Hyster H10.00 Transmission

TRANSMISSION
H8.00-12.00XM (H170-280HD) [G007];

H13.00-14.00XM (H300-330HD) [F019];
H16.00XM-6 (H360HD) [F019];
H10.00-12.00XM-12EC (H360HD-EC) [F019]
PART NO. 1556600 1300 SRM 1082

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Transmission Table of Contents
TABLE OF CONTENTS
Description of Operation...................................................................................................................................... 1
General ............................................................................................................................................................. 1
Torque Convertor, Pump Drive, and Pressure Regulating Valve.................................................................. 1
Input Shaft and Directional Clutches ............................................................................................................ 1
Range Clutches ................................................................................................................................................ 3
Output Section ................................................................................................................................................. 3
Transmission Controls..................................................................................................................................... 4
Operation of the Valve................................................................................................................................. 5
Selection of Range ....................................................................................................................................... 9
Pressure Switch........................................................................................................................................... 9
Electric Solenoid Controls ............................................................................................................................. 10
Transmission Specifications.......................................................................................................................... 26
Transmission Identification ...................................................................................................................... 26
Weight, Dimensions, and Oil Capacity .................................................................................................... 26
Transmission Repair .......................................................................................................................................... 28
Remove ........................................................................................................................................................... 28
Disassemble ................................................................................................................................................... 30
Transmission Case, Disassemble.............................................................................................................. 31
Torque Converter Housing, Disassemble ................................................................................................. 48
Forward Clutch, Disassemble................................................................................................................... 53
First-Speed Clutch, Disassemble.............................................................................................................. 55
Reverse and Second-Speed Clutch ........................................................................................................... 60
Reverse Clutch, Disassemble ............................................................................................................... 60
Second-Speed Clutch, Disassemble...................................................................................................... 65
Third-Speed Clutch, Disassemble ............................................................................................................ 67
Third Clutch Shaft, Disassemble ............................................................................................................. 69
Turbine Shaft, Disassemble ...................................................................................................................... 70
Output Shaft, Disassemble ....................................................................................................................... 71
Impeller, Disassemble ............................................................................................................................... 72
Turbine, Disassemble ................................................................................................................................ 74
Clean and Inspect .......................................................................................................................................... 76
Housings .................................................................................................................................................... 76
Oil Seals and Gaskets ............................................................................................................................... 77
Bearings ..................................................................................................................................................... 77
Gears and Shafts ....................................................................................................................................... 77
Assemble ........................................................................................................................................................ 78
Turbine, Assemble ..................................................................................................................................... 78
Impeller, Assemble .................................................................................................................................... 79
Output Shaft, Assemble ............................................................................................................................ 81
Turbine Shaft, Assemble ........................................................................................................................... 83
Third Clutch Shaft, Assemble .................................................................................................................. 84
Third-Speed Clutch, Assemble ................................................................................................................. 85
Reverse and Second-Speed Clutch ........................................................................................................... 88
Second-Speed Clutch, Assemble........................................................................................................... 88
Reverse Clutch, Assemble .................................................................................................................... 91
First-Speed Clutch, Assemble................................................................................................................... 95
Forward Clutch, Assemble...................................................................................................................... 100
Torque Converter Housing, Assemble .................................................................................................... 103
Transmission Case, Assemble................................................................................................................. 108
Install ........................................................................................................................................................... 129
Control Valve Repair........................................................................................................................................ 131
©2008 HYSTER COMPANY i

Table of Contents Transmission
TABLE OF CONTENTS (Continued)

Remove ......................................................................................................................................................... 131
Disassemble and Assemble ......................................................................................................................... 131
Clean and Inspect ........................................................................................................................................ 133
Housings .................................................................................................................................................. 133
Oil Seals and Gaskets ............................................................................................................................. 133
Install ........................................................................................................................................................... 134
Stall Test........................................................................................................................................................... 135
Transmission Calibration and Electrical Troubleshooting ............................................................................ 136
Userlink® ...................................................................................................................................................... 136
Connection ................................................................................................................................................... 136
Clutch Filling Calibration ........................................................................................................................... 136
Purpose .................................................................................................................................................... 136
Clutch Filling Calibration Procedure..................................................................................................... 137
Alternative Clutch Filling Calibration Procedure ................................................................................. 137
Heat-up Mode .......................................................................................................................................... 138
Heat-up Mode Stall Test ......................................................................................................................... 138
Inching Pedal Calibration [Up to S/N 2325 (F019)] and [Up to 3001 (G007)] ......................................... 139
Purpose .................................................................................................................................................... 139
Brake Pedal Adjustment......................................................................................................................... 139
Dry Brake ............................................................................................................................................ 139
Wet Brake ............................................................................................................................................ 139
Inching Pedal Adjustment ...................................................................................................................... 139
Inching Pedal Sensor Adjustment .......................................................................................................... 140
Inching Pedal Calibration Procedure ..................................................................................................... 140
Verification/Adjustment of Inching Pedal Sensor When the Pedal is Fully Released......................... 140
Manual Inching Pedal Sensor Calibration Procedure........................................................................... 141
Inching Pedal Calibration[S/N 2326 and Up (F019)], [S/N 3002 and Up (G007)] ................................... 141
Purpose .................................................................................................................................................... 141
Brake Pedal Adjustment......................................................................................................................... 141
Dry Brake ............................................................................................................................................ 141
Wet Brake ............................................................................................................................................ 141
Inching Pedal Adjustment ...................................................................................................................... 142
Dry Brake ............................................................................................................................................ 142
Wet Brake ............................................................................................................................................ 142
Inching Pedal Sensor Adjustment Using Userlink® Program .............................................................. 142
Inching Pedal Sensor Calibration Procedure Using Userlink® Program............................................. 143
Inching Pedal Sensor Adjustment Using the APC200 .......................................................................... 143
Inching Pedal Sensor Calibration Procedure Using the APC200......................................................... 144
Troubleshooting ........................................................................................................................................... 144
Transmission Display Warning Codes........................................................................................................ 144
Access ....................................................................................................................................................... 144
Clear......................................................................................................................................................... 145
Exit........................................................................................................................................................... 145
Limp Home Mode .................................................................................................................................... 180
Shutdown Mode ....................................................................................................................................... 181
Pressure Feedback Sensor ...................................................................................................................... 181
Transmission Oil Pressure Check ................................................................................................................... 181
Pressure and Temperature Specifications.................................................................................................. 181
Electrical Specifications................................................................................................................................... 186
Hydraulic Cooler Lines Specifications ............................................................................................................ 186
Torque Specifications ....................................................................................................................................... 186
ii
Transmission Table of Contents
TABLE OF CONTENTS (Continued)

Torque Specifications for Lubricated or Plated Screw Threads ................................................................ 186
Troubleshooting................................................................................................................................................ 189
Diagrams, Schematics, or Arrangements ....................................................................................................... 190
Figure 45. APC200 Wiring Diagram...................................................................................................... 192
This section is for the following models:
H8.00-12.00XM (H170-280HD) [G007];

H13.00-14.00XM (H300-330HD) [F019];
H16.00XM-6 (H360HD) [F019];
H10.00-12.00XM-12EC (H360HD-EC) [F019]
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1300 SRM 1082 Description of Operation
Description of Operation
GENERAL shaft is at zero RPM (stall). Therefore we can say
that as the turbine shaft is decreasing in speed, the
NOTE: Terms and abbreviations used throughout torque multiplication is increasing. The hydraulic
this manual are for the transmission system only. pump is connected with the pump drive gear. This
When terms and abbreviations refer to the operation pump drive gear is driven by the impeller hub gear.
of the truck it is specifically stated. Since the impeller hub gear is connected with the
impeller cover, the pump speed is in direct relation
This manual provides detailed information on oper-
with the engine speed.
ation, removal, disassemble, inspect, clean, assem-
ble, and install procedures for the TE10 transmis-
INPUT SHAFT AND DIRECTIONAL
sion. Transmission calibration procedures and elec-
trical troubleshooting, use display warning codes for CLUTCHES
both engine and transmission. For electrical system The turbine shaft driven from the turbine transmits
diagrams, see the section Diagrams 8000 SRM 1103. power to the forward or reverse clutch. See Fig-
Transmission parts are installed in the transmission ure 2. These clutches consist of a drum with internal
cover and housing. The PTO drive gears for the hy- splines and a bore to receive a hydraulic actuated
draulic pump and the transmission pump are on the piston. The piston is oil tight by the use of sealing
inside of the transmission cover and torque conver- rings. The steel discs with external splines, and
tor housing. The transmission control valve, mod- friction discs with internal splines, are alternately
ulator valve, and the hydraulic pumps are installed fitted in the required quantity. A backup plate is
on the outside of the transmission cover. The clutch then inserted and secured with a retainer ring. A
and shaft assemblies are installed inside the trans- hub with outer diameter splines is inserted into the
mission housing. splines of discs with teeth on the inner diameter. The
discs and hub are free to increase in speed or rotate
TORQUE CONVERTOR, PUMP DRIVE, in the opposite direction as long as no pressure is
present in that specific clutch.
AND PRESSURE REGULATING VALVE
To engage the clutch, the current on the electronic
Engine power is transmitted from the engine fly-
controlled modulation solenoids should go from 100
wheel to the impeller through the impeller cover.
mA to 0 mA in order to change the pressure to the
This element is the pump portion of the hydraulic
clutch from 0 to maximum pressure via a modulated
torque convertor and is the primary component
way. The oil under pressure will go through tubes
which starts the oil flowing to the other components
and passages to the selected clutch shafts. This
which results in torque multiplication. This element
means that clutch pressure is built up gradually.
can be compared to a centrifugal pump, that picks
This will enable the unit to make forward, reverse
up fluid at its center and discharges it at the outer
shifts while the vehicle is still moving and will allow
diameter. The torque convertor turbine is mounted
smooth engagement of drive.
opposite the impeller and is connected to the turbine
shaft of the torque convertor. See Figure 1. This Oil sealing rings are located on the clutch shafts.
element receives fluid at its outer diameter and These rings prevent oil from escaping when the oil
discharges it at its center. The reaction member of is directed through a drilled passage in the shaft to
the torque convertor is located between and at the the desired clutch.
center of the inner diameters of the impeller and
turbine elements. Its function is to take the fluid Pressure of the oil forces the piston and discs against
which is exhausting from the inner portion of the the backup plate. The discs with splines on the outer
turbine and change its direction to allow correct en- diameter clamping against discs with teeth on the in-
try for recirculation into the impeller element. This ner diameter enables the drum and hub to be locked
recirculation will make the convertor to multiply together and allows them to drive as one unit. When
torque. The torque multiplication is a function of the clutch is released, a return spring will push the
the blading (impeller, turbine and reaction member) piston back and oil will drain back via the shift spool,
and the convertor output speed (turbine speed). The the bleed valve, or holes in the clutch piston into the
convertor will multiply engine torque to its designed transmission sump. These bleed valves allow quick
maximum multiplication ratio when the turbine
1
Description of Operation 1300 SRM 1082
escape of oil when the pressure to the piston is re-

leased.
Figure 1. Transmission Operation
2
Legend for Figure 1

1. INPUT SHAFT 12. LOW AND SECOND-SPEED SHAFT
2. PUMP IDLER GEAR 13. OUTPUT GEAR
3. PUMP DRIVE GEAR 14. OUTPUT SHAFT
4. TRANSMISSION OIL PUMP 15. OUTPUT YOKE
5. OIL FILTER 16. THIRD GEAR CLUTCH
6. FORWARD CLUTCH 17. SUMP
7. FIRST-SPEED CLUTCH 18. THIRD-SPEED SHAFT
8. MANIFOLD 19. REVERSE CLUTCH
9. FORWARD AND FIRST-SPEED SHAFT 20. REVERSE AND SECOND-SPEED SHAFT
10. SECOND GEAR CLUTCH 21. TORQUE CONVERTOR HOUSING
11. SECOND GEAR
RANGE CLUTCHES OUTPUT SECTION

Once a directional clutch is engaged, engine power is With a range clutch engaged, engine power is finally
transmitted to the range clutches (1st, 2nd, or 3rd). transmitted to the output shaft. Output rotation is
Operation and actuation of the range clutches are the same as the input rotation when the forward
similar to the directional clutches. See Figure 2. clutch is engaged.
1. FORWARD CLUTCH 6. THIRD-SPEED CLUTCH

2. FIRST-SPEED CLUTCH 7. REVERSE CLUTCH
3. OUTPUT YOKE 8. OUTPUT SHAFT
4. OUTPUT GEAR 9. INPUT SHAFT
5. SECOND-SPEED CLUTCH 10. DRIVE GEAR
Figure 2. Gear and Clutch Layout
3
TRANSMISSION CONTROLS function of the control valve assembly is to direct oil

under pressure to the desired directional and speed
The transmission is controlled by the control valve. clutches.
The control valve assembly is mounted directly on
the side of the convertor housing. See Figure 3. The
1. CONTROL VALVE
Figure 3. Control Valve
4
Operation of the Valve clutch. Between each electronic controlled variable

force solenoid and pressure intensifier, an accumu-
Regulated pressure 16.5 bar (239 psi) is directed to lator is placed to dampen any hydraulic vibration.
the total neutral shift spool and the pressure reducer See Figure 4.
that will decrease the pressure to 10 bar (145 psi).
This reduced pressure will be used to supply the elec- If the total neutral solenoid is not activated, then no
tronic controlled variable force solenoids (VFS), total pressure is supplied to the pressure intensifiers. To-
neutral solenoid, 3rd/1st solenoid, and reverse sole- tal neutral solenoid is always actuated in normal con-
noid. ditions.
Each electronic controlled variable force solenoid is When forward is selected, total neutral solenoid and
current controlled, meaning that full current corre- the reverse electronic modulation solenoid are actu-
sponds to no pressure, while no current corresponds ated (full current). See Figure 5. The forward clutch
to full pressure and to all the variations in between. is fed with pressure supplied through the forward
pressure intensifier.
When actuating the electronic controlled variable
force solenoid from 100 mA to 0 mA, the output When reverse is selected, total neutral solenoid and
pressure will result in a curve from 0 to 6 bar (0 to the forward electronic modulation solenoid are actu-
87 psi). The pressure intensifiers will multiply this ated (full current). See Figure 6. The reverse clutch
pressure curve so that a curve from 0 to 16.5 bar (0 is fed with pressure supplied through the reverse
to 239 psi) is available for each directional and range pressure intensifier.
A. VARIABLE FORCED SOLENOID D. HIGH PRESSURE 0 TO 20 bar (0 TO 290 psi)

B. PRESSURE INTENSIFIER E. DRAIN
C. LOW PRESSURE 0 TO 6 bar (0 TO 87 psi)
1. VFS FWD 7. VFS 1ST/3RD
2. ACCUMULATOR 8. ACCUMULATOR
3. VFS REV 9. PRESSURE INTENSIFIER 1ST/3RD
4. ACCUMULATOR 10. PRESSURE INTENSIFIER 2ND
5. VFS 2ND 11. PRESSURE INTENSIFIER REV
6. ACCUMULATOR 12. PRESSURE INTENSIFIER FWD
Figure 4. Operation of the Valve
5
Figure 5. Forward 1st Speed
6
Legend for Figure 5

A. VARIABLE FORCED SOLENOID D. LOW PRESSURE 0 TO 6 bar (0 TO 87 psi)
B. PRESSURE INTENSIFIER E. HIGH PRESSURE 0 TO 20 bar (0 TO 290 psi)
C. LUBRICATION F. DRAIN
1. OPERATOR COMPARTMENT 17. INTENSIFIER 2ND
2. TEMPERATURE GAUGE 18. INTENSIFIER REV
3. PRESSURE GAUGE 19. INTENSIFIER FWD
4. PRESSURE REDUCER VALVE 20. PRESSURE SWITCH
5. TOTAL NEUTRAL 21. BYPASS VALVE
6. VFS FWD 22. SCREEN
7. VFS REV 23. AIR BREATHER
8. VFS 2ND 24. PUMP
9. VFS 1ST/3RD 25. HOSE
10. INTENSIFIER 1ST/3RD 26. FILTER
11. 3RD/1ST 27. PRESSURE REGULATOR VALVE
12. 3RD CLUTCH 28. SAFETY VALVE
13. 1ST CLUTCH 29. LUBRICATION RANGE CLUTCHES
14. 2ND CLUTCH 30. HOSE
15. REV CLUTCH 31. COOLER
16. FWD CLUTCH 32. TORQUE CONVERTOR
7
Figure 6. Reverse 1st Speed
8
Legend for Figure 6

8. VFS 2ND 24. PUMP
Selection of Range Pressure Switch

NOTE: When 2nd clutch receives full pressure, the The control valve also has a pressure switch installed
2nd electronic controlled solenoid will have no cur- between the total neutral shift spool and the pressure
rent. intensifiers supply. This switch will verify that pres-
sure to the various pressure intensifiers is supplied
2nd clutch is fed with modulated pressure supplied only when the total neutral solenoid is activated, and
through its respective pressure intensifier and elec- that both direction clutches and range clutches can-
tronic controlled modulator solenoid. not be under pressure at the same time. This infor-
mation is an input of the APC200 box.
3rd/1st clutches are selected when 2nd electronic con-
trolled modulation solenoid and 1st/3rd solenoid are NOTE: A value of 1100 equals high pressure, while
actuated. The pilot pressure of the 1st/3rd solenoid a value of 2200 equals low pressure.
will move the shift spool so that 1st clutch can be fed
with modulated pressure.
9
ELECTRIC SOLENOID CONTROLS Figure 7, Figure 8, Figure 9, Figure 10, Figure 11,
Figure 12, Figure 13, Figure 14, Figure 15, Figure 16,
The following table explains the activated solenoids, Figure 17, and Figure 18.
activated Variable Force Solenoids (VFS), and acti-
vated clutches for each gear. See Figure 5, Figure 6,
Transmission Gear Activated On/Off Activated VFSs Activated Clutches

Solenoids (Full Current)
Forward 3 Drive Reverse, 2nd Forward 3rd
Forward 2 Drive Reverse, 1st/3rd Forward 2nd
Forward 1 Drive, 1st/3rd selector Reverse, 2nd Forward 1st
Neutral 3 Drive Forward, Reverse, 2nd Neutral 3rd
Neutral 2 Drive Forward, Reverse, Neutral 2nd
1st/3rd
Neutral 1 Drive, 1st/3rd selector Forward, Reverse, 2nd Neutral 1st
Reverse 3 Drive Forward, 2nd Reverse 3rd
Reverse 2 Drive Forward, 1st/3rd Reverse 2nd
Reverse 1 Drive, 1st/3rd selector Forward, 2nd Reverse 1st
10
Figure 7. Neutral and 3rd
11
Legend for Figure 7

8. VFS 2ND 24. PUMP
Figure 8. Neutral and 3rd Flow
12
Figure 9. Forward 1st Speed Flow
13
Figure 10. Forward 2nd Speed
14
Legend for Figure 10

8. VFS 2ND 24. PUMP
15
Figure 11. Forward 2nd Speed Flow
16
Figure 12. Forward 3rd Speed
17

8. VFS 2ND 24. PUMP
18
Figure 13. Forward 3rd Speed Flow
19
Figure 14. Reverse 1st Speed Flow
20
Figure 15. Reverse 2nd Speed
21

8. VFS 2ND 24. PUMP
22
Figure 16. Reverse 2nd Speed Flow
23
Figure 17. Reverse 3rd Speed
24

8. VFS 2ND 24. PUMP
25
Figure 18. Reverse 3rd Speed Flow
TRANSMISSION SPECIFICATIONS Maximum length: 840 mm (33.1 in.)
Transmission Identification Maximum width: 526 mm (20.7 in.)
The transmission data plate shows the model, type Maximum height: 783 mm (30.8 in.)
of the unit, and serial number. See Figure 19.
Oil Capacity: 25.4 liter (6.7 gal) without cooler and
Weight, Dimensions, and Oil Capacity hydraulic lines. Consult operator’s manual on appli-
cable machine for system capacity.
Weight (dry): 362 kg (800 lb).
26
1. MODEL AND TYPE OF THE UNIT 2. SERIAL NUMBER
Figure 19. Transmission Data Plate
27
Transmission Repair 1300 SRM 1082
Transmission Repair
REMOVE 13. Install blocks and a jack under the flywheel end
of the engine as a support. If the support is under
1. Tilt the mast fully forward to release hydraulic the engine oil sump, make sure that the support
pressure in the system. is across the width of the oil sump so the weight
of the engine does not damage the oil sump.
2. Turn the key to OFF position to shutdown the
engine. 14. A 3/4-inch machined hole with UNC threads is
in the top of the transmission housing. Install
3. Apply the parking brake.
an eyebolt in the 3/4-inch UNC hole. Connect
4. Disconnect the cables at the battery. Disconnect a lifting device to the transmission. Make sure
the ground cable first and then the positive cable. the lifting device has a lifting capacity of at least
1200 kg (2650 lb). To stabilize the transmission,
5. Tilt the operator compartment up to gain access wrap a lifting strap around the output yoke to
to the transmission. See the section Operator’s keep the transmission from tipping while being
Cab 100 SRM 1100. removed. See Figure 21.
6. Disconnect the drive shaft at the yokes. Remove 15. Remove the two 3/4 × 31/2-inch bolts that fasten
the drive shaft between the transmission and the the transmission mounts to the frame.
differential. See Figure 20.
16. Remove the access plug to gain access to the fly-
7. Disconnect the wiring harnesses on the trans- wheel. See Figure 22.
mission and wires for the temperature sending
unit on the transmission. Put identification tags 17. Remove the access plug to gain access to the fly-
on the wires so they can be correctly connected wheel. See Figure 23.
again.
8. Place a suitable container under the transmis-

CAUTION
sion sump and remove the transmission sump Do not drop the capscrews into the converter
drain plug and drain the transmission oil [ap- housing. They will be difficult to retrieve.
proximately 25.4 liter (6.7 gal)].
NOTE: You must turn the flywheel to gain access to
9. Disconnect the oil lines to the oil cooler at the each screw. See Figure 22.
transmission. Drain the oil into a drain pan. Put
18. Remove the eight capscrews retaining the drive
plugs and caps on open lines/fittings.
plate to the flywheel. See Figure 23.
10. Disconnect the oil hoses at the hydraulic pump.
19. Raise the lifting device to hold the weight of the
Disconnect the hose from the hydraulic pump to
transmission only. Remove the twelve capscrews
the steering system. Put plugs and caps on open
that fasten the torque converter housing to the
lines/fittings.
flywheel housing.
11. The hydraulic pump is connected to the trans-
mission cover with four capscrews. Attach a lift- CAUTION
ing device to hold the hydraulic pump, remove Keep the transmission level when the transmis-
the capscrews, and remove the hydraulic pump. sion is separated from the engine so the drive
The drive shaft of the hydraulic pump is engaged plate is not damaged.
in the splines of the drive gear. The drive shaft
of the hydraulic pump will slide out of the drive 20. Make sure that all connections have been re-
gear when the hydraulic pump is removed. moved and carefully lift the transmission assem-
bly from the frame and engine.
12. Disconnect and remove the dipstick assembly
from the transmission.
28
1300 SRM 1082 Transmission Repair
1. FRAME (REFERENCE) 6. TRANSMISSION

2. DIPSTICK ASSEMBLY 7. TORQUE CONVERTER
3. DRIVE SHAFT 8. CAPSCREWS (8 EACH)
4. OUTPUT YOKE 9. CAPSCREWS (12 EACH)
5. TRANSMISSION MOUNT
Figure 20. Transmission Arrangement
29
1. ACCESS HOLE TO CAPSCREWS (8 EACH)

2. ACCESS PLUG
3. CONVERTER HOUSING
Figure 23. Access Plug for Drive Plate

Capscrews
DISASSEMBLE
Figure 24 shows the front view of the TE10 3-speed
transmission.
1. 3/4-INCH UNC HOLE
Figure 21. Rear View of Transmission
Figure 24. TE10 3-Speed Transmission
1. CONVERTER HOUSING
2. ACCESS HOLE TO FLYWHEEL
3. ACCESS PLUG
Figure 22. Access Plug to Flywheel
30
Transmission Case, Disassemble

STEP 1.
Remove the control valve assembly. See Control
Valve Repair, Remove.
NOTE: Place a suitable container below the oil filter to catch remaining oil in filter.
STEP 2.
Remove the oil filter.
STEP 3.
Remove the capscrews and washers retaining the
pressure regulating valve and the charging pump.
Remove the pressure regulating valve and the charg-
ing pump as an assembly.
31
STEP 4.
If used, remove the capscrews and washers retaining
the shipping cover. Remove the shipping cover.
STEP 5.
Remove the capscrews retaining the auxiliary pump
adaptor and remove the auxiliary pump adaptor.
STEP 6.
Remove the four speed sensors.
32
STEP 7.
Remove the drive plate nuts and lockwashers. Re-
move drive plates and locking rings.
STEP 8.
Use a small screwdriver and pry the impeller cover
bearing cap from the impeller cover.
STEP 9.
Remove the impeller cover bearing cap O-ring.
33
STEP 10.
Remove the retaining ring from the turbine shaft
that retains the turbine hub.
NOTE: Use a suitable container to catch the oil remaining in the converter.
STEP 11.
Remove the bolts and washers retaining the impeller
cover to the impeller.
STEP 12.
Remove the impeller cover and turbine as an assem-
bly.
34
STEP 13.
Remove the turbine locating ring from the turbine
shaft.
STEP 14.
Remove the stator retaining ring.
STEP 15.
Remove the stator.
35
STEP 16.
Remove the stator spacer.
STEP 17.
Remove the oil baffle retaining ring.
STEP 18.
Remove the impeller, impeller hub, and oil baffle as
an assembly.
36
STEP 19.
Remove the pump drive idler gear retaining ring.
STEP 20.
Remove the idler gear and bearing as an assembly.
STEP 21.
Remove the pump drive gear bearing support bolts
and remove the gear and bearing as an assembly.
37
STEP 22.
Remove the auxiliary pump drive gear bearing sup-
port bolts. Remove the gear and bearing as an as-
sembly from behind.
STEP 23.
Support the converter housing with an overhead lift-
ing device.
STEP 24.
Remove the converter housing to transmission case
bolts.
38
STEP 25.
Separate the converter housing from the transmis-
sion case.
NOTE: Rev/2nd and 3rd clutches will remain in the

converter housing.
STEP 26.
Remove the 2nd speed clutch disc hub snap ring re-
tainer, outer ring, and ring retainer.
STEP 27.
Remove 2nd clutch disc hub.
39
STEP 28.
Remove 3rd speed disc hub snap ring retainer, outer
ring, and ring retainer.
STEP 29.
Remove 3rd clutch disc hub.
STEP 30.
Remove the nut, washer, and O-ring retaining the
output yoke.
40
STEP 31.
Remove output yoke.
STEP 32.
Remove the bolts and lockwashers retaining the out-
put shaft bearing cap.
STEP 33.
Remove the bearing cap, seal, and gasket.
STEP 34.
Remove the speedometer gear.
41
STEP 35.
Remove the bolts and lockwashers retaining the 1st
clutch shaft bearing cap.
STEP 36.
Remove the low clutch shaft bearing cap and gasket.
STEP 37.
Remove the low clutch shaft rear bearing locating
ring.
42
STEP 38.
Remove the output shaft rear locating ring.
STEP 39.
Remove the capscrews and lockwashers retaining the
rear cover.
STEP 40.
Support the rear cover with an overhead lifting de-
vice. Using the provided pry slots, pry the cover from
the transmission housing, tapping the shafts with a
soft hammer to assist in removal.
43
STEP 41.
With the rear cover removed, remove the rear cover
to transmission case gasket.
STEP 42.
Remove the output shaft rear locking ball.
STEP 43.
Remove the low clutch shaft rear bearing retainer
ring.
44
NOTE: Newer low clutch shaft rear bearings do not have spacers.
STEP 44.
Remove the low clutch shaft rear bearing and spacer.
STEP 45.
Remove the output shaft assembly and 1st speed
clutch assembly from the housing at the same time.
STEP 46.
Remove the oil baffle plate.
45
STEP 47.
Remove the forward clutch gear retainer ring and
gear.
STEP 48.
Remove the forward clutch as an assembly.
46
STEP 49.
If necessary, remove the sealing ring sleeve retaining
ring.
STEP 50.
If necessary, remove the sealing ring sleeve and bear-
ing.
STEP 51.
Remove the suction tube bolts, washers, and O-rings.
47
Torque Converter Housing, Disassemble

STEP 1.
Remove reverse and 3rd clutch needle bearing.
STEP 2.
Remove forward clutch shaft needle bearing.
STEP 3.
Spread the ears on the reverse clutch front bearing
locating snap ring. Pry Rev/2nd clutch drum assem-
bly from converter housing.
48
STEP 4.
Spread the ears on the reverse clutch front bearing lo-
cating snap ring. Pry 3rd clutch drum assembly from
converter housing
STEP 5.
Remove the idler shaft nut and spacer.
STEP 6.
Remove the idler gear and outer taper bearing from
idler shaft.
49
STEP 7.
Remove the bearing spacer.
STEP 8.
Tap the idler shaft from the housing.
STEP 9.
Remove the inner taper bearing and spacer.
50
CAUTION
Do not lose the shaft lock ball.
STEP 10.
Remove idler shaft.
STEP 11.
Using spreading type of pliers, spread the ears on the
turbine shaft bearing locating snap ring. Tap turbine
shaft and bearing assembly from the stator support.
STEP 12.
If the stator support is to be removed, remove the
screws and tap the support from the converter hous-
ing.
51
STEP 13.
Remove the oil sealing ring sleeve retainer screw and
washer. Remove the sleeve lock.
STEP 14.
Using a sleeve puller, remove the sleeve.
STEP 15.
Sleeve removed.
52
Forward Clutch, Disassemble

STEP 1.
Remove end plate retaining ring.
STEP 2.
Remove end plate.
STEP 3.
Remove inner and outer clutch discs.
53
WARNING
The spring has a force of 1350 N•m (996 lbf ft).
STEP 4.
Compress the piston return disc spring pack and re-
move the spring retainer snap ring.
CAUTION
Do not mix the disc springs with any other disc springs as they are matched in spring packs.
STEP 5.
Remove piston return spring disc pack.
STEP 6.
Remove return spring spacer.
54
STEP 7.
Remove clutch piston.
STEP 8.
Turn the clutch over and remove the three clutch
shaft piston rings.
First-Speed Clutch, Disassemble

STEP 1.
Use a bearing puller, remove the front bearing from
the shaft.
55
STEP 2.
Remove the front bearing spacer.
STEP 3.
Remove low gear.
STEP 4.
Remove spacer.
56
STEP 5.
Remove the end plate retaining ring.
STEP 6.
Remove the end plate.
STEP 7.
Remove the inner and outer clutch discs.
57
STEP 8.
Use a bearing puller and remove the rear bearing.
STEP 9.
Remove the bearing locating ring.
STEP 10.
Remove the bearing locating ring snap ring.
58
WARNING
STEP 11.
Compress the return spring and remove the return
spring retaining snap ring.
STEP 12.
Remove the return spring retaining ring retainer.
CAUTION
STEP 13.
Remove the piston return discs springs.
59
STEP 14.
Remove the piston spacer.
STEP 15.
Remove the clutch piston.
Reverse and Second-Speed Clutch
Reverse Clutch, Disassemble
STEP 1.
Remove the clutch shaft piston rings.
60
STEP 2.
Remove the front bearing retaining ring.
STEP 3.
Remove the front bearing.
STEP 4.
Remove the clutch gear bearing retaining ring.
61
STEP 5.
Use a puller and remove the reverse gear.
STEP 6.
Remove the bearing spacer. Use a bearing puller and
remove the bearing.
STEP 7.
62
STEP 8.
STEP 9.
WARNING
STEP 10.
Compress the piston return disc spring and remove
the spring retainer snap ring.
63
CAUTION
STEP 11.
Remove the return disc springs.
STEP 12.
STEP 13.
64
Second-Speed Clutch, Disassemble
STEP 1.
STEP 2.
STEP 3.
65
WARNING
STEP 4.
Compress the piston return disc springs and remove
the spring retaining snap ring.
STEP 5.
Remove the piston return disc springs.
STEP 6.
66
STEP 7.
Remove the piston.
Third-Speed Clutch, Disassemble

STEP 1.
STEP 2.
67
STEP 3.
WARNING
STEP 4.
Compress the piston return disc springs and remove
the spring retaining snap ring.
STEP 5.
Remove the clutch disc springs.
68
STEP 6.
Remove the spacer.
STEP 7.
Third Clutch Shaft, Disassemble

STEP 1.
Remove the piston rings.
69
STEP 2.
Remove the bearing retaining ring.
STEP 3.
Use a bearing puller and remove the bearing.
Turbine Shaft, Disassemble

STEP 1.
Remove the oil seal ring.
70
STEP 2.
Remove the bearing retaining ring and washer.
STEP 3.
Use a hydraulic press and remove the bearing.
Output Shaft, Disassemble

STEP 1.
Use a bearing puller and remove the output gear and
double tapered bearing.
71
STEP 2.
Remove the spacer.
STEP 3.
Remove the bearing.
Impeller, Disassemble
STEP 1.
Remove the impeller hub capscrews.
72
STEP 2.
Remove the backing ring.
STEP 3.
Remove the impeller.
STEP 4.
Remove the impeller hub O-ring.
73
STEP 5.
Remove the oil baffle.
Turbine, Disassemble
STEP 1.
Remove the turbine retaining ring.
STEP 2.
Tap the turbine from the turbine cover with a soft
hammer.
74
STEP 3.
Remove the bearing from the turbine cover.
STEP 4.
Remove the turbine hub capscrews.
STEP 5.
Remove the turbine backing plate.
75
STEP 6.
Remove the turbine from the hub.
CLEAN AND INSPECT Clean all parts thoroughly using solvent type clean-
ing fluid. It is recommended that parts be immersed
WARNING in cleaning fluid and moved up and down slowly un-
til all old lubricant and foreign material is dissolved
To prevent serious eye injury, always wear safe
and parts are thoroughly cleaned.
eye protection when performing vehicle main-
tenance or service. The importance of careful and thorough inspection of
all parts cannot be overstressed. Replacement of all
WARNING parts showing indication of wear or stress will elim-
To avoid personal injury when cleaning parts, inate costly and avoidable failures at a later date.
work in a well-ventilated area, wear protective
clothing (face shield or safety glasses and pro- Housings
tective gloves), and follow chemical manufac-
Clean interior and exterior of housings, bearing caps,
turer’s recommendations for safe usage.
etc., thoroughly. Cast parts may be cleaned in hot so-
Solvent cleaners can be flammable, poisonous, lution tanks with mild alkali solution providing these
and cause burns. Examples of solvent clean- parts do not have ground or polished surfaces. Parts
ers are carbon tetrachloride, emulsion-type should remain in solution long enough to be thor-
cleaners, and petroleum-based cleaners. To oughly cleaned and heated. This will aid the evapo-
avoid serious personal injury when using sol- ration of the cleaning solution and rinse water. Parts
vent cleaners, carefully follow manufacturer’s cleaned in solution tanks must be thoroughly rinsed
instructions and these procedures: with clean water to remove all traces of alkali. Cast
• Wear safe eye protection. parts may also be cleaned with steam cleaner.
• Wear clothing that protects skin.
Inspect housings, covers and bearing caps to ensure
• Work in a well-ventilated area.
that they are thoroughly clean and that mating sur-
• Do not use gasoline or solvents that contain
faces, bearing bores, etc., are free from nicks or burrs.
gasoline. Gasoline can explode.
Check all parts carefully for evidence of cracks or con-
• Use hot solution tanks or alkaline solutions
ditions which would cause subsequent oil leaks or
correctly. Carefully follow manufacturer’s
failures.
instructions.
76
Oil Seals and Gaskets Remove bearings from cleaning fluid and strike flat
against a block of wood to dislodge solidified particles
Replacement of spring load oil seals, O-rings, metal of lubricant. Immerse again in cleaning fluid to flush
sealing rings, gaskets, and snap rings is more out particles. Repeat above operation until bearings
economical when the unit is disassembled than pre- are thoroughly clean. Dry bearings using moisture-
mature overhaul to replace these parts at a future free compressed air. Be careful to direct air stream
time. Further loss of lubricant through a worn seal across bearing to avoid spinning. Bearings may be
may result in failure of other more expensive parts rotated slowly by hand to facilitate drying process.
of the assembly. Sealing members should be handled
carefully, particularly when being installed. Cutting, NOTE: Do not replace a bearing cone or cup individu-
scratching, or curling under of lips of seals seriously ally without replacing the mating cup or cone at the
impairs its efficiency. When assembling new metal same time.
type sealing rings, these should be lubricated with
a coat of chassis grease to stabilize rings in their Carefully inspect all rollers: cages and cups for wear,
grooves for ease of assembly of mating members. chipping, or nicks to determine fitness of bearings for
Lubricate all O-rings and seals with recommended further use. After inspection, dip bearings in Auto-
type Automatic Transmission Fluid before assembly. matic Transmission Fluid and wrap in clean lint-free
cloth or paper to protect them until installed.
Bearings
Gears and Shafts
WARNING If Magna-Flux process is available, use process to
Compressed air can move particles so that they check parts. Examine teeth on all gears carefully
cause injury to the user or to other personnel. for wear, pitting, chipping, nicks, cracks or scores. If
Make sure that the path of the compressed air gear teeth show spots where case hardening is worn
is away from all personnel. Wear protective through or cracked, replace with new gear. Small
goggles or a face shield to prevent injury to the nicks may be removed with suitable hone. Inspect
eyes. shafts and quills to make certain they are not sprung,
bent or spline-twisted, and that shafts are true.
NOTE: Do not spin the bearings when drying.
77
ASSEMBLE
Turbine, Assemble
STEP 1.
Install the turbine onto the hub. Place the backing
ring in position.
NOTE: Assembly of hub must be completed within a 15-minute period from start of capscrew installation. The
special capscrew is to be used for one installation only. If the capscrew is removed for any reason, it must be
replaced. The epoxy left in the hub holes must be removed with the proper tap and cleaned with solvent. Dry
holes thoroughly and use a new capscrew for reinstallation.
STEP 2.
Install the self-locking capscrews and tighten to 79 to
87 N•m (58 to 64 lbf ft).
STEP 3.
Install the turbine hub bearing.
78
STEP 4.
Install a new O-ring in the impeller cover. Place the
turbine assembly in the impeller cover.
STEP 5.
Install the turbine retaining ring.
Impeller, Assemble
STEP 1.
Install a new seal in the oil baffle and install the oil
baffle over the hub.
79
STEP 2.
Install a new O-ring.
STEP 3.
Clean the hub mounting surface and tapped holes
with solvent. Verify that the hub and tapped holes
are dry.
Install the impeller on the hub.
STEP 4.
Install the backing plate.
80
NOTE: Assembly of hub must be completed within a 15-minute period from start of capscrew installation. The
special capscrew is to be used for one installation only. If the capscrew is removed for any reason it must be
replaced. The epoxy left in the hub holes must be removed with the proper tap and cleaned with solvent. Dry
holes thoroughly and use a new capscrew for reinstallation.
STEP 5.
Install the self locking capscrews and tighten to 79 to
87 N•m (58 to 64 lbf ft).
Output Shaft, Assemble
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns.
STEP 1.
Warm the bearing to 120 C (248 F). Install the bear-
ing on the shaft.
STEP 2.
Place the spacer on the shaft.
81
STEP 3.
Install the output gear.
WARNING
STEP 4.
Warm the inner bearing cage to 120 C (248 F). Install
the bearing on the shaft.
STEP 5.
Install the spacer.
82
STEP 6.
Install the bearing outer race.
WARNING
STEP 7.
Warm the outer bearing cage to 120 C (248 F). Install
the bearing on the shaft.
Turbine Shaft, Assemble
WARNING
STEP 1.
ing on the shaft with the groove down.
83
STEP 2.
Install the washer and bearing retainer.
STEP 3.
Install the oil seal ring.
Third Clutch Shaft, Assemble
WARNING
STEP 1.
ing on the shaft with the groove up.
84
STEP 2.
Install the bearing retaining ring.
STEP 3.
Install the two piston rings.
Third-Speed Clutch, Assemble

NOTE: The ring must be sized before installing the clutch piston in the clutch drum. Sizing is best accomplished
by rotating the piston while holding a round object against the new seal ring. Rotate the piston until the seal
ring is flush with the outer diameter of the piston.
STEP 1.
Install new clutch piston inner and outer sealing
rings. Install the clutch piston in the clutch drum.
Use caution not to damage the new sealing rings.
85
STEP 2.
Install the spacer.
STEP 3.
Install the piston return disc springs. Install the first
spring with the large diameter toward the spacer. Al-
ternate the five springs.
1. PISTON
2. SPACER
3. SHAFT
86
WARNING
STEP 4.
Compress the piston return disc springs and install
the spring retaining snap ring. Ensure the snap ring
is seated completely in the groove.
STEP 5.
Install one steel disc and then one friction disc. Al-
ternate the steel and friction discs until the proper
amount are installed. The first disc installed next to
the piston is steel and the last disc installed is fric-
tion.
STEP 6.
Install the end plate.
87
STEP 7.
Install the end plate retaining ring.
Reverse and Second-Speed Clutch
Second-Speed Clutch, Assemble
STEP 1.
STEP 2.
Install the piston return spring spacer.
88
STEP 3.
Install the piston return disc springs. Install the first
ternate the five springs.
1. PISTON
2. SPACER
3. SHAFT
WARNING
STEP 4.
Compress the piston return disc springs and install
the spring retaining snap ring. Ensure the snap ring
is seated completely in the groove.
89
STEP 5.
tion.
STEP 6.
Install the end plate.
STEP 7.
90
Reverse Clutch, Assemble
STEP 1.
STEP 2.
Install piston return spring spacer.
91
STEP 3.
Install the piston return springs. Install the first
spring with the large diameter toward the spacer.
Alternate the thirteen springs.
1. PISTON
2. SPACER
3. SHAFT
WARNING
STEP 4.
Compress the springs and install the retainer ring
snap ring. Ensure the snap ring is seated completely
in the groove.
92
STEP 5.
tion.
STEP 6.
Install a new seal in the end plate and install the end
plate into the clutch drum.
STEP 7.
Install the end plate retainer ring.
93
WARNING
STEP 8.
Warm the reverse gear and hub to 120 C (248 F). In-
stall the reverse gear and hub into the clutch drum.
Align the splines on the reverse gear with internal
teeth of the friction discs and gently place the gear
into position.
STEP 9.
Install the bearing retaining snap ring.
WARNING
STEP 10.
Warm the front bearing to 120 C (248 F). Install the
bearing on the shaft with the groove up.
94
STEP 11.
STEP 12.
Install the three clutch shaft piston rings.
First-Speed Clutch, Assemble

STEP 1.
Verify the bleed valve in the clutch piston is clean and
free of any foreign material. Install new clutch pis-
ton inner and outer sealing rings. Install the clutch
piston in the clutch drum. Use caution not to damage
the new sealing rings.
95
STEP 2.
Install the piston return spring spacer.
STEP 3.
Install the piston return springs. Install the first
spring with the large diameter toward the spacer.
Alternate the eleven springs.
1. PISTON
2. SPACER
3. SHAFT
96
STEP 4.
Install the piston return spring retaining ring re-
tainer on the clutch shaft.
STEP 5.
Compress the springs and install the retainer ring
snap ring. Ensure the snap ring is seated completely
in the groove.
STEP 6.
Install the inner bearing locating ring snap ring.
97
STEP 7.
Position the inner bearing retaining ring retainer.
STEP 8.
tion.
STEP 9.
Install the clutch end plate.
STEP 10.
98
WARNING
CAUTION
Do not force the gear into position.
STEP 11.
Heat the clutch drive gear assembly to 120 C (248 F).
Align the splines on the clutch gear with internal
teeth of the friction discs and gently place the gear
into position.
STEP 12.
Install the front bearing spacer.
WARNING
STEP 13.
Warm the front bearing to 120 C (248 F). Install the
bearing on the shaft with the groove down.
99
Forward Clutch, Assemble

STEP 1.
Verify the bleed valve in the clutch piston is clean and
free of any foreign material. Install new clutch pis-
ton inner and outer sealing rings. Install the clutch
piston in the clutch drum. Use caution not to damage
the new sealing rings.
STEP 2.
Install piston return spring spacer.
100
STEP 3.
Install piston return disc springs. Install the first
ternate the thirteen disc springs.
1. PISTON
2. SPACER
3. SHAFT
WARNING
STEP 4.
Compress the return disc springs and install the
spring retaining snap ring. Ensure the snap ring is
seated completely in the groove.
101
STEP 5.
tion.
STEP 6.
Install a new seal in the clutch end plate. Install the
end plate in the clutch drum.
STEP 7.
102
STEP 8.
Turn the clutch over and install the new piston seal
rings and expander rings.
Torque Converter Housing, Assemble

STEP 1.
If stator support was disassembled, install a new sealing ring and oil sealing ring on support. Press support
bearing into position.
Clean stator support mounting surface and tapped holes with solvent. Dry thoroughly, being certain tapped
holes are clean and dry.
Position stator support in converter housing alignment holes in support with holes in housing. Tap support
into place with a soft hammer.
Install six stator support screws and tighten to 16 to 22 N•m (12 to 16 lbf ft).
Assembly of stator support to converter housing must be completed within a 15-minute period from start of
screw installation. The screw is to be used for one installation only. If the screw is removed for any reason it
must be replaced. The Loctite® left in the holes must be removed with the proper tap and cleaned with solvent.
Dry hole thoroughly and install a new screw.
STEP 2.
Install a new O-ring on the idler shaft and position in the converter housing. Align the groove in the shaft with
the groove in the converter housing. Tap into place.
103
STEP 3.
Drop the lock ball into position.
STEP 4.
Install idler shaft spacer.
WARNING
STEP 5.
Warm the lower bearing race to 120 C (248 F) and in-
stall on shaft.
104
STEP 6.
Install spacer.
STEP 7.
Install idler gear.
WARNING
STEP 8.
Warm the upper bearing race to 120 C (248 F) and
install on shaft with the larger diameter up.
105
STEP 9.
Install spacer.
STEP 10.
Install the retainer nut and torque to 271 to 339 N•m
(200 to 250 lbf ft).
STEP 11.
Stake nut securely in shaft notch.
106
STEP 12.
Spread the ears on the turbine shaft retainer ring lo-
cated in the reaction member support. Tap the tur-
bine shaft and bearing into position. Ensure the snap
ring is seated completely in the groove.
STEP 13.
Spread the ears on the reverse clutch front bearing lo-
cating snap ring. Tap the clutch drum into place. En-
sure the snap ring is seated completely in the groove.
STEP 14.
Spread the ears on the third clutch front bearing lo-
cating snap ring. Tap the clutch drum into place. En-
sure the snap ring is seated completely in the groove.
107
Transmission Case, Assemble

STEP 1.
Install a new O-ring on the suction tube and install
the suction tube.
STEP 2.
Install the suction tube bolts and tighten to the spec-
ified torque in the Torque Specifications.
STEP 3.
Install the forward clutch rear bearing with bearing
locating ring toward the front of the transmission
case. Align the clutch oil sealing ring sleeve with the
notch in the transmission case. Tap the sleeve into
position.
108
STEP 4.
Install the sleeve retaining ring.
CAUTION
Do not damage oil sealing rings on clutch shaft when installing the drum assembly.
STEP 5.
Install the forward clutch drum assembly into the
sleeve.
109
STEP 6.
Install the forward shaft gear on the rear of the clutch
shaft with the long hub toward the bearing. Install
the gear retaining ring.
STEP 7.
Position the oil baffle in the transmission case.
110
STEP 8.
Install the output shaft and first clutch assemblies at
the same time. It is recommended to lower the output
shaft with an overhead lifting device while installing
the first clutch drum.
WARNING
STEP 9.
Warm the first clutch rear bearing to 120 C (248 F)
and install the bearing with the locating ring groove
up.
STEP 10.
111
STEP 11.
Install the speedometer drive gear.
NOTE: A light coat of grease will hold the gasket and O-ring in position.
STEP 12.
Position the gasket and O-ring onto the rear trans-
mission case.
NOTE: A light coat of grease will hold the lock ball in position.
STEP 13.
Place the lock ball into the output shaft rear bearing.
112
NOTE: The use of alignment studs will help in the installation of the rear cover.
STEP 14.
Align the lock ball in the bearing with the notch in
the rear cover. Tap the rear cover into position.
STEP 15.
Apply Loctite® #262 to the rear cover bolts and install
the washers and rear cover bolts. Tighten the bolts
to the specified torque in the Torque Specifications.
STEP 16.
From the front, tap the first speed clutch and output
shaft to the rear until the rear bearing locating ring
groove is exposed on both bearings. Install the first
speed clutch rear bearing locating ring in the groove.
113
STEP 17.
Install the output shaft rear bearing locating ring in
the groove.
STEP 18.
Place the gasket into position on the output shaft.
STEP 19.
Apply a very light coat of Permatex #2 to the outer
diameter of the rear output seal. Press the seal into
the bearing cap with the lip of the seal in. Verify that
the seal depth is 11.18 mm (0.44 in.).
114
STEP 20.
Install the washers and bolts and tighten to the
torque specified in the Torque Specifications.
STEP 21.
Place a new gasket in position on the first speed rear
bearing shaft.
STEP 22.
Install a new O-ring in the first speed rear bearing
shaft cap.
STEP 23.
Apply Loctite® #262 to the bearing cap bolts and in-
stall the washers and bolts. Tighten the bolts to the
torque specified in the Torque Specifications.
115
STEP 24.
Install the output flange.
STEP 25.
Install the output flange O-ring, washer, and nut.
STEP 26.
Tighten the flange nut to 271 to 339 N•m (200 to
250 lbf ft).
116
STEP 27.
Place the second speed clutch hub into position on the
first speed clutch shaft.
STEP 28.
Install the disc hub retaining ring, retaining ring re-
tainer, and retainer retaining ring snap ring.
STEP 29.
Place the third speed disc hub into position on the
output shaft.
117
STEP 30.
Install the disc hub retaining ring, retaining ring re-
tainer, and retainer retaining ring snap ring.
STEP 31.
Install the pilot bearing on the low clutch shaft.
NOTE: A light coat of grease will hold the gasket and O-ring in position.
STEP 32.
Place a new gasket and O-ring in position on the
transmission case.
118
STEP 33.
Install the pilot bearing on the second and third
speed clutch shaft.
CAUTION
Do not force this operation. When all clutches are properly aligned, the converter case will be tight
against the transmission.
STEP 34.
Use two alignment studs to help in the alignment of
the torque converter housing and the transmission
case. Install the converter housing assembly to the
transmission case using extreme caution as to align
the clutch pilots into the clutch disc hubs. As the
clutch pilots enter the disc hubs, turn the turbine
shaft and the output shaft back and forth to help
align the clutch inner discs with the disc hubs.
Install two housing to housing bolts and lockwashers.

Remove the alignment studs and install the remain-
ing bolts and lockwashers. Tighten the bolts to the
specified torque in the Torque Specifications.
STEP 35.
Place the auxiliary pump drive gear and bearing as-
sembly into position in the converter housing and in-
stall the capscrews.
119
STEP 36.
Tighten the capscrews to the torque specified in the
Torque Specifications.
STEP 37.
Place the charging pump drive gear and bearing as-
sembly into position. Install the capscrews.
STEP 38.
Tighten the capscrews to the torque specified in the
Torque Specifications.
120
STEP 39.
Install the pump idler gear and bearing assembly on
the shaft.
STEP 40.
Install the idler gear retaining ring.
CAUTION
Do not cut, break, or unhook the oil sealing ring on the support.
STEP 41.
Apply a thin coat of Permatex #2 to the outer diam-
eter of the oil baffle oil seal. Install the impeller as-
sembly and oil baffle.
121
STEP 42.
Install the oil baffle retaining ring. Ensure the snap
ring is seated completely in the groove.
STEP 43.
Place the impeller hub bearing spacer in position on
the stator support.
STEP 44.
Install the reaction member with the thick side of the
blades out.
122
STEP 45.
Install the reaction member retaining ring.
STEP 46.
Install the turbine hub locating ring.
STEP 47.
With a new impeller cover to impeller O-ring in place,
install the turbine and impeller cover assembly on
the turbine shaft.
123
STEP 48.
Install the impeller cover to impeller capscrews and
lockwashers. Tighten the capscrews to the torque
specified in the Torque Specifications.
STEP 49.
Install the turbine hub to turbine shaft retaining
ring.
STEP 50.
Install a new O-ring over the impeller cover bearing.
124
STEP 51.
Place the impeller bearing cap into position on the
impeller cover.
STEP 52.
Install the drive plate. See the Install section for in-
stallation details.
NOTE: A light coat of grease will hold the gasket in position.
STEP 53.
Place a new auxiliary pump adaptor gasket into po-
sition.
125
STEP 54.
Install the auxiliary pump adaptor.
STEP 55.
Install the capscrews and lockwashers. Tighten the
capscrew to the specified torque in the Torque Speci-
fications.
STEP 56.
If used, install the auxiliary pump adaptor gasket
and shipping cover.
126
STEP 57.
Install the capscrews and lockwashers. Tighten the
capscrews to the specified torque in the Torque Spec-
ifications.
STEP 58.
Place the new charging pump drive gasket into posi-
tion.
STEP 59.
Place the charging pump into position on the con-
verter housing. Install the washers and capscrews
and tighten to the specified torque in the Torque
Specifications.
127
STEP 60.
Place the filter adapter into position. Install the
washers and capscrews and tighten to the specified
torque in the Torque Specifications.
NOTE: It is recommended that the oil filter be changed after 50 and 100 hours of operation on a new, rebuilt,
or repaired transmission.
STEP 61.
Install a new oil filter.
STEP 62.
Use alignment studs for the reassembly of the control
valve to the transmission case. Install a new gasket.
128
STEP 63.
Install the control valve. See Control Valve Repair,
Install.
STEP 64.
Install the four speed sensors and tighten to the spec-
ified torque in the Torque Specifications.
INSTALL 4. Connect a lifting device to the transmission.

Make sure the lifting device has a lifting capac-
1. Remove all burrs from the flywheel mounting ity of at least 1200 kg (2650 lb). To stabilize
face and bore. the transmission, wrap a lifting strap around
the output yoke to keep the transmission from
2. Clean the drive plate surface with solvent.
tipping while being installed. Install the trans-
3. Check engine flywheel and housing for confor- mission into the frame.
mance to standard SAE No. 3 per SAE J927
5. Install two 63.50 mm (2.50 in.) long guide studs
and J1033 tolerance specifications for pilot bore
in the engine flywheel housing as shown in Fig-
size, pilot bore runout, and mounting face flat-
ure 26. Rotate the engine flywheel to align a
ness. Measure and record engine crankshaft end
drive plate mounting capscrew hole with the fly-
play. See Figure 25.
wheel housing access hole.
CAUTION 6. Rotate the torque converter to align the locat-

ing stud in the drive plate with the flywheel
Keep the transmission level when the transmis-
drive plate mounting capscrew hole positioned
sion is installed to the engine so the drive plate
in Step 5. Locate transmission on flywheel hous-
is not damaged.
ing. See Figure 27.
129

1. FLYWHEEL HOUSING
2. ALIGNMENT STUDS
3. FLYWHEEL
1. FLYWHEEL HOUSING
2. DIAL INDICATOR MOUNTING POSITION
3. FLYWHEEL
4. FLYWHEEL PILOT BORE
5. ENGINE 1. FLYWHEEL HOUSING
2. STUD WITH LOCK NUT AND WASHER
Figure 25. Flywheel and Housing Check 3. FLYWHEEL
4. IMPELLER COVER
5. DRIVE PLATES
Figure 27. Flywheel Housing and Drive Plates

Alignment
7. Align drive plate to flywheel and transmission to

flywheel housing guide studs. Install transmis-
sion to flywheel housing capscrews. Tighten cap-
screws to specified torque in the Torque Speci-
fications. Remove transmission to engine guide
studs. Install remaining capscrews and tighten
to specified torque.
8. Install drive plate attaching capscrew and

washer. Snug capscrew but do not tighten. Some
engine flywheel housings have a hole located on
Figure 26. Flywheel Alignment Studs the flywheel housing circumference in line with
130
1300 SRM 1082 Control Valve Repair
the drive plate capscrew access hole. See Fig- 14. Connect the oil lines to the oil cooler at the trans-
ure 23. A screwdriver or pry bar used to hold the mission.
drive plate against the flywheel will facilitate
installation of the drive plate capscrews. Rotate 15. Connect the wiring harnesses on the transmis-
the engine flywheel and install the seven re- sion and wires for the temperature sending unit
maining capscrews. Snug capscrews but do not on the transmission.
tighten. After all eight capscrews are installed,
16. Place the drive shaft between the transmission
torque each one to 35 to 39 N•m (26 to 29 lbf ft).
and the differential. Connect the drive shaft at
This will require tightening each capscrew and
the yokes.
rotating the engine flywheel until all eight cap-
screws have been tightened to specified torque. 17. Connect the heater hoses at the engine. Connect
wires and wiring harnesses at the transmission/
9. Measure engine crankshaft end play after trans-
engine.
mission has been completely installed on engine
flywheel. This value must be within 0.025 mm 18. Connect the cables at the battery. Connect the
(0.001 in.) of the end play recorded in Step 3. positive cable first and then the ground cable.
10. Install the two 3/4 × 31/2-inch bolts that fasten 19. Fill the transmission to the correct level [approx-
the transmission mounts to the frame. imately 25.6 liter (6.7 gal)].
11. Install the dipstick assembly on the transmis- 20. Check all oil levels and that all connections have
sion. been made.
12. Use a lifting device to hold and lift the hydraulic 21. Start the engine and check for leaks and for cor-
pump. Install the hydraulic pump. The drive rect operation.
shaft of the hydraulic pump is engaged in splines.
The pump will slide into the drive gear when the 22. Turn the key to OFF position to shutdown the
hydraulic pump is installed. engine.
13. Connect the hose from the hydraulic pump to the 23. Lower cab into position. See the section Opera-
steering system. Connect the oil hoses at the hy- tor’s Cab 100 SRM 1100.
draulic pump.
Control Valve Repair

REMOVE DISASSEMBLE AND ASSEMBLE
NOTE: Ensure that the area around the valve is clean
and that no foreign material can enter the control
WARNING
valve during removal. The transmission control valve has com-
pressed springs. When a plug is removed,
1. Disconnect the control valve electrical connector make sure a compressed spring does not sud-
and remove the wiring harness. See Figure 28 denly release and cause an injury.
and Figure 39.
The transmission control valve and the modulator
2. Loosen 15 bolts on control valve. You should be valve are normally only disassembled to repair a
able to move the valve slightly. leak, remove dirt, or replace a damaged spring.
Disassemble the control valve only as required to
3. Remove two bolts and replace with alignment make repairs. The machined parts are made to
studs. close tolerances. Make sure dirt does not enter the
control valve and cause a problem. See Figure 28
4. Remove the remaining loose bolts and remove
for information on disassembly and assembly of the
the valve.
transmission control valve.
131
Control Valve Repair 1300 SRM 1082
Figure 28. Control Valve Disassembly
132
1300 SRM 1082 Control Valve Repair

1. SPACER PLATE 21. PRESSURE CHECK SPOOL (4)
2. ADAPTER PLATE 22. PRESSURE CHECK SPRING (4)
3. SPACER PLATE GASKET 23. STOP (4)
4. PLUG 24. SPOOL INTENSIFIER (4)
5. SPOOL BODY 25. SPRING (4)
6. VFS SOLENOID (4) 26. O-RING
7. 12V SOLENOID (2) 27. RESTRICTOR PLUG
8. VFS CLAMP 28. STOP SPOOL (4)
9. CLAMP ON/OFF 29. ACCUMULATOR SPOOL (4)
10. PRESSURE SWITCH CLAMP 30. ACCUMULATOR SPRING (4)
11. SCREW 31. PLUG
12. WIRING HARNESS 32. O-RING
13. SOLENOIDS COVER 33. CAPSCREW
14. SPOOL 34. LOCKWASHER
15. SPOOL 35. SCREW
16. PILOT VALVE SPRING 36. LOCKWASHER
17. SWITCH PILOT SPOOL 37. PROTECTION COVER GASKET
18. PIN 38. PLUG
19. PRESSURE REDUCER SPOOL (4) 39. O-RING
20. PRESSURE REDUCER SPRING (4)
CLEAN AND INSPECT The importance of careful and thorough inspection of

all parts cannot be overstressed. Replacement of all
WARNING parts showing indication of wear or stress will elim-
inate costly and avoidable failures at a later date.
To prevent serious eye injury, always wear safe
eye protection when performing vehicle main-
tenance or service.
Housings
Clean interior and exterior of housings, bearing caps,
WARNING etc., thoroughly. Cast parts may be cleaned in hot so-
To avoid personal injury when cleaning parts, lution tanks with mild alkali solution providing these
work in a well-ventilated area, wear protective parts do not have ground or polished surfaces. Parts
clothing (face shield or safety glasses and pro- should remain in solution long enough to be thor-
tective gloves), and follow chemical manufac- oughly cleaned and heated. This will aid the evapo-
turer’s recommendations for safe usage. ration of the cleaning solution and rinse water. Parts
cleaned in solution tanks must be thoroughly rinsed
Solvent cleaners can be flammable, poisonous, with clean water to remove all traces of alkali. Cast
and cause burns. Examples of solvent clean- parts may also be cleaned with steam cleaner.
ers are carbon tetrachloride, emulsion-type
cleaners, and petroleum-based cleaners. To Oil Seals and Gaskets
avoid serious personal injury when using sol-
vent cleaners, carefully follow manufacturer’s Replacement of spring-loaded oil seals, O-rings,
instructions and these procedures: metal sealing rings, gaskets, and snap rings is more
• Wear safe eye protection. economical when the unit is disassembled than pre-
• Wear clothing that protects skin. mature overhaul to replace these parts at a future
• Work in a well-ventilated area. time. Further loss of lubricant through a worn seal
• Do not use gasoline or solvents that contain may result in failure of other more expensive parts
gasoline. Gasoline can explode. of the assembly. Sealing members should be handled
• Use hot solution tanks or alkaline solutions carefully, particularly when being installed. Cutting,
correctly. Carefully follow manufacturer’s scratching, or curling under of lips of seals seriously
instructions. impairs its efficiency. When assembling new metal
type sealing rings, these should be lubricated with
Clean all of the parts except the solenoids in solvent. a coat of chassis grease to stabilize rings in their
Clean the gaskets from the surfaces of the parts. In- grooves for ease of assembly of mating members.
spect the spools and bores for wear or damage. The Lubricate all O-rings and seals with recommended
spools must move freely in the bores. type Automatic Transmission Fluid before assembly.
133
Control Valve Repair 1300 SRM 1082
INSTALL 3. Torque all bolts in the same sequence to 20 to

25 N•m (14.8 to 18.5 lbf ft).
1. Using alignment studs install valve and a new
gasket. 4. Connect the control valve electrical connector.
2. Hand tighten all bolts in the proper sequence.

See Figure 29.
Figure 29. Control Valve Torque Pattern
134
1300 SRM 1082 Stall Test
Stall Test
The stall test checks the condition of the engine, Do not push (apply) the brake pedal. This action will
transmission clutches, and torque convertor. If the release the clutches in the transmission.
engine is not operating correctly, the stall speed will
be lower than the stall speed shown in the specifica- If the lift truck is equipped with a MONOTROL®
tion. If the torque convertor is not working correctly, pedal, do not apply the parking brake for the stall
the engine speed will not increase to the correct speed test. The application of the parking brake will
rpm. If the engine speed is greater than the stall put the transmission into NEUTRAL. Use the ser-
speed shown in the specification, the transmission vice brakes to stop the drive wheels from turning.
clutches are not holding or the wheels are turning.
The transmission clutches will not hold if the clutch CAUTION
pressure is not great enough or the clutches are
Do not hold the throttle open for more than 15
worn. The stall test is done in the highest possible
seconds at a time. Permit the engine to operate
gear.
at idle speed for 2 minutes between tests.
NOTE: Verify the engine governor is adjusted cor-
Release the accelerator immediately if the engine
rectly.
speed increases to the speed limit of the governor:
Verify the coolant level in the cooling system is cor- • Perkins Diesel Engine - 2300 rpm
rect. Verify the oil level in the transmission is correct. • Convertor Torque Stall Ratio for the Perkins Diesel
is 2.29.
• Cummins Diesel Engine - 2500 rpm
CAUTION • Convertor Torque Stall Ratio for the Cummins
Do not operate the convertor at stall condition Diesel is 1.94.
longer than 30 seconds at one time. Shift to • Cummins LPG Plus Engine - 2300 rpm
neutral for 15 seconds and repeat the proce- • Convertor Torque Stall Ratio for the Cummins LPG
dure until desired temperature is reached. is 1.94.
Excessive temperature, 120 C (248 F) maxi- If the stall speed is 50 to 200 rpm below the specifica-
mum, will cause damage to the transmission tion, the engine is not operating at full power. Check
clutches, fluid, convertor, and seals. the timing of the fuel injector, air filter, fuel system,
and compression.
Do a stall test to check the operation of the trans-
mission clutches. The engine and hydraulic oil must If the engine is operating correctly and the engine
be at operating temperature. Put a capacity load on speed is 250 to 500 rpm below the specification,
the forks to prevent the wheels from turning. Con- the torque convertor is not operating correctly. The
nect a tachometer to the engine. Put the lift truck torque convertor must be replaced as a unit. If the
against an object that cannot move and apply the engine governor is not adjusted correctly, the results
parking brake. Start the engine, put the transmis- will be wrong.
sion in FORWARD, and release the parking brake.
Push the accelerator pedal to half throttle and oper- If the stall speed is greater than the specification,
ate the transmission until the oil in the transmission the engaged clutch is not holding or the convertor is
is at least 70 C (158 F). damaged. Put the transmission in REVERSE to test
the other clutch assembly. Verify the truck is placed
After the transmission is at operating temperature, against an object that cannot move. If the engine rpm
push the accelerator pedal to full throttle. is greater than the specification in either direction,
do the pressure checks to check for the possible cause.
The correct stall speed for an engine with greater
than 50 hours of operation is 1950 rpm.
135
Transmission Calibration and Electrical Troubleshooting 1300 SRM 1082
Transmission Calibration and Electrical Troubleshooting

USERLINK® modulation can be achieved during range shifting
and forward reverse shifting.
The Userlink® is a system consisting of a laptop
computer, diagnostic software, and a USB (Univer- The clutch pack then will be used in a controlled and
sal Serial Bus) interface cable. With the Userlink secured way to its maximum capabilities for smooth
system, electronic diagnostics can be visualized and shifting, yet ensuring a proper lifetime.
software settings can be executed. The help text
contains all information required to work with the This provides the feature to shift up a gear under full
diagnostic software. traction. Two clutches then operate simultaneously
for a short period.
The Userlink is a total system comprising the follow-
ing: During the life of the transmission, it is advised to re-
1. A laptop computer. calibrate the clutch pre-fill after 2000 clutch engage-
2. Userlink software CD. ment hours (not engine hours).
3. USB interface cable.
A warning to recalibrate will appear on the instru-
4. Software for the interface cable (Included in the
ment cluster.
Userlink).
CONNECTION
Install the Userlink and USB interface drivers on a
laptop per instructions delivered with the Userlink
and USB interface cable.
Connect the Userlink to the truck using the USB in-

terface cable. The truck connector is located in the
side console of the cab. See Figure 30.
CLUTCH FILLING CALIBRATION

Purpose
This automatic calibration determines the amount
of pre-fill possible for each individual clutch pack by
statistical findings.
Because each clutch pack contains a considerable

number of parts, each having a tolerance and a posi-
tion tolerance, each clutch pack is slightly different.
Therefore the calibration needs to be done for each

new or repaired transmission for optimum shift char-
acteristics.
1. PLUG
By applying pre-fill through the modulation valves
before the real modulation starts, a more accurate Figure 30. Calibration Connection
136
1300 SRM 1082 Transmission Calibration and Electrical Troubleshooting
Clutch Filling Calibration Procedure during these 15 seconds, start the engine and let
the engine idle.
5. Stop pushing the "S" button when the screen dis-
2. Block the drive tires. plays:
3. Verify the forward reverse lever is in Neutral/
Reverse. Alternatively, the MONOTROL® pedal
should be in reverse.
NOTE: The help function of the Userlink gives guid-

ance how to use the tool.
4. Start the engine, go to the “Automatic calibra- 6. Push the "S" button again (once), the screen dis-
tion” tab via “Interface” and click the button plays:
“Clutch Filling Calibration.”
NOTE: To start the calibration, the transmission

oil temperature must be above 60 C (140 F). See
Heat-up Mode.
NOTE: Do not interfere with the calibration. Activat-

ing any controls or components will stop the calibra- NOTE: To start the calibration, the transmission
tion mode before completion. Switching to reverse oil temperature must be above 60 C (140 F). See
will stop the calibration. Heat-up Mode.
5. As soon as the forward reverse lever is put in NOTE: Do not interfere with the calibration. Activat-
forward, or the MONOTROL® pedal is switched ing any controls or components will stop the calibra-
to forward, the automatic calibration starts. tion mode before completion. Switching to reverse
The engine speed will remain at idle during will stop the calibration.
calibration. The complete automatic calibration 7. As soon as the forward reverse lever is put in
process takes approximately 12 to 15 minutes. forward or the MONOTROL® pedal is switched
The screen will show when the calibration has to forward, the automatic calibration starts. The
been completed. screen will display:
6. Switch the ignition OFF and wait a minimum of
5 seconds to restart the engine to view the results
of the new calibration.
Alternative Clutch Filling Calibration

Procedure
When the calibration has been completed, the display
It is possible to do the automatic clutch fill calibra- on the APC200 will show:
tion using the “S” button, only on the transmission
controller, without the Userlink as follows.
2. Block the drive tires.
3. Verify the forward reverse lever is in neutral/

reverse. Alternatively, the MONOTROL® pedal 8. Switch the ignition OFF and wait a minimum of
should be in reverse. 5 seconds to restart the engine to make use of the
result of the new calibration.
4. Press the button “S” on the APC200 transmission
controller for 15 seconds. Switch the ignition on
137
Heat-up Mode
The heat up mode allows the selecting of forward/re-
verse while the parking brake is activated, without
forcing neutral and will disable the inching and de-
clutch function. During the heat up mode the highest
gear is forced even when the shift lever is in a lower
gear. This combination allows the driver to heat up
the transmission by going into stall.
Heat-up Mode Stall Test

NOTE: During this warm-up procedure, it is possi-
ble that the converter out temperature of the trans-
mission exceeds the maximum limit. This is a con-
sequence of heating up the transmission using this
quick procedure. When this occurs, the engine speed
will be limited to half throttle when the APC200 has
engine control or forcing neutral when the APC200
has no engine control. To solve this, simply leave the
transmission in neutral for a minute and throttle the
engine to around 1300 rpm. This will allow the heat
in the converter to be evacuated. After one or two
minutes, you can resume the heating up procedure if
the transmission temperature has not reached 60 C
(140 F) yet.
Perform the following steps in order to heat up the

transmission:
1. DISPLAY DURING POWER-UP
Figure 31. APC200 Calibration Mode Display
2. Block the drive tires.
7. Press the "S" button again and release, the actual
3. Connect the Userlink (to monitor engine rpm). transmission temperature will display.
4. Verify the forward/reverse lever is in neutral/re- 8. When using the Userlink program open the
verse. Alternately the MONOTROL pedal "Monitor" screen to access the engine speed
should be in reverse. tachometer.
NOTE: There is an "S" and "M" button on the face of 9. Apply/hold the service brake.
the APC200 that allows transmission diagnostic/test
modes. 10. As soon as the forward/reverse lever is put in
forward position or the MONOTROL pedal is
5. Start the truck while holding the "S" button, con- switched to forward, you are in Heat-up Mode,
tinue holding the "S" button for approximately stalling in highest gear.
15 seconds, until the word "tran" displays on the
APC200. See Figure 31. 11. You will feel the transmission engage the gear
with a slight jerk.
NOTE: Four number 8s will show on the display for
the first 15 seconds. 12. Keep the engine at full throttle for about 15 sec-
onds and then put the gearbox in neutral by se-
6. Press the "M" button once and release, the word lecting NEUTRAL with the shift lever. Keep the
"heat" will replace the word "tran." engine at full throttle! See Figure 32.
138
1. Adjust the bolt on the brake pedal assembly until

there is 5 to 10 mm (0.20 to 0.40 in.) travel until
the brake lights come ON. See Figure 33.
Wet Brake
1. Adjust the bolt behind the pedal on the brake

pedal assembly so that the roller has contact with
the bolt on the valve and there is no free travel.
See Figure 33.
A. FULL C. FORWARD
B. IDLE D. NEUTRAL
Figure 32. Heat-Up Procedure
13. Keep the gearbox in NEUTRAL at full engine

throttle for about another 15 seconds.
14. Release the throttle pedal and decelerate the en-

gine to idle.
1. BRAKE PEDAL
2. PEDAL
15. Repeat Step 12 through Step 14 until the 3. ADJUSTMENT BOLT FOR BRAKE PEDAL
APC200 display shows a temperature above 4. ADJUSTMENT BOLT FOR BRAKE PEDAL
60 C (140 F). When the temperature is above COUPLING
60 C (140 F), the temperature indication on the 5. ADJUSTMENT BOLT FOR INCHING PEDAL
display starts blinking.
Figure 33. Brake Pedal Assembly
INCHING PEDAL CALIBRATION [UP TO
Inching Pedal Adjustment
S/N 2325 (F019)] AND [UP TO 3001 (G007)]
NOTE: Adjust the inching pedal so that the brake
Purpose pedal will move immediately with the inching pedal,
which means there is no free play with the brake
Inching is a controlled traction and braking mode de-
pedal.
pending on how far the inch-brake pedal has been
pressed in. NOTE: When the brake pedal and inching pedal
are in the released position, their position must be
It enables higher engine rpm to use hydraulics at a
equally high or in line.
wanted speed while the truck travel speed remains
low. 1. When activating the inching pedal, the brake
pedal should be activated as soon as the top of
The inching sensor calibration will set three points
the inching pedal and the top of brake pedal are
for the transmission controller to know the pedal be-
on same plane. Use the adjustment bolt for the
havior relative to braking in order to enable inching
brake pedal for adjustment. See Figure 33.
at the right inch-brake pedal position (braking).
2. Use the adjustment bolt for the inching pedal to
Brake Pedal Adjustment eliminate free travel of the inching pedal before
braking action occurs. See Figure 33
Dry Brake
3. Proceed with inching pedal sensor adjustment.
NOTE: Verify the dry brakes are properly adjusted.
139
Inching Pedal Sensor Adjustment 2. Use the Automatic Calibration mode of the User-
link program.
NOTE: When the brake pedals are not activated, the
analog output of the inch sensor should be between 3. Select the Inching Pedal Calibration mode of the
600 and 700 mV. Use Userlink to verify voltage. This Userlink program and follow the instructions.
means the sensor is slightly turned as the lowest
reading is 450 mV. NOTE: See the section Diagrams 8000 SRM 1103,
Brake System Schematic for the locations of the pres-
1. Loosen the two, one shown, sensor mounting sure check ports.
bolts. See Figure 34.
It’s important to move slowly from fully released
pedal to brake pressure point. Never engage the
pedal while calibrating or an error in the calibration
will occur. If the brake pressure point has been
exceeded without calibrating, engage pedal till fully
release pedal and repeat the movement.
With trucks that have Air Brakes: the brake pres-

sure point is when the brake lights first come ON
and should be within0.3 ± 0.05 bar (4 ± 1 psi).
With trucks that have Wet Brakes: the brake pres-

sure point is when the brake pressure reaches 30 bar
(435 psi).
NOTE: Before the 3 calibration points are inserted

and saved, the APC200 will make use of its default
calibration points. It’s possible that a certain per-
centage will be shown. This percentage however will
1. MOUNTING BOLT adjust itself after the new calibration points have
been entered.
Figure 34. Sensor Adjustment
4. The following three points have to be calibrated
2. Rotate the sensor in the slotted holes underneath while the engine is running:
the inching pedal so that the output voltage of the • Fully released pedal. (dry and wet brake: 600-
sensor of the released inching pedal is between 700 mV)
600 and 700 mV. • Brake pressure point. [dry brake: 900-1300
mV when brake lights first come ON: wet
NOTE: To read the voltage, use the Inching Pedal brake: 1800-2200 mV when brake pressure
Calibration mode of the Userlink program. reaches 30 bar (435 psi)].
• Fully depressed pedal. (dry and wet brake:
3. Tighten the mounting screws and verify the volt- 2500-4000 mV)
age output of the sensor is correct.
Verification/Adjustment of Inching Pedal
Inching Pedal Calibration Procedure
Sensor When the Pedal is Fully Released
NOTE: Verify the inching pedal sensor is installed
1. Turn the start key to the ON position.
and adjusted properly.
2. Push the "S" button until 8888 shows in the
NOTE: Start the calibration once the air tank is fully
APC200 display.
pressurized (compressor switched off) or when the
hydraulic accumulators are fully pressurized (± 30 3. Push the "M" button several times until AinP
seconds after starting the engine). shows in the APC200 display.
1. Start the lift truck. 4. Push the "S" button several times until 03.47
shows in the APC200 display
140
NOTE: The voltage setting must be between 600-700 It enables higher engine rpm to use hydraulics at a
mV. wanted speed while the truck travel speed remains
low.
5. Voltage reading of the inching pedal sensor will
be shown after a 1 to 2 second delay. The inching sensor calibration will set two points for
the transmission controller to know the pedal behav-
6. The voltage setting must be between 600-700 mV. ior relative to braking in order to enable inching at
the right inching/brake pedal position (braking).
7. Turn the start key to the OFF position.
Brake Pedal Adjustment
Manual Inching Pedal Sensor Calibration
Procedure Dry Brake
NOTE: This procedure will be done without the User- NOTE: Verify the dry brakes are properly adjusted.
link software.
1. Adjust the bolt (3) behind the pedal on the brake
1. Turn the start key to the ON position. pedal assembly until there is 5 to 10 mm (0.20 to
0.40 in.) travel until the brake lights come ON.
2. Push the S-button until "trAn" shows in the See Figure 35.
APC200 display.
Wet Brake
3. Push the "M" button several times until "brAH"
shows in the APC200 display. 1. Adjust the bolt (3) behind the pedal on the brake
pedal assembly so that the roller has contact with
4. Push the "S" button once, "brA_" will show in the the bolt on the valve and there is no free travel.
APC200 display. See Figure 35.
5. Push the "S" button in the pedal up position.
6. Apply the inching pedal slowly until the brake

lights come ON with a air brake system, or un-
til brake pressure reads 30 bar (435 psi)with a
wet brake system. When the pedal is depressed
too far, fully release the pedal and slowly apply
again. Then push the S-button.
7. Fully depress the inching pedal and push the

S-button again.
8. When done appears in the APC200 display, turn

the start key to the OFF position and wait a min-
imum of 5 seconds before switching the start key
to the ON position.
1. BRAKE PEDAL
INCHING PEDAL CALIBRATION[S/N 2326 2. INCHING PEDAL
3. ADJUSTMENT BOLT FOR BRAKE PEDAL
AND UP (F019)], [S/N 3002 AND UP (G007)] 4. ADJUSTMENT BOLT FOR BRAKE PEDAL
COUPLING
Purpose 5. ADJUSTMENT BOLT FOR INCHING PEDAL
Inching is a controlled traction and braking mode de- Figure 35. Brake Pedal Assembly
pending on how far the inching/brake pedal has been
pressed in.
141
Inching Pedal Adjustment customer requirements. See Figure 35 and Fig-

ure 37.
Dry Brake
1. Adjust the bolt (5) behind the pedal on the inch-

ing pedal assembly to same plane with brake
pedal in not activated position (pedal up posi-
tion). See Figure 35.
2. Adjust the adjustment bolt for brake pedal cou-

pling (4) so that the inching pedal will have a free
play of approximately 20 to 25 mm (0.8 to 1 in.)
before the brake pedal starts to move. See Fig-
ure 35 and Figure 36
Figure 37. Wet Brake Inching Pedal Adjustment
Inching Pedal Sensor Adjustment Using

Userlink® Program
NOTE: When the inching pedal is not activated (pedal
up position), the analog output of the inch sensor
should be between 500 and 600 mV.
NOTE: A slight pre-load of the potentiometer arm is

required to achieve the output voltage for the pedal
up position. Use Userlink to verify voltage.
Figure 36. Dry Brake Inching Pedal
Adjustment 1. Loosen the two, one shown, sensor mounting
bolts. See Figure 38.
Wet Brake
2. Rotate the sensor in the slotted holes underneath
1. Adjust the bolt (5) behind the pedal on the inch-
the inching pedal so that the output voltage of the
ing pedal assembly to same plane with brake
sensor of the released inching pedal is between
pedal in not activated position (pedal up posi-
500 and 600 mV.
tion). See Figure 35.
NOTE: To read the voltage, use the Inching Pedal
2. Adjust the adjustment bolt for brake pedal cou-
Calibration mode of the Userlink program.
pling (4) so that the inching pedal has no free
play. Both pedals should move together when ap- 3. Tighten the mounting screws and verify the volt-
plying the inching pedal. The additional spring age output of the sensor is between 500 and 600
installed under the inch pedal provides flexibility mV, with the pedal in up position.
when adjusting the brake/inching overlap, per
142
• Fully depressed pedal. (dry and wet brake:

2500-3700 mV)
5. Check the inching percentage of the transmis-

sion by using the Userlink program. When the
pedal is released, the inching percentage should
be at 0%. If that value deviates from 0% the
“Inching Pedal Calibration” process must be re-
peated.
Inching Pedal Sensor Adjustment Using

the APC200
NOTE: This program will be done without the User-
link software.
1. Turn the start key to the ON position.
2. Push the “S” button until the APC200 display

1. MOUNTING BOLT
shows:
Figure 38. Sensor Adjustment
Inching Pedal Sensor Calibration

Procedure Using Userlink® Program
NOTE: Verify the inching pedal sensor is installed
and adjusted properly.
3. Push the “M” button until the APC200 display
NOTE: Start the calibration once the air tank is fully shows analog input:
pressurized (compressor switched off) or when the
hydraulic accumulators are fully pressurized (± 30
seconds after starting the engine).
1. Start the lift truck.
2. Use the Automatic Calibration mode of the User-

link program. 4. Push the “S” button until the APC200 display
shows voltage in V:
3. Select the Inching Pedal Calibration mode of the
Userlink program and follow the instructions.
NOTE: Never engage the pedal while calibrating or

an error in the calibration will occur.
NOTE: Before the 2 calibration points are inserted

and saved, the APC200 will make use of its default NOTE: The voltage reading of the inching pedal sen-
calibration points. It’s possible that a certain per- sor will be shown after a 1-2 second delay.
centage will be shown. This percentage however will
adjust itself after the new calibration points have NOTE: The voltage setting must be between 500-600
been entered. mV.
4. The following two points have to be calibrated 5. Verify the voltage reading of the inching pedal
while the engine is running: sensor. The reading must be between 500-600
• Fully released pedal. (dry and wet brake: 500- mV.
600 mV)
6. If the reading is not within range, adjust the
inching pedal sensor as mentioned in section
143
Inching Pedal Sensor Adjustment until the read- TROUBLESHOOTING

ing is within specifications.
For troubleshooting, use the Userlink by using the
7. Turn start key to the OFF position. help text.
Inching Pedal Sensor Calibration The help functions provide the necessary education
Procedure Using the APC200 and guidance.
NOTE: This procedure will be done without the User- All sensors and switches feature electric/electronic
link software. resistance in different modes to enable the controller
to detect wiring or connecting problems (full open or
1. Turn the start key to the ON position. close/shortcut condition).
2. Push the “S” button until the APC200 display TRANSMISSION DISPLAY WARNING
shows: CODES
NOTE: The wire and controller pin numbers listed in
Table 2 are as shown in Figure 45.
When there is an engine or transmission fault, the

instrument cluster will display a fault code. See Ta-
ble 6.
3. Push the “M” button until the APC200 display
shows: NOTE: The wires referred to in Table 6 are not the
wires shown in Figure 39 and Figure 40. The pin
numbers that are used in Figure 39 and Figure 39
are shown in Table 1 and Table 2.
The transmission fault starts with a "t", followed by

zero’s, then the warning code. The instrument clus-
ter logs the warning code. To access the warning
4. Push the “S” button once, the APC200 display codes, see the following procedures:
shows:
Access
The display keeps records of the warning codes. To
gain access to the warning codes, proceed as follows:
1. Apply parking brake.
5. Push the "S" button in the pedal up position. 2. Turn ON ignition, but do not start lift truck.
6. Fully depress inching pedal and push the "S" but- 3. Turn ignition OFF and ON 3 times, switch 1 time
ton again. per second. After the first OFF and ON cycle, the
display will show a 1. After the second OFF and
7. When the calibration has been completed, the ON cycle, the display will show a 2. After the
APC200 display will show: third OFF and ON cycle, the display will show a
3.
The display is now in fault log mode and after approx-

imately 3 seconds, faults that have been recorded
will be displayed. The display shows a letter and 4
numbers for each warning code. For engine warn-
ing codes, the letter is E. For transmission warning
8. Switch the ignition OFF and wait a minimum of codes, the letter is t. The numbers represent the fol-
5 seconds to start the engine to make use of the lowing:
results of the new calibration. • Transmission/Engine warning code
144
• Hourmeter reading at last occurrence

• Hourmeter reading at first occurrence
• Number of occurrences of current fault
The faults will be shown in the opposite sequence of

occurrence: The last fault that occurred first and the
first fault that occurred last. When all warning codes
logged have been shown, the display will continue to
show all logged warning codes until the user exits the
system.
Figure 40. Controller Connector (Rear View)
Display warning code "t.com" is shown when the fol-
lowing occurs: Table 1. Controller Connector J2 Wire to
• Cyclic message not received Pin Number Cross Reference Chart
• Wrong error messages from transmission con-
troller Wire Pin Hyster Pin Description/
Function Abbreviation
Clear
599D M2 CANH Line for
To clear the warning codes logged in the display, pro- communication
ceed as follows: with
controllers/
1. Access into the fault log mode. See Access. PC’s/CAN Hi
2. Repeat the same procedure to clear the fault log. 439 N2 RXD RS232 RXD
communication/
When completed, the display will show "ok clr", oth- TUNING LINK
erwise "no clr".
438 P2 TXD RS232 TXD
Exit communication/
TUNING LINK
To exit the fault log mode, turn the ignition OFF
and ON and leave ignition ON for more than 2 sec- 437 R2 SS3 +8 Volt supply
onds. The cluster will also exit to normal mode when to Turbine
the parking brake is released or when the engine is speed sensor
started. 121 S2 SPWR Battery Supply
Voltage (Key
switch ON)
812 M3 DIGIN 7 Transmission
Shift Lever
Position D and
2/3 Selection
Manual/
Automatic
819B N3 DIGIN 8 Status of
Parking Brake,
OFF/ON
479 R3 ANI 3 Ref. Voltage,
Brake Pedal
Position
Figure 39. Control Valve Electrical Connector
646 S3 SGND Ground/GND
Pin Configuration (View From Pin Side)
145
Table 1. Controller Connector J2 Wire to Pin Table 2. Controller Connector J1 Wire to Pin
Number Cross Reference Chart (Continued) Number Cross Reference Chart (Continued)
Wire Pin Hyster Pin Description/ Wire Pin Hyster Pin Description/
Function Abbreviation Function Abbreviation
477 M1 ANI 4 5 Volt Reference 480 F1 VFS2 + Pulse width
Voltage modulated
voltage supply
598D L2 CANL Line for
for Reverse
communication
Variable Force
with
Solenoid/VFS
controllers/
REV+
PC’s/CAN Lo
481 G1 VFS2 Sense return
line of Reverse
Table 2. Controller Connector J1 Wire to Variable Force
Pin Number Cross Reference Chart Solenoid/VFS
REV -
Wire Pin Hyster Pin Description/
484 H1 VFS3 + Pulse width
Function Abbreviation
modulated
394B A1 PPWR Power; Battery voltage, supply
plus/PPWR for 1st/3rd gear
Variable Force
482 B1 VFSO + Pulse width
Solenoid/VFS
modulated
1st/3rd +
voltage supply
for Forward 485 J1 VFS3 Sense return
Variable Force line of 1st/3rd
Solenoid/VFS gear Variable
FWD + Force Solenoid/
VFS 1st/3rd -
483 C1 VFSO Sense return
line of Forward 488 K1 DO0 + Voltage
Variable Force supply for
Solenoid/VFS Drive Solenoid/
FWD - DRIVE + (Drive
solenoid will be
486 D1 VFS1 + Pulse width
activated when
modulated
operational
voltage supply
conditions are
for 2nd gear
correct)
Variable Force
Solenoid/VFS 489 K2 DO3 - supply to
2nd + Drive Solenoid/
DRIVE -
487 E1 VFS1 Sense return
line of 2nd gear 433 E3 SS1 - supply to
Variable Force Output Speed
Solenoid/VFS Sensor
2nd -
434 F3 SS2 + 8 Volt supply
to Engine Speed
Sensor
146
Table 2. Controller Connector J1 Wire to Pin Table 2. Controller Connector J1 Wire to Pin
Number Cross Reference Chart (Continued) Number Cross Reference Chart (Continued)
Wire Pin Hyster Pin Description/ Wire Pin Hyster Pin Description/
Function Abbreviation Function Abbreviation
435 G3 SS2 - supply to 808C J2 DIGIN 5 XMSN Shift
Engine Speed Lever Position
Sensor R
436 H3 ANI 1 Transmission 490 A2 ANI 0 Transmission
Temperature hydraulic
oil pressure
809 B2 DIGIN 0 XMSN Shift
Control
Lever Position
Solenoid/
1, 1st gear
PRESSURE FB
811 C2 DIGIN 1 XMSN Shift
645 A3 GND Ground/GND
Lever Position
2, 2nd gear 417 B3 SS0 + 8 Volt supply
to Drum speed
810 D2 DIGIN 2 XMSN Shift
sensor
Lever Position
2-3, 2nd/3rd 418 C3 SS0 - supply to
gear Drum speed
sensor
492 F2 DO2 + Voltage
supply for 419 D3 SS1 + 8 Volt to
Selection Output speed
1st/3rd gear sensor
Solenoid 1/3
477B J3 ANI 2 Cooler
SELECT
Temperature
807B H2 DIGIN 4 XMSN Shift
478C K3 GND Ground/GND
Lever Position
F
147
Table 3. Common Calibration Condition Messages
Code Cause Action

The APC200 expects the shift Put the shift lever back in NEUTRAL.
lever to be in NEUTRAL, but
finds it in another position.
(FORWARD OR REVERSE)
The APC200 expects the parking Apply the parking brake.
brake to be ON while it is OFF.
The APC200 has detected Verify that the parking brake is ON and
output speed. working properly. If this is already the case,
you will have to hold the lift truck at a
standstill by applying the service brake.
Once the lift truck has been stopped,
the APC200 will ask the operator to
shift to FORWARD before continuing
the calibration.
Engine rpm is too low according If the lift truck is equipped with
to the limit that is necessary throttle-by-wire, the engine rpm will be
for calibration. automatically adapted. In the other case,
the operator has to change the throttle pedal
Engine rpm is too high according position until the display looks as follows:
to the limit that is necessary
for calibration.
After being too low or too high, the

engine rpm is coming back into the
correct boundaries for calibration.
When the temperature becomes Use the "M" button on the APC200 to
too low during the automatic go back to the heat mode and the "S"
calibration, the APC200 display button to trigger this mode. Warm-up the
indicates the actual transmission transmission again until the temperature
temperature. reaches 60 C (140 F). Then go back to the
automatic tuning mode by the "M" button
and trigger this one again to continue.
148
Table 4. Calibration Codes During Calibration
Calibration Code Explanation

E.1.XX Touch pressure calibration
E.2.XX Optimize fill time
Table 5. Error Codes During Calibration
XX Error When Code Possible Causes

Code Appears
1-5, 7-9, Unexpected • Engine does not respond to target engine speed.
11-13, 15, Algorithm • Vehicle started moving.
17- 24 response during • Bad parameter configuration.
calibration.
06 During calibration • Turbine speed does not reach minimum value during shifting itera-
the turbine speed tion process caused by slipping clutch or bad turbine speed signal.
signal does not
reach a minimum
value.
10 Transmission • Caused by shutdown error code during calibration. Example: 20.60
failure during error code during calibration.
calibration.
14 During calibration • Turbine speed does not decrease caused by too high internal leakage
the turbine speed and/or slipping clutch or bad turbine speed signal.
signal does not
decrease.
16 During calibration • Turbine speed does not decrease, caused by too high internal leakage
the turbine speed and/or slipping clutch.
signal is too low to
start calibration.
25 Early touch • Too much drag because of thick oil.
detection during • Sticking or burnt clutch with causes turbine drop before pressure is
touch pressure applied.
calibration. Too • Speed sensor problem.
much drag • Faulty VFS (Variable Forced Solenoid).
26 No touch • Slipping clutch or too high internal leakage.
detection during • Speed sensor problem.
touch pressure • Faulty VFS (Variable Forced Solenoid).
calibration.
149
Table 6. Display Warning Codes
Controller’s
DWC Type Explanation Driver Action Fault Cause Troubleshooting
Action
See Figure 40 and Table 2 for the cross referencing of the controller wire to pin numbers.
t0050 S There is a Controller Stop machine Hardware Replace the
problem related reverts to and contact related fault transmission
to the internal a shutdown maintenance for - related to controller.
RAM (in CPU). mode and force troubleshooting. the internal
neutral 0. RAM.
to the system a shutdown maintenance for - related to controller.
RAM (in CPU). mode and force troubleshooting. the system
neutral 0. RAM.
to the external a shutdown maintenance for - related to controller.
RAM (in CPU). mode and force troubleshooting. the external
neutral 0. RAM.
t0053 S There is Controller Stop machine Hardware Replace the
a problem reverts to and contact related fault transmission
related to the a shutdown maintenance for - related to controller.
Flash program mode and force troubleshooting. the flash
memory. neutral 0. program
memory.
t2060 S Pressure Controller Stop machine The pressure Check the wiring
feedback line reverts to and contact feedback between the
is indicating a shutdown maintenance for sensor is in controller and the
there is no mode and force troubleshooting. the 1500 - pressure feedback
system pressure neutral 0. 4000 ohm sensor. Check the
present, range, while pressure feedback
although it should be sensor (engine
pressure should in the 500 running/stopped).
be there. - 1500 ohm
range.
t2061 S Pressure Controller Stop machine The pressure Check the wiring
feedback line reverts to and contact feedback between the
is indicating a shutdown maintenance for sensor is in controller and the
there is system mode and force troubleshooting. the 500 - pressure feedback
pressure neutral 0. 1500 ohm sensor. Check the
present, range, while pressure feedback
although it should be sensor (engine
pressure should in the 1500 running/stopped).
NOT be there. - 4000 ohm Check the engine
range. speed sensor signal.
150
Table 6. Display Warning Codes (Continued)
Controller’s
Action
t3004 S Power supply Controller will Stop machine Power supply Check power
(24V) out of save all logged and contact to the supply cables to the
range - below information to maintenance for controller is controller. Check
minimum. flash, will power troubleshooting. below 16V. alternator, check
down, and force the connection
all outputs off. cables between the
battery and the
alternator, check
the battery.
t3005 A Power supply Controller will Contact Power supply Check power
(24V) out of have reduced maintenance for to the supply, check if
range - above proportional troubleshooting. controller is a jump start setup
maximum. control accuracy above 32V. is still connected.
due to reduced
PWM duty
cycle.
t3100 A Voltage supply The controller Contact Voltage Check power
for the sensors: will have maintenance for supply for supply. Check the
Vsense (8V) reduced sensor troubleshooting. the sensors: controller.
is out of signals. Vsense (8V)
range - below is below 7.2V.
minimum.
t3101 A Voltage supply The controller Contact Voltage Check power
for the sensors: will have maintenance for supply for supply. Check the
Vsense (8V) reduced sensor troubleshooting. the sensors: controller.
is out of signals. Vsense (8V)
range - above is above 8.8V.
maximum.
t4006 A Invalid shift The controller Contact The Check the wiring
lever direction will force maintenance for controller between the
detected. neutral. troubleshooting. receives controller and
from the the shift lever
shift lever concerning the
a request forward and the
to engage reverse signal.
forward and
reverse at the
same time.
151
Controller’s
Action
t4008 B Seat orientation The controller Stop the vehicle, Seat Check the seat
input was will force put the shift orientation orientation switch
changed while neutral. lever in neutral input was or train the driver
the parking and put the changed to change the
brake was not parking brake while the seat orientation
active, or/and on until the fault parking according to the
the shift lever disappears. brake was correct procedure.
was not in not active,
neutral, or/and or/and the
the machine shift lever
was not at was not
standstill. in neutral,
or/and the
machine
was not at
standstill.
t4106 A Invalid shift The controller Contact The Check the wiring
lever position will not allow maintenance for controller between the
detected. range shifting; troubleshooting. receives from controller and
however, the shift the shift lever
driving is still lever an concerning the
possible. unknown range signals.
range shift
pattern.
t4204 S/A The actual Controller will Contact The Check the
transmission flag the fault maintenance for transmission transmission, in
ratio is too low. - this fault is troubleshooting. ratio order to understand
indicating that measured by if and which clutch
one or more the controller is slipping. Check
clutches are is more than the transmission
slipping. 5% below the ratio settings of
value of what the controller.
it should be. Check speed sensor
signals.
t4205 S/A The actual Controller will Contact The Check the
transmission flag the fault maintenance for transmission transmission, in
ratio is too high. - this fault is troubleshooting. ratio order to understand
indicating that measured by if and which clutch
one or more the controller is slipping. Check
clutches are is more than the transmission
slipping. 5% above the ratio settings of
value of what the controller.
it should be. Check speed sensor
signals.
152
Controller’s
Action
t4303 A The Controller will Contact The Check the wiring
transmission flag the fault. maintenance for converter out between the
converter out troubleshooting. temperature controller and
temperature sensor is not the converter
sensor is out of connected or out temperature
range. shorted. sensor. Check
the converter
out temperature
sensor.
t4307 A The Controller will Take notice of The Check the
transmission flag the fault in the fault, and controller converter out
converter out order to indicate try to bring measured a temperature and
temperature the driver of the the converter converter out the converter
sensor > 100 C warning level. temperature to temperature out temperature
(212 F). a lower level. between sensor.
100 C
(212 F)and
the allowed
limit.
t4308 A The The controller Stop machine, The Check the
transmission is protecting the select neutral controller converter out
converter out transmission and apply full measured a temperature and
temperature and does not throttle (limited converter out the converter
sensor > 120 C allow that the to 50%) in order temperature out temperature
(248 F). converter out to cool the above the sensor.
temperature transmission allowed
exceeds its oil below 100 C limit.
limit. The (212 F) (until
controller the fault t4303
will force the is gone). Once
transmission to the converter
neutral, and out temperature
if engine is is below 100 C
controlled, the (212 F), continue
engine will be driving the
limited 50% of machine.
its maximum
speed.
153
Controller’s
Action
t4410 A No EEC2 The controller Contact No EEC2 Check engine
message will flag the maintenance for message on controller and CAN
(throttle fault and the troubleshooting. the CANbus connection to the
position from TSC1 message when APC200.
the engine will send the expected.
controller) on idle position
the CANbus to the engine
when expected. controller.
t4506 B Invalid pattern The controller Contact Invalid Check the
for the reduced will limit the maintenance for pattern for redundant reduced
vehicle speed vehicle speed troubleshooting. the reduced vehicle speed
redundant to the reduced vehicle speed switches and the
digital inputs speed. redundant wiring connected
(2 inputs used). digital inputs from these switches
(2 inputs to the APC200.
used).
t4605 A The The controller Release the The Release the inching
transmission will open inching pedal transmission pedal and cycle
has exceeded or close the and cycle the has the shift lever via
the maximum inching clutch shift lever via exceeded the neutral back in the
torque during depending of the neutral back maximum selected direction.
inching. GDE parameter in the selected torque
selection. direction in during
order to get drive inching.
again.
t5000 S Pressure Controller Contact The Check the wiring
feedback sensor reverts to a maintenance for resistance of between the
(wire on pin "limp home" troubleshooting. the pressure controller and the
A2) related mode. feedback pressure feedback
fault: pressure sensor is sensor. Check the
feedback sensor below 500 pressure feedback
is shorted to ohms. sensor.
ground.
t5001 S Pressure Controller Contact The Check the wiring
feedback sensor reverts to a maintenance for resistance of between the
(wire on pin "limp home" troubleshooting. the pressure controller and the
A2) related mode. feedback pressure feedback
fault: pressure sensor sensor. Check the
feedback exceeds 4000 pressure feedback
sensor is not ohms. sensor.
connected.
154
Controller’s
Action
t5100 A Temperature The controller Contact The Check the wiring
sensor (wire will limit the maintenance for temperature between the
on pin H3) transmission troubleshooting. sensor is controller and
related fault: temperature shorted to the combined
temperature measurement ground. transmission
sensor is to the lowest sump temperature
shorted to clipped value and speed
ground. in its settings, sensor. Check
which will the combined
result in a bad transmission sump
temperature temperature and
compensation. speed sensor.
t5101 A Temperature The controller Contact The Check the wiring
sensor (wire will limit the maintenance for temperature between the
on pin H3) transmission troubleshooting. sensor is not controller and
related fault: temperature connected. the combined
temperature measurement transmission
sensor is not to the highest sump temperature
connected. clipped value and speed
in its settings, sensor. Check
which will the combined
result in a bad transmission sump
temperature temperature and
compensation. speed sensor.
t5200 B Temperature Controller will Contact The temper- Check the wiring
switch cooler in flag the fault, maintenance for ature switch between the
(wire on pin J3) and will use the troubleshooting. cooler in is controller and
related fault: lowest clipped shorted to the temperature
temperature value in its ground or switch. Check
switch cooler settings. measured the temperature
in is shorted to input value switch.
ground. is below the
minimum
value (cor-
responding
with 0%).
155
Controller’s
Action
t5201 B Temperature Controller will Contact The tempera- Check the wiring
switch cooler in flag the fault, maintenance for ture switch between the
(wire on pin J3) and will use the troubleshooting. cooler in controller and
related fault: lowest clipped is not con- the temperature
temperature value in its nected, or switch. Check
switch cooler settings. measured the temperature
in is not input value switch.
connected. is above the
maximum
value (cor-
responding
with 100%).
(wire on pin J3) and will use the troubleshooting. cooler in controller and the
related fault: lowest clipped measured device connected to
temperature value in its input value this temperature
switch cooler settings. is below the switch. Check this
in value is minimum device connected.
below the value (cor- Check if the
minimum value responding calibration is
calibrated. with 0%). done correctly -
recalibration of
this temperature
switch.
(wire on pin J3) and will use troubleshooting. cooler in controller and the
related fault: the highest measured device connected to
temperature clipped value input value this temperature
switch cooler in its settings. is above the switch. Check this
in value is maximum device connected.
above the value (cor- Check if the
maximum value responding calibration is
calibrated. with 100%). done correctly -
recalibration of
this temperature
switch.
156
Controller’s
Action
t5300 B Inching pedal Controller will Contact The inching Check the wiring
sensor (wire on flag the fault, maintenance for pedal sensor between the
pin R3) related and will use the troubleshooting. is shorted controller and
fault: inching lowest clipped to ground, the inching pedal
pedal sensor value in its or measured sensor. Check
is shorted to settings. input value the inching pedal
ground. is below the sensor. Check if
minimum the calibration is
value (200 done correctly -
mV). recalibration of
the inching pedal
sensor.
sensor (wire on flag the fault, maintenance for pedal sensor between the
pin R3) related and will use the troubleshooting. is not controller and
fault: inching lowest clipped connected, the inching pedal
pedal sensor is value in its or measured sensor. Check
not connected. settings. input value the inching pedal
is above the sensor. Check if
maximum the calibration is
value (4800 done correctly -
mV). recalibration of
the inching pedal
sensor.
sensor (wire flag the fault, maintenance for pedal sen- between the
on pin R3) and will use the troubleshooting. sor measured controller and the
related fault : lowest clipped input value device connected
inching pedal value in its is below the to this inching
sensor value settings. minimum pedal sensor.
is below the value (cor- Check this device
minimum value responding connected. Check
calibrated. with 0% - 100 if the calibration
mV). is done correctly
- recalibration of
this inching pedal
sensor.
157
Controller’s
Action
sensor (wire flag the fault, maintenance for pedal sen- between the
on pin R3) and will use troubleshooting. sor measured controller and the
related fault : the highest input value device connected
inching pedal clipped value is above the to this inching
sensor value in its settings. maximum pedal sensor.
is above the value (cor- Check this device
maximum value responding connected. Check
calibrated. with 100% + if the calibration
100 mV). is done correctly
- recalibration of
this inching pedal
sensor.
t5400 A 5 volt reference Controller will Contact The Check the reference
voltage out flag the fault. maintenance for reference power supply of the
(wire on pin M1) The controller troubleshooting. power supply temperature switch
related fault: 5 uses the 5 (5V ref.) and inching pedal.
volt reference volt reference for the
voltage out voltage out temperature
is shorted to to have a switch and
ground. reference power inching pedal
supply for the is below 4.8V.
temperature
switch and
inching pedal
sensor.
t5401 A 5 volt reference Controller will Contact The Check the reference
voltage out flag the fault. maintenance for reference power supply of the
(wire on pin M1) The controller troubleshooting. power supply temperature switch
related fault: 5 uses the 5 (5V ref.) and inching pedal
volt reference volt reference for the sensor.
voltage out is voltage out temperature
not connected. to have a switch and
reference power inching pedal
supply for the sensor is
temperature above 5.2V.
switch and
inching pedal
sensor.
158
Controller’s
Action
t5500 B Hydraulic lever Controller will Contact The Check the wiring
(wire on pin P1) flag the fault, maintenance for hydraulic between the
related fault : and will use the troubleshooting. lever is controller and the
hydraulic lever lowest clipped shorted to hydraulic lever.
is shorted to value in its ground, or Check if this device
ground. settings. measured is connected.
input value
is below the
minimum
value (200
mV).
t5501 B Hydraulic lever Controller will Contact The Check the wiring
(wire on pin P1) flag the fault, maintenance for hydraulic between the
related fault and will use the troubleshooting. lever is not controller and the
: hydraulic lowest clipped connected, hydraulic lever.
lever is not value in its or measured Check if this device
connected. settings. input value is connected.
is above the
maximum
value (4800
mV).
t5504 B Hydraulic lever Controller will Contact The hy- Check the wiring
(wire on pin P1) flag the fault, maintenance for draulic lever between the
related fault and will use the troubleshooting. measured in- controller and the
: hydraulic lowest clipped put value is hydraulic lever.
lever value value in its below the Check if this device
is below the settings. minimum is connected.
minimum value value (cor-
calibrated. responding
with 0% - 100
mV).
t5505 B Hydraulic lever Controller will Contact The hy- Check the wiring
(wire on pin P1) flag the fault, maintenance for draulic lever between the
related fault and will use troubleshooting. measured in- controller and the
: hydraulic the highest put value is hydraulic lever.
lever value clipped value above the Check if this device
is above the in its settings. maximum is connected.
maximum value value (cor-
calibrated. responding
with 100% +
100 mV).
159
Controller’s
Action
t5600 B Analog input 6 Controller will Contact The analog Check the wiring
(wire on pin S1) flag the fault, maintenance for input ANI6 between the
related fault: and will use the troubleshooting. is shorted controller and the
analog input lowest clipped to ground, device connected to
is shorted to value in its or measured this analog input.
ground. settings. input value Check this device
is below the connected. Check
minimum if the calibration
value (200 is done correctly -
mV). recalibration of this
analog input.
(wire on pin S1) flag the fault, maintenance for input ANI6 between the
related fault: and will use the troubleshooting. is not controller and the
analog input is lowest clipped connected, device connected to
not connected. value in its or measured this analog input.
settings. input value Check this device
is above the connected. Check
maximum if the calibration
value (4800 is done correctly -
analog input.
(wire on pin flag the fault, maintenance for input ANI6 between the
S1) related and will use the troubleshooting. measured in- controller and the
fault : analog lowest clipped put value is device connected to
input value value in its below the this analog input.
is below the settings. minimum Check this device
minimum value value (cor- connected. Check
calibrated. responding if the calibration
with 0% - 100 is done correctly -
analog input.
(wire on pin flag the fault, maintenance for input ANI6 between the
S1) related and will use troubleshooting. measured controller and the
fault : analog the highest input value device connected to
input value clipped value is above the this analog input.
is above the in its settings. maximum Check this device
maximum value value (cor- connected. Check
calibrated. responding if the calibration
with 100% + is done correctly -
100 mV). recalibration of this
analog input.
160
Controller’s
Action
t6000 S/A Drum speed When only 1 Contact Drum speed Check the wiring
sensor (wire on speed sensor maintenance for sensor is between the
pin B3) related has a failure, troubleshooting. shorted to controller and the
fault: drum and which ground. drum speed sensor.
speed sensor is not the Check the drum
is shorted to engine speed speed sensor.
ground. sensor, the
controller will
calculate what
the missing
speed should
be. If several
speed sensors
have a failure,
or the engine
speed sensor
has a failure,
the controller
reverts to a
"limp home"
mode.
t6001 S/A Drum speed When only 1 Contact Drum speed Check the wiring
sensor (wire on speed sensor maintenance for sensor is not between the
pin B3) related has a failure, troubleshooting. connected. controller and the
fault: drum and which drum speed sensor.
speed sensor is is not the Check the drum
not connected. engine speed speed sensor.
sensor, the
controller will
calculate what
the missing
speed should
be. If several
speed sensors
have a failure,
or the engine
speed sensor
has a failure,
the controller
reverts to a
"limp home"
mode.
161
Controller’s
Action
t6100 S/A Output speed When only 1 Contact Output speed Check the wiring
pin D3) related has a failure, troubleshooting. shorted to controller and
fault: output and which ground. the output speed
speed sensor is not the sensor. Check
is shorted to engine speed the output speed
ground. sensor, the sensor.
controller will
calculate what
the missing
speed should
be. If several
speed sensors
have a failure,
or the engine
speed sensor
has a failure,
the controller
reverts to a
"limp home"
mode.
t6101 S/A Output speed When only 1 Contact Output speed Check the wiring
pin D3) related has a failure, troubleshooting. connected. controller and
fault: output and which the output speed
speed sensor is is not the sensor. Check
not connected. engine speed the output speed
sensor, the sensor.
controller will
calculate what
the missing
speed should
be. If several
speed sensors
have a failure,
or the engine
speed sensor
has a failure,
the controller
reverts to a
"limp home"
mode.
162
Controller’s
Action
t6200 S/A Engine speed When only 1 Contact Engine speed Check the wiring
pin F3) related has a failure, troubleshooting. shorted to controller and
fault: engine and which ground. the engine speed
is shorted to engine speed the engine speed
controller will
calculate what
the missing
speed should
be. If several
speed sensors
have a failure,
or the engine
speed sensor
has a failure,
the controller
reverts to a
"limp home"
mode.
t6201 S/A Engine speed When only 1 Contact Engine speed Check the wiring
pin F3) related has a failure, troubleshooting. connected. controller and
fault: engine and which the engine speed
not connected. engine speed the engine speed
sensor, the sensor.
controller will
calculate what
the missing
speed should
be. If several
speed sensors
have a failure,
or the engine
speed sensor
has a failure,
the controller
reverts to a
"limp home"
mode.
163
Controller’s
Action
t6300 S/A Turbine speed When only 1 Contact Turbine Check the wiring
sensor (wire on speed sensor maintenance for speed sensor between the
pin R2) related has a failure, troubleshooting. is shorted to controller and
fault: turbine and which ground. the turbine speed
is shorted to engine speed the turbine speed
controller will
calculate what
the missing
speed should
be. If several
speed sensors
have a failure,
or the engine
speed sensor
has a failure,
the controller
reverts to a
"limp home"
mode.
t6301 S/A Turbine speed When only 1 Contact Turbine Check the wiring
sensor (wire on speed sensor maintenance for speed sensor between the
pin R2) related has a failure, troubleshooting. is not controller and
fault: turbine and which connected. the turbine speed
not connected. engine speed the turbine speed
sensor, the sensor.
controller will
calculate what
the missing
speed should
be. If several
speed sensors
have a failure,
or the engine
speed sensor
has a failure,
the controller
reverts to a
"limp home"
mode.
164
Controller’s
Action
t7000 S FWD VFS Controller Stop machine, The output Check the wiring
solenoid (wires reverts to a go to neutral wires of the between the
on pin B1 and "limp home" and select back FWD VFS controller and the
C1) related mode. drive. If the solenoid are FWD VFS solenoid.
fault: output controller can shorted to Check the FWD
wires are control that each other, or VFS solenoid.
shorted to drive direction, the sense line
each other, or the machine will is shorted to
the sense line drive, but in battery +, or
is shorted to a "limp home" the plus line
battery +, or mode. If not, is shorted to
the plus line the opposite ground.
is shorted to drive direction
ground. has to be
selected to move
the machine
and contact
maintenance for
troubleshooting.
t7001 S FWD VFS Controller Stop machine, An output Check the wiring
solenoid (wires reverts to a go to neutral wire of the between the
on pin B1 and "limp home" and select back FWD VFS controller and the
C1) related mode. drive. If the solenoid FWD VFS solenoid.
fault: the controller can is not Check the FWD
output wire is control that connected, or VFS solenoid.
not connected, drive direction, its plus line
or its plus line the machine will is shorted
is shorted to drive, but in to battery +,
battery +. a "limp home" or the FWD
mode. If not, VFS solenoid
the opposite is defective.
drive direction
has to be
selected to move
the machine
and contact
maintenance for
troubleshooting
165
Controller’s
Action
t7002 S FWD VFS Controller Stop machine, The current Check the wiring
solenoid (wires reverts to a go to neutral of the FWD between the
on pin B1 and "limp home" and select back VFS solenoid controller and the
C1) related mode. drive. If the is exceeding FWD VFS solenoid.
fault: the controller can 1400 mA. Check the FWD
output current control that VFS solenoid.
exceeds 1400 drive direction,
mA. the machine will
drive, but in
a "limp home"
mode. If not,
the opposite
drive direction
has to be
selected to move
the machine
and contact
maintenance for
troubleshooting
t7003 S FWD VFS Controller Stop machine, The current Check the wiring
solenoid (wires reverts to a go to neutral of the FWD between the
on pin B1 and "limp home" and select back VFS solenoid controller and the
C1) related mode. drive. If the is out of FWD VFS solenoid.
fault: the controller can range. Check the FWD
is out of rang, drive direction,
occurs when the machine will
the load has drive, but in
the incorrect a "limp home"
impedance. mode. If not,
the opposite
drive direction
has to be
selected to move
the machine
and contact
maintenance for
troubleshooting
166
Controller’s
Action
t7100 S REV VFS Controller Stop machine, The output Check the wiring
on pin D1 and "limp home" and select back REV VFS controller and the
E1) related mode. drive. If the solenoid are REV VFS solenoid.
fault: output controller can shorted to Check the REV
wires are control that each other, or VFS solenoid.
shorted to range selection, the sense line
the plus line an other range ground.
is shorted to gear will be
ground. used and contact
maintenance for
troubleshooting.
t7101 S REV VFS Controller Stop machine, An output Check the wiring
solenoid (wires reverts to a go to neutral of the REV between the
on pin D1 and "limp home" and select back VFS solenoid controller and the
E1) related mode. drive. If the is not REV VFS solenoid.
fault: the controller can connected, or Check the REV
output wire is control that its plus line VFS solenoid.
not connected, range selection, is shorted to
or its plus line the machine will battery +, or
is shorted to drive, but in the REV VFS
battery +. a "limp home" solenoid is
mode. If not, defective.
an other range
gear will be
used and contact
maintenance for
troubleshooting.
167
Controller’s
Action
t7102 S REV VFS Controller Stop machine, The current Check the wiring
E1) related mode. drive. If the is exceeding REV VFS solenoid.
fault: the controller can 1400 mA. Check the REV
exceeds 1400 range selection,
drive, but in
a "limp home"
mode. If not,
an other range
gear will be
used and contact
maintenance for
troubleshooting.
t7103 S REV VFS Controller Stop machine, The current Check the wiring
E1) related mode. drive. If the is out of REV VFS solenoid.
fault: the controller can range. Check the REV
is out of range, range selection,
an other range
gear will be
used and contact
maintenance for
troubleshooting.
168
Controller’s
Action
t7200 S 2nd VFS Controller Stop machine, The output Check the wiring
on pin F1 and "limp home" and select back 2nd VFS controller and the
G1) related mode. drive. If the solenoid are 2nd VFS solenoid.
fault: output controller can shorted to Check the 2nd VFS
wires are control that each other, or solenoid.
shorted to drive direction, the sense line
battery +, or mode. if not, is shorted to
the plus line the opposite ground.
is shorted to drive direction
ground. has to be
selected to move
the machine
and contact
maintenance for
troubleshooting.
t7201 S 2nd VFS Controller Stop machine, An output Check the wiring
on pin F1 and "limp home" and select back 2nd VFS controller and the
G1) related mode. drive. If the solenoid 2nd VFS solenoid.
fault: the controller can is not Check the 2nd VFS
output wire is control that connected, or solenoid.
not connected, drive direction, its plus line
or its plus line the machine will is shorted to
is shorted to drive, but in battery +, or
battery +. a "limp home" the 2nd VFS
mode. if not, solenoid is
the opposite defective.
drive direction
has to be
selected to move
the machine
and contact
maintenance for
troubleshooting.
169
Controller’s
Action
t7202 S 2nd VFS Controller Stop machine, The current Check the wiring
solenoid (wires reverts to a go to neutral of the 2nd between the
on pin F1 and "limp home" and select back VFS solenoid controller and the
G1) related mode. drive. If the is exceeding 2nd VFS solenoid.
fault: the controller can 1400 mA. Check the 2nd VFS
output current control that solenoid.
exceeds 1400 drive direction,
drive, but in
a "limp home"
mode. if not,
the opposite
drive direction
has to be
selected to move
the machine
and contact
maintenance for
troubleshooting.
t7203 S 2nd VFS Controller Stop machine, The current Check the wiring
solenoid (wires reverts to a go to neutral of the 2nd between the
on pin F1 and "limp home" and select back VFS solenoid controller and the
G1) related mode. drive. If the is out of 2nd VFS solenoid.
fault: the controller can range. Check the 2nd VFS
output current control that solenoid.
is out of range, drive direction,
impedance. mode. if not,
the opposite
drive direction
has to be
selected to move
the machine
and contact
maintenance for
troubleshooting.
170
Controller’s
Action
t7300 S 1st/3rd VFS Controller Stop machine, The output Check the wiring
on pin H1 and "limp home" and select back 1st/3rd VFS controller and
J1) related mode. drive. If the solenoid are the 1st/3rd VFS
fault: output controller can shorted to solenoid. Check
wires are control that each other, or the 1st/3rd VFS
shorted to range selection, the sense line solenoid.
the plus line an other range ground.
is shorted to gear will be
ground. used and contact
maintenance for
troubleshooting.
t7301 S 1st/3rd VFS Controller Stop machine, An output Check the wiring
on pin H1 and "limp home" and select back 1st/3rd VFS controller and
J1) related mode. drive. If the solenoid the 1st/3rd VFS
fault: the controller can is not solenoid. Check
output wire is control that connected, or the 1st/3rd VFS
not connected range selection, its plus line solenoid.
or its plus line the machine will is shorted to
is shorted to drive, but in battery +, or
battery +. a "limp home" the 1st/3rd
mode. If not, VFS solenoid
an other range is defective.
gear will be
used and contact
maintenance for
troubleshooting.
171
Controller’s
Action
t7302 S 1st/3rd VFS Controller Stop machine, The current Check the wiring
solenoid (wires reverts to a go to neutral of the 1st/3rd between the
on pin H1 and "limp home" and select back VFS solenoid controller and
J1) related mode. drive. If the is exceeding the 1st/3rd VFS
fault: the controller can 1400 mA. solenoid. Check
output current control that the 1st/3rd VFS
exceeds 1400 range selection, solenoid.
drive, but in
a "limp home"
mode. If not,
an other range
gear will be
used and contact
maintenance for
troubleshooting.
t7303 S 1st/3rd VFS Controller Stop machine, The current Check the wiring
solenoid (wires reverts to a go to neutral of the 1st/3rd between the
on pin H1 and "limp home" and select back VFS solenoid controller and
J1) related mode. drive. If the is out of 1st/3rd VFS
fault: the controller can range. solenoid. Check
output current control that the 1st/3rd VFS
is out of range, range selection, solenoid.
an other range
gear will be
used and contact
maintenance for
troubleshooting.
t7400 A Analog output 4 Controller will Contact The output Check the wiring
(wire on pin L1) flag the fault, maintenance for wire of between the
related fault: but no actions troubleshooting. analog controller and the
output wire will be taken. output 4 is device connected on
is shorted to shorted to the analog output
ground. ground. 4.
172
Controller’s
Action
output wire will be taken. output 4 device connected on
is shorted to is shorted the analog output
battery +, or not to battery 4.
connected. +, or not
connected.
the output will be taken. output 4 is device connected on
current exceeds exceeding the analog output
1400 mA. 1400 mA. 4.
(wire on pin flag the fault, maintenance for wire of between the
L1) related but no actions troubleshooting. analog controller and the
fault: the will be taken. output 4 is device connected on
output current out of range. the analog output
is out of range, 4. Check the device
occurs when connected.
the load has
the incorrect
impedance.
(wire on pin N1) flag the fault, maintenance for wire of between the
ground. ground. 5.
battery +, or not to battery 5.
connected. + or not
connected.
1400 mA. 1400 mA. 5.
173
Controller’s
Action
N1) related but no actions troubleshooting. analog controller and the
the load has
the incorrect
impedance.
t7600 S Analog output 6 Controller will Contact The output Check the wiring
(wire on pin R1) flag the fault, maintenance for wire of between the
ground. ground. 6.
battery + or not to battery 6.
connected. + or not
connected.
1400 mA. 1400 mA. 6.
R1) related but no actions troubleshooting. analog controller and the
the load has
the incorrect
impedance.
174
Controller’s
Action
t7702 S All VFS Controller Stop machine One or more Check the
grounds are reverts to a & Contact VFSs have combined fault,
switched off "shut down" maintenance for an over and see the
due to an over mode and will troubleshooting. current, not troubleshooting
current on one force neutral 0. that this for that fault.
or more VFSs. fault will
be combined
with a 70.02
and/or 71.02
and/or 72.02
and/or 73.02.
t8000 S RSP drive Controller Stop machine RSP drive Check the wiring
solenoid (wire reverts to a and contact solenoid is between the
on pin K1) shutdown mode maintenance for shorted to controller and the
related fault: and will force troubleshooting. ground. RSP drive solenoid
RSP drive neutral 0. + line. Check the
solenoid is RSP drive solenoid.
shorted to
ground.
t8001 S RSP drive Controller Stop machine RSP drive Check the wiring
solenoid (wire revert to a and contact solenoid between the
on pin K1) shutdown mode maintenance for is not controller and the
related fault: and will force troubleshooting. connected or RSP drive solenoid
RSP drive neutral 0. shorted to + line. Check the
solenoid is battery +. RSP drive solenoid.
not connected,
or shorted to
battery +.
t8100 S 2/4 VFS selector Controller Stop machine, 2/4 VFS Check the wiring
solenoid (wire reverts to a go to neutral selector between the
on pin E2) "limp home" and select back solenoid is controller and the
related fault: mode. drive. If the shorted to 2/4 VFS selector
2/4 VFS selector controller can ground. solenoid + line.
solenoid is control that Check the 2/4 VFS
shorted to range selection, selector solenoid.
ground. the machine will
drive, but in
a "limp home"
mode. If not,
an other range
gear will be
used and contact
maintenance for
troubleshooting.
175
Controller’s
Action
t8101 S 2/4 VFS selector Controller Stop machine, 2/4 VFS Check the wiring
solenoid (wire reverts to a go to neutral selector between the
on pin E2) "limp home" and select back solenoid controller and the
related fault: mode. drive. If the is not 2/4 VFS selector
2/4 VFS selector controller can connected or solenoid + line.
solenoid is control that shorted to Check the 2/4
not connected range selection, battery +. selector solenoid.
or shorted to the machine will
battery +. drive, but in
a "limp home"
mode. If not,
an other range
gear will be
used and contact
maintenance for
troubleshooting.
t8200 S 1st/3rd VFS Controller Stop machine, 1st/3rd VFS Check the wiring
selector reverts to a go to neutral selector between the
solenoid "limp home" and select back solenoid is controller and
(wire on pin mode. drive. If the shorted to the 1st/3rd VFS
F2) related controller can ground. selector solenoid
fault: 1st/3rd control that + line. Check
VFS selector range selection, the 1st/3rd VFS
solenoid is the machine will selector solenoid.
shorted to drive, but in
ground. a "limp home"
mode. If not,
an other range
gear will be
used and contact
maintenance for
troubleshooting.
176
Controller’s
Action
t8201 S 1st/3rd VFS Controller Stop machine, 1st/3rd VFS Check the wiring
selector reverts to a go to neutral selector between the
solenoid "limp home" and select back solenoid controller and
(wire on pin mode. drive. If the is not the 1st/3rd VFS
F2) related controller can connected or selector solenoid
fault: 1st/3rd control that shorted to + line. Check
VFS selector range selection, battery +. the 1st/3rd VFS
solenoid is the machine will selector solenoid.
not connected, drive, but in
or shorted to a "limp home"
battery +. mode. If not,
an other range
gear will be
used and contact
maintenance for
troubleshooting.
t8300 S RSP drive The controller Stop machine RSP drive Check the wiring
solenoid (wire reverts to a and contact solenoid is between the
on pin K2) "shutdown" maintenance for shorted to controller and the
related fault: mode and will troubleshooting. ground. RSP drive solenoid
RSP drive force neutral 0. line. Check the
solenoid is RSP drive solenoid.
shorted to
ground.
t8301 S RSP drive The controller Stop machine RSP drive Check the wiring
solenoid (wire reverts to a and contact solenoid between the
on pin K2) "shutdown" maintenance for is not controller and the
related fault: mode and will troubleshooting. connected or RSP drive solenoid
RSP drive force neutral 0. shorted to line. Check the
solenoid is battery +. RSP drive solenoid
not connected
or shorted to
battery +.
t90xx S/B/H System Error. Controller Contact Software Contact your local
- reverts to a maintenance for related fault. Hyster dealer and
t99xx "shutdown" troubleshooting. inform the fault
mode and will code and the time
force neutral 0. that it was active.
t9090 S Wrong The controller Flash the correct Wrong Flash the correct
firmware is reverts to a firmware into firmware is firmware into the
flashed into the "shutdown" the APC200. flashed into APC200.
APC200. mode and will the APC200.
force neutral 0.
177
Controller’s
Action
t9310 S Initialization Controller will Stop machine, Memory Reset controller.
of statistical flag the fault, restart conflict
data in flash but no actions controller. in flash
memory, caused will be taken. memory.
by firmware
upgrade
or memory
conflict.
t9311 S Initialization Controller will Stop machine, Memory Reset controller.
of logged error flag the fault, restart conflict
data in flash but no actions controller. in flash
memory, caused will be taken. memory.
by firmware
upgrade
or memory
conflict.
t9571 S Data in the The controller Download Wrong APT Download an APT
APC200 is reverts to a an APT file file (data file compatible
not compatible shutdown mode compatible file) is in with the active
with the data and will force with the active the APC200 firmware into the
expected by neutral 0. firmware into (typically APC200 If the error
the APC200 the APC200. after APC200 code still persists,
firmware. firmware the data flash
upgrade). may be corrupt
(contact Spicer
Off-Highway).
t9995 B CAN peak Controller will No action Overload of No action required.
load detected: reply on the requested. incoming
APC200 could CAN messages CAN
not temporarily which are messages to
process all available in the the APC200.
incoming buffer.
messages, due
to an excessive
peak of CAN
requests.
txx49 S Fault with Controller will Contact Software Contact Spicer
undefined flag the fault maintenance for related fault. Off-Highway and
cause. - action will troubleshooting. inform the fault
depend on the code and the time
fault. that is was active.
178
Table 7. Display Warning Exceed Codes
Exceed
Type Explanation Controller’s Action Driver’s Action
Code
tE001 E The vehicle speed is too The controller will disable Slow the vehicle down so
high to make the requested the downshift in order to the requested downshift can
downshift. protect the transmission, be made.
until the vehicle speed
decreases below the
downshift limit.
tE101 E The vehicle speed is to The controller will not Slow the vehicle down so the
high to make the requested allow the direction change requested direction change
directional change. in order to protect the can be made.
transmission and will
place the transmission in
neutral, until the vehicle
speed decreases below the
direction change vehicle
speed limit.
tE201 E The engine speed (rpm) is to The controller will not Lower the engine speed
high to make the requested allow the direction change (rpm) so the requested
direction change or the or re-engagement of the direction change or direction
requested re-engagement of direction, until the engine re-engagement can be made.
the direction. speed (rpm) decreases below
the direction change or
direction re-engagement
engine speed limit.
tE300 E The reduced vehicle speed The controller is limiting the No action, the vehicle speed
limitation is active. vehicle speed to the reduced is limited due to request.
vehicle speed limit.
tE301 E The reduced vehicle The controller is limiting Slow the vehicle down so
speed limitation is active. the vehicle speed to the the vehicle speed decreases
However, the vehicle speed reduced vehicle speed limit, below the reduced vehicle
is above the limit. but detects a higher vehicle speed limit.
speed.
tE302 E The vehicle speed is above The controller is limiting Slow the vehicle down so
the maximum vehicle speed the vehicle speed to the the vehicle speed decreases
limit. maximum vehicle speed below the maximum vehicle
limit, but detects a higher speed.
vehicle speed.
tE400 E An abnormal deceleration The controller detected an Slow the vehicle down so
is detected. abnormal deceleration, and the wheels cannot continue
will disable the automatic slipping.
shifting for a certain time.
tE401 E An abnormal acceleration is The controller detected an Lower engine speed (rpm) so
detected. abnormal acceleration, and the wheels cannot continue
will disable the automatic spinning.
shifting for a certain time.
179
Table 7. Display Warning Exceed Codes (Continued)
Exceed
Type Explanation Controller’s Action Driver’s Action
Code
tE501 E The amount of time The controller detected that Contact maintenance
the transmission was the transmission was in to recalibrate the
in gear exceeded the gear exceeded the time to transmission.
time to recalibrate the recalibrate the transmission.
transmission.
tE600 E Operator is not seated with The controller detected that The driver should take place
shift lever not in neutral the operator is not seated in the operator seat and
and/or the parking brake with the shift lever not in confirm his presence (cycle
not activated. neutral and/or the parking the shift lever through
brake not activated. neutral and/or release the
throttle pedal).
Table 8. Type of Warning Codes
Type Severity of Effect Level Description

S High Severe Warning Vehicle inoperable, with loss of primary function.
Vehicle operable, but at a reduced level of
performance.
A Moderate Warning Vehicle operable, but comfort/convenience item(s)
inoperable.
B Low Information Vehicle operable, but comfort/convenience item(s)
operable at reduced levels.
H Very Low Information Vehicle operable, defect not noticed.
E None Exceeds Driver is requesting an action which is protected by
parameter the controller.
information
Limp Home Mode In this mode, the user can operate the transmission
in either direction in 1st and 2nd only. If the fault
Display Warning t_LMP occurs at a higher gear position, the user is allowed
to shift down manually.
The controller defaults to the Limp Home mode when
any of the following occurs: NOTE: On some transmissions, ratios normally not
• A single fault on a transmission control output is selectable are used to substitute those that can no
detected. longer be selected.
• A fault related to the engine speed is detected.
The controller uses default limits, all shifts use a de-
• Two out of three vehicle speed sensors are in fault.
fault modulation curve.
If one of the above conditions is present, the trans-
Inching is disabled.
mission is put in neutral. In order to continue driv-
ing, neutral must first be selected on the shift lever.
Once the shift lever has been placed in neutral, the
driver can re-engage a direction.
180
1300 SRM 1082 Transmission Oil Pressure Check
Shutdown Mode However, in case the error is related to the pressure

feedback signal, Shutdown mode remains selected
Display Warning t_SHT until the controller is switched off.
The ECM transmission control valve has a built-in When a fault related to the parameter settings lo-
redundant shutdown solenoid and a pressure switch cated in the FLASH memory is detected, the con-
that monitors the pressure controlled by that sole- troller reverts to Shutdown mode
noid. This solenoid is controlled by the APC200 us-
ing both a high side and a low side switch. Pressure Feedback Sensor
When the controller enters shutdown mode, all four The pressure feedback signal is evaluated as an
pressure modulators are put at zero and both control- ON/OFF pressure switch, with internal resistance of
ling outputs of the redundant shutdown solenoid are 2 kOhms when open and kOhms when pressurized.
switched off.
If resistance is substantially lower than 1 kOhm, a
This mode is activated when a severe internal or ex- shortcut (SC) condition is assumed.
ternal problem is detected. If it is an intermittent
If it’s higher than 2 kOhms, an open load (OL) condi-
problem, the controller will exit the shutdown mode
tion is assumed.
and enter the Limp Home mode.
Transmission Oil Pressure Check

PRESSURE AND TEMPERATURE • Clutch pressures at
SPECIFICATIONS • Transmission case:
– 1st clutch: port 41. See Figure 43.
Refer to Figure 41, Figure 42, Figure 43, and Fig- – 3rd clutch: port 43. See Figure 43.
ure 44 for the transmission pressure check points. – Forward clutch: port 45. See Figure 43.
• Transmission Control Valve
NOTE: All pressures and flows to be measured with – 3rd/1st clutch: port 60/62. See Figure 44.
oil temperature of 82 to 93 C (180 to 200 F). – 2nd clutch: port 61. See Figure 44
– Forward clutch: port 64. See Figure 44
NOTE: There are two locations where clutch pres-
– Reverse clutch: port 65. See Figure 44
sures can be measured.
• At 2000 RPM
The reverse and 2nd clutch can only be measured at – 16.5 to 19.3 bar (240 to 280 psi) clutch activated.
the transmission control valve. – 0 to 0.2 bar (0 to 3 psi) clutch released.
• Filter bypass valve set at 1.5 to 1.7 bar (22 to
• Normal operating temperature 70 to 120 C (158 to 25 psi).
248 F) measured at temperature check port conver- • Lube pressure (port 34), see Figure 41, 0.6
tor out (port 71). See Figure 41. to 1.9 bar (8.7 to 27.6 psi) at 64.3 liter/min
• Maximum allowed transmission temperature (17 gal/min) pump flow (±1800 RPM).
120 C (248 F). • Safety valve: cracking pressure 8.3 to 12.1 bar (120
• Transmission regulator pressure (neutral) - port to 175 psi).
31. See Figure 42. • Convertor out pressure (port 32). See Figure 41,
– At 600 RPM min. 16.5 bar (240 psi) minimum. 1.7 bar (25 psi) at 2000 RPM. 4.8 bar (70 psi) at no
– At 2200 RPM: 19.3 bar (280 psi) maximum. load governed speed.
• Pump flow
– At 1800 RPM: 67.4 liter/min (17.8 gal/min) min-
imum.
181
Transmission Oil Pressure Check 1300 SRM 1082
Figure 41. Check Points, Front and Rear View
182

A. FRONT VIEW B. REAR VIEW
1. PORT 34 - PRESSURE CHECK PORT 2. PORT 71 - CONVERTOR OUT TEMPERATURE
SWITCH
1. PORT 31 - CHECK PORT REGULATOR PRESSURE
Figure 42. Check Points, Top View
183
Transmission Oil Pressure Check 1300 SRM 1082
Figure 43. Check Points, Right and Left View
184

A. RIGHT VIEW B. LEFT VIEW
1. PORT 41 - CHECK PORT 1ST CLUTCH 4. PORT 12 - CHECK PORT PRESSURE
PRESSURE 5. PORT 11 - CHECK PORT PRESSURE
2. PORT 45 - CHECK PORT FORWARD CLUTCH
PRESSURE
3. PORT 43 - CHECK PORT 3RD CLUTCH
PRESSURE
1. PORT 55 - VFS REV 8. PORT 61 - PRESSURE INTENSIFIER 2ND

2. PORT 65 - PRESSURE INTENSIFIER REV 9. PORT 51 - VFS 2ND
3. PORT 64 - PRESSURE INTENSIFIER FWD 10. PORT 56 - SYSTEM PRESSURE (AFTER TOTAL
4. PORT 59 - DIRECTION CLUTCHES NEUTRAL)
5. PORT 57 - PILOT PRESSURE 11. PORT 50/52 - VFS 3RD/1ST
6. PORT 31A - REGULATOR PRESSURE (BEFORE 12. PORT 60/62 - PRESSURE INTENSIFIER
TOTAL NEUTRAL) 3RD/1ST
7. PORT 58 - RANGE CLUTCHES 13. PORT 54 - VFS FWD
Figure 44. Check Points, Control Valve
185
Torque Specifications 1300 SRM 1082
Electrical Specifications
Electronic controlled modulation solenoids Table 9. Temperature Sensor (In Speed Sensor)
VFS 2nd - VFS 1st/3rd - VFS Fwd - VFS Rev Resistance Versus Temperature (Continued)
Coil resistance - 4.35 ±0.35 at 25 C (77 F)
ON/OFF solenoids AMBIENT RESISTANCE

Total neutral and selector solenoids TEMPERATURE
Coil resistance - 12V - 28 ±2 at 20 C (68 F) 10 C (50 F) 1772
Coil resistance - 24V - 87 ±2 at 20 C (68 F)
20 C (68 F) 1922
Speed sensor 25 C (77 F) 2000
Type - Magneto resistive sensor.
Sensing distance - 0 to 1.8 mm (0 to 0.07 in.) 30 C (86 F) 2080
Sensor signal - Generates a square current with a 40 C (104 F) 2245
fixed amplitude changing between 7 and 14 mA.
50 C (122 F) 2417
Table 9. Temperature Sensor (In Speed Sensor)
60 C (140 F) 2597
Resistance Versus Temperature
70 C (158 F) 2785
AMBIENT RESISTANCE
80 C (176 F) 2980
TEMPERATURE
90 C (194 F) 3182
55 C ( 67 F) 980
100 C (212 F) 3392
50 C ( 58 F) 1030
110 C (230 F) 3607
40 C ( 40 F) 1135
120 C (248 F) 3817
30 C ( 22 F) 1247
125 C (257 F) 3915
20 C ( 4 F) 1367
130 C (266 F) 4008
10 C (14 F) 1496
140 C (284 F) 4166
0 C (32 F) 1630
150 C (302 F) 4280
Hydraulic Cooler Lines Specifications

There is a minimum 19 mm (0.75 in.) internal di- must withstand 30 bar (435 psi) continuous pressure
ameter for lines and fittings. They must be suitable and 45 bar (652 psi) intermittent surges. Conform
for operation from ambient temperature to 120 C SAE J1019 and SAE J517, 100RI.
(248 F) continuous operating temperature. They
Torque Specifications
TORQUE SPECIFICATIONS FOR LUBRICATED OR PLATED SCREW THREADS
Table 10. Grade 5
Nom. Fine Thread Coarse Thread

Size
0.2500 12.2 to 14.9 N•m (9 to 11 lbf ft) 10.8 to 13.6 N•m (8 to 10 lbf ft)
186
1300 SRM 1082 Torque Specifications
Table 10. Grade 5 (Continued)

Size
0.4375 55.6 to 61 N•m (41 to 45 lbf ft) 50.2 to 55.6 N•m (37 to 41 lbf ft)
0.5625 123.4 to 135.6 N•m (91 to 100 lbf ft) 111.2 to 122 N•m (82 to 90 lbf ft)
Table 11. Grade 8

Size
0.3125 38 to 43.4 N•m (28 to 32 lbf ft) 35.2 to 40.7 N•m (26 to 30 lbf ft)
187
Torque Specifications 1300 SRM 1082
Table 12. Grades 8.8, 10.9, and 12.9
Nom. Size Grade 8.8 Grade 10.9 Grade 12.9

Coarse Thread Coarse Thread Coarse Thread
M5 5 to 6 N•m 7 to 8 N•m 8 to 10 N•m
(3.7 to 4.4 lbf ft) (5.2 to 5.9 lbf ft) (5.9 to 7.4 lbf ft)
M6 8 to 10 N•m 12 to 15 N•m 13 to 16 N•m
M8 20 to 25 N•m 30 to 35 N•m 35 to 40 N•m
M10 40 to 50 N•m 60 to 65 N•m 65 to 75 N•m
M12 68 to 75 N•m 100 to 110 N•m 115 to 130 N•m
M14 110 to 125 N•m 150 to 175 N•m 180 to 210 N•m
M16 170 to 190 N•m 240 to 275 N•m 280 to 320 N•m
(125.4 to 140.1 lbf ft) (177 to 202.8 lbf ft) (206.5 to 236 lbf ft)
M20 320 to 360 N•m 450 to 500 N•m 525 to 600 N•m
(236 to 265.5 lbf ft) (331.9 to 368.8 lbf ft) (387.2 to 442.5 lbf ft)
M24 570 to 650 N•m 800 to 900 N•m 900 to 1050 N•m
M30 1150 to 1300 N•m 1600 to 1800 N•m 1850 to 2100 N•m
M36 2000 to 2250 N•m 2749 to 3149 N•m 3249 to 3699 N•m
Table 13. O-ring Port Plug Torque Chart Table 13. O-ring Port Plug Torque
Chart (Continued)
Thread Size
Torque
NPTF Thread Size
Torque
1/16 × 27 7 to 9 N•m (5 to 7 lbf ft) NPTF
1/8 × 27 9 to 14 N•m (7 to 10 lbf ft) 1 1/4 × 11 1/2 81 to 88 N•m (60 to 65 lbf ft)
1/4 × 18 20 to 27 N•m (15 to 20 lbf ft) M10 × 1 8 to 10 N•m (6 to 7 lbf ft)
3/8 × 18 34 to 41 N•m (25 to 30 lbf ft) M14 × 1.5 10 to 12 N•m (7 to 9 lbf ft)
1/2 × 14 41 to 47 N•m (30 to 35 lbf ft) M18 × 1.5 34 to 41 N•m (25 to 30 lbf ft)
3/4 × 10 or 14 54 to 61 N•m (40 to 45 lbf ft) M22 × 1.5 48 to 60 N•m (35 to 44 lbf ft)
1 × 11 1/2 68 to 75 N•m (50 to 55 lbf ft) M33 × 2 112 to 140 N•m (83 to 103 lbf ft)
188
1300 SRM 1082 Troubleshooting
Table 14. Pipe Plug Torque Chart
Plugs
Nom. (Permanent Plugs)
Size
Torque
M18 × 1.5 34 to 41 N•m (25 to 30 lbf ft)
6H
M26 × 1.5 61 to 68 N•m (45 to 50 lbf ft)
6H
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Low clutch pressure. Low oil level. Fill to proper level.
Clutch pressure regulating valve Clean valve spool and housing.

stuck open.
Faulty charging pump. Replace pump.
Broken or worn clutch shaft or piston Replace piston rings.

rings.
Clutch piston bleed valve stuck open. Clean bleed valves thoroughly.
Low charging pump output. Low oil level. Fill to proper level.
Suction screen plugged. Clean suction pump.
Defective charging pump. Replace pump.
Overheating Worn oil sealing rings. Remove, disassemble, and rebuild

convertor assembly.
Worn charging pump. Replace charging pump.
Low oil level. Fill to proper level.
Dirty oil cooler. Clean cooler.
Restriction in cooler lines. Change cooler lines.
189
Diagrams, Schematics, or Arrangements 1300 SRM 1082
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Noisy convertor. Worn charging pump. Replace charging pump.
Worn or damaged bearings. A complete disassembly will be nec-

essary to determine which bearing is
faulty.
Lack of power. Low engine RPM at convertor stall. Tune engine, check governor.
See Overheating and make same Make corrections as explained in

checks. Overheating.
190
NOTES
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191
Diagrams, Schematics, or Arrangements 1300 SRM 1082
192
1300 SRM 1082 Diagrams, Schematics, or Arrangements
Figure 45. APC200 Wiring Diagram
193
NOTES
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194
TECHNICAL PUBLICATIONS
1300 SRM 1082 9/08 (10/07)(3/07)(12/06)(12/05)(6/05)(1/05)(3/04)(1/04) Printed in United Kingdom

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TRANSMISSION

H8.00-12.00XM (H170-280HD) [G007];

PART NO. 1556600 1300 SRM 1082

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2008 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

H8.00-12.00XM (H170-280HD) [G007];

escape of oil when the pressure to the piston is re-

Figure 1. Transmission Operation

Legend for Figure 1

RANGE CLUTCHES OUTPUT SECTION

1. FORWARD CLUTCH 6. THIRD-SPEED CLUTCH

Figure 2. Gear and Clutch Layout

TRANSMISSION CONTROLS function of the control valve assembly is to direct oil

Figure 3. Control Valve

Operation of the Valve clutch. Between each electronic controlled variable

A. VARIABLE FORCED SOLENOID D. HIGH PRESSURE 0 TO 20 bar (0 TO 290 psi)

Figure 4. Operation of the Valve

Figure 5. Forward 1st Speed

Legend for Figure 5

Figure 6. Reverse 1st Speed

Legend for Figure 6

Selection of Range Pressure Switch

Transmission Gear Activated On/Off Activated VFSs Activated Clutches

Figure 7. Neutral and 3rd

Legend for Figure 7

Figure 8. Neutral and 3rd Flow

Figure 9. Forward 1st Speed Flow

Figure 10. Forward 2nd Speed

Legend for Figure 10

Figure 11. Forward 2nd Speed Flow

Figure 12. Forward 3rd Speed

Legend for Figure 12

Figure 13. Forward 3rd Speed Flow

Figure 14. Reverse 1st Speed Flow

Figure 15. Reverse 2nd Speed

Legend for Figure 15

Figure 16. Reverse 2nd Speed Flow

Figure 17. Reverse 3rd Speed

Legend for Figure 17

Figure 18. Reverse 3rd Speed Flow

TRANSMISSION SPECIFICATIONS Maximum length: 840 mm (33.1 in.)

Transmission Identification Maximum width: 526 mm (20.7 in.)

1. MODEL AND TYPE OF THE UNIT 2. SERIAL NUMBER

Figure 19. Transmission Data Plate

8. Place a suitable container under the transmis-

1. FRAME (REFERENCE) 6. TRANSMISSION

Figure 20. Transmission Arrangement

1. ACCESS HOLE TO CAPSCREWS (8 EACH)

Figure 23. Access Plug for Drive Plate

1. 3/4-INCH UNC HOLE

Figure 21. Rear View of Transmission

Figure 24. TE10 3-Speed Transmission

Figure 22. Access Plug to Flywheel

Transmission Case, Disassemble

NOTE: Rev/2nd and 3rd clutches will remain in the

Torque Converter Housing, Disassemble

Forward Clutch, Disassemble