by the operator will Display fault code E-CON is shown when the fol-
not be executed because of certain circumstances. lowing occurs:
APC200 Fault Code Guide 1300SRM1435 lists • The engine controller does not reply to the
the exceed codes with a description of the encoun- engine identification request or request for
tered circumstances. fault codes.

Fault Codes • The engine controller stops sending one of


the regular messages, e.g. engine RPM or en-
gine coolant temperature.
Description
Display fault code t-CON is shown when the instru-
Under normal conditions the hour meter/fault code
ment cluster does not receive a cyclic message or
display on the instrument cluster shows engine
receives wrong error messages from the APC200.
running hours. The maximum hours that can be
displayed is 99.999 hours.
Fault codes that appear as tE1.23 are for faults
that occur during calibration of the transmission.
• Hourmeter reading
Fault Log Mode

Access
If the engine and/or transmission controller detect The instrument cluster has a memory that records
a fault, the hourmeter/fault code display will show each fault when it occurs. These faults that have
a fault code instead of the engine running hours. occurred can be reviewed at a later point in time by
entering into the fault log mode. Proceed as follows
Fault codes starting with "E" refer to engine fault to enter into the fault log mode:
codes.
1. Apply parking brake.
• Fault code number(s)
2. Turn ON ignition, but do not start lift truck.

3. Turn ignition OFF and ON 3 times, switch 1


time per second. After the first OFF and ON
cycle, the display will show a 1. After the sec-
Fault codes starting with "t" refer to transmission
ond OFF and ON cycle, the display will show a
fault codes, which are listed in APC200 Fault
2. After the third OFF and ON cycle, the dis-
Code Guide 1300SRM1435.
play will show a 3.
When more than one fault occurs at the same time,
The display is now in fault log mode. When no
the fault codes will be displayed in succession.
faults have been recorded, the LCD display shows
When circumstances have changed, and all faults
"clear." When faults have been recorded, the dis-
have ceased to exist, the hour meter/fault code dis-
play shows a letter and 4 numbers for each fault
play will show engine running hours again.
code. For engine fault codes, the letter is "E." For
transmission fault codes, the letter is "t".
Fault code E-CON and t-CON indicate a communi-
cation problem.

13
Control System 1300 SRM 1358

After the fault code, three further numbers are Fault Rectification
shown.
Fault codes are listed in APC200 Fault Code
The numbers represent the following: Guide 1300SRM1435, which provides an explana-
• Fault code tion of the fault, the resulting action of the
APC200, and checks for troubleshooting. Each fault
• Hourmeter reading at last occurrence
code represents a specific defect or malfunction.
• Hourmeter reading at first occurrence
• Number of occurrences of current fault In most cases the suggested rectification is by
checking electrical functionality between the
Each number is shown for 3 seconds, after which APC200, the wiring and the sensors, solenoids, or
the following number is shown. The faults will be switches.
shown in the opposite sequence of occurrence: The
most recent fault first and the first occurred fault Before disassembling components for test purposes,
last. When all recorded fault codes have been connect the TE-Userlink program. The screen
shown, the display will continue to repeat these re- Dashboard-Monitor’ allows verification of the func-
corded fault codes until the user exists the fault log tionality of speed sensors, the pressure switch, and
mode. the shift lever. In case several possible defects are
indicated, TE-Userlink may narrow down the num-
Exit ber of possible defects, preventing unnecessary re-
moval of components that function correctly.
To exit the fault log mode, turn the ignition OFF
and ON and leave ignition ON for more than 2 sec- To rectify problems with switches, solenoids and
onds. The cluster will also exit to normal mode sensors, look up their actual location, and test the
when the parking brake is released or when the en- component. The location of the solenoids are shown
gine is started. in the section Hydraulic Control Valve. The loca-
tion of sensors and switches are shown in the sec-
Clear tion Pressure, Speed, and Temperature Sensors,
and Figure 6. Test values of solenoids and sensors
are shown in Electrical Specifications.
To clear the fault codes logged in the display, pro-
ceed as follows:
NOTE: The Dana Dashboard software and the
APC200 Fault Code Guide 1300SRM1435 have
1. Access into the fault log mode. See Access.
wire and input references that relate to the
2. Clear the fault log by cycling the ignition key APC200. Refer to Table 13 for the conversion from
OFF and ON three more times. This is a repe- APC200 wire numbers to Hyster numbers.
tition of the procedure to access the fault log
mode. See Access. To identify a harness problem, first determine con-
nectivity between the APC200 and the connector of
If the data-erasing process is successful, the display the component that was indicated in the Fault
will show ’clear’. If the data-erasing process is not Code Guide.
successful, the display will show the fault codes in
the memory, shown in the order by the time of the Look up the connector code and/or the wire number
occurrence. To return to the normal mode, follow in Figure 36, which shows to which harness the
the procedure as described in Exit. To retry erasing connector and/or wire belongs.
stored fault codes, follow Step 2 of the procedure to
clear fault codes.

14
1300 SRM 1358 Control System

The wire harness figures in Electrical System Table 2. Control Valve Pressure Check Ports
2200SRM1499 show the actual location of connec-
tors. Port Description
Number
31a Filter Out - Regulator Pressure
50/52 Intensifier Pressure 1st - 3rd
51 Intensifier Pressure 2nd
54 Intensifier Pressure Forward
55 Intensifier Pressure Reverse
56 System Pressure - Intensifier Pressure
57 VFS Valve Pressure in Pilot Pressure
58 System Pressure - Intensifier Pressure
59 System Pressure - Intensifier Pressure
60/62 Selection Valve 1st - 3rd Intensifier
61 Clutch Pressure 2nd
64 Clutch Pressure Forward
65 Clutch Pressure Reverse

To identify the harness problem, first determine


connectivity between the APC200 and the connec-
tor of the component that was indicated in the
Fault Code Guide. If unsatisfactorily, measure con-
nectivity from harness to harness.

NOTE: FOR LEGEND, SEE TABLE 2.

Figure 6. Check Ports, Control Valve

15
Control System 1300 SRM 1358

HYDRAULIC CONTROL VALVE

The hydraulic control valve is located at the left-


hand side of the transmission and contains the
pressure switches, all solenoids, and most of the
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 in Figure 4.

The locations of the different solenoids and pres-


sure senders are shown in Figure 7.

The location of the main components of the control


valve are in Figure 8.

1. VFS 2ND GEAR SOLENOID


2. VFS FORWARD SOLENOID
3. VFS 1ST/3RD GEAR SOLENOID
4. VFS REVERSE SOLENOID
5. TOTAL NEUTRAL SOLENOID
6. 1ST/3RD SELECTOR SOLENOID
7. PRESSURE FEED BACK SWITCH
8. CONTROL VALVE

Figure 7. Solenoid Locations

16
1300 SRM 1358 Control System

1. INTENSIFIER SPOOL 12. SPRING


2. SPRING 13. PRESSURE SWITCH
3. STOP 14. O-RING
4. STOP 15. PRESSURE SWITCH SPOOL
5. TOTAL NEUTRAL SOLENOID 16. PRESSURE SWITCH SPOOL
6. TOTAL NEUTRAL AND CLUTCH SUPPLY 17. SPRING
SPOOL 18. PIN
7. SPRING 19. MODULATION SOLENOID (VFS)
8. SPRING 20. MODULATION SPOOL
9. 10 bar (145 psi) PRESSURE REDUCER 21. ACCUMULATOR SPRING
10. 1ST/3RD SELECTOR SOLENOID 22. CONTROL VALVE
11. 1ST/3RD SELECTOR SPOOL
Figure 8. Control Valve Components

17
Control System 1300 SRM 1358

Hydraulic Control Valve Repair The control valve includes the pilot pressure reduc-
ing valve.
Repairs to the control valve are limited to replacing
solenoids and gaskets. Hydraulic components of the With the transmission control valve removed, oil
control valve may be inspected, but cannot be ad- ports leading to the various clutches can be pres-
justed and are not separately available for replace- surized with air. The amount of air pressure ap-
ment. plied should be approximately 14 bar (200 psi).
When applying air pressure to the control valve
Solenoid Replacement ports, clutch engagement and obvious leaks can be
established. This test will not work using the trans-
To inspect components of the control valve, first the mission pressure test ports, as the air will escape
transmission has to be lifted until the frame sup- through the intensifier valve. For the location of
port bracket no longer obstructs removal of the sol- the ports see Figure 9.
enoid cover. Remove the nuts and bolts that con-
nect both sides of the transmission to the frame.
Place a jack with a wide support surface under the
transmission housing and raise the transmission
slightly. Remove the left hand transmission
bracket. Raise the jack further until the frame sup-
port bracket no longer obstructs removal of the con-
trol valve cover. For further details of control valve
replacement see the section Transmission Repair
1300SRM1356.

Pressure Check

Most of the transmission oil pressures can be meas-


ured at the side of the control valve. See Figure 6
and Table 2 that lists the check port numbers and
their description. Further check points for trans-
mission oil pressures are at different locations on
the transmission. See Figure 10 through Figure 13
and Table 3. The port numbers mentioned at each
check point correspond with the port numbers as
shown on Figure 4.

None of the oil pressures are adjustable. If a pres- A. TOP


sure is out of specification, the cause has to be es- 1. FORWARD CLUTCH
tablished by further checking. If a pressure reduc- 2. REVERSE CLUTCH
ing valve causes the problem, then the entire as- 3. SECOND GEAR CLUTCH
sembly that includes this valve must be replaced. 4. FIRST GEAR CLUTCH
5. THIRD GEAR CLUTCH
6. REGULATOR PRESSURE
The transmission pump includes the pressure regu-
lating valve, the safety valve, and the filter bypass Figure 9. Control Valve Clutch Ports
valve.

18
1300 SRM 1358 Control System

Pressure Specifications higher temperatures. Make sure that oil quality


meets the required specification and that oil has
The relief pressures in this transmission are influ- been replaced in time. Temperature of the oil must
enced by the volume and viscosity of the oil passing be 82 to 93°C (180 to 199°F) for correct pressure
through the relief valves. Smaller supply volumes measurement.
and lower viscosity result in lower system pres-
sures. Bigger supply volumes and higher viscosity In the cooling and lubrication circuit the torque
result in higher system pressures. The volume of oil converter causes additional flow resistance with in-
through the relief valves depends on engine speed. creasing speed difference between engine and
Viscosity depends on oil quality and decreases with transmission input shaft.

Description Port Pressure Specification


Filter Bypass Valve --- 1.5 to 1.7 bar (22 to 24 psi)
Regulator Pressure - Filter out 31 16.5 bar (239 psi) minimum at 600 rpm.
Regulator Pressure - Filter out 31 19.3 bar (280 psi) maximum at 2200 rpm.
Minimum Clutch Pressure See Table 2 16.5 bar (239 psi) minimum at 600 rpm.
and Ta-
ble 3.
Maximum Clutch Pressure See Table 2 19.3 bar (280 psi) maximum at 2200 rpm.
and Ta-
ble 3.
Clutch Release Pressure See Table 2 0 to 0.2 bar (0 to 3 psi)
and Ta-
ble 3.
Torque Converter in - minimum pressure 37 8.2 bar (199 psi) at 600 rpm no load.
Torque Converter in - maximum pressure 37 12.1 bar (175 psi) at 1800 rpm stalled.
Torque Converter Out - minimum pressure 32 1.7 bar (25 psi) at 2000 rpm stalled.
Torque Converter Out - maximum pressure 32 4.8 bar (70 psi) at 2000 no load.
Lubrication Pressure - minimum 34 0.6 bar (8.7 psi) at 2000 rpm stalled
Lubrication Pressure - maximum 34 1.9 bar (27.6 psi)

PRESSURE, SPEED, AND The location of the speed and temperature sensors
TEMPERATURE SENSORS are included in Figure 10, Figure 11, Figure 12,
and Figure 13. The engine speed sensor is located
Before disassembling components for test purposes, at the pump drive gear. The schematic location of
connect the TE-Userlink program. The screen the other speed sensors is shown in Figure 14.
Dashboard-Monitor’ allows verification of the func-
tionality of several components, preventing unnec-
essary removal.

19
Control System 1300 SRM 1358

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

Figure 10. Check Ports, Front View

20
1300 SRM 1358 Control System

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

Figure 11. Check Ports, Top View

21
Control System 1300 SRM 1358

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

Figure 12. Check Ports, Left View

22
1300 SRM 1358 Control System

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

Figure 13. Check Ports, Right View

23
Control System 1300 SRM 1358

Table 3. Transmission Housing Check Ports

Port Description Figure Fitting


Number
31 Filter Out - Regulator Pressure Figure 11 0.5625 - 12 UN - 2B O-ring
32 Torque Converter Out - To Cooler Figure 10 1/8 - 87 NPTF
34 Lubrication Range Clutches Figure 13 0.5625 - 18 UNF -2B O-ring
37 Torque Convertor In Figure 13 0.500 - 20 UNF - 2B O-ring
41 Clutch Pressure 1st Figure 12 0.5625 - 18 UNF -2B O-ring
43 Clutch Pressure 3rd Figure 12 1/4 NPTF Thread
45 Clutch Pressure Forward Figure 12 0.5625 - 18 UNF -2B O-ring

Table 4. Sensors and Switches

Item Sensor or Switch Figure


A Engine Speed and Temperature Sensor Figure 10 and Figure 12
B Forward Drum Speed Sensor Figure 10 and Figure 12
C Output Speed Sensor Figure 10 and Figure 12
D Turbine Speed Sensor Figure 10 and Figure 13
E, 71 Torque Convertor Out Temperature Switch Figure 10

Pressure Switch

The function of the pressure switch is to signal if


system pressure is admitted by the clutch supply
valve to the intensifier valves.

Test

When system pressure is applied,


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 kOhm. The
APC200 signals a fault when the resistance is in-
correct for the given circumstances, or when the re-
sistance sensed is below 400 Ohm or above 4000
Ohm. TE-Userlink shows the measured resistance
value under Pressure switch resistance’. The loca-
tion of the Pressure Switch is shown on Figure 8.
1. TURBINE SPEED
2. FORWARD CLUTCH DRUM SPEED
3. OUTPUT SPEED
Figure 14. Schematic Location Speed Sensors

24
1300 SRM 1358 Control System

Speed Sensor value of the remaining sensors. This


allows continued operation of the
The function of the speed sensors is to determine transmission. Speed sensor failure is
the rotation speed of the different groups of gears. indicated by a fault code. If the engine
The APC200 calculates the speed ratios between speed sensor fails, or if more than one
the different groups and compares the calculated speed sensor fails, then the APC200
values with the programmed values. If deviation will enter the Limp Home Mode and
exceeds an allowable value, the APC200 generates flag a fault.
a fault code and eventually enters a protection • Maximum Torque During Inching
mode. Below are a few examples of speed inputs
- The APC200 programming interprets
and ratios that are monitored by the APC200:
the inching pedal position as the re-
• Converter Speed Ratio quired pressure for the inching clutch.
- The ratio between engine speed and The heat generated in the inching
turbine speed is called the converter clutch is proportional to the power
speed ratio, which is a measure of the transferred by the torque converter (=
power being transferred through the converter speed ratio). When the
converter. This ratio is a major factor power transferred is at too high level
for the APC200 to determine in the during too long a time, the APC200
automatic selection mode, if a next will release pressure in the clutch and
higher or lower gear is to be selected. flag a fault.
During calibration, a sudden change
in converter speed ratio is used to de- Test
termine the clutch piston position, at
the moment the clutch starts clamp- TE-Userlink shows functionality of each of the
ing. speed sensors under "Speed Monitor". Electrical
• Transmission Ratio functionality can be tested by using the schematic
shown in Figure 15. Observe the correct sensor po-
- Each selected transmission gear has a larity. Pin 1 has to be connected to 12 volt +. Pin 2
specific transmission ratio. When one has to be connected to 12 Volt -. Figure 15 shows
of the direction clutches is closed and the connector as fitted to the speed sensors. Con-
the output speed has reached a certain necting the sensor with an incorrect polarity will
value for checking, then the actual ra- destruct the sensor. Table 5 shows acceptable test
tio is compared with the specified ra- values. Replace the sensor if it fails the test.
tio. If deviation exceeds 5%, one of the
clutches is assumed to be slipping. A Speed sensors should be fitted as close as possible
fault is flagged and the APC200 enters to the gear. Speed signal will fail if distance ex-
the Shut Down Mode. ceeds 1.8 mm (0.07 in.). The sensor mounting
• Gear Ratio bracket normally ensures correct sensor installa-
- If the turbine, drum or output speed tion.
sensor fails, then the APC200 calcu-
lates the actual ratio’ based on the

25
Control System 1300 SRM 1358

Figure 15. Speed Sensor Test

Table 5. Speed Sensor Check Values ature. TE-Userlink indicates function-


ality of this sensor under Transmis-
Voltage Current sion sump temperature’.
Reading Level
• Torque Converter Out, Port 71
Gear tooth sensed 1.2 to 1.6 volt 6 to 8 mA
- This sensor is a switch that connects
No gear tooth 2.6 to 3.0 volt 13 to 15 mA to ground when temperature has ex-
sensed ceeded 120°C (248°F). The function is
to trigger a protection mode. Function-
Temperature Sensors ality can only be tested by immersing
the temperature switch in hot oil, and
There are two temperature sensors which measure measure if it switches at
the temperature at two different locations as fol- 120°C (248°F).
lows:
• Pump Supply, Close to Port 31 Test
- This sensor is combined with the en- Table 6 shows electrical resistance values of the
gine speed sensor in one unit and is sump temperature sensor for different tempera-
connected with the APC200. The sig- tures. Resistance can be measured with a normal
nal to the APC200 is translated into a ohmmeter, provided correct polarity is observed.
CANbus signal to the dashboard and
represents transmission sump temper-

26
1300 SRM 1358 Transmission Test and Calibration

Transmission Test and Calibration


PRECAUTIONS STALL TEST

Before testing or calibrating the transmission, ver- Description


ify the following:
• Make sure the coolant level in the engine The stall test provides indications for the condition
cooling system is correct. of the engine, transmission clutches, and torque
converter. The stall test is performed with the
• Make sure the parking brake and service
transmission engaged and operating the engine at
brakes operate correctly.
full throttle while blocking the drive wheels. The
• Make sure the oil level in the transmission is stall speed for all engine options should be between
at "Full Level" when hot. 1950 rpm and 2100 rpm.
• Make sure the transmission oil temperature
is at least 80°C (180°F). Stall Test Procedure

See the Operating Manual for instructions on


how to add coolant and transmission oil.
CAUTION
Do not hold the throttle open for more than 15
To raise the oil temperature, run the engine while seconds at a time. Permit the engine to operate at
stalling the torque converter as follows: idle speed for two minutes between tests.

1. Put the lift truck against an object that cannot CAUTION


move.
Release the accelerator immediately if the engine
2. Apply the parking brake for trucks with a for- speed increases to its governed speed:
ward reverse lever. Cummins LPG Engine - 2600 rpm ±2%
3. Apply the brake pedal for trucks with a MONO-
TROL® pedal. Cummins Diesel Engine, H8.00-14.00XM,
H16.00XM-6, H10.00-12.00XM-12EC - 2450
4. Select the third gear in manual mode. rpm ±2%
5. Run the engine at half throttle until the oil
temperature gauge indicates 80°C (180°F). Cummins Diesel Engine, H170-360HD,
H360HD-EC - 2600 rpm ±2%
NOTE: Trucks with a forward/reverse lever will
shift to NEUTRAL when the brake pedal is ap-
plied. CAUTION
Performing a stall test in 1st or 2nd gear may
Trucks with a MONOTROL pedal will shift to
damage the internal parts of the drive axle.
NEUTRAL when the parking brake is applied.
Perform the stall test in 3rd gear only.

27
Transmission Test and Calibration 1300 SRM 1358

1. Connect a laptop computer to the Userlink plug When shifting up, the clutch to be released will
in the side console. Select the screen to read the start relieving its pressure at the same moment
engine speed. when the engaging clutch starts clamping. For a
short period of time, these two clutches are both
2. Put a capacity load on the forks to prevent the partially engaged. This provides the feature to shift
wheels from turning. up a gear smoothly under full traction.
3. Put the lift truck against an object that cannot
As the clutch plates wear, they will get slightly
move.
thinner. This implies that the piston of the engag-
4. Apply the parking brake for trucks with a for- ing clutch will have longer travel until the piston
ward/reverse lever. starts clamping the discs. The releasing clutch
would start slipping too early. The transmission
5. Apply the brake pedal for trucks with a MONO- would no longer shift smoothly.
TROL pedal.
The APC200 has a calibration program to readjust
6. Start the engine and select the 3rd gear in the clutch filling time and the time to reach full en-
manual mode. gagement. Clutch filling time is determined by the
elapsed time between clutch fill start and the mo-
7. Push the accelerator pedal to full throttle.
ment when the turbine speed sensor detects a
8. Read the stall speed and release the throttle change in speed (touch detection). The time to
pedal. reach full engagement is determined by the elapsed
time between touch detection and full clutch en-
If the stall speed is 50 to 200 rpm below the specifi- gagement. An automatic warning to recalibrate the
cation, the engine is not operating at full power. transmission appears on the instrument cluster ev-
Check if engine fault codes are present and rectify ery 2000 hours as exceed code (te501).
any indicated problems.
During clutch calibration, codes may be displayed
If the stall speed is higher than specification, the that indicate incorrect circumstances for proper
engaged clutch(es) may not be holding or the torque clutch calibration. The explanation of these codes is
converter is damaged. Check if transmission fault in APC200 Fault Code Guide 1300SRM1435.
codes are present and rectify any indicated prob-
lems. During clutch calibration, fault codes with a pre-
ceding "E" may be displayed. For example E1.25.
If no transmission fault codes are present and the The first digit after the "E" can be a "1" or a "2". "1"
stall speed is much higher than specification, re- relates to faults during clutch filling time. "2" re-
move the torque converter for inspection. lates to faults during clutch engagement. The last
two digits indicate calibration faults, which are lis-
If stall speed is only slightly higher than specifica- ted and explained in APC200 Fault Code Guide
tion, consider service life of the torque converter 1300SRM1435.
and the option to replace the torque converter im-
mediately or at a later point in time. Procedure
1. Apply the parking brake.
CLUTCH CALIBRATION
2. Connect a laptop computer to the Userlink plug
Description in the side console.

The APC200 is programmed to quickly fill the 3. Verify the forward/reverse lever is in NEU-
clutch until the piston starts clamping the discs TRAL or REVERSE.
and only then raise clutch pressure further within
4. Verify the MONOTROL pedal is in REVERSE.
a certain period of time until full engagement has
been reached.

28
1300 SRM 1358 Transmission Test and Calibration

5. Start the engine. lating the inching pedal position to clutch pressure.
The relation between pedal position and clutch
6. Make sure the transmission oil temperature is pressure results in a natural reaction of the opera-
at least 60°C (140°F). tor to depress the inching pedal further when ac-
tual truck speed is too high. A further depressed in-
7. Select the screen "Automatic Calibration," se-
ching pedal causes that the pressure in the inching
lect "Interface" and click the button "Clutch
clutch will get lower, which reduces truck speed, ir-
Filling Calibration."
respective of engine speed. In case too much heat is
8. The automatic calibration starts when the for- generated during inching, the APC200 will release
ward/reverse lever or MONOTROL is moved all pressure and show fault code 46.05.
into the FORWARD position and the transmis-
sion oil temperature is at least 60°C (140°F). The inching pedal sensor has to be calibrated for
two pedal positions: Inching pedal completely de-
9. When transmission oil temperature has drop- pressed and inching pedal released. Calibration is
ped below 60°C (140°F), the automatic calibra- required when the inching sensor has been re-
tion program will first heat the transmission placed or when its fixation became loose. Further,
before proceeding with the calibration. This fea- calibration is an annual requirement due to wear
ture is part of the calibration program and and creep of pedals and linkages. Before calibrating
should not be interfered, as interference will the inching sensor, verify adjustment of the brake
stop the calibration. pedal and the inching sensor. Incorrect sensor cali-
bration triggers fault codes during operation. By
10. The complete automatic calibration process slightly varying the free travel of the brake pedal it
takes 12 to 15 minutes. The screen will show is possible to vary the moment when brakes start to
'done' when the calibration has been completed. apply. With an early brake application, too much
The engine speed will remain at idle during cal- heat will be generated both in the inching clutch
ibration. and the brakes. With a later application of the
brakes, pedal travel will get longer before brakes
11. Switch the ignition OFF, when the APC200
are fully applied. Always make small adjustments
display indicates that the calibration has been
in the free travel of the brake pedal and check that
completed. Observe the display and wait until
both the inching and brake pedal will have gener-
all segments no longer light up. When the dis-
ous distance to the floor plate when the brakes are
play remains OFF, the new calibration has
fully applied.
been entered in the APC200 memory. The new
calibration settings will get lost if the ignition
is switched ON too early.
Brake and Inching Pedal Adjustment

NOTE: Do not interfere with the calibration. Acti- 1. Make sure the release position of the brake
vating any controls or components will stop the cal- pedal has been properly adjusted.
ibration mode before completion. The screen will a. Wet Brakes - Turn the adjustment bolt for
show when the calibration has been completed. the brake pedal until there is no play be-
tween the bolt on the brake valve and the
During calibrations the APC200 display may show roller under the brake pedal. See Figure 16.
calibration condition messages, or error codes dur-
ing calibration. For explanation of these codes see b. Dry Brakes - Turn the adjustment bolt for
APC200 Fault Code Guide 1300SRM1435. the brake pedal until there is 5 to 10 mm (0.2
to 0.4 in.) travel until the brake light comes
INCHING CALIBRATION ON.

Description

Inching is a controlled traction and braking mode.


It enables higher engine speeds for increased hy-
draulic function speeds, while truck travel speed re-
mains low. The inching function is obtained by re-

29
Transmission Test and Calibration 1300 SRM 1358

1. BRAKE PEDAL
2. INCHING PEDAL
3. ADJUSTMENT BOLT FOR BRAKE PEDAL
4. ADJUSTMENT BOLT FOR BRAKE PEDAL COU-
PLING
5. ADJUSTMENT BOLT FOR INCHING PEDAL

Figure 16. Brake Pedal Assembly


Figure 17. Dry Brake Inching Pedal Adjustment
2. Position the top of the inching pedal and the
brake pedal at equal height.
b. Loosen the two mounting bolts of the inching
a. Wet Brakes - Adjust the adjustment bolt for sensor.
the brake pedal coupling so that the inching
c. Rotate the sensor in the slotted holes until
pedal has no free play.
output voltage is between 600 and 700 mV.
b. Dry Brakes - Adjust the adjustment bolt for
d. Tighten the two mounting bolts and verify
brake pedal coupling so that the inching
output voltage is still correct.
pedal will have a free play of approximately
20 to 25 mm (0.80 to 1.0 in.) before the brake
Inching Sensor Calibration
pedal starts to move. See Figure 17.
1. Make sure pedals and inching sensor have been
Inching Sensor Adjustment correctly adjusted.
1. Attach a laptop to the Userlink. 2. Start the engine and let it run for about 30 sec-
onds.
2. Select "Inching Pedal Calibration Mode."
3. Attach a laptop to the Userlink and select "Au-
3. Verify if the analog output of the inching sensor
tomatic Calibration."
is between 600 and 700 mV.
4. Select "Inching Pedal Calibration" and follow
4. If the analog output is incorrect, proceed as fol-
the instructions. Normal values to be reached
lows:
for both dry and wet brake are as follows:
a. Raise the cab until the latch locks in the par- • Fully released pedal - 600-700 mV
tial open position • Fully depressed pedal - 2500-4000 mV

30
1300 SRM 1358 Transmission Test and Calibration

5. Switch the ignition OFF, when the APC200 been entered in the APC200 memory. The new
display indicates that the calibration has been calibration settings will get lost if the ignition
completed. Observe the display and wait until is switched ON too early.
all segments do not longer light up. When the
display remains OFF, the new calibration has

Electrical Specifications
Electronic controlled modulation solenoids Table 6. Temperature Sensor (In Speed Sensor)
VFS 2nd - VFS 1st/3rd - VFS Fwd - VFS Rev Resistance Versus Temperature (Continued)
Coil resistance - 4.35 ±0.35Ω at 25°C (77°F) AMBIENT RESISTANCE
TEMPERATURE Ω
ON/OFF solenoids 20°C (68°F) 1922
Total neutral and selector solenoids
25°C (77°F) 2000
Coil resistance - 12V - 28 ±2Ω at 20°C (68°F)
30°C (86°F) 2080
Coil resistance - 24V - 87 ±2Ω at 20°C (68°F)
40°C (104°F) 2245
Speed sensor 50°C (122°F) 2417
Type - Magneto resistive sensor. 60°C (140°F) 2597
Sensing distance - 0 to 1.8 mm (0 to 0.07 in.) 70°C (158°F) 2785
Sensor signal - Generates a square current 80°C (176°F) 2980
with a fixed amplitude changing between 7
90°C (194°F) 3182
and 14 mA.
100°C (212°F) 3392
Table 6. Temperature Sensor (In Speed Sensor) 110°C (230°F) 3607
Resistance Versus Temperature
120°C (248°F) 3817
AMBIENT RESISTANCE
125°C (257°F) 3915
TEMPERATURE Ω
130°C (266°F) 4008
−55°C (−67°F) 980
140°C (284°F) 4166
−50°C (−58°F) 1030
150°C (302°F) 4280
−40°C (−40°F) 1135
−30°C (−22°F) 1247
−20°C (−4°F) 1367
−10°C (14°F) 1496
0°C (32°F) 1630
10°C (50°F) 1772

31
APC200 Display information 1300 SRM 1358

APC200 Display information


GENERAL The LED lamp labeled "D" is yellow and will be ON
to indicate diagnostic modes.
The APC200 controller is located in the side console
of the cab and has a display and push buttons to The LED lamp labeled "E" is yellow and blinks to
call off information. See Figure 18. indicate faults.

The information is provided by means of codes. The The LED lamp labeled "F" is red and is ON when
interpretation of these codes depends on the dis- the APC200 is in the reset condition.
play mode being activated. The following display
modes are available: The push button marked "M" is used to scroll to one
of the three display groups.
• General Information
• Test The push button marked "S" is used to scroll to a
• Calibration next sub group within a display group.

These display modes provide an alternative method


to calibrate or obtain information in case TE-User-
link is not available.

Figure 18. APC200 Front Panel

32
1300 SRM 1358 APC200 Display information

GENERAL INFORMATION GROUP After startup the display will show the sub group
that was selected when the APC200 was switched
Table 7 shows the structure of the General Infor- OFF.
mation Group. Figure 19 schematically shows that
by pressing the M button the display scrolls to a
next display group, and by pressing the S button
the display scrolls to a next sub group. When but-
ton M is pressed to scroll to a next display group,
the display will first show the sub group that is
highest on the display group list (6PoS, or cPoS, or
Err). Starting from these positions it will be possi-
ble 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 a next display group, first scroll to the


sub group (6PoS, or cPoS, or Err) that is highest on
the display group list. Only when starting at 6PoS,
cPoS, or Err, it will be possible to scroll to a next
display group by pressing the M button.

To read the value of a sub group, press and release


the S button. After half a second the display shows
the code of the sub group, followed by the actually
measured value. See Table 7 for sequence and ex-
planation of the sub groups. See Figure 19 and Ta- Figure 19. APC200 Display Groups
ble 7.

33
APC200 Display information 1300 SRM 1358

Table 7. General Information Group

Display Description Explanation Example


Gear, Vehicle Speed, Distance
6PoS Gear Position Shows actually engaged gear direction (F, R) and range (1, 2, 3). F3
USPd Vehicle Speed Shows truck speed in 0.1 km/hr resolution. 167
diSt Travel Distance Shows travelled distance in 0.1 km resolution. 1258
Press "S" button during 3 seconds to reset to zero.
oPEr Operating Shows total truck running hours in one hour resolution and has 12.3.4.
Hours 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 Po- Shows the current shift lever position (F, R) (1, 2, 3). F3
sition
ESPd Engine Speed Shows measured engine speed. 1580
tSPd Turbine Speed Shows measured turbine speed. 885
oSPd Output Speed Shows measured output speed. 600
SrAt Speed Ratio Shows the speed ratio turbine/engine speed. 0.56
tq i Turbine Torque Measured turbine torque at transmission input side in N•m. 125
ttnP Transmission Shows transmission temperature in °C. 65
Temperature
ctnP Cooler in Tem- Shows cooler input temperature in °C. 75
perature
Fault Codes
Err Fault Code Shows the transmission fault code number. 31.01

34
1300 SRM 1358 APC200 Display information

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-
Figure 20. Indication of Protection Mode
LED is blinking a fault is active, which will be
shown on the display.

If more than one fault has been detected, the most TEST FUNCTION GROUP
severe one will be shown first. Push and release the
"S" button once to display the next fault code. After To enter the Test Function Group, press the S-but-
the last code has been displayed, the display will ton while turning the ignition switch to ON. Re-
show “- - - -.“ lease the S-button when the display shows:
8.8.8.8.’. After releasing the S-button the display
Displayed fault codes appear either blinking or are will show: diSP’. See Figure 21.
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 been shown again. The advice is to write
down the codes of inactive faults, or use the dash- Figure 21. Test Function Group Mode
board display. The memory of the dashboard dis-
play retains all fault codes until its memory has
been cleared. The only way to leave the test function group is by
switching the ignition switch to OFF.
INDICATION OF PROTECTION MODES
Figure 22 schematically shows that by pressing the
The Limp Home Mode and Shutdown Mode as de- M button the display scrolls to a next display
scribed under Control System’ are only made visi- group, and by pressing the S button the display
ble on the APC200 display when it is in the 6PoS- scrolls to a next sub group. When button M is
or cPoS-mode. The display shows the letters LH for pressed to scroll to a next display group, the display
Limp Home or the letters Sd for Shut Down and will first show the sub group that is highest on the
also the direction and the gear selected at that mo- display group list (diSP, dinP, etc). Starting from
ment. Once in the Shut Down mode, the APC200 these positions it will be possible to scroll to sub
will already have selected NEUTRAL. The E-LED groups that are lower on the sub group list. To re-
on the APC200 front panel will be blinking. See turn to the highest positioned sub group, press the
Figure 20. S-button after having reached the lowest positioned
sub group.

35
APC200 Display information 1300 SRM 1358

Figure 22. Test Function Group Schematic

To scroll to a 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 a next dis-
play group by pressing the M button.
Figure 23. Digital Input Test
Instructions for how to call off information for each
test group is described separately.
In the example shown on Figure 25, the segments
DIGITAL INPUT TEST 1, 4, and 5 are ON, indicating that DIGIN1,
DIGIN4, and DIGIN5 are active. By moving the se-
APC200 has 10 digital inputs, which measure con- lector lever, different segments will be switched
nectivity of the wires listed in Table 8. After the ON.
display has shown dinP,' see Figure 23, push and
release the S-button. The display indicates the ac-
tive inputs by switching ON certain segments of
the display, see Figure 24. The numbered segments
0-9 represent the digital inputs DIGIN0 until
DIGIN9.

36
1300 SRM 1358 APC200 Display information

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


ther hi’ or lo.’ hi’ is shown when the lever switch is
making a connection or has a short circuit. lo’ is
shown when the lever switch does not connect or
has an open circuit. Unsupported connections will
show lo.’

Pressing the S-button after 9.46 returns the display


to dinP.’

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
input number with the matching SOH wire num- Figure 25. Active Digital Inputs
ber. The example on Figure 26 shows that DIGIN0
relates to wire A12. Table 8 provides reference to
HYSTER wire numbers.

Table 8. Digital Input Test

Code Name Wire Wire APC Wire Description Output


0.12 DIGIN0 A12 549 - C B2 Shift Lever 1st hi/lo
1.13 DIGIN1 A13 550 - C C2 Shift Lever 2nd hi/lo
2.14 DIGIN2 A14 551 - A D2 Seat Occupied, Switch Relay hi/lo
3.17 DIGIN3 A17 713 - E G2 OPEN lo
4.18 DIGIN4 A18 553- E H2 Shift Lever Forward hi/lo
5.19 DIGIN5 A19 554 - G J2 Shift Lever Reverse hi/lo
6.43 DIGIN6 B13 OPEN L3 OPEN hi/lo
7.44 DIGIN7 B14 556 - C M3 Automatic/Manual Mode hi/lo
8.45 DIGIN8 B15 938 - C N3 Park BrakeON/OFF hi/lo
9.46 DIGIN9 B16 714 - E P3 Inching Pedal lo

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 five inputs. Values below 1 kOhm are shown as
0.’ Each input value is separated by a dot. See Fig-
Figure 26. Digital Input Code ure 28.

ANALOG INPUT TEST

APC200 has 5 analog resistance inputs, which


measure the actual resistance of the sensors listed
in Table 9. Figure 27. Analog Input Test

37
APC200 Display information 1300 SRM 1358

ber. The first input shown concerns ANI0 and SOH


wire A11. Table 9 provides reference to Hyster
wire numbers.

When releasing the S-button, the display shows the


Figure 28. Analog Resistance Values resistance value in Ohm. Pressing the S-button af-
ter 6.36 returns the display to AinP.’ See Figure 27.
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 SOH wire num-

Table 9. Analog Input Test

Code Name Wire Wire APC Wire Description Output


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
4.36 ANI6 B06 568 - A S1 1st/3rd Pressure Sensor Ohm

SPEED SENSOR TEST ber. The first sensor is indicated by 0.22,’ meaning
that sensor SS0 relates to wire A22. Table 10 pro-
APC200 has 4 speed sensor inputs, which represent vides reference to HYSTER wire numbers.
the number of teeth that pass the sensor per sec-
ond. Table 10 lists the different speed sensors. Af- When releasing the S-button, the display shows a c’
ter the display has shown SPd,’ see Figure 29, push to indicate a current type sensor and a dot and
and release the S-button. The display will show the three digits to indicate the frequency in kHz. Fig-
value in kilo Ohm in sequence of each input. Each ure 30 shows a frequency of 0.933 kHz. Pressing
value is separated by a dot. the S-button after 3.41 returns the display to SPd.’

Figure 29. Speed Sensor Test Figure 30. Measured Frequency

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 SOH wire num-

38
1300 SRM 1358 APC200 Display information

Table 10. Speed Sensor Test

Code Name Wire Wire APC Wire Description Output


0.22 SSO+ A22 417 B3 Drum Speed Sensor + kHerz
1.24 SS1+ A24 419 D3 Output Speed Sensor + kHerz
2.26 SS2+ A26 434 F3 Engine Speed Sensor + kHerz
3.41 SS3+ B11 437 R2 Turbine Speed Sensor + kHerz

OUTPUT TEST The first output is indicated by 0.2,’ meaning that


VFS0 relates to SOH wire A02. Table 11 provides
The Output Test Group shows the outputs to the reference to HYSTER wire numbers.
VFS solenoids and to the ON/OFF solenoids. After
the display has shown outP,’ see Figure 31, push When releasing the S-button, the display shows the
and release the S-button. The display indicates the current provided to the VFS solenoids in mA, or the
active outputs by switching ON certain segments of resistance value in Ohm.
the display. The numbered segments 0 - 3 repre-
sent the outputs for VFS0 - VFS3. Segments 4 - 6 When releasing the S-button, the display shows ei-
are not used. Segments 7 - 10 represent the outputs ther a value for VFS solenoids, or hi’/lo’ for
for DO0 - DO3. ON/OFF solenoids. The value shown for VFS sole-
noids is in mA. hi’ is shown when the solenoid is ac-
tivated. lo’ is shown when the solenoid is NOT acti-
vated.

If an output is currently at fault, the respective seg-


ment in the overview screen blinks slowly. On the
Figure 31. Output Test output specific screen the display alternates be-
tween mA or hi’/lo’, and a fault type. Fault types
used are Open, Short, Curr, or Oor (out of range).
Press and hold the S-button to scroll to the individ-
ual outputs. The display will show the logic refer- Pressing the S-button after 10.20 returns the dis-
ence number with the matching SOH wire number. play to SPd.’

39
APC200 Display information 1300 SRM 1358

Table 11. Output Test

Code Name Wire Wire APC Wire Description Output


Output Test Variable Force Solenoids
0.2 VFSO+ A02 482 B1 VFS Forward Hi Side Out mA
1.4 VFS1+ A04 486 D1 VFS 2nd VFS Hi Side Out mA
2.6 VFS2+ A06 480 F1 VFS Rev Hi Side Out mA
3.8 VFS3+ A08 484 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 488 K1 Total Neutral Solenoid + hi/lo
8.15 DO1 A15 OPEN E2 OPEN lo
9.16 DO2 A16 492 F2 1st/3rd Selector solenoid hi/lo
10.20 DO3 A20 489 K2 Total Neutral Solenoid - hi/lo

VOLTAGE TEST

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 wire Figure 32. Voltage Test
394b.
• VS’ Switched Voltage as measured on wire
121. Table 13 provides the conversion of APC200 wire
numbers to HYSTER numbers.
• VSEn’ Sensor Voltage as measured at any
analog input.

Pressing the S-button after VSEn’ returns the dis-


play to Volt.’

40
1300 SRM 1358 APC200 Display information

Table 12. Voltage Test

Code Wire APC200 Hyster Wire APC200 Wire Description Output


Name Wire Nr Nr Pin Nr
Voltage Test
VP PPWR A01 394-B A1 Permanent Battery + 24.0 Volt
VS SPWR B12 121 S2 Switched Battery + 24.0 Volt

Table 13. APC200 Wire Number to Hyster Wire Number Conversion

APC200 Wire Wire Hyster Wire APC200 Pin Wire Description Output
Nr Name Nr Nr
A01 PPWR 394-B A1 Permanent Battery + 24.0 Volt
A02 VFS0+ 482 B1 VFS Forward Hi Side Out mA
A03 VFS0 483 C1 VFS Forward Lo Side Out mA
A04 VFS1+ 486 D1 VFS 2nd VFS Hi Side Out mA
A05 VFS1 487 E1 VFS 2nd VFS Lo Side Out mA
A06 VFS2+ 480 F1 VFS Rev Hi Side Out mA
A07 VFS2 481 G1 VFS Rev Lo Side Out mA
A08 VFS3+ 484 H1 VFS 1st/3rd Hi Side Out mA
A09 VFS3 485 J1 VFS 1st/3rd Lo Side Out mA
A10 DO0 488 K1 Total Neutral Solenoid + hi/lo
A11 ANI0 490 A2 Pressure Feedback Switch + Ohm
A12 DIGIN0 809 B2 Shift Lever 1st hi/lo
A13 DIGIN1 811 C2 Shift Lever 2nd hi/lo
A14 DIGIN2 878 D2 Seat Occupied, Switch Relay hi/lo
A15 DO1 Open E2 Open
A16 DO2 492 F2 1st/3rd Selector Solenoid hi/lo

41
APC200 Display information 1300 SRM 1358

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

APC200 Wire Wire Hyster Wire APC200 Pin Wire Description Output
Nr Name Nr Nr
A17 DIGIN3 Open G2 Open
A18 DIGIN4 807-B H2 Shift Lever Forward hi/lo
A19 DIGIN5 808-C J2 Shift Lever Reverse hi/lo
A20 DO3 489 K2 Total Neutral Solenoid - hi/lo
A21 GND 645 A3 APC200 Ground Volt
A22 SS0+ 417 B3 Drum Speed Sensor + kHerz
A23 SS0- 418 C3 Drum Speed Sensor - kHerz
A24 SS1+ 419 D3 Output Speed Sensor + kHerz
A25 SS1- 433 E3 Output Speed Sensor - kHerz
A26 SS2+ 434 F3 Engine Speed Sensor + kHerz
A27 SS2- 436 H3 Engine Speed Sensor - kHerz
A28 ANI1 435 G3 Transmission Temperature Ohm
A29 ANI2 477-B J3 Converter Out Temperature Ohm
A30 GND 478-C K3 Ground Ohm
B01 VFS4+ Open L1 Open
B02 ANI4 477 M1 Inching Pedal Ohm
B03 VFS5+ Open N1 Open
B04 ANI5 408-B P1 Open
B05 VFS6+ Open R1 Open
B06 ANI6 Open S1 Open
B07 CAN L 598-D L2 CAN Low
B08 CAN H 599-D M2 CAN High
B09 RXD 439 N2 Open
B10 TXD 438 P2 Open
B11 SS3+ 437 R2 Turbine Speed Sensor + kHerz
B12 SPWR 121 S2 Switched Battery + 24.0 Volt
B13 DIGIN6 810-A L3 Start in 2nd Gear hi/lo
B14 DIGIN7 812 M3 Automatic/Manual Mode hi/lo
B15 DIGIN8 819-B N3 Park Brake ON/OFF hi/lo
B16 DIGIN9 Open P3 Open
B17 ANI3 479 R3 Inching Pedal Signal Ohm
B18 GND 646 S3 Ground Volt

42
1300 SRM 1358 APC200 Display information

CALIBRATION GROUP Clutch Filling Calibration


NOTE: Do not interfere with the calibration. Acti-
Calibration Mode
vating any controls or components will stop the cal-
ibration mode before completion.
Figure 33 schematically shows the procedure to en-
ter the calibration mode. The only relevant modes 1. Apply the parking brake.
are under trAn, (clutch filling calibration), hEAt,
(heating the transmission), and brAH, (inching sen- 2. Block the drive tires.
sor calibration). See Figure 34. To enter the calibra-
tion mode, press and hold the S-button, and turn 3. Make sure the transmission temperature is at
the ignition switch to ON. During the first 15 sec- least 60°C (140°F).
onds the display will show “8888”. Release the S
4. Make sure the forward/reverse lever is in NEU-
button when after 15 seconds the display shows
TRAL or REVERSE.
“trAn.”
5. Make sure the MONOTROL pedal is in RE-
VERSE.

6. Enter the calibration mode. Push the "M" but-


ton until 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 MONOTROL pedal is
moved into to the FORWARD position. The
screen will display:

Figure 33. Calibration Mode

10. When the calibration has been completed, the


APC200 display will show:

Figure 34. Entering Calibration Mode

43
APC200 Display information 1300 SRM 1358

11. Switch the ignition OFF, when the APC200 10. Decelerate the engine to idle.
display indicates that the calibration has been
completed, observe the display and wait until 11. Repeat step Step 6 through Step 10 until the
all segments no longer light up. When the dis- APC200 display shows a temperature above
play remains OFF, the new calibration has 60°C (140°F).
been entered into the APC200 memory. The
12. Push the "M" button to scroll to the desired cal-
new calibration settings will be lost if the igni-
ibration mode.
tion is switched ON too early.
INCHING SENSOR CALIBRATION
Heat Up Mode
Inching Pedal Sensor Adjustment
The heat up mode provides a convenient way to
quickly heat the transmission for test and calibra- NOTE: Before calibrating the inching sensor, the
tion purposes. During the heat up mode only the sensor must be adjusted correctly.
highest gear is selected and the inputs from the
parking brake and the brake pedal position are ig- 1. Push the "S" button and turn the ignition
nored. switch to the ON position.

1. Press and hold the S-button, and turn the igni- 2. Release the "S" button when “8888” appears on
tion switch to ON. During the first 15 seconds the display.
the display will show “8888.” Release the S but-
3. Push the “M” button until the APC200 display
ton when after 15 seconds the display shows
shows: "AinP."
“trAn.”
4. Push the "S" button 3 times. The display will
2. Start the engine.
show 0.11, 1.28, 2.29 and a value. Pushing an-
3. Press the "M" button once and release. The other time changes the display into 3.47. Re-
word heat will show. leasing the button shows the value in Ohm for
the inching pedal sensor. Eg "0.652."

5. The reading should be between 0.600 and


0.700.

6. Adjust the inching pedal sensor at the under-


4. Press the "S" button again and release. The ac- side of the cab accordingly.
tual transmission sump temperature will be
shown. 7. Leave the test function group in the APC200 by
turning the key switch to the OFF position.

Inching Sensor Calibration


NOTE: Calibration will fail under following circum-
stances:
5. Apply the service brakes.
• Inching sensor adjustment is below 450 mV.
6. Put the MONOTROL pedal or the shift lever in • During calibration the voltage at the inching
the FORWARD position. sensor does not reach 2500 mV or exceeds
4.000 mV.
7. Push the throttle for approximately 15 seconds.
1. Enter the Calibration Mode until trAn’ appears
8. Put the shift lever in NEUTRAL or the MON- on the display.
OTROL pedal in REVERSE.
2. Push the "M" button several times until brAH’
9. Run the engine at 1300 rpm for approximately appears on the display.
15 seconds in NEUTRAL.

44
1300 SRM 1358 APC200 Display information

3. Push the "S" button once to start the sensor cal- 7. When the value has been accepted, the display
ibration. brA_’ will show, which is the request shows: donE.’
to enter the pedal up position.
NOTE: Calibration procedure has to be repeated if
4. Make sure to not touch the inching pedal and the ignition is turned ON too early.
push the "S" button.
8. Switch the ignition OFF, when the APC200
5. The display will show brA_ which is the request display indicates that the calibration has been
to fully depress the inching pedal. completed, observe the display, and wait until
all segments no longer light up. When the dis-
play remains OFF, the new calibration has
been entered into the APC200 memory. The
new calibration settings will be lost if the igni-
tion is switched ON too early.
6. Fully depress the inching pedal and press the
"S" button.

TE-Userlink
DESCRIPTION

For a convenient way of visualizing diagnostics and


executing software settings, a system called TE-
Userlink can be used.

The Userlink system consists of a laptop computer,


diagnostic software, and a USB (Universal Serial
Bus) interface cable. To obtain these items order
the following part numbers:
• 1550633 - Userlink software, including soft-
ware for the interface cable.
• 1534010 - USB interface cable.

CONNECTION

Install the TE-Userlink and USB interface drivers


on a laptop per instructions delivered with the TE-
Userlink and USB interface cable. The help text 1. APC200 CONTROLLER
contains all information required to work with the 2. DIAGNOSTIC PLUG
diagnostic software and also provide the necessary Figure 35. APC200 Connector Location
education and guidance.

Connect the TE-Userlink to the truck using the


USB interface cable (Hyster P/N 1534010). The
DIAGRAMS, SCHEMATICS, OR
truck connector is located in the side console of the ARRANGEMENTS
cab. See Figure 35.

45
Diagrams, Schematics or Arrangements 1300 SRM 1358

46
1300 SRM 1358 Diagrams, Schematics or Arrangements

Figure 36. APC200 Wiring Diagram

47
Diagrams, Schematics or Arrangements 1300 SRM 1358

Legend for Figure 36

Item Description Code Connector Figure Wire Harness Wire Harness


No. Figure
1 Diagnostic Plug C535 Figure 46 Cab Side Console Figure 37
2 Tuning Link C415 Figure 45 Cab Side Console Figure 37
3 Turbine Speed Sensor C340 Figure 52 Frame Figure 47
4 Resistor Converter Out C105 Figure 38 Cab Side Console Figure 37
5 Converter Out Temperature. C330 Figure 53 Frame Figure 47
Sensor
6 Inching Pedal C90 Figure 60 Under Cab Floor Figure 56
7 APC200 R2 C110 Figure 40 Cab Side Console Figure 37
8 APC200 R1 C120 Figure 39 Cab Side Console Figure 37

9 Control Valve C80 Figure 49 Frame Figure 47


10 Drum Speed Sensor C90 Figure 48 Frame Figure 47
11 MONOTROL® Pedal C30 Figure 58 Under Cab Floor Figure 56
12 Transmission Lever C50 Figure 63 Steering Column Figure 61
13 Engine Speed Sensor C150 Figure 50 Frame Figure 47
14 Output Speed Sensor C120 Figure 51 Frame Figure 47

48
NOTES

49
Diagrams, Schematics or Arrangements 1300 SRM 1358

50
1300 SRM 1358 Diagrams, Schematics or Arrangements

Figure 37. Cab Side Console Harness

51
Diagrams, Schematics or Arrangements 1300 SRM 1358

Legend for Figure 37

Item Connector Description Connector Connecting Connector Description


No. Figure Harness
1 C105 Resistor Converter Out Figure 38 --- --- ---
2 C120 APC200 R1 Figure 39 --- --- ---
3 C110 APC200 R2 Figure 40 --- --- ---
4 C90 Park brake Diode --- --- --- ---
5 C80 Armrest Figure 41 --- --- ---
6 C60 Cab Signals Figure 42 Frame C144 Cab Signals
7 C70 Cab Supplies Figure 43 Frame C146 Cab Supplies
8 C130 Under Cab Floor Figure 44 Under Cab Floor C10 Side Console
9 C415 Tuning Link Figure 45 --- --- ---
10 C535 Diagnostic Plug Figure 46 --- --- ---

52
1300 SRM 1358 Diagrams, Schematics or Arrangements

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
1 478 SGND Ground K3 Splice WN --- APC200
Controller
2 477b ANI2 Converter Out J3 C120 J3 See ---
Temperature Figure 39
3 477c ANI2 Converter Out J3 splice WP --- ---
Temperature
4 477a ANI2 Converter Out J3 C70 5 See Cab
Temperature Figure 43 Supplies

Figure 38. Resistor Converter Out Connector C105 of Wire Harness Side Console Cab

53
Diagrams, Schematics or Arrangements 1300 SRM 1358

Pin No. Wire APC200 Wire Description APC200 Pin Mating Connector
No. Name Code Pin Figure Description
A1 394B PPWR Permanent Battery Plus A1 C380 10 --- Fuse Panel
B1 482 VFSO+ VFS Forward Hi Side Out B1 C60 16 See Cab Signals
Figure 42
C1 483 VFSO- VFS Forward Lo Side Out C1 C60 17 See Cab Signals
Figure 42
D1 486 VFS1+ VFS 2nd VFS Hi Side Out D1 C60 21 See Cab Signals
Figure 42
E1 487 VFS1- VFS 2nd Lo Side Out E1 C60 31 See Cab Signals
Figure 42
F1 480 VFS2+ VFS Rev Hi Side Out F1 C60 9 See Cab Signals
Figure 42
G1 481 VFS2- VFS Rev Lo Side Out G1 C60 12 See Cab Signals
Figure 42
H1 484 VFS3+ VFS 1st/3rd Hi Side Out H1 C60 18 See Cab Signals
Figure 42
J1 485 VFS3- VFS 1st/3rd Lo Side In J1 C60 19 See Cab signals
Figure 42
K1 488 DO0 Total Neutral Solenoid + K1 C60 37 See Cab Signals
Figure 42
A2 490 ANIO Pressure Feedback A2 C60 39 See Cab Signals
Switch + Figure 42
B2 809 DIGIN0 Shift Lever 1st B2 C130 5 See Under Floor
Figure 44
C2 811 DIGIN1 Shift Lever 2nd C2 C130 7 See Under Floor
Figure 44

54
1300 SRM 1358 Diagrams, Schematics or Arrangements

Pin No. Wire APC200 Wire Description APC200 Pin Mating Connector
No. Name Code Pin Figure Description
D2 878 DIGIN2 Seat Occupied, Switch D2 C480 6C --- Relays
Relay
E2 --- DO1 Not Used E2 --- --- --- ---
F2 492 DO2 1st/3rd Selector solenoid F2 C60 53 See Cab Signals
Figure 42
G2 --- DIGIN3 Not Used G2 --- --- --- ---
H2 807b DIGIN4 Shift Lever Forward H2 C130 3 See Under Floor
Figure 44
J2 808c DIGIN5 Shift Lever Reverse J2 --- --- --- Relay Panel
K2 489 DO3 Total Neutral Solenoid - K2 C60 38 See Cab Signals
Figure 42
A3 645 GND Transmission ECM A3 C70 3 See Cab Supplies
Ground Figure 43
B3 417 SSO+ Drum Speed Sensor + B3 C60 41 See Cab Signals
Figure 42
C3 418 SSO- Drum Speed Sensor - C3 C60 42 See Cab Signals
Figure 42
D3 419 SS1+ Output Speed Sensor + D3 C60 43 See Cab Signals
Figure 42
E3 433 SS1- Output Speed Sensor - E3 C60 44 See Cab Signals
Figure 42
F3 434 SS2+ Engine Speed Sensor + F3 C60 45 See Cab Signals
Figure 42
G3 435 SS2- Engine Speed Sensor - G3 C60 46 See Cab Signals
Figure 42
H3 436 ANI1 Transmission H3 C60 47 See Cab Signals
Temperature Figure 42
J3 477b ANI2 Converter Out J3 C105 2 See Resistors
Temperature Figure 38 'Converter
Out'
K3 478c SGND Ground K3 C60 11 See Cab Signals
Figure 42

Figure 39. Connector C120 of Wire Harness Side Console Cab

55
Diagrams, Schematics or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
L1 --- PWM4+ OPEN L1 --- --- --- ---
M1 477d REF5V 5V Ref Voltage Out M1 C130 28 See Under Floor
Figure 44
N1 --- PWM5+ OPEN N1 --- --- --- ---
P1 408b ANI5 Hydraulic lift lever P1 C80 10 See Arm Rest
signal Figure 41
R1 --- PWM6+ OPEN R1 --- --- --- ---
S1 --- ANI6 OPEN S1 --- --- --- ---
L2 598d CANL CAN Low L2 C540 B --- Resistor
Terminal
M2 599d CANH CAN High M2 C540 A --- Resistor
Terminal
N2 439 RXD Tuning Link N2 C415 4 See Tuning Link
RS232RXD Figure 45
P2 438 TXD Tuning Link P2 C415 1 See Tuning Link
RS232TXD Figure 45
R2 437 SS3+ Turbine Speed R2 C60 48 See Cab Signals
Sensor + Figure 42
S2 121 SPWR Switched Battery S2 C380 14 --- Fuse Panel
Plus
L3 810a DIGIN6 Start in 2nd gear L3 C130 6 See Under Floor
Figure 44
M3 812 DIGIN7 Automatic/Manual M3 C130 8 See Under Floor
Mode Figure 44
N3 819B DIGIN8 Park Brake ON/OFF N3 C90 1 --- Park Brake
diode
P3 --- DIGIN9 OPEN P3 --- --- --- ---
R3 479 ANI3 Inching Sensor R3 C130 27 See Under Floor
Output Figure 44
S3 646 VFSGND Transmission ECM S3 C70 3 See Cab
Ground Figure 43 Supplies

56
1300 SRM 1358 Diagrams, Schematics or Arrangements

Figure 40. APC 200 Connector C110 of Wire Harness Side Console

Figure 41. Armrest Connector C80 of Wire Harness Cab Side Console

Figure 42. Cab Signals Connector C60 of Wire Harness Cab Side Console

57
Diagrams, Schematics or Arrangements 1300 SRM 1358

Figure 43. Cab Supplies Connector C70 of Wire Harness Cab Side Console

Figure 44. Under Floor Connector C130 of Wire Harness Cab Side Console

58
1300 SRM 1358 Diagrams, Schematics or Arrangements

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
1 438 TXD Tuning Link P2 C110 P2 See APC200
RS232TXD Figure 40 Controller
2 --- --- --- --- --- --- --- ---
3 652 --- Ground --- --- --- --- ---
4 439 RXD Tuning Link N2 C110 N2 See APC200
RS232RXD Figure 40 Controller

Figure 45. Transmission Diagnostic Connector (Tuning Link) C415 of Wire Harness Side Console Cab

59
Diagrams, Schematics or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
A 599A CANH CAN High L2 --- --- --- Resistor
Terminal
B 598A CANL Can Low M2 --- --- --- Resistor
Terminal
C --- --- --- --- --- --- --- ---

Figure 46. Diagnostic Plug C535 of Wire Harness Side Console Cab

60
NOTES

61
Diagrams, Schematics or Arrangements 1300 SRM 1358

62
1300 SRM 1358 Diagrams, Schematics or Arrangements

Figure 47. Frame Wire Harness

63
Diagrams, Schematics or Arrangements 1300 SRM 1358

Legend for Figure 47

Item Connector Description Connector Connecting Connector Description


No. Figure Harness
1 C90 Drum Speed Figure 48 --- --- ---
2 C80 Control Valve Figure 49 --- --- ---
3 C150 Engine Speed Figure 50 --- --- ---
4 C120 Output Speed Figure 51 --- --- ---
5 C340 Turbine Speed Figure 52 --- --- ---
6 C330 Converter Out Figure 53 --- --- ---
Temperature.
7 C144 Cab Signals Figure 54 Side Console Cab C60 Cab Signals
8 C146 Cab Supplies Figure 55 Side Console Cab C70 Cab Supplies

64
1300 SRM 1358 Diagrams, Schematics or Arrangements

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
1 417 SSO+ Drum Speed Sensor + B3 C144 41 See Cab Signals
Figure 54
2 418 SSO-- Drum Speed Sensor - C3 C144 42 See Cab Signals
Figure 54

Figure 48. Drum Speed Connector C90 of Wire Harness Frame

65
Diagrams, Schematics or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
1 480 VFS2+ VFS Rev Hi Side Out F1 C144 9 See Cab Signals
Figure 54
2 481 VFS2- VFS Rev Lo Side Out G1 C144 12 See Cab Signals
Figure 54
3 482 VFSO+ VFS Forward Hi Side B1 C144 16 See Cab Signals
Out Figure 54
4 483 VFSO- VFS Forward Lo Side C1 C144 17 See Cab Signals
Out Figure 54
5 484 VFS3+ VFS 1st/3rd Hi Side H1 C144 18 See Cab Signals
Out Figure 54
6 485 VFS3- VFS 1st/3rd Lo Side In J1 C144 19 See Cab Signals
Figure 54
7 486 VFS1+ VFS 2nd VFS Hi Side D1 C144 21 See Cab Signals
Out Figure 54
8 487 VFS1- VFS 2nd Lo Side Out E1 C144 31 See Cab Signals
Figure 54
9 488 DO0 Total Neutral Solenoid K1 C144 37 See Cab Signals
+ Figure 54
10 489 DO3 Total Neutral Solenoid K2 C144 38 See Cab Signals
- Figure 54
11 490 ANIO Pressure Feedback A2 C144 39 See Cab Signals
Switch + Figure 54
12 --- --- Linked to pin 16. --- --- --- --- ---
13 492 DO2 1st/3rd Selector F2 C144 53 See Cab Signals
solenoid Figure 54
14 693 VFSGND 1st/3rd select ground Ground C146 3 See Cab Supplies
Figure 55
15 478D SGND Ground K3 C144 11 See Cab Signals
Figure 54
16 --- --- Linked to pin 12. --- --- --- --- ---

Figure 49. Control Valve Connector C80 of Wire Harness Frame

66
1300 SRM 1358 Diagrams, Schematics or Arrangements

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
1 434 SS2+ Engine Speed F3 C144 45 See Cab Signals
Sensor + Figure 54
2 435 SS2- Engine Speed G3 C144 46 See Cab Signals
Sensor - Figure 54
3 436 ANI1 Transmission H3 C144 47 See
Temperature Figure 54

Figure 50. Engine Speed Connector C150 of Wire Harness Frame

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
1 419 SS1+ Output Speed Sensor D3 C144 43 See Cab Signals
+ Figure 54
2 433 SS1- Output Speed Sensor E3 C144 44 See Cab Signals
- Figure 54

Figure 51. Output Speed Connector C120 of Wire Harness Frame

67
Diagrams, Schematics or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
1 437 SS3+ Turbine Speed R2 C144 48 See Cab signals
Sensor+ Figure 54
2 478e SGND Ground K3 C144 11 See Cab signals
Figure 54

Figure 52. Turbine Speed Connector C340 of Wire Harness Frame

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
1 477a ANI2 Convertor Out J3 C146 5 See Cab
Temperature Figure 55 supplies

Figure 53. Converter Out Temperature Connector C330 of Wire Harness Frame

68
1300 SRM 1358 Diagrams, Schematics or Arrangements

Figure 54. Cab Signals Connector C144 of Wire Harness Frame

Figure 55. Cab Supplies Connector C146 of Wire Harness Frame

69
Diagrams, Schematics or Arrangements 1300 SRM 1358

Figure 56. Under Cab Floor Wire Harness

70
1300 SRM 1358 Diagrams, Schematics or Arrangements

Legend for Figure 56

Item Connector Description Connector Connecting Connector Description


No. Figure Harness
1 C10 Side Console Figure 57 Side Console Cab C130 Under Cab Floor
2 C30 MONOTROL Figure 58 --- --- ---
Pedal
3 C60 Steering Column Figure 59 Steering Column C10 Under Cab Floor
4 C90 Inching Pedal Figure 60 --- --- ---

Figure 57. Side Console Connector C10 of Wire Harness Under Floor

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Diagrams, Schematics or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Mating Connector


No. No. Name Pin Code Pin Figure Description
A 807a DIGIN4 Shift Lever Forward H2 C10 3 See Side Console
Figure 57
B 808a DIGIN5 Shift Lever Reverse J2 C10 4 See Side Console
Figure 57
C 103d --- Ignition plus --- C10 1 See Side Console
Figure 57

Figure 58. MONOTROL Pedal Connector C30 of Wire Harness Cab Under Floor

Figure 59. Steering Column Connector C60 of Wire Harness Under Floor

72
1300 SRM 1358 Diagrams, Schematics or Arrangements

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
A 477d REF5V 5V Ref Voltage Out M1 C10 28 See Side
Figure 57 console
B 479 ANI3 Inching Sensor R3 C10 26 See Side
Output Figure 57 console
C 478a SGND Ground K3 C10 27 See Side
Figure 57 console

Figure 60. Inching Pedal Connector C90 of Wire Harness Under Floor

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Diagrams, Schematics or Arrangements 1300 SRM 1358

Figure 61. Steering Column Wire Harness

74
1300 SRM 1358 Diagrams, Schematics or Arrangements

Legend for Figure 61

Item Connector Description Connector Connecting Connector Description


No. Figure Harness
1 C10 Cab Under Floor Figure 62 Under Floor C60 Steering Column
2 C50 Transmission Figure 63 --- --- ---
Lever

Figure 62. Cab Under Floor Connector C10 of Wire Harness Steering Column

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Diagrams, Schematics or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Pin Mating Connector


No. No. Name Code Pin Figure Description
1 103c --- Ignition plus --- C10 1 See Cab
Figure 62
2 811 DIGIN1 Shift Lever 2nd C2 C10 7 See Cab
Figure 62
3 810a DIGIN6 Start in 2nd gear L3 C10 6 See Cab
Figure 62
4 812a DIGIN7 Automatic/Manual M3 C10 8 See Cab
Mode Figure 62
5 808c DIGIN5 Shift Lever Reverse J2 C10 4 See Cab
Figure 62
6 807b DIGIN4 Shift Lever Forward H2 C10 3 See Cab
Figure 62
7 806 --- Shift Lever Neutral --- C10 2 See Cab
Figure 62
8 809 DIGIN0 Shift Lever 1st B2 C10 5 See Cab
Figure 62

Figure 63. Transmission Lever Connector C50 of Wire Harness Steering Column

76
TECHNICAL PUBLICATIONS

1300 SRM 1358 1/16 (11/11)(7/11)(3/11)(5/10)(12/09)