TRANSMISSION

OPERATION AND DIAGNOSTICS

H8.00-12.00XM (H170-280HD) [H007];
H13.00-14.00XM (H300-330HD) [G019];
H16.00XM-6 (H360HD) [G019];
H10.00-12.00XM-12EC (H360HD-EC) [G019]

PART NO. 1671895 1300 SRM 1358

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

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

• Wear safety glasses.

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

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

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
General ........................................................................................................................................................... 1
Operation............................................................................................................................................................ 4
Hydraulic Operation...................................................................................................................................... 4
1st/3rd Selector Valve .................................................................................................................................... 6
Cooling and Lubrication................................................................................................................................ 7
Control System................................................................................................................................................... 9
General ........................................................................................................................................................... 9
APC200 Controller......................................................................................................................................... 9
Self Test...................................................................................................................................................... 9
Protection Modes ....................................................................................................................................... 9
Limp Home Mode .................................................................................................................................. 9
Shut Down Mode ................................................................................................................................... 9
Transmission Exceed Codes ................................................................................................................. 9
Fault Codes................................................................................................................................................ 10
Description ............................................................................................................................................ 10
Fault Log Mode.......................................................................................................................................... 10
Access..................................................................................................................................................... 10
Exit ........................................................................................................................................................ 11
Clear ...................................................................................................................................................... 11
Fault Rectification..................................................................................................................................... 11
Hydraulic Control Valve ................................................................................................................................ 12
Hydraulic Control Valve Repair ............................................................................................................... 14
Solenoid Replacement ............................................................................................................................... 14
Pressure Check.......................................................................................................................................... 14
Pressure Specifications ............................................................................................................................. 15
Pressure, Speed, and Temperature Sensors................................................................................................. 16
Pressure Switch......................................................................................................................................... 19
Test......................................................................................................................................................... 19
Speed Sensor.............................................................................................................................................. 20
Test......................................................................................................................................................... 20
Temperature Sensors ................................................................................................................................ 21
Test......................................................................................................................................................... 21
Transmission Test and Calibration ................................................................................................................... 22
Precautions .................................................................................................................................................... 22
Stall Test ........................................................................................................................................................ 22
Description................................................................................................................................................. 22
Stall Test Procedure .................................................................................................................................. 22
Clutch Calibration ......................................................................................................................................... 23
Description................................................................................................................................................. 23
Procedure ................................................................................................................................................... 23
Inching Calibration ....................................................................................................................................... 24
Description................................................................................................................................................. 24
Brake and Inching Pedal Adjustment...................................................................................................... 24
Inching Sensor Adjustment ...................................................................................................................... 25
Inching Sensor Calibration....................................................................................................................... 25
Electrical Specifications..................................................................................................................................... 26
APC200 Display information............................................................................................................................. 26
General ........................................................................................................................................................... 26
General Information Group .......................................................................................................................... 27

©2010 HYSTER COMPANY i

Table of Contents Transmission

TABLE OF CONTENTS (Continued)

Fault Codes .................................................................................................................................................... 28
Indication of Protection Modes ..................................................................................................................... 28
Test Function Group ...................................................................................................................................... 28
Digital Input Test .......................................................................................................................................... 29
Analog Input Test .......................................................................................................................................... 30
Speed Sensor Test .......................................................................................................................................... 31
Output Test .................................................................................................................................................... 32
Voltage Test .................................................................................................................................................... 33
Calibration Group.......................................................................................................................................... 35
Calibration Mode....................................................................................................................................... 35
Clutch Filling Calibration......................................................................................................................... 35
Heat Up Mode............................................................................................................................................ 36
Inching Sensor Calibration ........................................................................................................................... 36
Inching Pedal Sensor Adjustment ............................................................................................................ 36
Inching Sensor Calibration....................................................................................................................... 37
TE-Userlink........................................................................................................................................................ 37
Description ..................................................................................................................................................... 37
Connection ..................................................................................................................................................... 37
Diagrams, Schematics, or Arrangements ......................................................................................................... 37
Figure 36. APC200 Wiring Diagram........................................................................................................ 38
Figure 37. Cab Side Console Harness...................................................................................................... 42
Figure 38. Resistor Converter Out Connector C105 of Wire Harness Side Console Cab ..................... 44
Figure 39. Connector C120 of Wire Harness Side Console Cab ............................................................. 45
Figure 40. APC 200 Connector C110 of Wire Harness Side Console ..................................................... 47
Figure 41. Armrest Connector C80 of Wire Harness Cab Side Console ................................................ 48
Figure 42. Cab Signals Connector C60 of Wire Harness Cab Side Console .......................................... 48
Figure 43. Cab Supplies Connector C70 of Wire Harness Cab Side Console ........................................ 49
Figure 44. Under Floor Connector C130 of Wire Harness Cab Side Console ........................................ 49
Figure 45. Transmission Diagnostic Connector (Tuning Link) C415 of Wire Harness Side
Console Cab ............................................................................................................................................... 50
Figure 46. Diagnostic Plug C535 of Wire Harness Side Console Cab .................................................... 51
Figure 47. Frame Wire Harness............................................................................................................... 52
Figure 48. Drum Speed Connector C90 of Wire Harness Frame ........................................................... 54
Figure 49. Control Valve Connector C80 of Wire Harness Frame ......................................................... 55
Figure 50. Engine Speed Connector C150 of Wire Harness Frame ....................................................... 56
Figure 51. Output Speed Connector C120 of Wire Harness Frame ....................................................... 57
Figure 52. Turbine Speed Connector C340 of Wire Harness Frame ...................................................... 57
Figure 53. Converter Out Temperature Connector C330 of Wire Harness Frame ............................... 58
Figure 54. Cab Signals Connector C144 of Wire Harness Frame .......................................................... 58
Figure 55. Cab Supplies Connector C146 of Wire Harness Frame ........................................................ 59
Figure 56. Under Cab Floor Wire Harness.............................................................................................. 60
Figure 57. Side Console Connector C10 of Wire Harness Under Floor ................................................. 61
Figure 58. MONOTROL Pedal Connector C30 of Wire Harness Cab Under floor ............................... 62
Figure 59. Steering Column Connector C60 of Wire Harness Under Floor .......................................... 62
Figure 60. Inching Pedal Connector C90 of Wire Harness Under floor................................................. 63
Figure 61. Steering Column Wire Harness ............................................................................................. 64
Figure 62. Cab Under floor Connector C10 of Wire Harness Steering Column ................................... 65
Figure 63. Transmission Lever Connector C50 of Wire Harness Steering Column .............................. 66

ii
Transmission Table of Contents

TABLE OF CONTENTS (Continued)

This section is for the following models:

H8.00-12.00XM (H170-280HD) [H007];

H13.00-14.00XM (H300-330HD) [G019];
H16.00XM-6 (H360HD) [G019];
H10.00-12.00XM-12EC (H360HD-EC) [G019]

iii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1300 SRM 1358
General
This manual provides information on operation and
diagnostics of the TE10 transmission as fitted on
G019 and H007 series lift trucks.
The repair procedures for the transmission and con-
trol valve are shown in Transmission, Repair 1300
SRM 1356.
Description
GENERAL
The function of the transmission is to transfer engine
power from the engine flywheel to the drive wheels
and to the hydraulic pumps that are attached to the
transmission.
The engine flywheel is connected to the torque con-
verter housing through drive plates. See Figure 1.
The flexing properties of the drive plate reduce
transfer of axial forces between engine crankshaft
and torque converter. A gear on the torque converter
housing drives the transmission pump and the at-
tached 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
engine 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 multiplication
factor that matches the engine power characteristics.
Speed difference between engine and transmission
input shaft is a measure of engine power being
Description
Electrical system diagrams are shown in Diagrams
8000 SRM 1346.
transferred. With increasing speed difference, also
an increasing amount of heat is generated in the
converter. The heat generated is removed by the
transmission lubrication oil, which flows through
the torque converter.
The different speed ratios between input shaft and
drive shaft are obtained by engaging and disengaging
the different clutches. Three groups of gears are con-
tinuously engaged with each other: the input gears,
the interconnecting gears, and the output gears. See
Figure 2.
If clutches belonging to one group would be engaged
simultaneously, the transmission would lock. The
clutches Forward and Reverse should not be engaged
at the same time. Also, the speed clutches for the 1st,
2nd, and 3rd speed should not be engaged at the same
time. Erroneous clutch engagement is prevented by
the transmission control system.
The different speeds are obtained by engaging either
the forward or reverse clutch, and by engaging either
one of the clutches for the 1st, 2nd, and 3rd speed.
When the transmission is in NEUTRAL, both the
forward and reverse clutch are disengaged, while one
of the speed clutches remains engaged.
The clutches consist of a hub which carries friction
discs with internal splines, and a drum which carries
steel discs with external splines. See Figure 3.
1
Description 1300 SRM 1358

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

2
1300 SRM 1358 Description

Legend for Figure 2

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

Figure 2. Gear Engagement

1. CLUTCH HUB 9. PISTON

2. CLUTCH END PLATE 10. PISTON SPRING SPACER
3. CLUTCH DRUM REVERSE GEAR 11. FRICTION DISCS
4. PISTON SEALS 12. PISTON SPRING SET
5. INTERCONNECTING GEAR 13. OIL SEALS
6. CLUTCH DRUM 2ND GEAR 14. OIL SUPPLY FOR LUBRICATION AND COOLING
7. CLUTCH HUB 2ND GEAR 15. PRESSURE SUPPLY 2ND CLUTCH
8. SHAFT 16. PRESSURE SUPPLY REVERSE CLUTCH

Figure 3. Clutch Components

3
Operation
Friction discs and steel discs are alternately fitted.
By pressurizing the clutch piston, the friction discs
and steel discs are clamped together, which cause the
hub and drum to rotate as one unit. When hydraulic
pressure is released, return springs push the piston
back against the clutch housing and allow hub and
drum to rotate independently. The drum, steel discs,
Operation
HYDRAULIC OPERATION
The transmission sump is the main reservoir for
the transmission oil. The sump screen keeps large
particles from entering the transmission pump. The
pump is driven by gears that connect with the torque
converter housing. The pump transfers oil through
the transmission filter, and further to the 10 bar
(145 psi) pressure reducer valve and to the 16.5 bar
(239.3 psi) pressure regulator valve. See Figure 4.
The 16.5 bar (240 psi) pressure regulator valve regu-
lates system pressure, by relieving excess oil through
the torque converter, oil cooler, and lubrication sys-
tem. See Cooling and Lubrication. System pressure
is used to fill and pressurize the clutches.
The 10 bar (145 psi) pressure reducer valve provides
pilot pressure to the total neutral valve and to the
modulation solenoids. The function of the total neu-
tral valve is to activate the clutch supply valve when
the control system allows this. The activated clutch
supply valve will transfer system pressure, 16.5 bar
(239.3 psi), to each of the clutch intensifier valves.
If the APC200 control does NOT receive the proper
signals, the total neutral valve will be deactivated,
causing the clutch supply valve to close. All clutches
release immediately when the clutch supply valve
closes.
4
1300 SRM 1358
piston, spacer and return springs rotate at the same
speed. The hub rotates at the same speed with the
friction discs.
The transmission control system pressurizes and de-
pressurizes the clutches.
The total neutral spool and the clutch supply spool
are in reality combined on one spool. See Figure 8.
The modulation solenoids (Variable Force Solenoids)
transfer a proportional pressure to the clutch intensi-
fier valves depending on the signal from the APC200.
With increasing pressure from the modulation sole-
noid, the clutch intensifier valve increasingly admits
system pressure to the relevant clutch. When the
clutch is fully engaged, full system 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 solenoid
and the clutch intensifier. Actuation of the clutches
forward, reverse, and 2nd speed is through separate
modulation and intensifier valves.
The actuation of the modulation solenoids (VFS) is
opposite from normal expectation. When there is
NO signal from the APC200, the modulation valve
admits full pressure to the clutch intensifier valve.
When the signal has reached 100mA, oil supply from
the modulation valve to the clutch intensifier valve
is closed.
1300 SRM 1358 Operation

Figure 4. Hydraulic Diagram

5
Operation 1300 SRM 1358

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, 16.5 bar 21. INTENSIFIER SPOOL, REVERSE
(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

1ST/3RD SELECTOR VALVE
Actuation of the clutches for 1st speed and 3rd
speed is through a common modulation solenoid
(VFS 1st/3rd), which activates a common clutch in-
tensifier valve. The transferred system oil pressure
connects with the 1st/3rd selector valve, which either
transfers to the 1st or to the 3rd clutch depending
on an electric signal from the APC200. When the
1st speed selection solenoid is activated, the 1st/3rd
selector valve transfers system pressure to the 1st
speed clutch. When the 1st speed selection valve is
NOT activated, the 1st/3rd selector valve transfers
system pressure to the 3rd speed clutch.
Table 1 provides an overview of the activated
solenoids and clutches for the different transmission
speeds. Neutral selection is by disengagement of
both the forward and reverse clutch. Trucks with a
MONOTROL® pedal will only shift to NEUTRAL
by applying the hand or service brake, or when the
operator has left his seat.

Table 1. Activated Solenoids and Gear Selection

Transmission Gear Activated ON/OFF Deactivated Clutches Activated

Solenoids Clutches
Direction Speed
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

6
1300 SRM 1358
Table 1. Activated Solenoids and Gear Selection (Continued)
Transmission Gear Activated ON/OFF
Solenoids
Direction Speed
Full Current
Reverse 2nd Total Neutral
Reverse 1st Total Neutral
1st/3rd Selector
COOLING AND LUBRICATION
Heat is primarily generated at the torque converter
and at the clutch plates during transmission opera-
tion. The heat generated by mechanical friction at
gears, shafts and bearings is relatively low.
Heat generated in the torque converter relates di-
rectly to the degree of stall, i.e. the speed difference
between engine and turbine. In a stall situation most
of the supplied engine power is transferred into heat.
This heat accumulates in the torque converter be-
cause of the reduced oil flow during a stall situation.
With increasing turbine speed, the volume of added
heat reduces, while simultaneously the increased oil
flow more rapidly transfers the accumulated heat.
Heat generated at the clutch plates varies with the
actually available engine power at time of clutch
engagement and the duration of clutch engagement.
During normal operation, the transmission control
system determines the duration of clutch engage-
ment. During inching it is the driver who controls
the added heat in the clutch by varying engine power
and clutch engagement. The transmission control
system will close the forward or reverse clutch when
a certain amount of generated heat has been ex-
ceeded.
Only a minor portion of the total transmission pump
supply is used for clutch filling. The majority of
transmission oil supply is used for the cooling and
lubrication circuit that functions at a pressure that
is lower than system pressure. See Figure 5. The
pressure regulator valve admits oil that is not re-
quired for clutch filling. The safety valve reduces
oil pressure to 9 bar (131 psi) to protect the torque
converter and oil cooler. The normal oil flow is
Operation
Deactivated Clutches Activated
Clutches
Activated VFSs Deactivated VFS
Full Current No Current
Forward, Reverse, 1st/3rd Reverse + 2nd
Forward + Reverse + 2nd Reverse + 1st
through the torque converter, the transmission oil
cooler and to the transmission lubrication port. The
volume of oil and the oil flow resistance causes that
the initial 9 bar (131 psi) supply pressure is reduced
to 0.4 to 0.85 bar (5.8 to 12.3 psi) at the transmission
lubrication port. Flow resistance increases during
torque converter stall or when oil temperature is low.
When the transmission is at operating temperature
and no load is applied, the volume of lubrication oil
is 64 liter (17 gal) at 1800 rev/min.
From the transmission lubrication port the oil flows
into channels in the different shafts, which lead to
the shaft bearings for lubrication, and to the inside of
the clutch packs where the oil absorbs the heat that
is generated at the clutch plates.
To speed the warming-up process, a thermostat valve
is installed between the torque converter outlet port
and the transmission radiator. The thermostat
starts opening at 70 C (158 F) and is completely
opened at 85 C (185 F). At temperatures below 70 C
(158 F), oil flow is directly returned to the trans-
mission. At temperatures above 85 C (185 F), the
entire oil flow from the outlet port passes through
the transmission radiator before it is returned to the
transmission.
To speed up the warming up process, a thermostat
valve is fitted between the torque converter outlet
port and the transmission radiator. The thermostat
starts opening at 70 C (158 F) and is completely
opened at 85 C (185 F). At temperatures below 70 C
(158 F), oil flow is directly returned to the transmis-
sion. At temperatures above 85 C (185 F), the entire
oil flow from the outlet port has to pass the radiator
before it is returned to the transmission.
7
Operation 1300 SRM 1358

1. OIL FLOW
2. OIL CHANNEL
3. LUBRICATION PRESSURE PORT

Figure 5. Cooling and Lubrication

8
1300 SRM 1358
Control System
GENERAL
The control system of the transmission consists of
the APC200 controller, several switches and senders
that provide information to the APC200, and the
hydraulic control valve that regulates pressures
depending on signals from the APC200.
APC200 CONTROLLER
The APC200 has software to control the operation
of the transmission and performs the following func-
tions:
• Perform self-test and troubleshooting.
• Functional control of the transmission.
– Automatic shifting.
– Inching.
• Enter a protection mode when required.
– Improper pressures, temperatures, and speeds.
– No operator present.
– Parking brake applied.
– Gear or direction change at improper speeds.
• Logging a fault code when circumstances have ex-
ceeded certain values.
• Allow diagnostics and calibration with a laptop
(TE-Userlink).
Depending on the signals of the shift lever and var-
ious switches and senders, the APC200 activates or
deactivates the solenoids and VFS valves in the con-
trol valve, which transfer hydraulic pressure to the
clutches in the transmission. If an input signal does
not comply with the programming of the APC200, the
APC200 will record the fault and react by activating
a protection mode. All events recorded are stored as
a fault code and are shown on the instrument cluster
when the fault occurs. Faults can also be read at a
later point in time, making it possible to trace inter-
mittent problems.
Protection modes and self tests are part of the
APC200 programming and cannot be influenced.
The APC200 controller is located in the side console
of the cab and has a display and push buttons to call
off information. Normally the gauges and displays
on the dashboard are used to read transmission re-
lated information. For diagnostics and settings, it
is more convenient to use the TE-Userlink system
Control System
instead of pushing the buttons on the APC200. The
section APC200 Display information has the instruc-
tions for how to call off information from the APC200
when TE-Userlink is not available.
Self Test
At power up a series of checks is done. If the APC200
fails these checks, it will shut off all outputs. The
transmission cannot be operated until the problem is
rectified. The relevant fault code will be displayed.
Protection Modes
Limp Home Mode
The transmission is put in NEUTRAL if a fault is
detected on the following:
• Outputs for solenoids, VFS or Pressure Switch
• Engine speed sensor
• Two out of three vehicle speed sensors
To continue driving, first the shift lever must be put
in NEUTRAL. After that, the driver can reengage a
direction. When Limp Home Mode has been entered,
the user can operate the transmission in either direc-
tion in 1st and 2nd only. Inching is disabled.
Shut Down Mode
If an intolerable combination of faults is detected,
the Shut Down Mode will be entered. The APC200
puts the transmission in NEUTRAL by putting all
VFS signals at zero pressure and by switching OFF
the total neutral solenoid, cutting off pressure to the
clutches. Intolerable faults are also referred to as Re-
dundant Shutdown Path errors (RSP).
Transmission Exceed Codes
During operation of the truck, the APC200 con-
troller may display transmission exceed codes on the
hourmeter/fault code display. These exceed codes
reflect that the request made by the operator will
not be executed because of certain circumstances.
APC200 Fault Code Guide 1300 SRM 1435 lists
the exceed codes with a description of the encoun-
tered circumstances.
9
Control System
Fault Codes
Description
Under normal conditions the hour meter/fault code
display on the instrument cluster shows engine run-
ning hours. The maximum hours that can be dis-
played is 99.999 hours.
• Hourmeter reading
If the engine and/or transmission controller detect a
fault, the hourmeter/fault code display will show a
fault code instead of the engine running hours.
Fault codes starting with "E" refer to engine fault
codes.
• Fault code number(s)
Fault codes starting with "t" refer to transmission
fault codes, which are listed in APC200 Fault Code
Guide 1300 SRM 1435.
When more than one fault occurs at the same time,
the fault codes will be displayed in succession. When
circumstances have changed, and all faults have
ceased to exist, the hour meter/fault code display
will show engine running hours again.
Fault code E-CON and t-CON indicate a communica-
tion problem.
Display fault code E-CON is shown when the follow-
ing occurs:
• The engine controller does not reply to the engine
identification request or request for fault codes.
10
1300 SRM 1358
• The engine controller stops sending one of the reg-
ular messages, e.g. engine RPM or engine coolant
temperature.
Display fault code t-CON is shown when the instru-
ment cluster does not receive a cyclic message or re-
ceives wrong error messages from the APC200.
Fault codes that appear as tE1.23 are for faults that
occur during calibration of the transmission.
Fault Log Mode
Access
The instrument cluster has a memory that records
each fault when it occurs. These faults that have
occurred can be reviewed at a later point in time by
entering into the fault log mode. Proceed as follows
to enter into the fault log mode:
1. Apply parking brake.
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 second OFF and
ON cycle, the display will show a 2. After the
third OFF and ON cycle, the display will show a
3.
The display is now in fault log mode. When no faults
have been recorded, the LCD display shows "clear."
When faults have been recorded, the display shows a
letter and 4 numbers for each fault code. For engine
fault codes, the letter is "E." For transmission fault
codes, the letter is "t".
After the fault code, three further numbers are
shown.
The numbers represent the following:
• Fault code
• Hourmeter reading at last occurrence
• Hourmeter reading at first occurrence
• Number of occurrences of current fault
Each number is shown for 3 seconds, after which the
following number is shown. The faults will be shown
in the opposite sequence of occurrence: The most re-
cent fault first and the first occurred fault last. When
all recorded fault codes have been shown, the display
will continue to repeat these recorded fault codes un-
til the user exists the fault log mode.
1300 SRM 1358
Exit
To exit the fault log mode, turn the ignition OFF
and ON and leave ignition ON for more than 2 sec-
onds. The cluster will also exit to normal mode when
the parking brake is released or when the engine is
started.
Clear
To clear the fault codes logged in the display, proceed
as follows:
1. Access into the fault log mode. See Access.
2. Clear the fault log by cycling the ignition key
OFF and ON three more times. This is a repeti-
tion of the procedure to access the fault log mode.
See Access.
If the data-erasing process is successful, the display
will show ’clear’. If the data-erasing process is not
successful, the display will show the fault codes in
the memory, shown in the order by the time of the
occurrence. To return to the normal mode, follow
the procedure as described in Exit. To retry erasing
stored fault codes, follow Step 2 of the procedure to
clear fault codes.
Fault Rectification
Fault codes are listed in APC200 Fault Code Guide
1300 SRM 1435, which provides an explanation of
the fault, the resulting action of the APC200, and
checks for troubleshooting. Each fault code repre-
sents a specific defect or malfunction.
In most cases the suggested rectification is by check-
ing electrical functionality between the APC200, the
wiring and the sensors, solenoids, or switches.
Before disassembling components for test purposes,
connect the TE-Userlink program. The screen ‘Dash-
board-Monitor’ allows verification of the functional-
ity of speed sensors, the pressure switch, and the
Control System
shift lever. In case several possible defects are in-
dicated, TE-Userlink may narrow down the number
of possible defects, preventing unnecessary removal
of components that function correctly.
To rectify problems with switches, solenoids and sen-
sors, look up their actual location, and test the com-
ponent. The location of the solenoids are shown in
the section Hydraulic Control Valve. The location of
sensors and switches are shown in the section Pres-
sure, Speed, and Temperature Sensors, and Figure 6.
Test values of solenoids and sensors are shown in
Electrical Specifications.
NOTE: The Dana Dashboard software and the
APC200 Fault Code Guide 1300 SRM 1435 have
wire and input references that relate to the APC200.
Refer to Table 13 for the conversion from APC200
wire numbers to Hyster numbers.
To determine the exact location of a harness prob-
lem, look up the reference number of the component
involved in Figure 36. The legend of Figure 36 shows
the related connector code and wire harness. The
wire and pin information for these connectors are
shown in the legends for Figure 46 through Fig-
ure 51. The positions of the connector pin numbers
are shown in Figure 46 through Figure 51. The
figures represent the view facing the pin side of the
connector, NOT the harness side of the connector.
Figure 37 through Figure 61 show the four wire har-
nesses that are relevant for the APC200 wiring. Ac-
tual location of the connectors can be derived from
their position on the harness and from their descrip-
tion. At the legend of the wire harness figures, pin
location figures are shown for connectors intercon-
necting between harnesses.
To identify the harness problem, first determine con-
nectivity between the APC200 and the connector of
the component that was indicated in the Fault Code
Guide. If unsatisfactorily, measure connectivity from
harness to harness.
11
Control System
NOTE: FOR LEGEND, SEE TABLE 2.
Figure 6. Check Ports, Control Valve
12
1300 SRM 1358
Table 2. Control Valve Pressure Check Ports
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
HYDRAULIC CONTROL VALVE
The hydraulic control valve is located at the left-hand
side of the transmission and contains the pressure
switch, all solenoids, and most of the valves and
check ports. Functioning of the hydraulic control
valve depends on available pump supply pressure
and the activation of the electrical solenoids. Activa-
tion of these solenoids is controlled by the APC200
controller. Hydraulic functioning of the control valve
is schematically shown in Figure 4.
The location of the different solenoids are shown in
Figure 7.
The location of the main components of the control
valve are in Figure 8.
1300 SRM 1358 Control System

Legend for Figure 7

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

Figure 8. Control Valve Components

13
Control System 1300 SRM 1358

Legend for Figure 8

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 SPOOL 17. SPRING
7. SPRING 18. PIN
8. SPRING 19. MODULATION SOLENOID (VFS)
9. 10 bar (145 psi) PRESSURE REDUCER 20. MODULATION SPOOL
10. 1ST/3RD SELECTOR SOLENOID 21. ACCUMULATOR SPRING
11. 1ST/3RD SELECTOR SPOOL 22. CONTROL VALVE

Hydraulic Control Valve Repair
Repairs to the control valve are limited to replacing
solenoids and gaskets. Hydraulic components of the
control valve may be inspected, but cannot be ad-
justed and are not separately available for replace-
ment.
Solenoid Replacement
To inspect components of the control valve, first the
transmission has to be lifted until the frame support
bracket no longer obstructs removal of the solenoid
cover. Remove the nuts and bolts that connect 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 support bracket no longer ob-
structs removal of the control valve cover. For fur-
ther details of control valve replacement see the sec-
tion Transmission, Repair 1300 SRM 1356.
The transmission pump includes the pressure regu-
lating valve, the safety valve, and the filter bypass
valve.
The control valve includes the pilot pressure reduc-
ing valve.
With the transmission control valve removed, oil
ports leading to the various clutches can be pressur-
ized with air. The amount of air pressure applied
should be approximately 14 bar (200 psi). When ap-
plying air pressure to the control valve ports, clutch
engagement and obvious leaks can be established.
This test will not work using the transmission pres-
sure test ports, as the air will escape through the
intensifier valve. For the location of the ports see
Figure 9.

Pressure Check
Most of the transmission oil pressures can be mea-
sured 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 transmis-
sion 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-

sure is out of specification, the cause has to be es-
tablished by further checking. If a pressure reducing
valve causes the problem, then the entire assembly
that includes this valve must be replaced.
Figure 9. Control Valve Clutch Ports

14
1300 SRM 1358 Control System

Legend for Figure 9 result in higher system pressures. The volume of oil
through the relief valves depends on engine speed.
A. TOP Viscosity depends on oil quality and increases with
1. FORWARD CLUTCH higher temperatures. Make sure that oil quality
2. REVERSE CLUTCH meets the required specification and that oil has
3. SECOND GEAR CLUTCH been replaced in time. Temperature of the oil must
4. FIRST GEAR CLUTCH be 82 to 93 C (180 to 199 F) for correct pressure
5. THIRD GEAR CLUTCH
6. REGULATOR PRESSURE measurement.

In the cooling and lubrication circuit the torque con-

Pressure Specifications verter causes additional flow resistance with increas-
The relief pressures in this transmission are influ- ing speed difference between engine and transmis-
enced by the volume and viscosity of the oil passing sion input shaft.
through the relief valves. Smaller supply volumes
and higher viscosity result in lower system pres-
sures. Bigger supply volumes and lower viscosity

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 16.5 bar (239 psi) minimum at 600 rpm.
Table 2
and
Table 3.
Maximum Clutch Pressure See 19.3 bar (280 psi) maximum at 2200 rpm.
Table 2
and
Table 3.
Clutch Release Pressure See 0 to 0.2 bar (0 to 3 psi)
Table 2
and
Table 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)

15
Control System 1300 SRM 1358

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

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

Figure 10. Check Ports, Front View

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

16
1300 SRM 1358 Control System

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

Figure 11. Check Ports, Top View

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

17
Control System 1300 SRM 1358

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

Figure 12. Check Ports, Left View

18
1300 SRM 1358 Control System

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

Figure 13. Check Ports, Right View

Pressure Switch
The function of the pressure switch is to signal if sys-
tem 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 incorrect for the given circum-
stances, or when the resistance sensed is below 400
Ohm or above 4000 Ohm. TE-Userlink shows the
measured resistance value under ‘Pressure switch
resistance’. The location 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

19
Control System
Speed Sensor
The function of the speed sensors is to determine
the rotation speed of the different groups of gears.
The APC200 calculates the speed ratios between the
different groups and compares the calculated values
with the programmed values. If deviation exceeds an
allowable value, the APC200 generates a fault code
and eventually enters a protection mode. Below are
a few examples of speed inputs and ratios that are
monitored by the APC200:
• Converter Speed Ratio
– The ratio between engine speed and turbine
speed is called the converter speed ratio, which
is a measure of the power being transferred
through the converter. This ratio is a major
factor for the APC200 to determine in the auto-
matic selection mode, if a next higher or lower
gear is to be selected. During calibration, a
sudden change in converter speed ratio is used
to determine the clutch piston position, at the
moment the clutch starts clamping.
• Transmission Ratio
– Each selected transmission gear has a specific
transmission ratio. When one of the direction
clutches is closed and the output speed has
reached a certain value for checking, then the
actual ratio is compared with the specified ratio.
If deviation exceeds 5%, one of the clutches is
assumed to be slipping. A fault is flagged and
the APC200 enters the Shut Down Mode.
• Gear Ratio
– If the turbine, drum or output speed sensor fails,
then the APC200 calculates the ‘actual ratio’
20
1300 SRM 1358
based on the value of the remaining sensors.
This allows continued operation of the transmis-
sion. Speed sensor failure is indicated by a fault
code. If the engine speed sensor fails, or if more
than one speed sensor fails, then the APC200
will enter the Limp Home Mode and flag a fault.
• Maximum Torque During Inching
– The APC200 programming interprets the inch-
ing pedal position as the required pressure for
the inching clutch. The heat generated in the
inching clutch is proportional to the power trans-
ferred by the torque converter (= converter speed
ratio). When the power transferred is at too high
level during too long a time, the APC200 will re-
lease pressure in the clutch and flag a fault.
Test
TE-Userlink shows functionality of each of the speed
sensors under "Speed Monitor". Electrical function-
ality can be tested by using the schematic shown in
Figure 15. Observe the correct sensor polarity. Pin 1
has to be connected to 12 volt +. Pin 2 has to be con-
nected to 12 Volt . Figure 15 shows the connector
as fitted to the speed sensors. Connecting the sen-
sor with an incorrect polarity will destruct the sen-
sor. Table 5 shows acceptable test values. Replace
the sensor if it fails the test.
Speed sensors should be fitted as close as possible to
the gear. Speed signal will fail if distance exceeds
1.8 mm (0.07 in.). The sensor mounting bracket nor-
mally ensures correct sensor installation.
1300 SRM 1358 Control System

Figure 15. Speed Sensor Test

Table 5. Speed Sensor Check Values and represents transmission sump temperature.
TE-Userlink indicates functionality of this sen-
Voltage Current sor under ‘Transmission sump temperature’.
Reading Level • Torque Converter Out, Port 71
– This sensor is a switch that connects to ground
Gear tooth sensed 1.2 to 1.6 volt 6 to 8 mA
when temperature has exceeded 120 C (248 F).
No gear tooth 2.6 to 3.0 volt 13 to 15 mA The function is to trigger a protection mode.
sensed Functionality can only be tested by immersing
the temperature switch in hot oil, and measure
if it switches at 120 C (248 F).
Temperature Sensors
Test
There are two temperature sensors which measure
the temperature at two different locations as follows: Table 6 shows electrical resistance values of the
• Pump Supply, Close to Port 31 sump temperature sensor for different tempera-
– This sensor is combined with the engine speed tures. Resistance can be measured with a normal
sensor in one unit and is connected with the ohmmeter, provided correct polarity is observed.
APC200. The signal to the APC200 is trans-
lated into a CANbus signal to the dashboard

21
Transmission Test and Calibration
Transmission Test and Calibration
PRECAUTIONS
Before testing or calibrating the transmission, verify
the following:
• Make sure the coolant level in the engine cooling
system is correct.
• Make sure the parking brake and service brakes
operate correctly.
• Make sure the oil level in the transmission is at
"Full Level" when hot.
• Make sure the transmission oil temperature is at
least 80 C (180 F).
See the Operating Manual for instructions on how
to add coolant and transmission oil.
To raise the oil temperature, run the engine while
stalling the torque converter as follows:
1. Put the lift truck against an object that cannot
move.
2. Apply the parking brake for trucks with a for-
ward reverse lever.
3. Apply the brake pedal for trucks with a
MONOTROL® pedal.
4. Select the third gear in manual mode.
5. Run the engine at half throttle until the oil tem-
perature gauge indicates 80 C (180 F).
NOTE: Trucks with a forward/reverse lever will shift
to NEUTRAL when the brake pedal is applied.
Trucks with a MONOTROL pedal will shift to NEU-
TRAL when the parking brake is applied.
STALL TEST
Description
The stall test provides indications for the condition
of the engine, transmission clutches, and torque con-
verter. The stall test is performed with the transmis-
sion engaged and operating the engine at full throttle
while blocking the drive wheels. The stall speed for
all engine options should be between 1950 rpm and
2100 rpm.
22
1300 SRM 1358
Stall Test Procedure
CAUTION
Do not hold the throttle open for more than 15
seconds at a time. Permit the engine to operate
at idle speed for two minutes between tests.
CAUTION
Release the accelerator immediately if the en-
gine speed increases to its governed speed:
Cummins LPG Engine - 2600 rpm ±2%
Cummins Diesel Engine, H8.00-14.00XM,
H16.00XM-6, H10.00-12.00XM-12EC -
2450 rpm ±2%
Cummins Diesel Engine, H170-360HD,
H360HD-EC - 2600 rpm ±2%
CAUTION
Performing a stall test in 1st or 2nd gear may
damage the internal parts of the drive axle.
Perform the stall test in 3rd gear only.
1. Connect a laptop computer to the Userlink plug
in the side console. Select the screen to read the
engine speed.
2. Put a capacity load on the forks to prevent the
wheels from turning.
3. Put the lift truck against an object that cannot
move.
4. Apply the parking brake for trucks with a for-
ward/reverse lever.
5. Apply the brake pedal for trucks with a
MONOTROL pedal.
6. Start the engine and select the 3rd gear in man-
ual mode.
7. Push the accelerator pedal to full throttle.
8. Read the stall speed and release the throttle
pedal.
1300 SRM 1358
If the stall speed is 50 to 200 rpm below the specifica-
tion, the engine is not operating at full power. Check
if engine fault codes are present and rectify any indi-
cated problems.
If the stall speed is higher than specification, the en-
gaged clutch(es) may not be holding or the torque
converter is damaged. Check if transmission fault
codes are present and rectify any indicated problems.
If no transmission fault codes are present and the
stall speed is much higher than specification, remove
the torque converter for inspection.
If stall speed is only slightly higher than specifica-
tion, consider service life of the torque converter and
the option to replace the torque converter immedi-
ately or at a later point in time.
CLUTCH CALIBRATION
Description
The APC200 is programmed to quickly fill the clutch
until the piston starts clamping the discs and only
then raise clutch pressure further within a cer-
tain period of time until full engagement has been
reached.
When shifting up, the clutch to be released will start
relieving its pressure at the same moment when
the engaging clutch starts clamping. For a short
period of time, these two clutches are both partially
engaged. This provides the feature to shift up a gear
smoothly under full traction.
As the clutch plates wear, they will get slightly thin-
ner. This implies that the piston of the engaging
clutch will have longer travel until the piston starts
clamping the discs. The releasing clutch would start
slipping too early. The transmission would no longer
shift smoothly.
The APC200 has a calibration program to readjust
the clutch filling time and the time to reach full en-
gagement. Clutch filling time is determined by the
elapsed time between clutch fill start and the mo-
ment when the turbine speed sensor detects a change
in speed (touch detection). The time to reach full en-
gagement is determined by the elapsed time between
touch detection and full clutch engagement. An au-
tomatic warning to recalibrate the transmission ap-
pears on the instrument cluster every 2000 hours as
exceed code (te501).
Transmission Test and Calibration
During clutch calibration, codes may be displayed
that indicate incorrect circumstances for proper
clutch calibration. The explanation of these codes is
in APC200 Fault Code Guide 1300 SRM 1435.
During clutch calibration, fault codes with a preced-
ing "E" may be displayed. For example E1.25. The
first digit after the "E" can be a "1" or a "2". "1" re-
lates to faults during clutch filling time. "2" relates to
faults during clutch engagement. The last two digits
indicate calibration faults, which are listed and ex-
plained in APC200 Fault Code Guide 1300 SRM
1435.
Procedure
1. Apply the parking brake.
2. Connect a laptop computer to the Userlink plug
in the side console.
3. Verify the forward/reverse lever is in NEUTRAL
or REVERSE.
4. Verify the MONOTROL pedal is in REVERSE.
5. Start the engine.
6. Make sure the transmission oil temperature is at
least 60 C (140 F).
7. Select the screen "Automatic Calibration," select
"Interface" and click the button "Clutch Filling
Calibration."
8. The automatic calibration starts when the for-
ward/reverse lever or MONOTROL is moved into
the FORWARD position and the transmission
oil temperature is at least 60 C (140 F).
9. When transmission oil temperature has dropped
below 60 C (140 F), the automatic calibration
program will first heat the transmission before
proceeding with the calibration. This feature
is part of the calibration program and should
not be interfered, as interference will stop the
calibration.
10. The complete automatic calibration process
takes 12 to 15 minutes. The screen will show
when the calibration has been completed. The
engine speed will remain at idle during calibra-
tion.
11. Switch the ignition OFF, when the APC200
display indicates that the calibration has been
23
Transmission Test and Calibration 1300 SRM 1358

completed. Observe the display and wait un-
til all segments no longer light up. When the
display remains OFF, the new calibration has
been entered in the APC200 memory. The new
calibration settings will get lost if the ignition is
switched ON too early.
NOTE: Do not interfere with the calibration. Activat-
ing any controls or components will stop the calibra-
tion mode before completion. The screen will show
when the calibration has been completed.
During calibrations the APC200 display may show
calibration condition messages, or error codes dur-
ing calibration. For explanation of these codes see
APC200 Fault Code Guide 1300 SRM 1435.
INCHING CALIBRATION
check that both the inching and brake pedal will have
generous distance to the floor plate when the brakes
are fully applied.
Brake and Inching Pedal Adjustment
1. Make sure the release position of the brake pedal
has been properly adjusted.
a. Wet Brakes - Turn the adjustment bolt for the
brake pedal until there is no play between
the bolt on the brake valve and the roller
under the brake pedal. See Figure 16.
b. Dry Brakes - Turn the adjustment bolt for the
brake pedal until there is 5 to 10 mm (0.2
to 0.4 in.) travel until the brake light comes
ON.

2. Position the top of the inching pedal and the

Description
brake pedal at equal height.
Inching is a controlled traction and braking mode. It
a. Wet Brakes - Adjust the adjustment bolt for
enables higher engine speeds for increased hydraulic
the brake pedal coupling so that the inching
function speeds, while truck travel speed remains
pedal has no free play.
low. The inching function is obtained by relating
the inching pedal position to clutch pressure. The b. Dry Brakes - Adjust the adjustment bolt
relation between pedal position and clutch pressure for brake pedal coupling so that the inching
results in a natural reaction of the operator to de- pedal will have a free play of approximately
press the inching pedal further when actual truck 20 to 25 mm (0.80 to 1.0 in.) before the brake
speed is too high. A further depressed inching pedal pedal starts to move. See Figure 17.
causes that the pressure in the inching clutch will get
lower, which reduces truck speed, irrespective of en-
gine speed. In case too much heat is generated dur-
ing inching, the APC200 will release all pressure and
show fault code 46.05.

The inching pedal sensor has to be calibrated for two

pedal positions: Inching pedal completely depressed
and inching pedal released. Calibration is required
when the inching sensor has been replaced or when
its fixation became loose. Further, calibration is an
annual requirement due to wear and creep of pedals
and linkages. Before calibrating the inching sensor,
verify adjustment of the brake pedal and the inch-
ing sensor. Incorrect sensor calibration triggers fault
codes during operation. By slightly varying the free
travel of the brake pedal it is possible to vary the mo- 1. BRAKE PEDAL
ment when brakes start to apply. With an early brake 2. INCHING PEDAL
application, too much heat will be generated both in 3. ADJUSTMENT BOLT FOR BRAKE PEDAL
the inching clutch and the brakes. With a later ap- 4. ADJUSTMENT BOLT FOR BRAKE PEDAL
COUPLING
plication of the brakes, pedal travel will get longer 5. ADJUSTMENT BOLT FOR INCHING PEDAL
before brakes are fully applied. Always make small
adjustments in the free travel of the brake pedal and Figure 16. Brake Pedal Assembly

24
1300 SRM 1358
Figure 17. Dry Brake Inching Pedal
Adjustment
Inching Sensor Adjustment
1. Attach a laptop to the Userlink.
2. Select "Inching Pedal Calibration Mode."
3. Verify if the analog output of the inching sensor
is between 600 and 700 mV.
4. If the analog output is incorrect, proceed as fol-
lows:
Transmission Test and Calibration
a. Raise the cab until the latch locks in the par-
tial open position
b. Loosen the two mounting bolts of the inching
sensor.
c. Rotate the sensor in the slotted holes until
output voltage is between 600 and 700 mV.
d. Tighten the two mounting bolts and verify
output voltage is still correct.
Inching Sensor Calibration
1. Make sure pedals and inching sensor have been
correctly adjusted.
2. Start the engine and let it run for about 30 sec-
onds.
3. Attach a laptop to the Userlink and select "Auto-
matic Calibration."
4. Select "Inching Pedal Calibration" and follow the
instructions. Normal values to be reached for
both dry and wet brake are as follows:
• Fully released pedal - 600-700 mV
• Fully depressed pedal - 2500-4000 mV
5. Switch the ignition OFF, when the APC200 dis-
play indicates that the calibration has been com-
pleted. Observe the display and wait until all
segments do not longer light up. When the dis-
play remains OFF, the new calibration has been
entered in the APC200 memory. The new cal-
ibration settings will get lost if the ignition is
switched ON too early.
25
APC200 Display information 1300 SRM 1358

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 ±0.35 at 25 C (77 F)

ON/OFF solenoids AMBIENT RESISTANCE

Total neutral and selector solenoids TEMPERATURE
Coil resistance - 12V - 28 ±2 at 20 C (68 F) 20 C (68 F) 1922
Speed sensor 25 C (77 F) 2000
Type - Magneto resistive sensor. 30 C (86 F) 2080
Sensing distance - 0 to 1.8 mm (0 to 0.07 in.)
Sensor signal - Generates a square current with a 40 C (104 F) 2245
fixed amplitude changing between 7 and 14 mA. 50 C (122 F) 2417
Table 6. Temperature Sensor (In Speed Sensor) 60 C (140 F) 2597
Resistance Versus Temperature
70 C (158 F) 2785
AMBIENT RESISTANCE 80 C (176 F) 2980
TEMPERATURE
90 C (194 F) 3182
30 C ( 22 F) 1247
100 C (212 F) 3392
20 C ( 4 F) 1367
110 C (230 F) 3607
10 C (14 F) 1496
120 C (248 F) 3817
0 C (32 F) 1630
125 C (257 F) 3915
10 C (50 F) 1772

APC200 Display information

GENERAL
The APC200 controller is located in the side console
of the cab and has a display and push buttons to call
off information. See Figure 18.
The LED lamp labeled "F" is red and is ON when the
APC200 is in the reset condition.
The push button marked "M" is used to scroll to one
of the three display groups.

The information is provided by means of codes. The The push button marked "S" is used to scroll to a next
interpretation of these codes depends on the display sub group within a display group.
mode being activated. The following display modes
are available:
• General Information
• Test
• Calibration

These display modes provide an alternative method

to calibrate or obtain information in case TE-User-
link is not available.
Figure 18. APC200 Front Panel
The LED lamp labeled "D" is yellow and will be ON
to indicate diagnostic modes.

The LED lamp labeled "E" is yellow and blinks to

indicate faults.

26
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 Informa- OFF.
tion 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 dis-
play scrolls to a next sub group. When button 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 possible to scroll to sub
groups that are lower on the sub group list. To return
to the highest positioned sub group, press the S-but-
ton 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 expla-
nation of the sub groups. See Figure 19 and Table 7. Figure 19. APC200 Display Groups

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 Shows travelled distance in 0.1 km resolution. 1258
Distance
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 Shows the current shift lever position (F, R) (1, 2, 3). F3
Position
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

27
APC200 Display information 1300 SRM 1358

Table 7. General Information Group (Continued)

Display Description Explanation Example

tq i Turbine Measured turbine torque at transmission input side in N•m. 125
Torque
ttnP Transmission Shows transmission temperature in C. 65
Temperature
ctnP Cooler in Shows cooler input temperature in C. 75
Temperature
Fault Codes
Err Fault Code Shows the transmission fault code number. 31.01

FAULT CODES
When the M-button is pushed to scroll to the fault
code group (Err), the display normally shows “- - - -,“
to indicate that no faults are active. When the E-LED Figure 20. Indication of Protection Mode
is blinking a fault is active, which will be shown on
the display. TEST FUNCTION GROUP
If more than one fault has been detected, the most se- To enter the Test Function Group, press the S-button
vere one will be shown first. Push and release the "S" while turning the ignition switch to ON. Release the
button once to display the next fault code. After the S-button when the display shows: ‘8.8.8.8.’. After
last code has been displayed, the display will show “- releasing the S-button the display will show: ‘diSP’.
- - -.“ See Figure 21.
Displayed fault codes appear either blinking or are
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 Figure 21. Test Function Group Mode
the codes of inactive faults, or use the dashboard dis-
The only way to leave the test function group is by
play. The memory of the dashboard display retains
switching the ignition switch to OFF.
all fault codes until its memory has been cleared.
Figure 22 schematically shows that by pressing the
INDICATION OF PROTECTION MODES M button the display scrolls to a next display group,
and by pressing the S button the display scrolls to a
The Limp Home Mode and Shutdown Mode as de-
next sub group. When button M is pressed to scroll to
scribed under ‘Control System’ are only made visi-
a next display group, the display will first show the
ble on the APC200 display when it is in the 6PoS-
sub group that is highest on the display group list
or cPoS-mode. The display shows the letters LH for
(diSP, dinP, etc). Starting from these positions it will
Limp Home or the letters Sd for Shut Down and also
be possible to scroll to sub groups that are lower on
the direction and the gear selected at that moment.
the sub group list. To return to the highest positioned
Once in the Shut Down mode, the APC200 will al-
sub group, press the S-button after having reached
ready have selected NEUTRAL. The E-LED on the
the lowest positioned sub group.
APC200 front panel will be blinking. See Figure 20.

28
1300 SRM 1358 APC200 Display information

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., it
will be possible to scroll to a next display 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.

DIGITAL INPUT TEST

APC200 has 10 digital inputs, which measure con-
nectivity of the wires listed in Table 8. After the dis-
play has shown ‘dinP,’ see Figure 23, push and re-
lease the S-button. The display indicates the active
inputs by switching ON certain segments of the dis-
play, see Figure 24. The numbered segments 0-9 rep-
resent the digital inputs DIGIN0 until DIGIN9.
Figure 24. Display Segment Numbers

29
APC200 Display information 1300 SRM 1358

In the example shown on Figure 25, the segments 1, Pressing the S-button after 9.46 returns the display
4, and 5 are ON, indicating that DIGIN1, DIGIN4, to ‘dinP.’
and DIGIN5 are active. By moving the selector lever,
different segments will be switched ON.

Press and hold the S-button to scroll to the individual

digital inputs. The display will show the logic input
number with the matching SOH wire number. The
example on Figure 26 shows that DIGIN0 relates to Figure 25. Active Digital Inputs
wire A12. Table 8 provides reference to Hyster wire
numbers.

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 Figure 26. Digital Input Code
an open circuit. Unsupported connections will show
‘lo.’

Table 8. Digital Input Test

Code Name Wire Wire APC Wire Description Output

0.12 DIGIN0 A12 809 B2 Shift Lever 1st hi/lo
1.13 DIGIN1 A13 811 C2 Shift Lever 2nd hi/lo
2.14 DIGIN2 A14 878 D2 Seat Occupied, Switch Relay hi/lo
3.17 DIGIN3 A17 OPEN G2 OPEN lo
4.18 DIGIN4 A18 807b H2 Shift Lever Forward hi/lo
5.19 DIGIN5 A19 808c J2 Shift Lever Reverse hi/lo
6.43 DIGIN6 B13 810a L3 Start in 2nd Gear hi/lo
7.44 DIGIN7 B14 812 M3 Automatic/Manual Mode hi/lo
8.45 DIGIN8 B15 819b N3 Park Brake ON/OFF hi/lo
9.46 DIGIN9 B16 OPEN P3 OPEN lo

ANALOG INPUT TEST

APC200 has 4 analog resistance inputs, which mea-
sure the actual resistance of the sensors listed in Ta-
ble 9.
Figure 27. Analog Input Test
After the display has shown ‘AinP,’ see Figure 27,
push and release the S-button. The display will show
the value in kilo Ohm in sequence of each of the four
inputs. Values below 1 kOhm are shown as ‘0.’ Each
input value is separated by a dot. See Figure 28.

Figure 28. Analog Resistance Values

30
1300 SRM 1358 APC200 Display information

Press and hold the S-button to scroll to the individual
analog inputs. The display will show the logic input
number with the matching SOH wire number. 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
resistance value in Ohm. Pressing the S-button after
6.36 returns the display to ‘AinP.’ See Figure 27.

Table 9. Analog Input Test

Code Name Wire Wire APC Wire Description Output

0.11 ANI0 A11 490 A2 Pressure Feedback Switch + Ohm
1.28 ANI1 A28 436 H3 Transmission Temperature Ohm
2.29 ANI2 A29 477b J3 Converter Out Temperature Ohm
3.47 ANI3 B17 479 R3 Inching Pedal Signal Ohm

SPEED SENSOR TEST
APC200 has 4 speed sensor inputs, which represent
the number of teeth that pass the sensor per second.
Table 10 lists the different speed sensors. After the
display has shown ‘SPd,’ see Figure 29, push and re-
lease the S-button. The display will show the value
in kilo Ohm in sequence of each input. Each value is
separated by a dot.
input number with the matching SOH wire number.
The first sensor is indicated by ‘0.22,’ meaning that
sensor SS0 relates to wire A22. Table 10 provides
reference to Hyster wire numbers.
When releasing the S-button, the display shows a ‘c’
to indicate a current type sensor and a dot and three
digits to indicate the frequency in kHz. Figure 30
shows a frequency of 0.933 kHz. Pressing the S-but-
ton after 3.41 returns the display to ‘SPd.’

Figure 29. Speed Sensor Test

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

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

31
APC200 Display information 1300 SRM 1358

OUTPUT TEST relates to SOH wire A02. Table 11 provides reference

The Output Test Group shows the outputs to the VFS
solenoids and to the ON/OFF solenoids. After the
display has shown ‘outP,’ see Figure 31, push and re-
lease the S-button. The display indicates the active
outputs by switching ON certain segments of the dis-
play. The numbered segments 0 - 3 represent the out-
puts for VFS0 - VFS3. Segments 4 - 6 are not used.
Segments 7 - 10 represent the outputs for DO0 - DO3.
to Hyster wire numbers.
When releasing the S-button, the display shows the
current provided to the VFS solenoids in mA, or the
resistance value in Ohm.
When releasing the S-button, the display shows ei-
ther a value for VFS solenoids, or ‘hi’/‘lo’ for ON/OFF
solenoids. The value shown for VFS solenoids is in
mA. ‘hi’ is shown when the solenoid is activated. ‘lo’
is shown when the solenoid is NOT activated.

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

Figure 31. Output Test
Press and hold the S-button to scroll to the individual
outputs. The display will show the logic reference
number with the matching SOH wire number. The
first output is indicated by ‘0.2,’ meaning that VFS0
ment in the overview screen blinks slowly. On the
output specific screen the display alternates between
mA or ‘hi’/‘lo’, and a fault type. Fault types used are
Open, Short, Curr, or Oor (out of range).
Pressing the S-button after 10.20 returns the display
to ‘SPd.’

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

32
1300 SRM 1358 APC200 Display information

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 394b. Figure 32. Voltage Test
• ‘VS’ Switched Voltage as measured on wire 121.
• ‘VSEn’ Sensor Voltage as measured at any analog Table 13 provides the conversion of APC200 wire
input. numbers to Hyster numbers.
Pressing the S-button after ‘VSEn’ returns the dis-
play to ‘Volt.’

Table 12. Voltage Test

Code Wire APC200 Hyster APC200 Wire Description Output

Name Wire Nr Wire 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 Hyster APC200 Pin Wire Description Output

Wire Nr Name Wire 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
A17 DIGIN3 Open G2 Open
A18 DIGIN4 807-B H2 Shift Lever Forward hi/lo

33
APC200 Display information 1300 SRM 1358

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

APC200 Wire Hyster APC200 Pin Wire Description Output

Wire Nr Name Wire Nr Nr
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

34
1300 SRM 1358 APC200 Display information

CALIBRATION GROUP Clutch Filling Calibration

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

5. Make sure the MONOTROL pedal is in RE-

VERSE.

6. Enter the calibration mode. Push the "M" button

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
Figure 33. Calibration Mode screen will display:

Figure 34. Entering Calibration Mode

35
APC200 Display information
10. When the calibration has been completed, the
APC200 display will show:
11. Switch the ignition OFF, when the APC200 dis-
play indicates that the calibration has been com-
pleted, observe the display and wait until all seg-
ments no longer light up. When the display re-
mains OFF, the new calibration has been en-
tered into the APC200 memory. The new calibra-
tion settings will be lost if the ignition is switched
ON too early.
Heat Up Mode
The heat up mode provides a convenient way to
quickly heat the transmission for test and calibra-
tion purposes. During the heat up mode only the
highest gear is selected and the inputs from the
parking brake and the brake pedal position are
ignored.
1. Press and hold the S-button, and turn the igni-
tion switch to ON. During the first 15 seconds the
display will show “8888.” Release the S button
when after 15 seconds the display shows “trAn.”
2. Start the engine.
3. Press the "M" button once and release. The word
‘heat‘ will show.
4. Press the "S" button again and release. The
actual transmission sump temperature will be
shown.
36
1300 SRM 1358
5. Apply the service brakes.
6. Put the MONOTROL pedal or the shift lever in
the FORWARD position.
7. Push the throttle for approximately 15 seconds.
8. Put the shift lever in NEUTRAL or the
MONOTROL pedal in REVERSE.
9. Run the engine at 1300 rpm for approximately 15
seconds in NEUTRAL.
10. Decelerate the engine to idle.
11. Repeat step Step 6 through Step 10 until the
APC200 display shows a temperature above 60 C
(140 F).
12. Push the "M" button to scroll to the desired cali-
bration mode.
INCHING SENSOR CALIBRATION
Inching Pedal Sensor Adjustment
NOTE: Before calibrating the inching sensor, the sen-
sor must be adjusted correctly.
1. Push the "S" button and turn the ignition switch
to the ON position.
2. Release the "S" button when “8888” appears on
the display.
3. Push the “M” button until the APC200 display
shows: "AinP."
4. Push the "S" button 3 times. The display will
show 0.11, 1.28, 2.29 and a value. Pushing an-
other time changes the display into 3.47. Releas-
ing 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 underside
of the cab accordingly.
7. Leave the test function group in the APC200 by
turning the key switch to the OFF position.
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Inching Sensor Calibration

NOTE: Calibration will fail under following circum-
stances:
• Inching sensor adjustment is below 450 mV.
• During calibration the voltage at the inching sen-
sor does not reach 2500 mV or exceeds 4.000 mV.
1. Enter the Calibration Mode until ‘trAn’ appears
on the display.
2. Push the "M" button several times until ‘brAH’
appears on the display.
3. Push the "S" button once to start the sensor cali-
bration. ‘brA_’ will show, which is the request to
enter the pedal up position.
4. Make sure to not touch the inching pedal and
push the "S" button.
5. The display will show brA_ which is the request
to fully depress the inching pedal.
6. Fully depress the inching pedal and press the "S"
button.
7. When the value has been accepted, the display
shows: ‘donE.’
NOTE: Calibration procedure has to be repeated if
the ignition is turned ON too early.
8. Switch the ignition OFF, when the APC200 dis-
play indicates that the calibration has been com-
pleted, observe the display, and wait until all
segments no longer light up. When the display
remains OFF, the new calibration has been en-
tered into the APC200 memory. The new calibra-
tion settings will be lost if the ignition is switched
ON too early.

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 software
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-User-
link and USB interface cable. The help text contains
all information required to work with the diagnos- 1. APC200 CONTROLLER
tic software and also provide the necessary education 2. DIAGNOSTIC PLUG
and guidance.
Figure 35. APC200 Connector Location
Connect the TE-Userlink to the truck using the USB
interface cable (Hyster P/N 1534010). The truck
connector is located in the side console of the cab. See
Figure 35.

37
Diagrams, Schematics, or Arrangements 1300 SRM 1358

38
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Figure 36. APC200 Wiring Diagram

39
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

40
 NOTES

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41
Diagrams, Schematics, or Arrangements 1300 SRM 1358

42
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Figure 37. Cab Side Console Harness

43
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Legend for Figure 37

Item Connector Description Connector Connecting Connector Descrip-

No. Figure Harness tion
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 --- --- ---

Pin Wire APC200 Wire Description APC200 Mating Connector

No. No. Name Pin
Code Pin Figure Descrip-
tion
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

44
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Figure 39. Connector C120 of Wire Harness Side Console Cab

Legend for Figure 39

Pin Wire APC200 Wire Description APC200 Mating Connector

No. No. Name Pin
Code Pin Figure Descrip-
tion
A1 394B PPWR Permanent Battery A1 C380 10 --- Fuse
Plus Panel
B1 482 VFSO+ VFS Forward Hi B1 C60 16 See Cab
Side Out Figure 42 Signals
C1 483 VFSO- VFS Forward Lo C1 C60 17 See Cab
Side Out Figure 42 Signals
D1 486 VFS1+ VFS 2nd VFS Hi D1 C60 21 See Cab
Side Out Figure 42 Signals
E1 487 VFS1- VFS 2nd Lo Side E1 C60 31 See Cab
Out Figure 42 Signals
F1 480 VFS2+ VFS Rev Hi Side F1 C60 9 See Cab
Out Figure 42 Signals
G1 481 VFS2- VFS Rev Lo Side G1 C60 12 See Cab
Out Figure 42 Signals
H1 484 VFS3+ VFS 1st/3rd Hi Side H1 C60 18 See Cab
Out Figure 42 Signals
J1 485 VFS3- VFS 1st/3rd Lo Side J1 C60 19 See Cab
In Figure 42 signals
K1 488 DO0 Total Neutral K1 C60 37 See Cab
Solenoid + Figure 42 Signals
A2 490 ANIO Pressure Feedback A2 C60 39 See Cab
Switch + Figure 42 Signals
B2 809 DIGIN0 Shift Lever 1st B2 C130 5 See Under
Figure 44 Floor
C2 811 DIGIN1 Shift Lever 2nd C2 C130 7 See Under
Figure 44 Floor
D2 878 DIGIN2 Seat Occupied, D2 C480 6C --- Relays
Switch Relay

45
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Legend for Figure 39 (Continued)

Pin Wire APC200 Wire Description APC200 Mating Connector

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

46
1300 SRM 1358 Diagrams, Schematics, or Arrangements

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

Legend for Figure 40

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

No. No. Name
Code Pin Figure Descrip-
tion
L1 --- PWM4+ OPEN L1 --- --- --- ---
M1 477d REF5V 5V Ref Voltage Out M1 C130 28 See Under
Figure 44 Floor
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
RS232RXD Figure 45 Link
P2 438 TXD Tuning Link P2 C415 1 See Tuning
RS232TXD Figure 45 Link
R2 437 SS3+ Turbine Speed R2 C60 48 See Cab
Sensor + Figure 42 Signals
S2 121 SPWR Switched Battery S2 C380 14 --- Fuse
Plus Panel
L3 810a DIGIN6 Start in 2nd gear L3 C130 6 See Under
Figure 44 Floor
M3 812 DIGIN7 Automatic/Manual M3 C130 8 See Under
Mode Figure 44 Floor
N3 819B DIGIN8 Park Brake N3 C90 1 --- Park
ON/OFF Brake
diode

47
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Legend for Figure 40 (Continued)

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

No. No. Name
Code Pin Figure Descrip-
tion
P3 --- DIGIN9 OPEN P3 --- --- --- ---
R3 479 ANI3 Inching Sensor R3 C130 27 See Under
Output Figure 44 Floor
S3 646 VFSGND Transmission ECM S3 C70 3 See Cab
Ground Figure 43 Supplies

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

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

48
1300 SRM 1358 Diagrams, Schematics, or Arrangements

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

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

49
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

No. No. Name
Code Pin Figure Descrip-
tion
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

50
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

No. No. Name
Code Pin Figure Descrip-
tion
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

51
Diagrams, Schematics, or Arrangements 1300 SRM 1358

52
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Figure 47. Frame Wire Harness

53
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

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

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

Figure 48. Drum Speed Connector C90 of Wire Harness Frame

54
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Figure 49. Control Valve Connector C80 of Wire Harness Frame

Legend for Figure 49

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

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

55
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Legend for FIgure 49 (Continued)

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

No. No. Name
Code Pin Figure Descrip-
tion
14 693 VFSGND 1st/3rd select Ground C146 3 See Cab
ground Figure 55 Supplies
15 478D SGND Ground K3 C144 11 See Cab
Figure 54 Signals
16 --- --- Linked to pin 12. --- --- --- --- ---

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

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

Figure 50. Engine Speed Connector C150 of Wire Harness Frame

56
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

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

Figure 51. Output Speed Connector C120 of Wire Harness Frame

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

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

Figure 52. Turbine Speed Connector C340 of Wire Harness Frame

57
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

No. No. Name
Code Pin Figure Descrip-
tion
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

Figure 54. Cab Signals Connector C144 of Wire Harness Frame

58
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Figure 55. Cab Supplies Connector C146 of Wire Harness Frame

59
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Figure 56. Under Cab Floor Wire Harness

60
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

61
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Mating Connector

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

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

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

62
1300 SRM 1358 Diagrams, Schematics, or Arrangements

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

No. No. Name
Code Pin Figure Descrip-
tion
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

63
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Figure 61. Steering Column Wire Harness

64
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

65
Diagrams, Schematics, or Arrangements 1300 SRM 1358

Pin Wire APC200 Wire Description APC200 Pin Mating Connector

No. No. Name
Code Pin Figure Descrip-
tion
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 J2 C10 4 See Cab
Reverse Figure 62
6 807b DIGIN4 Shift Lever H2 C10 3 See Cab
Forward Figure 62
7 806 --- Shift Lever --- C10 2 See Cab
Neutral 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

66
 TECHNICAL PUBLICATIONS

1300 SRM 1358 5/10 (12/09)(7/08) Printed in U.S.A.