TE-17 TRANSMISSION

DESCRIPTION & OPERATION,

WITH FULL FLOW VALVE
H25-32XM-12, H25-30XMS-9
(H550-700HD, H550-700HDS) [G008]

PART NO. 4067208 1300 SRM 1602

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Upda-
ted technical service information may be available from your local authorized Hyster® dealer. Service Manuals pro-
vide general guidelines for maintenance and service and are intended for use by trained and experienced technicians.
Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in dam-
age to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being
lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Dis-
connect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON
BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifi-
cations of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.

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

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

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

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
TE-17 Transmission Table of Contents

TABLE OF CONTENTS

General ......................................................................................................................................................................................... 1
Description ................................................................................................................................................................................... 1
General .....................................................................................................................................................................................1
Operation ...................................................................................................................................................................................... 3
Hydraulic Operation ................................................................................................................................................................ 3
Clutch Release ......................................................................................................................................................................... 6
Neutral Selection ..................................................................................................................................................................... 6
Cooling and Lubrication .......................................................................................................................................................... 6
Control System ............................................................................................................................................................................. 7
General .....................................................................................................................................................................................7
APC216 Controller .................................................................................................................................................................. 7
Self Test .............................................................................................................................................................................. 8
Protection Modes ................................................................................................................................................................ 8
Limp Home Mode .......................................................................................................................................................... 8
Shut Down Mode ........................................................................................................................................................... 8
Transmission Exceed Codes .......................................................................................................................................... 8
Fault Codes ......................................................................................................................................................................... 8
Description ..................................................................................................................................................................... 8
Fault Log Mode ...................................................................................................................................................................9
Access ............................................................................................................................................................................ 9
Exit ................................................................................................................................................................................. 9
Clear ............................................................................................................................................................................... 9
Fault Rectification ...............................................................................................................................................................9
Transmission Control Valve .................................................................................................................................................. 10
Transmission Control Valve Repair ..................................................................................................................................12
Oil Pressure Check ............................................................................................................................................................13
Check by Air Pressure ...................................................................................................................................................... 13
Pressure Specifications ..................................................................................................................................................... 16
Pressure, Speed, and Temperature Sensors ........................................................................................................................... 17
Pressure Sensor ................................................................................................................................................................. 17
Test ...............................................................................................................................................................................17
Speed Sensor .....................................................................................................................................................................17
Test ...............................................................................................................................................................................19
Temperature Sensors .........................................................................................................................................................19
Test ...............................................................................................................................................................................20
Dana Dashboard Software ..........................................................................................................................................................20
Description .............................................................................................................................................................................20
Connection .............................................................................................................................................................................20
Transmission Test and Calibration .............................................................................................................................................20
Precautions .............................................................................................................................................................................20
Stall Test ................................................................................................................................................................................ 21
Description ........................................................................................................................................................................21
Stall Test Procedure .......................................................................................................................................................... 21
Inching Calibration ................................................................................................................................................................ 21
Description ........................................................................................................................................................................21
Brake and Inching Pedal Adjustment ............................................................................................................................... 22
Inching Pedal Sensor Adjustment .....................................................................................................................................22
Inching Pedal Sensor Calibration ......................................................................................................................................23
Electrical Specifications ............................................................................................................................................................. 23
APC216 Display Information .....................................................................................................................................................24

©2013 HYSTER COMPANY i

Table of Contents TE-17 Transmission

TABLE OF CONTENTS (Continued)

General ...................................................................................................................................................................................24
General Information Group ................................................................................................................................................... 25
Fault Codes ............................................................................................................................................................................ 26
Indication of Protection Modes ............................................................................................................................................. 26
Test Function Group .............................................................................................................................................................. 26
Digital Input Test ...................................................................................................................................................................27
Analog Input Test .................................................................................................................................................................. 28
Speed Sensor Test ..................................................................................................................................................................29
Output Test ............................................................................................................................................................................ 30
Voltage Test ...........................................................................................................................................................................31
Calibration Group .................................................................................................................................................................. 33
Calibration Mode .............................................................................................................................................................. 33
Clutch Filling Calibration ................................................................................................................................................. 34
Heat Up Mode ...................................................................................................................................................................34
Inching Pedal Sensor Calibration ......................................................................................................................................35
Inching Pedal Sensor Adjustment ................................................................................................................................ 35
Inching Pedal Sensor Calibration .................................................................................................................................35
Transmission Wiring Diagram ................................................................................................................................................... 36

This section is for the following models:

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

ii
1300 SRM 1602
General
This manual provides information on the operation and
diagnostics of the TE17 transmission with Full Flow Valve
as equipped on the G008 series lift trucks.
Note that for G008 trucks the indication 'Forward' and
'Reverse' needs to be considered for the transmission and
for the truck separately.
The reason is that the G008 drive axle input shaft requires
an opposite direction of rotation compared with the normal
rotation of the transmission output shaft.
To achieve that the truck moves according the position of
the shift lever or MONOTROL pedal, the APC216
software for G008 has been changed. The changed
programming causes the APC216 to send an output signal
to the solenoid which has the opposite direction compared
with the input signal for forward or reverse.
The indication 'forward' and 'reverse' has been retained for
pressure ports, clutches, solenoids, electrical connections
and fault codes.
Description
GENERAL
The transmission transfers engine power from the engine
flywheel to the drive wheels, and to the hydraulic pumps
that are attached to the transmission.
The engine flywheel is connected to the torque converter
through drive plates. See Figure 1.
The flexing properties of the drive plate reduce transfer of
axial forces between the engine crankshaft and the torque
converter. A gear on the torque converter housing drives
the transmission pump and the attached pumps for the lift
truck hydraulic system. The torque converter housing,
transmission, and attached pumps turn at proportional en-
gine speed.
The oil pressure generated by the transmission pump is
used for lubrication, internal cooling, and hydraulic control
of the transmission. Without oil pressure, the transmission
cannot function.
The torque converter hydraulically connects the engine fly-
wheel with the transmission input shaft. It functions as a
fluid clutch to smoothly transfer power from the engine to
General
When doing repairs or ordering spare parts, remember that
activating the forward clutch on G008 trucks causes the lift
truck to move in reverse direction, and activating the
reverse clutch causes the truck to move in forward
direction.
The repair procedures for the transmission and the control
valve are shown in TE-13 & TE-17 Transmission Repair
1300SRM1603.
For electrical system diagrams, see the Diagrams manual
for your lift truck.
For electrical connectors, see the Electrical System manual
for your lift truck.
the transmission, and as a torque multiplier when speed dif-
ference between engine and transmission input shaft increa-
ses. The torque converter has a specific torque multiplica-
tion factor which matches the engine power characteristics.
Speed difference between engine and transmission input
shaft is a measure of engine power being transferred.
With increasing speed difference (= increasing stall), also
an increasing amount of heat is generated in the converter.
The heat generated is removed by the transmission lubrica-
tion oil, which flows through the torque converter. How-
ever, oil flow through the torque converter is strongly re-
duced under stall conditions, which raises oil temperature
in the converter even further. A temperature switch at the
converter exit port provides protection against overheating
by sending a signal to the transmission controller to have
the clutches released. Resulting load removal and reinstate-
ment of the oil flow will lower oil temperature. When oil
temperature is acceptable again, the controller will allow
re-engagement of the clutches.
1
Description 1300 SRM 1602

The different speed ratios between input shaft and drive

shaft are obtained by engaging and disengaging the differ-
ent clutches. Clutch engagement is controlled by the
APC216 Control System, which activates and deactivates
solenoids in the control valve.

Three groups of gears are continuously engaged with each

other: the input gears, the interconnecting gears, and the
output gears. See Figure 2.

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

Figure 2. Gear Engagement

If clutches belonging to one group would be engaged si-

multaneously, the transmission would lock. Erroneous
clutch engagement is prevented by the transmission control
system.

Different speeds are obtained by engaging either the for-

ward or the reverse clutch, and by engaging the 1st, 2nd, or
3rd speed clutch.

When the transmission is in NEUTRAL, the forward

clutch and the reverse clutch are disengaged, while one of
the speed clutches remains engaged.

The clutches consist of a hub which carries friction discs

with internal splines, and a drum which carries steel discs
1. DRIVE PLATE with external splines. See Figure 3.
2. TORQUE CONVERTER
3. PUMP DRIVE GEAR The friction discs and the steel discs are alternately instal-
4. TRANSMISSION PUMP led. By pressurizing the clutch piston, the friction discs and
5. INPUT GEAR
6. INTERCONNECTING GEAR the steel discs are clamped together, which causes the hub
7. CLUTCH and the drum to rotate as one unit. When hydraulic pressure
8. TRANSMISSION FILTER is released, the return springs force the piston back against
9. TRANSMISSION INPUT SHAFT the clutch housing and allows the hub and drum to rotate
independently. The drum, steel discs, piston, spacer, and re-
Figure 1. Transmission Input Section
turn springs rotate at the same speed. The hub and friction
discs rotate at the same speed.

2
1300 SRM 1602 Operation

1. INTERCONNECTING GEAR 9. CLUTCH HUB, FWD GEAR

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

Figure 3. Clutch Components

Operation
HYDRAULIC OPERATION
The transmission sump is the main reservoir for the trans-
mission oil. The sump screen keeps large particles from en-
tering 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 28.5 to 31.5 bar (413.3 to 456.8 psi) pressure regulator
valve. See Figure 4.
The 28.5 to 31.5 bar (413.3 to 456.8 psi) pressure regulator
valve regulates system pressure, by relieving excess oil
through the torque converter, oil cooler, and lubrication
system. See Cooling and Lubrication. System pressure is
used to fill and pressurize the clutches.
System pressure is admitted to the clutches through propor-
tional valves and selector valves, which receive electrical
signals from the APC216.
The proportional valves admit and release oil pressure ac-
cording a varying signal from the APC216. The varying
signal allows a controlled engagement and release of the
clutches. To dampen hydraulic vibration, the oil channels
directly after the proportional valves have each been provi-
ded with a dampening spool.
In the supply channels for the speed clutches (1st/3rd and
2nd gear) the actual clutch pressure is measured by a sen-
sor. The APC216 uses this pressure signal and the signals
from speed sensors to control engagement and release of
the different clutches during shifting.

3
Operation
If the APC216 does NOT receive the proper signals, then
the proportional valves will be deactivated, causing all
clutches to release immediately.
The selector valves receive an ON or OFF signal to divert
pressure to the correct clutch.
• The 1st/3rd selector valve diverts pressure to the 1st
clutch when activated.
• The 1st/3rd selector valve diverts pressure to the 3rd
clutch when NOT activated.
• The Forward/Reverse selector valve diverts pres-
sure to the Forward or Reverse clutch, according ac-
tivation of the relevant solenoid.
4
1300 SRM 1602
When the signal is OFF, the Forward/Reverse selector
valve is in the neutral position, draining both the forward
and reverse clutches and blocking any pressure supply from
the proportional valve.
Table 1provides an overview of the activated solenoids and
clutches for the different transmission speeds. Neutral se-
lection 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.
1300 SRM 1602 Operation

Figure 4. Hydraulic Diagram

5
Operation 1300 SRM 1602

Legend for Figure 4

NOTE: THE CIRCLED NUMBERS IN THE HYDRAULIC DIAGRAM REFERENCE MEASURE POINT PORTS.

A. LUBRICATION C. HIGH PRESSURE

B. LOW PRESSURE D. DRAIN
1. CONTROL VALVE 2. DAMPING SPOOL

CLUTCH RELEASE • Park brake engagement.

When clutch pressure is released, the clutch spring returns
the piston into the clutch housing and pushes hydraulic oil
back to sump through the shift spool. For an improved
clutch release of the 1st speed clutch, a 0.9 mm hole has
been drilled in its piston. The volume of oil escaping
through this hole during clutch engagement is irrelevant
compared with oil supply capacity.
• Fully depressed inching pedal.
• Seat NOT occupied.
• Sensor inputs causing the APC216 controller to en-
gage neutral.
NOTE: Trucks equipped with a MONOTROL® pedal do
not have a shift lever with a neutral position.

NEUTRAL SELECTION NOTE: The transmission will automatically shift to neu-

Neutral selection is obtained by disengaging both the for-
ward clutch and reverse clutch. The signal from the
APC216 controller to select neutral is generated by each of
the following inputs:
tral a few seconds after the operator has left the seat.
NOTE: The speed clutch will remain engaged according
to the position of the gear shift lever, or will engage accord-
ing to the gear selection made by the automatic drive mode.

• Neutral position of the gear shift selector.

Table 1. Gear Selection and Activated Valves for VFS Control Valve

Direction Speed Activated Proportional Valves Activated Selector Valves Activated Clutches
Forward 1st FWD/REV + 1st/3rd Forward + 1st Forward + 1st
Forward 2nd FWD/REV + 2nd Forward + 2nd Forward + 2nd
FWD/REV
Forward 3rd 1st/3rd Forward Forward + 3rd
Neutral 1st ----- 1st 1st
Neutral 2nd ----- 2nd 2nd
Neutral 3rd ----- ----- 3rd
Reverse 1st FWD/REV + 1st/3rd Reverse + 1st Reverse + 1st
Reverse 2nd FWD/REV + 2nd Reverse + 2nd Reverse + 2nd
FWD/REV
Reverse 3rd 1st/3rd Reverse + 3rd Reverse + 3rd

COOLING AND LUBRICATION
Heat is primarily generated at the torque converter and at
the clutch plates during transmission operation. The heat
generated by mechanical friction at gears, shafts and bear-
ings is relatively low.
power is transferred into heat. This heat accumulates in the
torque converter because of the reduced oil flow during a
stall situation. With increasing turbine speed, the volume of
added heat reduces, while simultaneously the increased oil
flow more rapidly transfers the accumulated heat.

Heat generated in the torque converter relates directly to

the degree of stall, i.e. the speed difference between engine
and turbine. In a stall situation most of the supplied engine

6
1300 SRM 1602
Heat generated at the clutch plates varies with the actually
available engine power at time of clutch engagement and
the duration of clutch engagement. During normal opera-
tion, the transmission control system determines the dura-
tion of clutch engagement. During inching it is the driver
who controls the added heat in the clutch by varying engine
power and clutch engagement. The transmission control
system will close the forward or reverse clutch when a cer-
tain amount of generated heat has been exceeded.
Only a minor portion of the total transmission pump supply
is used for clutch filling. The majority of transmission oil
supply is used for the cooling and lubrication circuit that
functions at a pressure that is lower than system pressure.
See Hydraulic Diagram. The pressure regulator valve ad-
mits oil that is not required for clutch filling. The safety
valve reduces oil pressure to 9 bar (131 psi) to protect the
torque converter and oil cooler. The normal oil flow is
through the torque converter, the transmission oil cooler
and to the transmission lubrication port. The volume of oil
and the oil flow resistance causes that the initial
9 bar (131 psi) supply pressure is reduced to 1.55 to
Control System
GENERAL
The control system of the transmission consists of the
APC216 controller, several switches, and sensors. The sen-
sors provide information to the APC216 controller and to
the hydraulic control valve, which regulates pressures ac-
cording to signals from the APC216 controller.
Note that for G008 trucks the indication 'Forward' and 'Re-
verse' needs to be considered for the transmission and for
the truck separately.
The truck moves according the position of the shift lever or
MONOTROL pedal, but the signals forward and reverse
have been swapped with the transmission functions forward
and reverse. The indication 'forward' and 'reverse' for trans-
mission components is still identical to the original nomen-
clature of the manufacturer.
When doing repairs or ordering spare parts, remember that
activating the forward clutch on G008 trucks causes the lift
truck to move in reverse direction, and activating the re-
verse clutch causes the G008 truck to move in forward di-
rection.
Control System
2.25 bar (22.4 to 32.6 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 1500 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 in-
stalled between the torque converter outlet port and the
transmission radiator. The thermostat starts opening at
87°C (188.6°F) and is completely opened at
102°C (188.6°F). At temperatures below 87°C (215.6°F),
oil flow is directly returned to the transmission. At temper-
atures above 102°C (215.6°F), the entire oil flow from the
outlet port passes through the transmission radiator before
it is returned to the transmission.
APC216 CONTROLLER
The APC216 controller has software that controls the oper-
ation of the transmission and performs the following func-
tions:
• Self-testing and troubleshooting.
• Functional control of the transmission.
- Automatic shifting gear selection.
- Inching.
• Entering a protection mode when required:
- Improper pressures, temperatures, and
speeds.
- No operator present.
- Parking brake applied.
- Gear or direction change at improper speeds.
• Logging a fault code when circumstances have ex-
ceeded certain values.
• Allowing diagnostics and calibration with a laptop
(Dana Dashboard software).
7
Control System
Depending on the signals of the shift lever and various
switches and sensors, the APC216 controller activates or
deactivates the solenoids and VFS in the control valve,
which transfer hydraulic oil pressure to the clutches in the
transmission. If an input signal does not comply with the
programming of the APC216, the APC216 controller will
record the fault and react by activating a protection mode.
All recorded events are stored as fault codes and are shown
on the hourmeter/fault code display when the fault occurs.
Faults can also be retrieved and read at a later time, making
it possible to trace intermittent problems.
Protection modes and self tests are part of the APC216 pro-
gramming and cannot be influenced.
The APC216 controller is located in the side console of the
cab and has a display and push buttons to call off informa-
tion. Normally, the gauges and displays on the instrument
panel are used to read transmission-related information. For
diagnostics and settings, it is recommended to use the Dana
Dashboard software system. Refer to APC216 Display In-
formation for the instructions on how to access and retrieve
information from the APC216 controller when the Dana
Dashboard software is not available.
Self Test
A series of checks is done at power-up. If the APC216 con-
troller fails these checks, it will shut off all outputs. The
transmission cannot be operated until the problem is re-
solved or repaired. A fault code will be displayed.
Protection Modes
Limp Home Mode
The transmission shifts to NEUTRAL if a fault is detected
on the following:
• Outputs for solenoids, VFS, or pressure switch
• Engine speed sensor
• Two out of three transmission speed sensors (tur-
bine, drum, or output speed sensor).
To continue driving, place the shift lever in NEUTRAL,
and reengage a direction. When Limp Home Mode has
been entered, the user can operate the transmission in either
direction in 1st and 2nd gear only, and inching is disabled.
Shut Down Mode
If an intolerable combination of faults is detected, the Shut
Down Mode will be entered. The APC216 controller puts
the transmission in NEUTRAL by putting all VFS signals
8
1300 SRM 1602
at zero pressure and by switching OFF the total neutral sol-
enoid, cutting off pressure to the clutches. Intolerable faults
are also referred to as Redundant Shutdown Path (RSP) er-
rors.
Transmission Exceed Codes
During operation of the lift truck, the APC216 controller
may display transmission exceed codes on the hourmeter/
fault code display. These exceed codes show that the re-
quest made by the operator will not be executed because of
certain circumstances. APC200 Fault Code Guide
1300SRM1435 lists the transmission exceed codes with a
description of the encountered circumstances.
Fault Codes
Description
Under normal conditions, the hour meter/fault code display
on the instrument cluster shows engine running hours. The
maximum hours that can be displayed is 9999.9 hours.
• Hourmeter reading
If the engine and/or transmission controller detects a fault,
the hourmeter/fault code display will show a fault code in-
stead of the engine running hours.
Fault codes starting with E’ refer to engine fault codes.
• Fault code number(s)
Fault codes starting with t’ refer to transmission exceed and
fault codes, which are listed in APC200 Fault Code Guide
1300SRM1435.
When more than one fault occurs at the same time, the fault
codes will be displayed in succession. When circumstances
have changed and all faults have ceased to exist, the hour
meter/fault code display will show engine running hours
again.
1300 SRM 1602
Fault code E-CON and t-CON indicate a communication
problem.
Display fault code E-CON is shown when the following oc-
curs:
• The engine controller does not reply to the engine
identification request or request for fault codes.
• The engine controller stops sending one of the regu-
lar messages, such as engine RPM or engine coolant
temperature.
Display fault code t-CON is shown when the instrument
cluster does not receive a cyclic message or receives incor-
rect error messages from the APC216 controller.
Fault codes that appear as tE123 are for faults that occur
during calibration of the transmission.
Fault Log Mode
Access
The instrument cluster has a memory that records each fault
as it occurs. The faults that have occurred can be reviewed
at a later point in time by entering into the fault log mode.
Proceed as follows to enter into the fault log mode:
1. Apply the parking brake.
2. Turn the key switch to ON, but do not start the lift
truck.
3. Turn the key switch OFF and ON three times, switch-
ing one time per second. After the first OFF and ON
cycle, the display will show a 1’. After the second
OFF and ON cycle, the display will show a 2’. After
the third OFF and ON cycle, the display will show a
3’.
The display is now in fault log mode. When no faults have
been recorded, the LCD display shows clear’. When faults
have been recorded, the display shows a letter and four
numbers for each fault code. For engine fault codes, the let-
ter is E’. For transmission fault codes, the letter is t’.
After the fault code, three numbers are shown which repre-
sent the following:
• Fault code
• Hourmeter reading at last occurrence
Control System
• Hourmeter reading at first occurrence
• Number of occurrences of current fault
Each number is shown for three seconds, after which the
following number is shown. The faults will be shown in the
opposite sequence of occurrence: the most recent fault first
and the initial fault last. When all recorded fault codes have
been shown, the display will continue to repeat the recor-
ded fault codes until the user exits the fault log mode.
Exit
To exit the fault log mode, turn the key switch OFF and
then ON, leaving the key switch ON for more than two sec-
onds. The cluster will also exit to normal mode when the
parking brake is released or when the engine is started.
Clear
To clear the fault codes logged in the display, proceed as
follows:
1. Access the fault log mode. See Access.
2. Clear the fault log by cycling the ignition key OFF and
ON three more times. This is a repetition of the proce-
dure to access the fault log mode. See Access.
If the data-erasing process is successful, the display will
show 'clear'. If the data-erasing process is not successful,
the display will show the fault codes in the memory, shown
in the order by the time of the occurrence. To return to the
normal mode, follow the procedure as described in Exit. To
retry erasing stored fault codes, follow Step 2 of the proce-
dure to clear fault codes.
Fault Rectification
Fault codes are listed in APC200 Fault Code Guide
1300SRM1435, which provides an explanation of the fault,
the resulting action of the APC216 controller, and checks
for troubleshooting. Each fault code represents a specific
defect or malfunction.
In most cases, the suggested solution is to check electrical
functionality between the APC216, the wiring and sensors,
solenoids, or switches.
9
Control System
Before disassembling components for test purposes, con-
nect the Dana Dashboard software. The screen Dashboard-
Monitor’ allows verification of the functionality of speed
sensors, the pressure switch, and the shift lever. If several
possible defects are indicated, Dana Dashboard software
may narrow down the number of possible defects, prevent-
ing unnecessary removal of components that function cor-
rectly.
To rectify problems with switches, solenoids, and sensors,
look up their actual location, and test the component. The
location of the solenoids are shown in the section Trans-
mission Control Valve. The location of sensors and
switches are shown in the section Pressure, Speed, and
Temperature Sensors. Test values of solenoids and sensors
are shown in the section Table 6.
Note that the Dana Dashboard software and the APC200
Fault Code Guide 1300SRM1435 have wire references
and input references that relate to the APC216.
Refer to Table 13 for the conversion from APC216 wire
numbers to Hyster wire numbers.
To determine the exact location of a harness problem, refer
to the APC200 Fault Code Guide 1300SRM1435.
TRANSMISSION CONTROL VALVE
Note that for G008 trucks the indication 'Forward' and 'Re-
verse' needs to be considered for the transmission and for
the truck separately.
10
1300 SRM 1602
The truck moves according the position of the shift lever or
MONOTROL pedal, but the signals forward and reverse
have been swapped with the transmission functions forward
and reverse. The indication 'forward' and 'reverse' for trans-
mission components is still identical to the original nomen-
clature of the manufacturer.
When doing repairs or ordering spare parts, remember that
activating the forward clutch on G008 trucks causes the lift
truck to move in reverse direction, and activating the re-
verse clutch causes the G008 truck to move in forward di-
rection.
The transmission control valve is located at the front of the
transmission. It contains the pressure sensors, all solenoids
and most of the check ports.
Functioning of the control valve depends on available
pump supply pressure and the activation of the electrical
solenoids by the APC216 controller.
A hydraulic schematic of the control valve is included in
the Hydraulic Diagram. See Figure 4.
The transmission control valve consists of two separator
plates, the regulator valve and the full flow valve. See Fig-
ure 5
1300 SRM 1602 Control System

1. GASKET 3. REGULATOR VALVE

2. SEPARATOR PLATE 4. FULL FLOW VALVE

Figure 5. Control Valve Components

The function of the separator plates is to provide the proper The Regulator Valve houses all pressure regulating valves.
hydraulic connection between transmission housing, regu- See Figure 6. The filter by-pass valve is incorporated in the
lator valve and full flow valve. filter element.

1. SAFETY VALVE, 9 bar (131 psi) 4. PRESSURE REGULATOR, 28.5 TO

2. PORT 12, FROM COOLER 31.5 bar (413.3 TO 456.8 psi)
3. CONVERTER BYPASS VALVE, 5 bar (73 psi) 5. SUMP TEMPERATURE SENSOR
Figure 6. Regulator Valve Components

11
Control System 1300 SRM 1602

The Full Flow Valve houses all solenoids and pressure sen-
sors. See Figure 7 and Table 2. The pressure sensors meas-
ure applied pressure in the clutches for 1st, 2nd and 3rd
gear. The pressure signal is used by the APC216 to control
activation of the proportional solenoids. Activation of the
selector valve solenoids is through an on/off signal from
APC216.

Figure 7. Solenoid Locations

Table 2. Solenoid Description

Connector Description
1. CPS177 Reverse Selector Solenoid
2. CPS176 Forward Selector Solenoid
3. CPS167 1st/3rd Gear Selector Solenoid
4. CPS168 1st/3rd Gear Proportional Solenoid
5. CPS174 Forward/Reverse Proportional Solenoid
6. CPS175 2nd Gear Proportional Solenoid
7. CRP14 2nd Gear Pressure Sensor
8. CRP13 1st/3rd Gear Pressure Sensor

Transmission Control Valve Repair For details on control valve repairs or replacement, refer to
the manual TE-13 & TE-17 Transmission Repair
Repairs to the control valve are limited to replacing sole- 1300SRM1603.
noids and gaskets. Hydraulic components of the control
valve may be inspected, but cannot be adjusted and are not
available for replacement.

12
1300 SRM 1602 Control System

Oil Pressure Check

Most of the transmission oil pressures can be measured at

the side of the control valve. See Figure 9, which lists the
check port numbers and their descriptions. Additional
check ports for transmission oil pressures are at different
locations on the transmission. See, Figure 10, Figure 11,
Figure 12, and Table 4. The port numbers mentioned at
each check port correspond with the port numbers as shown
in Figure 4. Figure 4 also shows the nominal pressure val-
ues.

The oil pressures are not adjustable. If a pressure is out of

specification, its cause must be established. If a pressure re-
ducing valve causes the problem, replace the spring and or
the spool. If the failure persists, it may be necessary to re-
place the entire regulator valve

Check by Air Pressure

1. REGULATOR 4. 2ND CLUTCH
2. 3RD CLUTCH 5. REVERSE
It is possible to use air pressure to establish clutch piston 3. FORWARD 6. 1ST CLUTCH
movement and / or obvious piston leaks.
Figure 8. Transmission Control Valve Ports
Air pressure should be approximately 14 bar (200 psi).
Temporarily remove the transmission breather to avoid ac-
cidental pressurization of the transmission housing. Re-
move air pressure supply immediately when a big internal
leak is apparent.

When applying air pressure to the clutch test ports, make

sure that the related solenoids for selector valves and pro-
portional valves are activated and that the system pressure
supply line is sufficiently filled with oil.

With the transmission control valve removed, air pressure

can be applied to the clutch ports indicated in Figure 8.

13
Control System 1300 SRM 1602

Legend Port Description

Item No. Number
1. 45 Forward Clutch Pressure
2. 46 Reverse Clutch Pressure
3. 33 Pressure Cooler Return
4. 43 3rd Clutch Pressure
5. 31 System Pressure
6. 42 2nd Clutch Pressure
7. 66 FWD/REV Regulated Pressure
8. 67 1st/3rd Regulated Pressure
9. 41 1st Clutch Pressure

Figure 9. Check Ports, Control Valve

1. TEMPERATURE SWITCH 6. PORT 46, REVERSE CLUTCH

2. TURBINE SPEED SENSOR 7. PORT 45, FORWARD CLUTCH
3. OUTPUT SPEED SENSOR 8. DRUM SPEED SENSOR
4. PORT 46, REVERSE CLUTCH 9. ENGINE SPEED SENSOR
5. PORT 12, FROM COOLER 10. PORT 35, PUMP SUPPLY
Figure 10. Ports and Sensors, Top View

14
1300 SRM 1602 Control System

1. PORT 34, LUBRICATION 5. DRUM SPEED SENSOR

2. BREATHER 6. PORT 46, REVERSE CLUTCH
3. ENGINE SPEED SENSOR 7. PORT 45, FORWARD CLUTCH
4. PORT 35, PUMP SUPPLY 8. SUMP TEMPERATURE SENSOR

Figure 11. Ports and Sensors, Left View

15
Control System 1300 SRM 1602

1. OUTPUT SPEED SENSOR 6. TEMPERATURE SWITCH

2. DAMPING SPOOL 7. PORT 11, TO COOLER
3. PORT 43, 3RD SPEED CLUTCH 8. PORT 34, LUBRICATION
4. PORT 33, COOLER RETURN 9. PORT 32, COOLER SUPPLY
5. TURBINE SPEED SENSOR 10. PORT 37, SAFETY VALVE

Figure 12. Ports and Sensors, Right View

NOTE: The thread for check ports 45 and 46 is M12 x 1.5, ume of oil flowing through the relief valves depends on en-
O-ring. gine speed. Viscosity depends on the oil quality, and de-
creases with higher temperatures. Make sure the oil quality
All other control valve check ports are provided with meets the required specification and has been replaced at
threads M10 x 1, O-ring. the correct interval. Temperature of the oil must be 82 to
93°C (180 to 200°F) for correct pressure measurement. See
Pressure Specifications Table 3 for pressure specifications.

The relief pressures in the transmission are influenced by
the volume and viscosity of the oil passing through the re-
lief valves. Smaller supply volumes and lower viscosity re-
sult in lower system pressures. Larger supply volumes and
higher viscosity result in higher system pressures. The vol-
In the cooling and lubrication circuit, the torque converter
causes additional flow resistance with increasing speed dif-
ference between the engine and the transmission input
shaft.

Table 3. Pressure Specifications

Description Port Pressure Specification

Filter Bypass Valve In Filter Element 4.5 bar (65 psi)
Safety Valve 37 7.5 bar (109 psi) minimum at 600 rpm.
26 bar (377 psi) minimum at 700 rpm.
Regulator Pressure 31
31 bar (450 psi) maximum at 2300 rpm.

16
1300 SRM 1602 Control System

Table 3. Pressure Specifications (Continued)

Description Port Pressure Specification

26 bar (377 psi) minimum at 700 rpm.
Clutch Pressure 41, 42, 43, 45, and 46
30 bar (435 psi) maximum at 2200 rpm.
Torque Converter Out 32 3 to 3.5 bar (43 to 51 psi) at stall speed.
1.5 to 2.3 bar (22 to 33 psi) at 1500 rpm, Neu-
Lubrication Pressure 33
tral selected.

PRESSURE, SPEED, AND
TEMPERATURE SENSORS
Before disassembling components for test purposes, con-
nect the Dana Dashboard software. The screen Dashboard-
Monitor’ allows verification of the functionality of several
components, preventing unnecessary removal of compo-
nents that function correctly.
The location of the speed and temperature sensors are
shown in Figure 10, Figure 11, Figure 12 and Table 4. The
engine speed sensor is located at the pump drive gear. The
schematic location of the turbine, output, and drum speed
sensors is shown in Figure 13.

Table 4. Transmission Housing Pressure Check Ports

Port Number Description Figure Fitting Thread

32 To Cooler Figure 12 M12 x 1.5 O-ring
33 From Cooler Figure 12 M10 x 1 O-ring
34 Lubrication Figure 11 Figure 12 M12 x 1.5 O-ring
35 Pump Supply Figure 10 Figure 12 M12 x 1.5 O-ring
37 Safety Valve Figure 12 M22 x 1.5 O-ring
43 3rd Clutch Figure 12 M10 x 1 O-ring
45 Forward Clutch Figure 10 Figure 12 M12 x 1.5 O-ring
46 Reverse Clutch Figure 10 Figure 12 M12 x 1.5 O-ring

Pressure Sensor Speed Sensor

The function of the pressure sensors is to monitor pressure
overlap on range clutches during shifting.
Test
When system pressure is applied, the internal resistance of
the pressure sensor is about 500 Ohm. The APC216 signals
a fault when the resistance is incorrect for the given cir-
cumstances. Te-Userlink shows the measured resistance
value under Pressure Switch Resistance’. The location of
the pressure switches is shown on Figure 7.
The speed sensors determine the rotation speed of the dif-
ferent gear groups. The APC216 controller calculates the
speed ratios between the different groups and compares the
calculated values with the programmed values. If deviation
exceeds an allowable value, the APC216 controller gener-
ates a fault code and eventually enters a protection mode.
The following are a few examples of speed inputs and ra-
tios that are monitored by the APC216 controller:
• Converter Speed Ratio

Maximum current is 10 mA at a supply voltage between

4.5 and 5.5 Volt and applied pressure of 20 bar (290 psi).

17
Control System
- The ratio between engine speed and turbine
speed is called the converter speed ratio. The
converter speed ratio is a measure of the
power being transferred through the con-
verter. This ratio is a major factor for the
APC216 controller to determine if a higher
or lower gear is to be selected during the au-
tomatic selection mode. During calibration,
a sudden change in converter speed ratio is
used to determine the clutch piston position
at the moment the clutch starts clamping.
• Transmission Ratio
- Each selected transmission gear has a spe-
cific transmission ratio. When one of the di-
rection clutches is closed and the output
speed has reached a certain value for check-
ing, the actual ratio is compared with the
specified ratio. If deviation exceeds 5%, one
of the clutches is assumed to be slipping. A
fault is flagged and the APC216 controller
enters the Shut Down Mode.
• Gear Ratio
A. TURBINE SPEED B. DRUM SPEED
Figure 13. Schematic Speed Sensor Locations
18
1300 SRM 1602
- If the turbine, drum, or output speed sensor
fails, the APC216 controller calculates the
actual ratio’ based on the value of the re-
maining sensors. This allows continued op-
eration of the transmission. Speed sensor
failure is indicated by a fault code. If the en-
gine speed sensor fails, or if more than one
speed sensor fails, the APC216 controller
will enter the Limp Home Mode and flag a
fault.
• Maximum Torque During Inching
- The APC216 programming interprets the in-
ching pedal position as the required pressure
for the inching clutch. The heat generated in
the inching clutch is proportional to the
power transferred by the torque converter
(converter speed ratio). When the power is
transferred at an excessively high level for
an extended period of time, the APC216
controller will release pressure in the clutch
and flag a fault.
C. OUTPUT SPEED
1300 SRM 1602 Control System

Test ure 14 shows the connectors which are used to connect to

Dana Dashboard software shows functionality of each of
the speed sensors under Speed Monitor’. Electrical func-
tionality can be tested by using the schematic shown in Fig-
ure 14. Observe the correct sensor polarity. Pin 1 must be
connected to 12 Volt+. Pin 2 must be connected to 12
Volt-. For the engine speed sensor, pin A must be connec-
ted to 12 Volt+. Pin C must be connected to 12 Volt-. Fig-
the speed sensors. Connecting the sensor with an incorrect
polarity will destroy the sensor. Table 5 shows the accepta-
ble test values. Replace the sensor if it fails the test.
Speed sensors should be installed as close as possible to the
gear. The speed signal will fail if the distance exceeds
1.8 mm (0.07 in.). The sensor mounting bracket normally
ensures correct sensor installation.

Figure 14. Speed Sensor Test

Table 5. Speed Sensor Test Values temperature measured is from the oil return-
ing from filter 1, close to port 31. The signal
Voltage Reading Current Level to the APC216 controller is translated into a
Gear tooth 1.2 volt 6 to 8 mA CANbus signal to the instrument cluster and
sensed represents the transmission sump tempera-
ture. Dana Dashboard software indicates
No gear tooth 2.6 to 3.0 volt 13 to 15 mA
functionality of this temperature sensor un-
sensed
der Transmission sump temperature.’

Temperature Sensors • Torque Converter Out, Port 32

- This temperature sensor is a switch that con-
There are two temperature sensors which measure the tem- nects to ground when the temperature has
perature at two different locations: exceeded 120°C (248°F). The function of
• Pump Supply this temperature switch is to trigger a protec-
tion mode. Functionality can only be tested
- This temperature sensor is combined with by immersing the temperature switch in hot
the engine speed sensor in one unit and is oil, and measuring if it switches at
connected with the APC216 controller 120°C (248°F).
through pin B of the sensor connector. The

19
Dana Dashboard Software 1300 SRM 1602

Test

Shows the electrical resistance values of the sump tempera-

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

Dana Dashboard Software

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

The Dana Dashboard system consists of a laptop computer,

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

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

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

before connecting the Dana Dashboard system to the lift
truck.

Connect the Dana Dashboard software to the lift truck us-

ing the USB interface cable (Hyster P/N 1534010). The lift 1. APC216 CONTROLLER
2. DIAGNOSTIC PLUG
truck connector is located in the side console of the cab.
See Figure 15. Figure 15. APC216 Connector Location

Transmission Test and Calibration

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

20
1300 SRM 1602
To raise the oil temperature, run the engine while stalling
the torque converter as follows:
1. Place the lift truck against an object that cannot move.
2. Apply the brake pedal and release the parking brake.
3. Select the 3rd gear in manual mode.
4. Run the engine at half throttle until the transmission oil
temperature gauge indicates 60°C (140°F).
NOTE: The transmission will shift to NEUTRAL when
the parking brake is applied.
STALL TEST
Description
The stall test provides indications for the condition of the
engine, transmission clutches, and torque converter. The
stall test is performed with the transmission engaged and
the engine operating at full throttle, while the drive wheels
are being blocked. The stall speeds for the engines are as
follows:
• 160 kw engine, Tier 3 - 1,890 to 2,040 rpm
• 186 kw engine, Tier 3 - 1,980 to 2,130 rpm
• 194 kw engine, Tier 4 - 1,900 to 2,050 rpm
Stall Test Procedure
CAUTION
DO NOT hold the throttle open for more than 15
seconds at a time. Permit the engine to operate at
idle speed for 2 minutes between tests.
CAUTION
Release the accelerator immediately if the engine
speed increases to its governed speed of 2,130
rpm.
CAUTION
Performing a stall test in 1st or 2nd gear may
damage the internal parts of the drive axle.
Perform the stall test in 4th gear only.
1. Connect a laptop computer to the diagnostic plug in the
side console. Select the screen to read the engine
speed.
Transmission Test and Calibration
2. Place a capacity load on the forks to prevent the
wheels from turning.
3. Place the lift truck against an object that cannot move.
4. Apply the brake pedal and release the parking brake.
5. Start the engine and select the 3rd gear in manual
mode.
6. Push the accelerator pedal to full throttle.
7. Read the stall speed and release the throttle pedal.
If the stall speed is 50 to 200 rpm below the specification,
the engine is not operating at full power. Check if engine
fault codes are present and repair or correct any indicated
problems.
If the stall speed is higher than the specification, the en-
gaged clutch(es) may not be holding, or the torque con-
verter may be damaged. Check if transmission fault codes
are present and repair or correct any indicated problems.
If no transmission fault codes are present and the stall
speed is considerably higher than the specification, remove
the torque converter for inspection.
If the stall speed is only slightly higher than the specifica-
tion, consider the service life of the torque converter and
decide whether to replace the torque converter immediately
or at a later point in time.
INCHING CALIBRATION
Description
Inching is a controlled traction and braking mode. It ena-
bles higher engine speeds, resulting in increased hydraulic
function speeds, while the lift truck travel speed remains
low. The inching function is obtained by relating the in-
ching pedal position to clutch pressure. The relation be-
tween pedal position and clutch pressure results in the natu-
ral reaction of the operator to depress the inching pedal fur-
ther when the actual lift truck speed is too high. A further-
depressed inching pedal causes the pressure in the slipping
clutch to lower, which reduces lift truck speed regardless of
engine speed. If excessive heat is generated during inching,
the APC200 will release all pressure and show fault code
46.05.
21
Transmission Test and Calibration 1300 SRM 1602

The inching pedal sensor must be calibrated for two pedal 3. Adjust the adjustment bolt for the inching/brake pedal
positions: inching pedal completely depressed, and inching coupling so that the inching pedal has no play. Both
pedal released. Calibration is required when the inching pedals should move together when the inching pedal is
sensor has been replaced, or when it becomes loose. Cali- applied. The additional spring installed under the in-
bration is also required annually, due to wear and creep of ching pedal provides flexibility when adjusting the
pedals and linkages. Before calibrating the inching sensor, brake/inching overlap. See Figure 16 and Figure 17.
verify the adjustment of the brake pedal and the inching
sensor. Incorrect sensor calibration triggers fault codes dur-
ing operation. By slightly varying the free travel of the
brake pedal, it is possible to vary the moment when brakes
are applied. An early brake application will result in exces-
sive heat being generated in the inching clutch and in the
brakes. A delayed brake application results in longer pedal
travel time before the brakes are fully applied. Always
make small adjustments in the free travel of the brake pedal
and make sure there is adequate distance between the ped-
als and the floor plate when the pedals are in the fully-ap-
plied/depressed position.

Brake and Inching Pedal Adjustment

1. Adjust the adjustment bolt located behind the pedal on
the brake pedal assembly so that the roller has contact
with the capscrew on the valve and there is no play.
See Figure 16.

Figure 17. Brake Inching Pedal Adjustment

Inching Pedal Sensor Adjustment

NOTE: When the inching pedal is not activated and in the
released (pedal up) position, the analog output of the in-
ching pedal sensor should be between 600 and 700 mV.

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

quired to achieve the output voltage for the inching pedal in
1. BRAKE PEDAL the released (pedal up) position. Use Dana Dashboard soft-
2. INCHING PEDAL ware to check the output voltage.
3. ADJUSTMENT BOLT FOR BRAKE PEDAL
4. ADJUSTMENT BOLT FOR BRAKE PEDAL COU- 1. Connect a laptop computer to the diagnostic plug in the
PLING side console. See Figure 15.
5. ADJUSTMENT BOLT FOR INCHING PEDAL
2. Turn the key switch to the ON position.
Figure 16. Brake Pedal Assembly
3. Select Inching Pedal Calibration Mode’.
2. Adjust the adjustment bolt located behind the inching
4. Make sure the analog input of the inching pedal sensor
pedal on the inching pedal assembly so that the inching
is between 600 and 700 mV when the pedal is in the
pedal is at the same level as the brake pedal when both
pedal up position.
pedals are in the released (pedal up) position. See Fig-
ure 16.

22
1300 SRM 1602
5. If the analog input is not within specifications, proceed
as follows:
a. Raise the cab until the latch locks in the partially
open position. Refer to the manual Operator's Cab
0100SRM1390.
b. Loosen the two inching pedal sensor-mounting cap-
screws. See Figure 18.
c. Rotate the inching pedal sensor in the slotted holes
located beneath the inching pedal until the output
voltage of the released (pedal up) position inching
pedal is between 600 and 700 mV.
d. Tighten the two sensor-mounting capscrews and
make sure the output voltage of the inching pedal
sensor is between 600 and 700 mV, with the inching
pedal in the released (pedal up) position.
6. Turn the key switch to the OFF position.
7. Disconnect the laptop computer from the diagnostic
plug. See Figure 15.
1. SENSOR-MOUNTING CAPSCREW
2. INCHING PEDAL SENSOR
Figure 18. Sensor Adjustment
Electrical Specifications
Electronically controlled modulation valves:
Fwd/Rev/2nd/1st - 3rd
Coil resistance : 4.35 ±0.35Ω at 25°C (77°F)
ON/OFF solenoids:
Electrical Specifications
Inching Pedal Sensor Calibration
1. Make sure the pedals and the inching sensor have been
correctly adjusted.
2. Connect a laptop computer to the diagnostic plug in the
side console. See Figure 15.
3. Turn the key switch to the ON position.
4. Use the Automatic Calibration’ mode of the Dana
Dashboard program.
5. Select the Inching Pedal Calibration’ mode of the Dana
Dashboard program and follow the instructions.
6. The following must be calibrated with the key switch
in the ON position:
• Fully released pedal (600- 700 mV)
• Fully depressed pedal (2500-4000 mV)
7. Check the inching percentage of the transmission by
using the Dana Dashboard program. When the pedal is
released, the inching percentage should be at 0%. If the
value deviates from 0%, the Inching Pedal Calibration’
process must be repeated.
8. Exit the Dashboard program.
9. Turn the key switch to the OFF position.
10. Disconnect the laptop computer from the diagnostic
plug.
Forward/Reverse and 1st/3rd range solenoids
Coil resistance : 28.5 ±2Ω at 20°C (68°F)
23
APC216 Display Information 1300 SRM 1602

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

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

APC216 Display Information

GENERAL • Test
• Calibration
Note that for G008 trucks the indication 'Forward' and 'Re-
verse' needs to be considered for the transmission and for These display modes provide an alternative method to cali-
the truck separately. brate or obtain information if the Dana Dashboard software
is not available.
The truck moves according to the position of the shift lever
or MONOTROL pedal, but the signals forward and reverse
have been swapped with the transmission functions forward
and reverse. The indication 'forward' and 'reverse' for trans-
mission components is still identical to the original nomen-
clature of the manufacturer.

When doing repairs or ordering spare parts, remember that

activating the forward clutch on G008 trucks causes the lift
truck to move in reverse direction, and activating the re-
verse clutch causes the G008 truck to move in forward di- Figure 19. APC216 Front Panel
rection.

The APC216 controller is located in the side console of the
cab. The APC216 controller has a display and push buttons
to call off information. See Figure 19.
The information is provided by means of codes. The inter-
pretation of these codes depends on the display mode being
activated. The following display modes are available:
• General Information
The LED lamp labeled D’ is yellow and will be ON to indi-
cate diagnostic modes.
The LED lamp labeled E’ is yellow and blinks to indicate
faults.
The LED lamp labeled F’ is red and is ON when the
APC216 is in the reset condition.

24
1300 SRM 1602 APC216 Display Information

The push button marked M’ is used to scroll to one of the After startup, the display will show the sub group that was
three display groups. selected when the APC216 was switched OFF.

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

group within a display group. See Table 7.

GENERAL INFORMATION GROUP

Table 7 shows the structure of the General Information
Group. Figure 20 schematically shows that by pressing the
M button, the display scrolls to the next display group, and
by pressing the S button the display scrolls to the next sub
group. When the M button is pressed to scroll to the next
display group, the display will first show the sub group that
is highest on the display group list (GPoS, or cPoS, or Err).
From the sub group that is highest on the display group list,
it is possible to scroll to sub groups that are lower on the
sub group list. To return to the highest positioned sub
group, press the S button after having reached the lowest
positioned sub group.

To scroll to the next display group, first scroll to the sub

group (GPoS, or cPoS, or Err) that is highest on the display
group list. It will only be possible to scroll to the next dis-
play group by pressing the M button by starting in the
GPoS, cPoS, or Err display group. Figure 20. APC216 Display Groups

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

button. After half a second, the display will show the code
of the sub group, followed by the actual measured value.
See Table 7 for sequence and explanation of the sub
groups.

Table 7. General Information Group

Display Description Explanation Example

Gear, Vehicle Speed, Distance
GPoS Gear Position Shows the actual engaged gear direction (F, R) and range (1, 2, 3). F3
USPd Vehicle Speed Shows the lift truck speed in 0.1 km/hr resolution. 167
diSt Travel Distance Shows the travelled distance in 0.1 km resolution. 1258
Press the S button within 3 seconds to reset to zero.
oPEr Operating Hours Shows the total lift truck running hours in one hour resolution, and has 12.3.4.
a range of 0 to 49999 hours. The number digits show the hours, the
number of dots in between show the number of times 10000 hours
needs to be added to the number shown.
Lever Position, Transmission Speed, Temperature
cPoS Shift Lever Position Shows the current shift lever position (F, R) (1, 2, 3). F3

25
APC216 Display Information 1300 SRM 1602

Table 7. General Information Group (Continued)

Display Description Explanation Example

ESPd Engine Speed Shows the measured engine speed. 1580
tSPd Turbine Speed Shows the measured turbine speed. 885
oSPd Output Speed Shows the measured output speed. 600
SrAt Speed Ratio Shows the speed ratio, and turbine/engine speed. 0.56
T9 | Turbine Torque Shows the measured turbine torque at transmission input side in N•m. 125

ttNP Transmission Temper- Shows the transmission temperature in °C. 65

ature
ctNP Cooler in Temperature Shows the cooler input temperature in °C. 75
Fault Codes
Err Fault Code Shows the transmission fault code number. 31.01

FAULT CODES moment. Once in the Shut Down mode, the APC216 will
already have selected NEUTRAL. The E-LED on the
When the M button is pushed to scroll to the fault code APC216 front panel will be blinking. See Figure 21.
group (Err), the display normally shows - - - -’, to indicate
that no faults are active. When the E-LED is blinking, a
fault is active and will be shown on the display.

If more than one fault has been detected, the most severe
fault will be shown first. Push and release the S button once
to display the next fault code. Figure 21. Indication of Protection Mode

After the last code has been displayed, the display will
show - - - -’. TEST FUNCTION GROUP

Displayed fault codes either appear blinking, or are shown To enter the Test Function Group, press the S button while
uninterrupted. When shown uninterrupted, the fault code is turning the key switch to ON. Release the S button when
active. When blinking, the fault has occurred but is cur- the display shows: 8.8.8.8.’. After releasing the S button the
rently inactive. display will show: diSP’. See Figure 22.

Once an inactive fault code has been displayed, it will not

be shown again. Write down the codes of inactive faults, or
refer to the dashboard display. The memory of the dash-
board display retains all fault codes until its memory has
been cleared.
Figure 22. Test Function Group Mode
INDICATION OF PROTECTION MODES
The Limp Home Mode and Shutdown Mode as described The only way to leave the test function group is by switch-
under Control System’ are only made visible on the ing the key switch to OFF.
APC216 display when it is in the GPoS- or cPoS-mode.
The display shows LH’ for Limp Home, or Sd’ for Shut
Down, and also the direction and the gear selected at that

26
1300 SRM 1602
Figure 23 schematically shows that by pressing the M but-
ton the display scrolls to the next display group, and by
pressing the S button the display scrolls to the next sub
group. When the M button is pressed to scroll to the next
display group, the display will first show the sub group that
is highest on the display group list (diSP, dinP, etc.). Start-
ing from these positions, it will be possible to scroll to sub
groups that are lower on the sub group list. To return to the
highest positioned sub group, press the S button after hav-
ing reached the lowest positioned sub group.
Figure 23. Test Function Group Schematic
DIGITAL INPUT TEST
The APC216 has 10 digital inputs which measure connec-
tivity of the wires listed in Table 8. After the display has
shown dinP’ (see Figure 24), push and release the S button.
The display indicates the active inputs by switching ON
APC216 Display Information
To scroll to the next display group, first scroll to the sub
group (diSP, dinP, etc.) that is highest on the display group
list. Only when starting at diSP, dinP, etc., will it be possi-
ble to scroll to the next display group by pressing the M
button.
Instructions for how to call off information for each test
group are described separately.
certain segments of the display (see Figure 25). The num-
bered segments 0-9 represent the digital inputs DIGIN0
through DIGIN9.
27
APC216 Display Information 1300 SRM 1602

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

Figure 24. Digital Input Test
tal inputs. The display will show the logic input number
with the matching APC216 wire number. The example in
Figure 27 shows that DIGIN0 relates to APC216 wire A12.
Table 13 provides the conversion from APC216 wire num-
bers to Hyster wire numbers.

When releasing the S button, the display shows either hi’ or

In the example shown in Figure 26, the segments 1, 4, and lo’. When the lever switch is making a connection or has a
5 are ON, indicating that DIGIN1, DIGIN4, and DIGIN5 short circuit, hi’ is shown. When the lever switch does not
are active. By moving the selector lever, different segments connect or has an open circuit, lo’ is shown. Unsupported
will be switched ON. connections will show lo’.

Pressing the S button after 9.46 returns the display to dinP’.

Figure 26. Active Digital Inputs

Figure 25. Display Segment Numbers

Table 8. Digital Input Test

Code Wire APC216 Wire Hyster Wire APC216 Pin Wire Description Output
Name Nr Nr Nr
Digital Input Test
0.12 DIGIN0 A12 549-c B2 Shift Lever 1st hi/lo
1.13 DIGIN1 A13 550-c C2 Shift Lever 2nd hi/lo
2.14 DIGIN2 A14 551-a D2 Seat Occupied, Switch Re- hi/lo
lay
3.17 DIGIN3 A17 OPEN G2 OPEN lo
4.18 DIGIN4 A18 553-e H2 Shift Lever Forward hi/lo
5.19 DIGIN5 A19 554-f J2 Shift Lever Reverse hi/lo
6.43 DIGIN6 B13 555-c L3 Start in 2nd Gear hi/lo
7.44 DIGIN7 B14 556-c M3 Automatic/Manual Mode hi/lo
8.45 DIGIN8 B15 938-c N3 Park Brake ON/OFF hi/lo
9.46 DIGIN9 B16 OPEN P3 OPEN lo

ANALOG INPUT TEST

The APC216 has seven analog resistance inputs, which
measure the actual resistance of the sensors listed in Ta-
ble 9.
Figure 27. Digital Input Code

28
1300 SRM 1602 APC216 Display Information

After the display has shown AinP’ (see Figure 28), push
and release the S button. The display will show the value in
kilo Ohm in sequence of each of the four inputs. Values be-
low 1 kOhm are shown as 0’. Each input value is separated
by a dot. See Figure 29.
Press and hold the S button to scroll to the individual ana-
log inputs. The display will show the logic input number
with the matching APC216 wire number. The first input
shows ANI0 and APC216 wire A11. Table 9 provides the
conversion from APC216 wire numbers to Hyster wire
numbers.

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

ance value in Ohms. Pressing the S button after 6.36 returns
the display to AinP.’ See Figure 28.

Figure 28. Analog Input Test

Figure 29. Analog Resistance Values

Table 9. Analog Input Test

Code Wire APC216 Wire Hyster Wire APC216 Pin Wire Description Output
Name Nr Nr Nr
Analog Input Test
0.11 ANI0 A11 569-a A2 Pressure Feedback Switch + Ohm
1.28 ANI1 A28 396-a H3 Transmission Temperature Ohm
2.29 ANI2 A29 386-a J3 Converter Out Temperature Ohm
3.47 ANI3 B17 387-a R3 Inching Pedal Signal Ohm
4.32 ANI4 B02 251-a M1 Inching Pedal Ohm
5.34 ANI5 B04 open P1 open
6.36 ANI6 B06 open S1 open

SPEED SENSOR TEST
The APC216 has four speed sensor inputs which represent
the number of teeth that pass the sensor per second (see Ta-
ble 10). After the display has shown SPd’ (see Figure 30),
push and release the S button. The display will show the
value in kilo-Ohms in sequence of each input. Each value is
separated by a dot.
Press and hold the S button to scroll to the individual ana-
log inputs. The display will show the logic input number
with the matching APC216 wire number. The first sensor is
indicated by 0.22,’ meaning that sensor SS0 relates to
APC216 wire A22. Table 10 provides the conversion of
APC216 wire numbers to Hyster wire numbers.
When releasing the S button, the display shows a c’ to indi-
cate a current type sensor, and a dot and three digits to indi-
cate the frequency in kHz. Figure 31 shows a frequency of
0.933 kHz. Pressing the S button after 3.41 returns the dis-
play to SPd’.

Figure 30. Speed Sensor Test

29
APC216 Display Information 1300 SRM 1602

Figure 31. Measured Frequency

Table 10. Speed Sensor Test

Code Wire Name APC216 Wire Hyster Wire APC216 Pin Wire Description Output
Nr Nr Nr
Speed Sensor Test
0.22 SSO+ A22 391-a B3 Drum Speed Sensor + kHerz
1.24 SS1+ A24 393-a D3 Output Speed Sensor + kHerz
2.26 SS2+ A26 395-a F3 Engine Speed Sensor + kHerz
3.41 SS3+ B11 398-a R2 Turbine Speed Sensor + kHerz

OUTPUT TEST indicated by 0.2’, meaning that VFS0 relates to APC216

The Output Test Group shows the outputs to the VFS sole-
noids and to the ON/OFF solenoids. After the display has
shown outP’ (see Figure 32), push and release the S button.
The display indicates the active outputs by switching ON
certain segments of the display. The numbered segments 0 -
3 represent the outputs for VFS0 - VFS3. Segments 4 - 6
are not used. Segments 7 - 10 represent the outputs for DO0
- DO3.
wire A02. Table 11 provides the conversion of APC216
wire numbers to Hyster wire numbers.
When releasing the S button, the display shows either a
value for VFS solenoids, or hi’/lo’ for ON/OFF solenoids.
The value shown for VFS solenoids is in mA. When the
solenoid is activated, hi’ is shown. When the solenoid is
NOT activated, lo’ is shown.
If an output is currently at fault, the respective segment in
the overview screen blinks slowly. On the output specific
screen the display alternates between mA or hi’/lo’, and a
fault type. Fault types used are Open, Short, Curr, or Oor
(out of range).

Figure 32. Output Test Pressing the S button after 10.20 returns the display to
SPd’.
Press and hold the S button to scroll to the individual out-
puts. The display will show the logic reference number
with the matching APC216 wire number. The first output is

Table 11. Output Test

Code Wire Name APC216 Wire Hyster Wire APC216 Pin Wire Description Output
Nr Nr Nr
Output Test Variable Force Solenoids
0.2 VFSO+ A02 871-a B1 VFS Forward Hi Side Out mA
1.4 VFS1+ A04 873-a D1 VFS 2nd VFS Hi Side Out mA
2.6 VFS2+ A06 875-a F1 VFS Rev Hi Side Out mA

30
1300 SRM 1602 APC216 Display Information

Table 11. Output Test (Continued)

Code Wire Name APC216 Wire Hyster Wire APC216 Pin Wire Description Output
Nr Nr Nr
3.8 VFS3+ A08 877-a H1 VFS 1st/3rd Hi Side Out mA
4.31 VFS4+ B01 OPEN L1 OPEN ---
5.33 VFS5+ B03 OPEN N1 OPEN ---
6.35 VFS6+ B05 OPEN R1 OPEN ---
Output Test ON/OFF Solenoids
7.10 DO0 A10 763-a K1 Total Neutral Solenoid + hi/lo
8.15 DO1 A15 OPEN E2 OPEN lo
9.16 DO2 A16 765-a F2 1st/3rd Selector Solenoid hi/lo
10.20 DO3 A20 766-a K2 Total Neutral Solenoid − hi/lo

VOLTAGE TEST
After the display has shown Volt’ (see Figure 33), push and
release the S button to scroll to one of the three measured
voltages:
• VP’ - Permanent Voltage as measured on APC216 Figure 33. Voltage Test
wire A01.
• VS’ - Switched Voltage as measured on APC216
wire B12. Table 12 provides the conversion of APC216 wire numbers
to Hyster wire numbers.
• VSEn’ - Sensor Voltage as measured at any analog
input.

Pressing the S button after VSEn’ returns the display to

Volt’.

Table 12. Voltage Test

Code Wire Name APC216 Wire Hyster Wire APC216 Pin Wire Description Output
Nr Nr Nr
Voltage Test
VP PPWR A01 950-a A1 Permanent Battery + 24.0 Volt
VS SPWR B12 992-b S2 Switched Battery + 24.0 Volt

Table 13 provides the conversion of APC216 wire numbers

to Hyster wire numbers.

Table 13. APC216 Wire Number to Hyster Wire Number Conversion

APC216 Wire Wire Hyster Wire Color APC216 Pin Wire Description Output
Nr Name Nr Nr
A01 PPWR 950-a red A1 Permanent Battery + 24.0 Volt
A02 VFS0+ 871-a white B1 VFS Forward Hi Side Out mA
A03 VFS0 872-a green C1 VFS Forward Lo Side Out mA
A04 VFS1+ 873-a white D1 VFS 2nd VFS Hi Side Out mA

31
APC216 Display Information 1300 SRM 1602

Table 13. APC216 Wire Number to Hyster Wire Number Conversion (Continued)

APC216 Wire Wire Hyster Wire Color APC216 Pin Wire Description Output
Nr Name Nr Nr
A05 VFS1 874-a green E1 VFS 2nd VFS Lo Side Out mA
A06 VFS2+ 875-a white F1 VFS Rev Hi Side Out mA
A07 VFS2 876-a green G1 VFS Rev Lo Side Out mA
A08 VFS3+ 877-a white H1 VFS 1st/3rd Hi Side Out mA
A09 VFS3 878-a green J1 VFS 1st/3rd Lo Side Out mA
A10 DO0 763-a white K1 Total Neutral Solenoid + hi/lo
A11 ANI0 569-a white A2 Pressure Feedback Switch + Ohm
A12 DIGIN0 549-c white B2 Shift Lever 1st hi/lo
A13 DIGIN1 550-c white C2 Shift Lever 2nd hi/lo
A14 DIGIN2 551-a white D2 Seat Occupied, Switch Relay hi/lo
A15 DO1 Open E2 Open
A16 DO2 765-a white F2 1st/3rd Selector Solenoid hi/lo
A17 DIGIN3 Open G2 Open
A18 DIGIN4 553-e white H2 Shift Lever Forward hi/lo
A19 DIGIN5 554-f white J2 Shift Lever Reverse hi/lo
A20 DO3 766-a white K2 Total Neutral Solenoid - hi/lo
A21 GND 13-fh black A3 APC216 Ground Volt
A22 SS0+ 391-a white B3 Drum Speed Sensor + kHerz
A23 SS0- 392-a green C3 Drum Speed Sensor - kHerz
A24 SS1+ 393-a white D3 Output Speed Sensor + kHerz
A25 SS1- 394-a green E3 Output Speed Sensor - kHerz
A26 SS2+ 395-a white F3 Engine Speed Sensor + kHerz
A27 SS2- 397-a green G3 Engine Speed Sensor - kHerz
A28 ANI1 396-a white H3 Transmission Temperature Ohm
A29 ANI2 386-a white J3 Converter Out Temperature Ohm
A30 GND 582-a black K3 Ground Ohm
B01 VFS4+ Open L1 Open
B02 ANI4 251-a orange M1 Inching Pedal Ohm
B03 VFS5+ Open N1 Open
B04 ANI5 Open P1 Open
B05 VFS6+ Open R1 Open
B06 ANI6 Open S1 Open

32
1300 SRM 1602 APC216 Display Information

Table 13. APC216 Wire Number to Hyster Wire Number Conversion (Continued)

APC216 Wire Wire Hyster Wire Color APC216 Pin Wire Description Output
Nr Name Nr Nr
B07 CAN L 900-k green L2 CAN Low
B08 CAN H 901-k yellow M2 CAN High
B09 RXD Open N2 Open
B10 TXD Open P2 Open
B11 SS3+ 398-a white R2 Turbine Speed Sensor + kHerz
B12 SPWR 992-b red S2 Switched Battery + 24.0 Volt
B13 DIGIN6 555-c white L3 Start in 2nd Gear hi/lo
B14 DIGIN7 556-c white M3 Automatic/Manual Mode hi/lo
B15 DIGIN8 938-c white N3 Park Brake ON/OFF hi/lo
B16 DIGIN9 Open P3 Open
B17 ANI3 387-a white R3 Inching Pedal Signal Ohm
B18 GND 13-fm black S3 Ground Volt

CALIBRATION GROUP
Calibration Mode

Figure 34 schematically shows the procedure to enter the

calibration mode. The only relevant modes are under trAn
(clutch filling calibration), hEAt (heating the transmission),
and brAH (inching sensor calibration). See Figure 35. To
enter the calibration mode, press and hold the S button, and
turn the key switch to ON. During the first 15 seconds, the
display will show 8888’. Release the S button after 15 sec-
onds when the display shows trAn’.

Figure 34. Calibration Mode

33
APC216 Display Information
Figure 35. Entering Calibration Mode
Clutch Filling Calibration
NOTE: DO NOT interfere with the calibration. Activat-
ing any controls or components will stop the calibration
mode before completion.
1. Apply the parking brake.
2. Block the drive tires.
3. Make sure the transmission temperature is at least
60°C (140°F).
4. Make sure the shift lever is in NEUTRAL or RE-
VERSE for lift trucks with a shift lever.
5. Make sure the MONOTROL® pedal is in REVERSE
for lift trucks with a MONOTROL® pedal.
6. Press and hold the S button, and turn the key switch to
the ON position. During the first 15 seconds, the dis-
play will show 8888’. Release the S button after 15
seconds when the display shows trAn’:
NOTE: Keep engine speed at idle.
7. Start the engine.
8. Push the S button once. When all above conditions are
met, the APC216 display will show:
9. The automatic calibration starts when the forward/
reverse lever or the pedal is moved into the FOR-
WARD position. The screen will display:
34
1300 SRM 1602
10. When the calibration has been completed, the APC216
display will show donE’:
11. Switch the key switch OFF when the APC216 display
indicates that the calibration has been completed. Ob-
serve the display and wait until no segments are illumi-
nated. When the display remains OFF, the new cali-
bration has been entered into the APC216 memory.
The new calibration settings will be lost if the key is
switched ON too early.
Heat Up Mode
The heat up mode provides a convenient way to quickly
heat the transmission for test and calibration purposes. Dur-
ing the heat up mode, only the highest gear is selected and
the inputs from the parking brake and the brake pedal posi-
tion are ignored.
1. Press and hold the S button, and turn the key switch to
the ON position. During the first 15 seconds, the dis-
play will show 8888’. Release the S button after 15
seconds when the display shows trAn’.
2. 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 trans-
mission sump temperature will be shown:
5. Apply the service brakes.
6. Place the MONOTROL® pedal or the shift lever in the
FORWARD position.
7. Push the throttle for approximately 15 seconds.
8. Place the shift lever in NEUTRAL or the MONO-
TROL® pedal in REVERSE.
1300 SRM 1602
9. Run the engine at 1300 rpm for approximately 15 sec-
onds in NEUTRAL.
10. Decelerate the engine to idle.
11. Repeat Step 6 through Step 10 until the APC216 dis-
play shows a temperature above 60°C (140°F).
12. Push the M button to scroll to the desired calibration
mode. For a clutch calibration, scroll until 'tRan' is dis-
played.
Inching Pedal Sensor Calibration
Inching Pedal Sensor Adjustment
NOTE: Before calibrating the inching pedal sensor, the in-
ching pedal must be adjusted correctly. See Transmission
Test and Calibration, Step 2.
1. Press and hold the "S" button, and turn the key switch
to the ON position. During the first 15 seconds, the
display will show:
2. Release the "S" button after 15 seconds when the dis-
play shows:
3. Push the M button until the APC216 display shows an-
alog input:
4. Push the S button three times. The display will show
0.11, 1.28, 2.29, and a value. Pushing the S button an-
other time changes the display to 03.47. Releasing the
button shows the value in Ohms for the inching pedal
sensor (for example: 0.652).
APC216 Display Information
NOTE: The voltage reading of the inching pedal sensor
will be shown after a 1-2 second delay.
5. Check the voltage reading of the inching pedal sensor.
The reading must be between 0.600 and 0.700 mV
when the pedal is in the pedal up position.
6. If the reading is not between 0.600 and 0.700 mV, ad-
just the inching pedal sensor until the reading is within
specifications.
7. Turn the key switch to the OFF position to exit the
APC216 test function group.
Inching Pedal Sensor Calibration
NOTE: Calibration will fail under the following circum-
stances:
• Inching sensor adjustment is below 450 mV.
• During calibration, the voltage at the inching pedal
sensor does not reach 2,500 mV or exceeds 4,000
mV.
1. Press and hold the "S" button, and turn the key switch
to the ON position. During the first 15 seconds, the
display will show:
2. Release the "S" button after 15 seconds when the dis-
play shows:
3. Push the M button several times until the APC216 dis-
play shows brAH’:
4. Push the S button once to start the inching pedal sensor
calibration. The APC216 display will show:
35
Transmission Wiring Diagram 1300 SRM 1602

5. Push the S button in the pedal up position. The NOTE: The calibration procedure must be repeated if the
APC216 display will show: key switch is turned ON too early.

8. Turn the key switch to the OFF position to save the

calibration settings.

Observe the APC216 display and wait until no segments

6. Fully depress the inching pedal and press the S button
again.
7. When the calibration is complete, the APC216 display
will show donE’:
are illuminated. When the display remains OFF, the
new calibration has been entered into the APC216 mem-
ory. The new calibration settings will be lost if the key
switch is turned ON too early.

Transmission Wiring Diagram

36
1300 SRM 1602 Transmission Wiring Diagram

Figure 36. Transmission Wiring Diagram

37
Transmission Wiring Diagram 1300 SRM 1602

Legend for Figure 36

Item Description Code Location

No.
1 APC216 J2 CPS 27 Figure 15, Item 1
2 Transmission Lever CPS 29 Located in the steering column
3 MONOTROL® Pedal CPS 31 Located underneath the operator cab
4 Inching Pedal CPS 32 Figure 18
5 Transmission Resistors CPS 34 Behind the relays panel
6 APC216 J1 CPS 21 Figure 15, Item 1
7 Diagnostic Plug CPS 66 Figure 15, Item 2
8 Turbine Speed Sensor CPS 26 Figure 10
9 Transmission Temperature Switch TS 27 Figure 10
10 Transmission Control Valve CPS 22 Figure 7
11 Drum Speed Sensor CPS 25 Figure 10
12 Output Speed Sensor CPS 24 Figure 10
13 Engine Speed Sensor CPS 23 Figure 10

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1300 SRM 1602 12/12