Professional Documents
Culture Documents
OPERATION AND
DIAGNOSTICS
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................2
Description ...............................................................................................................................................................2
General ................................................................................................................................................................ 2
Operation ................................................................................................................................................................. 5
Hydraulic Operation ........................................................................................................................................... 5
1st/3rd Selector Valve ......................................................................................................................................... 8
Cooling and Lubrication ................................................................................................................................... 10
Control System ...................................................................................................................................................... 12
General .............................................................................................................................................................. 12
APC200 Controller ............................................................................................................................................12
Self Test .........................................................................................................................................................12
Protection Modes .......................................................................................................................................... 12
Limp Home Mode ..................................................................................................................................... 12
Shut Down Mode ...................................................................................................................................... 12
Transmission Exceed Codes .....................................................................................................................13
Fault Codes ................................................................................................................................................... 13
Description ................................................................................................................................................13
Fault Log Mode .............................................................................................................................................13
Access ........................................................................................................................................................ 13
Exit ............................................................................................................................................................14
Clear ..........................................................................................................................................................14
Fault Rectification ........................................................................................................................................ 14
Hydraulic Control Valve ...................................................................................................................................16
Hydraulic Control Valve Repair .................................................................................................................. 18
Solenoid Replacement .................................................................................................................................. 18
Pressure Check ............................................................................................................................................. 18
Pressure Specifications .................................................................................................................................19
Pressure, Speed, and Temperature Sensors ....................................................................................................19
Pressure Switch ............................................................................................................................................ 24
Test ............................................................................................................................................................24
Speed Sensor .................................................................................................................................................25
Test ............................................................................................................................................................25
Temperature Sensors ................................................................................................................................... 26
Test ............................................................................................................................................................26
Transmission Test and Calibration ......................................................................................................................27
Precautions ........................................................................................................................................................27
Stall Test ........................................................................................................................................................... 27
Description .................................................................................................................................................... 27
Stall Test Procedure ..................................................................................................................................... 27
Clutch Calibration ............................................................................................................................................ 28
Description .................................................................................................................................................... 28
Procedure ...................................................................................................................................................... 28
Inching Calibration ...........................................................................................................................................29
Description .................................................................................................................................................... 29
Brake and Inching Pedal Adjustment ......................................................................................................... 29
Inching Sensor Adjustment ..........................................................................................................................30
Inching Sensor Calibration .......................................................................................................................... 30
Electrical Specifications ........................................................................................................................................31
APC200 Display information ................................................................................................................................32
ii
Table of Contents
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1300 SRM 1358 Series Code / Model Designation Reference Table
1
General 1300 SRM 1358
General
This manual provides information on operation and Electrical system diagrams are shown in Dia-
diagnostics of the TE10 transmission as fitted on grams 8000SRM1346.
G019 and H007 series lift trucks.
Description
GENERAL The engine flywheel is connected to the torque con-
verter housing through drive plates. See Figure 1.
The function of the transmission is to transfer en-
gine power from the engine flywheel to the drive
wheels and to the hydraulic pumps that are at-
tached to the transmission.
2
1300 SRM 1358 Description
3
Description 1300 SRM 1358
The different speed ratios between input shaft and The clutches consist of a hub which carries friction
drive shaft are obtained by engaging and disengag- discs with internal splines, and a drum which car-
ing the different clutches. Three groups of gears are ries steel discs with external splines. See Figure 3.
continuously engaged with each other: the input
gears, the interconnecting gears, and the output Friction discs and steel discs are alternately fitted.
gears. See Figure 2. By pressurizing the clutch piston, the friction discs
and steel discs are clamped together, which cause
If clutches belonging to one group would be en- the hub and drum to rotate as one unit. When hy-
gaged simultaneously, the transmission would lock. draulic pressure is released, return springs push
The clutches Forward and Reverse should not be the piston back against the clutch housing and al-
engaged at the same time. Also, the speed clutches low hub and drum to rotate independently. The
for the 1st, 2nd, and 3rd speed should not be en- drum, steel discs, piston, spacer and return springs
gaged at the same time. Erroneous clutch engage- rotate at the same speed. The hub rotates at the
ment is prevented by the transmission control sys- same speed with the friction discs.
tem.
The transmission control system pressurizes and
The different speeds are obtained by engaging ei- depressurizes the clutches.
ther the forward or reverse clutch, and by engaging
either one of the clutches for the 1st, 2nd, and 3rd
speed.
4
1300 SRM 1358 Description
Operation
HYDRAULIC OPERATION que converter housing. The pump transfers oil
through the transmission filter, and further to the
The transmission sump is the main reservoir for 10 bar (145 psi) pressure reducer valve and to the
the transmission oil. The sump screen keeps large 16.5 bar (239.3 psi) pressure regulator valve. See
particles from entering the transmission pump. The Figure 4.
pump is driven by gears that connect with the tor-
5
Operation 1300 SRM 1358
6
1300 SRM 1358 Operation
7
Operation 1300 SRM 1358
The 16.5 bar (240 psi) pressure regulator valve reg- The actuation of the modulation solenoids (VFS) is
ulates system pressure, by relieving excess oil opposite from normal expectation. When there is
through the torque converter, oil cooler, and lubri- NO signal from the APC200, the modulation valve
cation system. See Cooling and Lubrication. System admits full pressure to the clutch intensifier valve.
pressure is used to fill and pressurize the clutches. When the signal has reached 100mA, oil supply
from the modulation valve to the clutch intensifier
The 10 bar (145 psi) pressure reducer valve pro- valve is closed.
vides pilot pressure to the total neutral valve and
to the modulation solenoids. The function of the to- 1ST/3RD SELECTOR VALVE
tal neutral valve is to activate the clutch supply
valve when the control system allows this. The acti- Actuation of the clutches for 1st speed and 3rd
vated clutch supply valve will transfer system pres- speed is through a common modulation solenoid
sure, 16.5 bar (239.3 psi), to each of the clutch in- (VFS 1st/3rd), which activates a common clutch in-
tensifier valves. tensifier valve. The transferred system oil pressure
connects with the 1st/3rd selector valve, which ei-
If the APC200 control does NOT receive the proper ther transfers to the 1st or to the 3rd clutch de-
signals, the total neutral valve will be deactivated, pending on an electric signal from the APC200.
causing the clutch supply valve to close. All When the 1st speed selection solenoid is activated,
clutches release immediately when the clutch sup- the 1st/3rd selector valve transfers system pressure
ply valve closes. to the 1st speed clutch. When the 1st speed selec-
tion valve is NOT activated, the 1st/3rd selector
The total neutral spool and the clutch supply spool valve transfers system pressure to the 3rd speed
are in reality combined on one spool. See Figure 8. clutch.
The modulation solenoids (Variable Force Sole- Table 1 provides an overview of the activated sole-
noids) transfer a proportional pressure to the clutch noids and clutches for the different transmission
intensifier valves depending on the signal from the speeds. Neutral selection is by disengagement of
APC200. With increasing pressure from the modu- both the forward and reverse clutch. Trucks with a
lation solenoid, the clutch intensifier valve increas- MONOTROL® pedal will only shift to NEUTRAL
ingly admits system pressure to the relevant by applying the hand or service brake, or when the
clutch. When the clutch is fully engaged, full sys- operator has left his seat.
tem pressure remains applied until the modulation
solenoid closes, causing the intensifier valve to
close as well, which drains clutch pressure to sump
and releases the clutch.
8
1300 SRM 1358 Operation
9
Operation 1300 SRM 1358
COOLING AND LUBRICATION that is lower than system pressure. See Figure 5.
The pressure regulator valve admits oil that is not
Heat is primarily generated at the torque converter required for clutch filling. The safety valve reduces
and at the clutch plates during transmission opera- oil pressure to 9 bar (131 psi) to protect the torque
tion. The heat generated by mechanical friction at converter and oil cooler. The normal oil flow is
gears, shafts and bearings is relatively low. through the torque converter, the transmission oil
cooler and to the transmission lubrication port. The
Heat generated in the torque converter relates di- volume of oil and the oil flow resistance causes that
rectly to the degree of stall, i.e. the speed difference the initial 9 bar (131 psi) supply pressure is re-
between engine and turbine. In a stall situation duced to 0.4 to 0.85 bar (5.8 to 12.3 psi) at the
most of the supplied engine power is transferred transmission lubrication port. Flow resistance in-
into heat. This heat accumulates in the torque con- creases during torque converter stall or when oil
verter because of the reduced oil flow during a stall temperature is low. When the transmission is at
situation. With increasing turbine speed, the vol- operating temperature and no load is applied, the
ume of added heat reduces, while simultaneously volume of lubrication oil is 64 liter (17 gal) at 1800
the increased oil flow more rapidly transfers the ac- rev/min.
cumulated heat.
From the transmission lubrication port the oil flows
Heat generated at the clutch plates varies with the into channels in the different shafts, which lead to
actually available engine power at time of clutch the shaft bearings for lubrication, and to the inside
engagement and the duration of clutch engage- of the clutch packs where the oil absorbs the heat
ment. During normal operation, the transmission that is generated at the clutch plates.
control system determines the duration of clutch
engagement. During inching it is the driver who To speed the warming-up process, a thermostat
controls the added heat in the clutch by varying en- valve is installed between the torque converter out-
gine power and clutch engagement. The transmis- let port and the transmission radiator. The thermo-
sion control system will close the forward or reverse stat starts opening at 70°C (158°F) and is com-
clutch when a certain amount of generated heat pletely opened at 85°C (185°F). At temperatures be-
has been exceeded. low 70°C (158°F), oil flow is directly returned to the
transmission. At temperatures above 85°C (185°F),
Only a minor portion of the total transmission the entire oil flow from the outlet port passes
pump supply is used for clutch filling. The majority through the transmission radiator before it is re-
of transmission oil supply is used for the cooling turned to the transmission.
and lubrication circuit that functions at a pressure
10
1300 SRM 1358 Operation
11
Control System 1300 SRM 1358
Control System
GENERAL The APC200 controller is located in the side console
of the cab and has a display and push buttons to
The control system of the transmission consists of call off information. Normally the gauges and dis-
the APC200 controller, several switches and send- plays on the dashboard are used to read transmis-
ers that provide information to the APC200, and sion related information. For diagnostics and set-
the hydraulic control valve that regulates pressures tings, it is more convenient to use the TE-Userlink
depending on signals from the APC200. system instead of pushing the buttons on the
APC200. The section APC200 Display information
APC200 CONTROLLER has the instructions for how to call off information
from the APC200 when TE-Userlink is not availa-
The APC200 has software to control the operation ble.
of the transmission and performs the following
functions: Self Test
• Perform self-test and troubleshooting. At power up a series of checks is done. If the
• Functional control of the transmission. APC200 fails these checks, it will shut off all out-
- Automatic shifting. puts. The transmission cannot be operated until
the problem is rectified. The relevant fault code will
- Inching. be displayed.
• Enter a protection mode when required.
- Improper pressures, temperatures, Protection Modes
and speeds.
- No operator present.
Limp Home Mode
- Parking brake applied. The transmission is put in NEUTRAL if a fault is
- Gear or direction change at improper detected on the following:
speeds. • Outputs for solenoids, VFS or Pressure
• Logging a fault code when circumstances Switch
have exceeded certain values. • Engine speed sensor
• Allow diagnostics and calibration with a lap- • Two out of three vehicle speed sensors
top (TE-Userlink).
To continue driving, first the shift lever must be
Depending on the signals of the shift lever and var- put in NEUTRAL. After that, the driver can reen-
ious switches and senders, the APC200 activates or gage a direction. When Limp Home Mode has been
deactivates the solenoids and VFS valves in the entered, the user can operate the transmission in
control valve, which transfer hydraulic pressure to either direction in 1st and 2nd only. Inching is disa-
the clutches in the transmission. If an input signal bled.
does not comply with the programming of the
APC200, the APC200 will record the fault and react Shut Down Mode
by activating a protection mode. All events recorded
are stored as a fault code and are shown on the in- If an intolerable combination of faults is detected,
strument cluster when the fault occurs. Faults can the Shut Down Mode will be entered. The APC200
also be read at a later point in time, making it pos- puts the transmission in NEUTRAL by putting all
sible to trace intermittent problems. VFS signals at zero pressure and by switching OFF
the total neutral solenoid, cutting off pressure to
Protection modes and self tests are part of the the clutches. Intolerable faults are also referred to
APC200 programming and cannot be influenced. as Redundant Shutdown Path errors (RSP).
12
1300 SRM 1358 Control System
Access
If the engine and/or transmission controller detect The instrument cluster has a memory that records
a fault, the hourmeter/fault code display will show each fault when it occurs. These faults that have
a fault code instead of the engine running hours. occurred can be reviewed at a later point in time by
entering into the fault log mode. Proceed as follows
Fault codes starting with "E" refer to engine fault to enter into the fault log mode:
codes.
1. Apply parking brake.
• Fault code number(s)
2. Turn ON ignition, but do not start lift truck.
13
Control System 1300 SRM 1358
After the fault code, three further numbers are Fault Rectification
shown.
Fault codes are listed in APC200 Fault Code
The numbers represent the following: Guide 1300SRM1435, which provides an explana-
• Fault code tion of the fault, the resulting action of the
APC200, and checks for troubleshooting. Each fault
• Hourmeter reading at last occurrence
code represents a specific defect or malfunction.
• Hourmeter reading at first occurrence
• Number of occurrences of current fault In most cases the suggested rectification is by
checking electrical functionality between the
Each number is shown for 3 seconds, after which APC200, the wiring and the sensors, solenoids, or
the following number is shown. The faults will be switches.
shown in the opposite sequence of occurrence: The
most recent fault first and the first occurred fault Before disassembling components for test purposes,
last. When all recorded fault codes have been connect the TE-Userlink program. The screen
shown, the display will continue to repeat these re- Dashboard-Monitor’ allows verification of the func-
corded fault codes until the user exists the fault log tionality of speed sensors, the pressure switch, and
mode. the shift lever. In case several possible defects are
indicated, TE-Userlink may narrow down the num-
Exit ber of possible defects, preventing unnecessary re-
moval of components that function correctly.
To exit the fault log mode, turn the ignition OFF
and ON and leave ignition ON for more than 2 sec- To rectify problems with switches, solenoids and
onds. The cluster will also exit to normal mode sensors, look up their actual location, and test the
when the parking brake is released or when the en- component. The location of the solenoids are shown
gine is started. in the section Hydraulic Control Valve. The loca-
tion of sensors and switches are shown in the sec-
Clear tion Pressure, Speed, and Temperature Sensors,
and Figure 6. Test values of solenoids and sensors
are shown in Electrical Specifications.
To clear the fault codes logged in the display, pro-
ceed as follows:
NOTE: The Dana Dashboard software and the
APC200 Fault Code Guide 1300SRM1435 have
1. Access into the fault log mode. See Access.
wire and input references that relate to the
2. Clear the fault log by cycling the ignition key APC200. Refer to Table 13 for the conversion from
OFF and ON three more times. This is a repe- APC200 wire numbers to Hyster numbers.
tition of the procedure to access the fault log
mode. See Access. To identify a harness problem, first determine con-
nectivity between the APC200 and the connector of
If the data-erasing process is successful, the display the component that was indicated in the Fault
will show ’clear’. If the data-erasing process is not Code Guide.
successful, the display will show the fault codes in
the memory, shown in the order by the time of the Look up the connector code and/or the wire number
occurrence. To return to the normal mode, follow in Figure 36, which shows to which harness the
the procedure as described in Exit. To retry erasing connector and/or wire belongs.
stored fault codes, follow Step 2 of the procedure to
clear fault codes.
14
1300 SRM 1358 Control System
The wire harness figures in Electrical System Table 2. Control Valve Pressure Check Ports
2200SRM1499 show the actual location of connec-
tors. Port Description
Number
31a Filter Out - Regulator Pressure
50/52 Intensifier Pressure 1st - 3rd
51 Intensifier Pressure 2nd
54 Intensifier Pressure Forward
55 Intensifier Pressure Reverse
56 System Pressure - Intensifier Pressure
57 VFS Valve Pressure in Pilot Pressure
58 System Pressure - Intensifier Pressure
59 System Pressure - Intensifier Pressure
60/62 Selection Valve 1st - 3rd Intensifier
61 Clutch Pressure 2nd
64 Clutch Pressure Forward
65 Clutch Pressure Reverse
15
Control System 1300 SRM 1358
16
1300 SRM 1358 Control System
17
Control System 1300 SRM 1358
Hydraulic Control Valve Repair The control valve includes the pilot pressure reduc-
ing valve.
Repairs to the control valve are limited to replacing
solenoids and gaskets. Hydraulic components of the With the transmission control valve removed, oil
control valve may be inspected, but cannot be ad- ports leading to the various clutches can be pres-
justed and are not separately available for replace- surized with air. The amount of air pressure ap-
ment. plied should be approximately 14 bar (200 psi).
When applying air pressure to the control valve
Solenoid Replacement ports, clutch engagement and obvious leaks can be
established. This test will not work using the trans-
To inspect components of the control valve, first the mission pressure test ports, as the air will escape
transmission has to be lifted until the frame sup- through the intensifier valve. For the location of
port bracket no longer obstructs removal of the sol- the ports see Figure 9.
enoid cover. Remove the nuts and bolts that con-
nect both sides of the transmission to the frame.
Place a jack with a wide support surface under the
transmission housing and raise the transmission
slightly. Remove the left hand transmission
bracket. Raise the jack further until the frame sup-
port bracket no longer obstructs removal of the con-
trol valve cover. For further details of control valve
replacement see the section Transmission Repair
1300SRM1356.
Pressure Check
18
1300 SRM 1358 Control System
PRESSURE, SPEED, AND The location of the speed and temperature sensors
TEMPERATURE SENSORS are included in Figure 10, Figure 11, Figure 12,
and Figure 13. The engine speed sensor is located
Before disassembling components for test purposes, at the pump drive gear. The schematic location of
connect the TE-Userlink program. The screen the other speed sensors is shown in Figure 14.
Dashboard-Monitor’ allows verification of the func-
tionality of several components, preventing unnec-
essary removal.
19
Control System 1300 SRM 1358
20
1300 SRM 1358 Control System
21
Control System 1300 SRM 1358
22
1300 SRM 1358 Control System
23
Control System 1300 SRM 1358
Pressure Switch
Test
24
1300 SRM 1358 Control System
25
Control System 1300 SRM 1358
26
1300 SRM 1358 Transmission Test and Calibration
27
Transmission Test and Calibration 1300 SRM 1358
1. Connect a laptop computer to the Userlink plug When shifting up, the clutch to be released will
in the side console. Select the screen to read the start relieving its pressure at the same moment
engine speed. when the engaging clutch starts clamping. For a
short period of time, these two clutches are both
2. Put a capacity load on the forks to prevent the partially engaged. This provides the feature to shift
wheels from turning. up a gear smoothly under full traction.
3. Put the lift truck against an object that cannot
As the clutch plates wear, they will get slightly
move.
thinner. This implies that the piston of the engag-
4. Apply the parking brake for trucks with a for- ing clutch will have longer travel until the piston
ward/reverse lever. starts clamping the discs. The releasing clutch
would start slipping too early. The transmission
5. Apply the brake pedal for trucks with a MONO- would no longer shift smoothly.
TROL pedal.
The APC200 has a calibration program to readjust
6. Start the engine and select the 3rd gear in the clutch filling time and the time to reach full en-
manual mode. gagement. Clutch filling time is determined by the
elapsed time between clutch fill start and the mo-
7. Push the accelerator pedal to full throttle.
ment when the turbine speed sensor detects a
8. Read the stall speed and release the throttle change in speed (touch detection). The time to
pedal. reach full engagement is determined by the elapsed
time between touch detection and full clutch en-
If the stall speed is 50 to 200 rpm below the specifi- gagement. An automatic warning to recalibrate the
cation, the engine is not operating at full power. transmission appears on the instrument cluster ev-
Check if engine fault codes are present and rectify ery 2000 hours as exceed code (te501).
any indicated problems.
During clutch calibration, codes may be displayed
If the stall speed is higher than specification, the that indicate incorrect circumstances for proper
engaged clutch(es) may not be holding or the torque clutch calibration. The explanation of these codes is
converter is damaged. Check if transmission fault in APC200 Fault Code Guide 1300SRM1435.
codes are present and rectify any indicated prob-
lems. During clutch calibration, fault codes with a pre-
ceding "E" may be displayed. For example E1.25.
If no transmission fault codes are present and the The first digit after the "E" can be a "1" or a "2". "1"
stall speed is much higher than specification, re- relates to faults during clutch filling time. "2" re-
move the torque converter for inspection. lates to faults during clutch engagement. The last
two digits indicate calibration faults, which are lis-
If stall speed is only slightly higher than specifica- ted and explained in APC200 Fault Code Guide
tion, consider service life of the torque converter 1300SRM1435.
and the option to replace the torque converter im-
mediately or at a later point in time. Procedure
1. Apply the parking brake.
CLUTCH CALIBRATION
2. Connect a laptop computer to the Userlink plug
Description in the side console.
The APC200 is programmed to quickly fill the 3. Verify the forward/reverse lever is in NEU-
clutch until the piston starts clamping the discs TRAL or REVERSE.
and only then raise clutch pressure further within
4. Verify the MONOTROL pedal is in REVERSE.
a certain period of time until full engagement has
been reached.
28
1300 SRM 1358 Transmission Test and Calibration
5. Start the engine. lating the inching pedal position to clutch pressure.
The relation between pedal position and clutch
6. Make sure the transmission oil temperature is pressure results in a natural reaction of the opera-
at least 60°C (140°F). tor to depress the inching pedal further when ac-
tual truck speed is too high. A further depressed in-
7. Select the screen "Automatic Calibration," se-
ching pedal causes that the pressure in the inching
lect "Interface" and click the button "Clutch
clutch will get lower, which reduces truck speed, ir-
Filling Calibration."
respective of engine speed. In case too much heat is
8. The automatic calibration starts when the for- generated during inching, the APC200 will release
ward/reverse lever or MONOTROL is moved all pressure and show fault code 46.05.
into the FORWARD position and the transmis-
sion oil temperature is at least 60°C (140°F). The inching pedal sensor has to be calibrated for
two pedal positions: Inching pedal completely de-
9. When transmission oil temperature has drop- pressed and inching pedal released. Calibration is
ped below 60°C (140°F), the automatic calibra- required when the inching sensor has been re-
tion program will first heat the transmission placed or when its fixation became loose. Further,
before proceeding with the calibration. This fea- calibration is an annual requirement due to wear
ture is part of the calibration program and and creep of pedals and linkages. Before calibrating
should not be interfered, as interference will the inching sensor, verify adjustment of the brake
stop the calibration. pedal and the inching sensor. Incorrect sensor cali-
bration triggers fault codes during operation. By
10. The complete automatic calibration process slightly varying the free travel of the brake pedal it
takes 12 to 15 minutes. The screen will show is possible to vary the moment when brakes start to
'done' when the calibration has been completed. apply. With an early brake application, too much
The engine speed will remain at idle during cal- heat will be generated both in the inching clutch
ibration. and the brakes. With a later application of the
brakes, pedal travel will get longer before brakes
11. Switch the ignition OFF, when the APC200
are fully applied. Always make small adjustments
display indicates that the calibration has been
in the free travel of the brake pedal and check that
completed. Observe the display and wait until
both the inching and brake pedal will have gener-
all segments no longer light up. When the dis-
ous distance to the floor plate when the brakes are
play remains OFF, the new calibration has
fully applied.
been entered in the APC200 memory. The new
calibration settings will get lost if the ignition
is switched ON too early.
Brake and Inching Pedal Adjustment
NOTE: Do not interfere with the calibration. Acti- 1. Make sure the release position of the brake
vating any controls or components will stop the cal- pedal has been properly adjusted.
ibration mode before completion. The screen will a. Wet Brakes - Turn the adjustment bolt for
show when the calibration has been completed. the brake pedal until there is no play be-
tween the bolt on the brake valve and the
During calibrations the APC200 display may show roller under the brake pedal. See Figure 16.
calibration condition messages, or error codes dur-
ing calibration. For explanation of these codes see b. Dry Brakes - Turn the adjustment bolt for
APC200 Fault Code Guide 1300SRM1435. the brake pedal until there is 5 to 10 mm (0.2
to 0.4 in.) travel until the brake light comes
INCHING CALIBRATION ON.
Description
29
Transmission Test and Calibration 1300 SRM 1358
1. BRAKE PEDAL
2. INCHING PEDAL
3. ADJUSTMENT BOLT FOR BRAKE PEDAL
4. ADJUSTMENT BOLT FOR BRAKE PEDAL COU-
PLING
5. ADJUSTMENT BOLT FOR INCHING PEDAL
30
1300 SRM 1358 Transmission Test and Calibration
5. Switch the ignition OFF, when the APC200 been entered in the APC200 memory. The new
display indicates that the calibration has been calibration settings will get lost if the ignition
completed. Observe the display and wait until is switched ON too early.
all segments do not longer light up. When the
display remains OFF, the new calibration has
Electrical Specifications
Electronic controlled modulation solenoids Table 6. Temperature Sensor (In Speed Sensor)
VFS 2nd - VFS 1st/3rd - VFS Fwd - VFS Rev Resistance Versus Temperature (Continued)
Coil resistance - 4.35 ±0.35Ω at 25°C (77°F) AMBIENT RESISTANCE
TEMPERATURE Ω
ON/OFF solenoids 20°C (68°F) 1922
Total neutral and selector solenoids
25°C (77°F) 2000
Coil resistance - 12V - 28 ±2Ω at 20°C (68°F)
30°C (86°F) 2080
Coil resistance - 24V - 87 ±2Ω at 20°C (68°F)
40°C (104°F) 2245
Speed sensor 50°C (122°F) 2417
Type - Magneto resistive sensor. 60°C (140°F) 2597
Sensing distance - 0 to 1.8 mm (0 to 0.07 in.) 70°C (158°F) 2785
Sensor signal - Generates a square current 80°C (176°F) 2980
with a fixed amplitude changing between 7
90°C (194°F) 3182
and 14 mA.
100°C (212°F) 3392
Table 6. Temperature Sensor (In Speed Sensor) 110°C (230°F) 3607
Resistance Versus Temperature
120°C (248°F) 3817
AMBIENT RESISTANCE
125°C (257°F) 3915
TEMPERATURE Ω
130°C (266°F) 4008
−55°C (−67°F) 980
140°C (284°F) 4166
−50°C (−58°F) 1030
150°C (302°F) 4280
−40°C (−40°F) 1135
−30°C (−22°F) 1247
−20°C (−4°F) 1367
−10°C (14°F) 1496
0°C (32°F) 1630
10°C (50°F) 1772
31
APC200 Display information 1300 SRM 1358
The information is provided by means of codes. The The LED lamp labeled "F" is red and is ON when
interpretation of these codes depends on the dis- the APC200 is in the reset condition.
play mode being activated. The following display
modes are available: The push button marked "M" is used to scroll to one
of the three display groups.
• General Information
• Test The push button marked "S" is used to scroll to a
• Calibration next sub group within a display group.
32
1300 SRM 1358 APC200 Display information
GENERAL INFORMATION GROUP After startup the display will show the sub group
that was selected when the APC200 was switched
Table 7 shows the structure of the General Infor- OFF.
mation Group. Figure 19 schematically shows that
by pressing the M button the display scrolls to a
next display group, and by pressing the S button
the display scrolls to a next sub group. When but-
ton M is pressed to scroll to a next display group,
the display will first show the sub group that is
highest on the display group list (6PoS, or cPoS, or
Err). Starting from these positions it will be possi-
ble to scroll to sub groups that are lower on the sub
group list. To return to the highest positioned sub
group, press the S-button after having reached the
lowest positioned sub group.
33
APC200 Display information 1300 SRM 1358
34
1300 SRM 1358 APC200 Display information
FAULT CODES
If more than one fault has been detected, the most TEST FUNCTION GROUP
severe one will be shown first. Push and release the
"S" button once to display the next fault code. After To enter the Test Function Group, press the S-but-
the last code has been displayed, the display will ton while turning the ignition switch to ON. Re-
show “- - - -.“ lease the S-button when the display shows:
8.8.8.8.’. After releasing the S-button the display
Displayed fault codes appear either blinking or are will show: diSP’. See Figure 21.
shown uninterrupted. When shown uninterrupted
the fault code is active. When blinking, the fault
has occurred but is currently inactive.
35
APC200 Display information 1300 SRM 1358
36
1300 SRM 1358 APC200 Display information
37
APC200 Display information 1300 SRM 1358
SPEED SENSOR TEST ber. The first sensor is indicated by 0.22,’ meaning
that sensor SS0 relates to wire A22. Table 10 pro-
APC200 has 4 speed sensor inputs, which represent vides reference to HYSTER wire numbers.
the number of teeth that pass the sensor per sec-
ond. Table 10 lists the different speed sensors. Af- When releasing the S-button, the display shows a c’
ter the display has shown SPd,’ see Figure 29, push to indicate a current type sensor and a dot and
and release the S-button. The display will show the three digits to indicate the frequency in kHz. Fig-
value in kilo Ohm in sequence of each input. Each ure 30 shows a frequency of 0.933 kHz. Pressing
value is separated by a dot. the S-button after 3.41 returns the display to SPd.’
38
1300 SRM 1358 APC200 Display information
39
APC200 Display information 1300 SRM 1358
VOLTAGE TEST
40
1300 SRM 1358 APC200 Display information
APC200 Wire Wire Hyster Wire APC200 Pin Wire Description Output
Nr Name Nr Nr
A01 PPWR 394-B A1 Permanent Battery + 24.0 Volt
A02 VFS0+ 482 B1 VFS Forward Hi Side Out mA
A03 VFS0 483 C1 VFS Forward Lo Side Out mA
A04 VFS1+ 486 D1 VFS 2nd VFS Hi Side Out mA
A05 VFS1 487 E1 VFS 2nd VFS Lo Side Out mA
A06 VFS2+ 480 F1 VFS Rev Hi Side Out mA
A07 VFS2 481 G1 VFS Rev Lo Side Out mA
A08 VFS3+ 484 H1 VFS 1st/3rd Hi Side Out mA
A09 VFS3 485 J1 VFS 1st/3rd Lo Side Out mA
A10 DO0 488 K1 Total Neutral Solenoid + hi/lo
A11 ANI0 490 A2 Pressure Feedback Switch + Ohm
A12 DIGIN0 809 B2 Shift Lever 1st hi/lo
A13 DIGIN1 811 C2 Shift Lever 2nd hi/lo
A14 DIGIN2 878 D2 Seat Occupied, Switch Relay hi/lo
A15 DO1 Open E2 Open
A16 DO2 492 F2 1st/3rd Selector Solenoid hi/lo
41
APC200 Display information 1300 SRM 1358
Table 13. APC200 Wire Number to Hyster Wire Number Conversion (Continued)
APC200 Wire Wire Hyster Wire APC200 Pin Wire Description Output
Nr Name Nr Nr
A17 DIGIN3 Open G2 Open
A18 DIGIN4 807-B H2 Shift Lever Forward hi/lo
A19 DIGIN5 808-C J2 Shift Lever Reverse hi/lo
A20 DO3 489 K2 Total Neutral Solenoid - hi/lo
A21 GND 645 A3 APC200 Ground Volt
A22 SS0+ 417 B3 Drum Speed Sensor + kHerz
A23 SS0- 418 C3 Drum Speed Sensor - kHerz
A24 SS1+ 419 D3 Output Speed Sensor + kHerz
A25 SS1- 433 E3 Output Speed Sensor - kHerz
A26 SS2+ 434 F3 Engine Speed Sensor + kHerz
A27 SS2- 436 H3 Engine Speed Sensor - kHerz
A28 ANI1 435 G3 Transmission Temperature Ohm
A29 ANI2 477-B J3 Converter Out Temperature Ohm
A30 GND 478-C K3 Ground Ohm
B01 VFS4+ Open L1 Open
B02 ANI4 477 M1 Inching Pedal Ohm
B03 VFS5+ Open N1 Open
B04 ANI5 408-B P1 Open
B05 VFS6+ Open R1 Open
B06 ANI6 Open S1 Open
B07 CAN L 598-D L2 CAN Low
B08 CAN H 599-D M2 CAN High
B09 RXD 439 N2 Open
B10 TXD 438 P2 Open
B11 SS3+ 437 R2 Turbine Speed Sensor + kHerz
B12 SPWR 121 S2 Switched Battery + 24.0 Volt
B13 DIGIN6 810-A L3 Start in 2nd Gear hi/lo
B14 DIGIN7 812 M3 Automatic/Manual Mode hi/lo
B15 DIGIN8 819-B N3 Park Brake ON/OFF hi/lo
B16 DIGIN9 Open P3 Open
B17 ANI3 479 R3 Inching Pedal Signal Ohm
B18 GND 646 S3 Ground Volt
42
1300 SRM 1358 APC200 Display information
43
APC200 Display information 1300 SRM 1358
11. Switch the ignition OFF, when the APC200 10. Decelerate the engine to idle.
display indicates that the calibration has been
completed, observe the display and wait until 11. Repeat step Step 6 through Step 10 until the
all segments no longer light up. When the dis- APC200 display shows a temperature above
play remains OFF, the new calibration has 60°C (140°F).
been entered into the APC200 memory. The
12. Push the "M" button to scroll to the desired cal-
new calibration settings will be lost if the igni-
ibration mode.
tion is switched ON too early.
INCHING SENSOR CALIBRATION
Heat Up Mode
Inching Pedal Sensor Adjustment
The heat up mode provides a convenient way to
quickly heat the transmission for test and calibra- NOTE: Before calibrating the inching sensor, the
tion purposes. During the heat up mode only the sensor must be adjusted correctly.
highest gear is selected and the inputs from the
parking brake and the brake pedal position are ig- 1. Push the "S" button and turn the ignition
nored. switch to the ON position.
1. Press and hold the S-button, and turn the igni- 2. Release the "S" button when “8888” appears on
tion switch to ON. During the first 15 seconds the display.
the display will show “8888.” Release the S but-
3. Push the “M” button until the APC200 display
ton when after 15 seconds the display shows
shows: "AinP."
“trAn.”
4. Push the "S" button 3 times. The display will
2. Start the engine.
show 0.11, 1.28, 2.29 and a value. Pushing an-
3. Press the "M" button once and release. The other time changes the display into 3.47. Re-
word heat will show. leasing the button shows the value in Ohm for
the inching pedal sensor. Eg "0.652."
44
1300 SRM 1358 APC200 Display information
3. Push the "S" button once to start the sensor cal- 7. When the value has been accepted, the display
ibration. brA_’ will show, which is the request shows: donE.’
to enter the pedal up position.
NOTE: Calibration procedure has to be repeated if
4. Make sure to not touch the inching pedal and the ignition is turned ON too early.
push the "S" button.
8. Switch the ignition OFF, when the APC200
5. The display will show brA_ which is the request display indicates that the calibration has been
to fully depress the inching pedal. completed, observe the display, and wait until
all segments no longer light up. When the dis-
play remains OFF, the new calibration has
been entered into the APC200 memory. The
new calibration settings will be lost if the igni-
tion is switched ON too early.
6. Fully depress the inching pedal and press the
"S" button.
TE-Userlink
DESCRIPTION
CONNECTION
45
Diagrams, Schematics or Arrangements 1300 SRM 1358
46
1300 SRM 1358 Diagrams, Schematics or Arrangements
47
Diagrams, Schematics or Arrangements 1300 SRM 1358
48
NOTES
49
Diagrams, Schematics or Arrangements 1300 SRM 1358
50
1300 SRM 1358 Diagrams, Schematics or Arrangements
51
Diagrams, Schematics or Arrangements 1300 SRM 1358
52
1300 SRM 1358 Diagrams, Schematics or Arrangements
Figure 38. Resistor Converter Out Connector C105 of Wire Harness Side Console Cab
53
Diagrams, Schematics or Arrangements 1300 SRM 1358
Pin No. Wire APC200 Wire Description APC200 Pin Mating Connector
No. Name Code Pin Figure Description
A1 394B PPWR Permanent Battery Plus A1 C380 10 --- Fuse Panel
B1 482 VFSO+ VFS Forward Hi Side Out B1 C60 16 See Cab Signals
Figure 42
C1 483 VFSO- VFS Forward Lo Side Out C1 C60 17 See Cab Signals
Figure 42
D1 486 VFS1+ VFS 2nd VFS Hi Side Out D1 C60 21 See Cab Signals
Figure 42
E1 487 VFS1- VFS 2nd Lo Side Out E1 C60 31 See Cab Signals
Figure 42
F1 480 VFS2+ VFS Rev Hi Side Out F1 C60 9 See Cab Signals
Figure 42
G1 481 VFS2- VFS Rev Lo Side Out G1 C60 12 See Cab Signals
Figure 42
H1 484 VFS3+ VFS 1st/3rd Hi Side Out H1 C60 18 See Cab Signals
Figure 42
J1 485 VFS3- VFS 1st/3rd Lo Side In J1 C60 19 See Cab signals
Figure 42
K1 488 DO0 Total Neutral Solenoid + K1 C60 37 See Cab Signals
Figure 42
A2 490 ANIO Pressure Feedback A2 C60 39 See Cab Signals
Switch + Figure 42
B2 809 DIGIN0 Shift Lever 1st B2 C130 5 See Under Floor
Figure 44
C2 811 DIGIN1 Shift Lever 2nd C2 C130 7 See Under Floor
Figure 44
54
1300 SRM 1358 Diagrams, Schematics or Arrangements
Pin No. Wire APC200 Wire Description APC200 Pin Mating Connector
No. Name Code Pin Figure Description
D2 878 DIGIN2 Seat Occupied, Switch D2 C480 6C --- Relays
Relay
E2 --- DO1 Not Used E2 --- --- --- ---
F2 492 DO2 1st/3rd Selector solenoid F2 C60 53 See Cab Signals
Figure 42
G2 --- DIGIN3 Not Used G2 --- --- --- ---
H2 807b DIGIN4 Shift Lever Forward H2 C130 3 See Under Floor
Figure 44
J2 808c DIGIN5 Shift Lever Reverse J2 --- --- --- Relay Panel
K2 489 DO3 Total Neutral Solenoid - K2 C60 38 See Cab Signals
Figure 42
A3 645 GND Transmission ECM A3 C70 3 See Cab Supplies
Ground Figure 43
B3 417 SSO+ Drum Speed Sensor + B3 C60 41 See Cab Signals
Figure 42
C3 418 SSO- Drum Speed Sensor - C3 C60 42 See Cab Signals
Figure 42
D3 419 SS1+ Output Speed Sensor + D3 C60 43 See Cab Signals
Figure 42
E3 433 SS1- Output Speed Sensor - E3 C60 44 See Cab Signals
Figure 42
F3 434 SS2+ Engine Speed Sensor + F3 C60 45 See Cab Signals
Figure 42
G3 435 SS2- Engine Speed Sensor - G3 C60 46 See Cab Signals
Figure 42
H3 436 ANI1 Transmission H3 C60 47 See Cab Signals
Temperature Figure 42
J3 477b ANI2 Converter Out J3 C105 2 See Resistors
Temperature Figure 38 'Converter
Out'
K3 478c SGND Ground K3 C60 11 See Cab Signals
Figure 42
55
Diagrams, Schematics or Arrangements 1300 SRM 1358
56
1300 SRM 1358 Diagrams, Schematics or Arrangements
Figure 40. APC 200 Connector C110 of Wire Harness Side Console
Figure 41. Armrest Connector C80 of Wire Harness Cab Side Console
Figure 42. Cab Signals Connector C60 of Wire Harness Cab Side Console
57
Diagrams, Schematics or Arrangements 1300 SRM 1358
Figure 43. Cab Supplies Connector C70 of Wire Harness Cab Side Console
Figure 44. Under Floor Connector C130 of Wire Harness Cab Side Console
58
1300 SRM 1358 Diagrams, Schematics or Arrangements
Figure 45. Transmission Diagnostic Connector (Tuning Link) C415 of Wire Harness Side Console Cab
59
Diagrams, Schematics or Arrangements 1300 SRM 1358
Figure 46. Diagnostic Plug C535 of Wire Harness Side Console Cab
60
NOTES
61
Diagrams, Schematics or Arrangements 1300 SRM 1358
62
1300 SRM 1358 Diagrams, Schematics or Arrangements
63
Diagrams, Schematics or Arrangements 1300 SRM 1358
64
1300 SRM 1358 Diagrams, Schematics or Arrangements
65
Diagrams, Schematics or Arrangements 1300 SRM 1358
66
1300 SRM 1358 Diagrams, Schematics or Arrangements
67
Diagrams, Schematics or Arrangements 1300 SRM 1358
Figure 53. Converter Out Temperature Connector C330 of Wire Harness Frame
68
1300 SRM 1358 Diagrams, Schematics or Arrangements
69
Diagrams, Schematics or Arrangements 1300 SRM 1358
70
1300 SRM 1358 Diagrams, Schematics or Arrangements
Figure 57. Side Console Connector C10 of Wire Harness Under Floor
71
Diagrams, Schematics or Arrangements 1300 SRM 1358
Figure 58. MONOTROL Pedal Connector C30 of Wire Harness Cab Under Floor
Figure 59. Steering Column Connector C60 of Wire Harness Under Floor
72
1300 SRM 1358 Diagrams, Schematics or Arrangements
Figure 60. Inching Pedal Connector C90 of Wire Harness Under Floor
73
Diagrams, Schematics or Arrangements 1300 SRM 1358
74
1300 SRM 1358 Diagrams, Schematics or Arrangements
Figure 62. Cab Under Floor Connector C10 of Wire Harness Steering Column
75
Diagrams, Schematics or Arrangements 1300 SRM 1358
Figure 63. Transmission Lever Connector C50 of Wire Harness Steering Column
76
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