357-03 Series Training

Service Training
Service
Container handling truck

truc
Toplift
oplift and Combi handler
Series 357-05
35702_00
This training material is only provided for your use and remains the exclusive property of
LINDE Heavy Truck Division
Chapter 1
Service Training Page 1
1 CUMMINS ENGINE.
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Chapter 1
Page 2 Service Training
1.1 CUMMINS ENGINE.
The Cummins QSM11 engine is fitted into this model as an option to the standard unit.
DATA.
Engine type Cummins. QSM11-c

Number of cylinders. 6
Power. 246Kw @ 2100 rpm.(330 HP)
Firing order. 153624
Emission specification Tier 3
Bore 125 mm (4.921")
Stroke 147 mm (5.787")
Displacement 10.8 ltr (659 CI")
Rotation direction, viewed from the front. Clockwise
Low idle 700 rpm
EngineMaximum speed 2100 rpm
Valve clearance cold, Inlet 0.36 mm (0.014")
Valve clearance cold, Exhaust Minimum oil pressure at idle speed 0.69mm (0.027")
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Minimum oil pressure at Maximum RPM 2 bar (30 psi)
C01. Register 04
Minimum oil pressure at idle speed 0.7 bar (10 psi)
Min/max dipstick difference 5 ltr (1.3 Gall)
Oil capacity 32 ltr (8.45 Gall)
Filter capacity LF9000 3 ltr (0.8 Gall)
Filter capacity LF9001 2.6 ltr (0.7 Gall)
Cooling system pressure 0.5 bar (7 psi)
Engine shutdown temperature 103°C(217.4F)
Thermostat begins to open at 82°C (179.6F)
Thermostat fully open at 93°C (199.4F)
Fuel system pressure (cranking speed) 1.72 bar (25psi) Minimum.
Fuel system pressure (1200 rpm) 8.27 bar (120psi) Minimum.
Fuel system pressure (maximum speed) 10.34-12.41 bar (150-180psi) Minimum.
Coolant capacity (system) 52 ltr (13.73 Gall) (engine only 9.5ltr)
Alternator Leece Neville 8SC3009ZA . 24V/175A
Starter motor Delco Remy 01E01
Weight, engine (dry) 940Kg
Chapter 1
1.1.2 ENGINE SERIAL NUMBER
10.1.2.1 LOCATION OF ENGINE DATA PLATE

The engine data plate is located at the rear left hand side of the
engine at the point arrowed "A".
1.1.2.2 INFORMATION ON DATA PLATE

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The engine data plate is as illustrated and carries all the engine data including the serial number.
The engine model in current use is:-
QSM11-C
This information indicates the following:-
1 Engine serial number.

2 CPL. (Control parts list for spares purposes).
3 Engine model.
4 Power and rpm rating.
Chapter 1
1.1.3 FUEL SYSTEM DESIGN AND FUNCTION
1.1.3.1 FUEL SYSTEM LAYOUT
The engine uses a fuel injecton system specific to Cummins; The system is known as the "PT system",
there is no fuel injection pump only a charging pump that raises the fuel pressure to up to 12.4 bar at
maximum rpm. (1.75 bar at cranking rpm). The fuel is passed through the ECM (Electronic control module)
plate to act as a cooling medium for the electronics. The fuel is then passed to all the injectors where it
is finaly pressurised and injected into each cylinder in turn by the action of a third rocker arm between the
inlet and exhaust valve rocker arms and driven by the camshaft like the valve rockers.. Each cylinder has
two inlet and two exhaust valves operated by a bridge plate from the normal rocker set, in the centre of
these is the injector operated by the third "centre" rocker arm.
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1 Fuel return to tank. 6 Fuel solenoid.

2 Fuel to injectors. 7 Fuel pump.
3 ECM Coolingplate. 8 Injector.
4 Fuel feed from water trap. 9 Injector rocker.
5 Fuel feed pipe.
Chapter 1
1.1.4 FUEL SYSTEM COMPONENTRY.
1.1.4.1 FUEL FILTER AND WATER TRAP.
The fuel filter and water trap assembly is mounted on the

chassis inside the access door to the battery compartment. Fuel
from the tank line (1) is passed through the filter, water being
denser than fuel, will sink to the bottom of the cannister 1
preventing water being passed into the fuel injection system
through the feed line (2).
2
The water trap should be drained daily by the truck operator by
unscrewing the drain valve (A) in the bottom of the unit by two 3
or three turns until clean fuel runs from the drain screw. The
screw should then be retightened by hand pressure only. The
10 micron Filter assembly (3) can be changed at the usual
service intervals or if the pressure difference across the filter
exceeeds 0.4 bar (12"HG). In the bottom of the unit is a sensor
that will illuminate a warning light if the water level in the filter
becomes too high.
A
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35702_10-05
1.1.4.2 FUEL CHARGE PUMP AND SOLENOID.
The charge pump is driven by the engine timing gears, it draws fuel from the tank, through the fuel filter
and water trap assembly and passes the fuel into the injector feed pipes. The pressure of the fuel within
the sytem will depend on the engine speed. The limits and characterisitcs are defined by the manufacturer
as follows.
Inlet line restricton (maximum) 254 mm HG. (10" HG)

Fuel system pressure (cranking speed) 1.72 bar (25psi) Minimum.
Fuel system pressure (1200 rpm) 8.27 bar (120psi) Minimum.
Fuel system pressure (maximum speed) 10.34-12.41 bar (150-180psi) Minimum.
Minimum cranking speed to achieve effective fuel pressure. 150 rpm.
Fuel solenoid coil resistance 12v HD. 7-9 ohms.
Chapter 1
1.1.4.2 FUEL CHARGE PUMP AND SOLENOID.
7 1
2
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3
5
4
35702_10_06
1 Fuel shut down solenoid.

2 Connection to soilenoid.
3 Fuel feed to charge pump.
4 Test point quick release adaptor A. For measuring inlet line restriction.
5 Test point quick release adaptor B. For measuring charge pump pressure.
6 Charge pump quick fill port.
7 Feed pipe to injectors.
Chapter 1
1.1.4.3 TESTING THECHARGE PUMP AND SOLENOID.
1.1.4.3.1 FLOW TEST.
A series of checks can be made to test the operation of the fuel

charge system as follows.
Check the fuel flow from the charge pump by loosening the outlet
pipe to the injector inlet line. Clean fuel should flow when the
engine is being cranked at normal speed. If no fuel flows the fuel
pump may need priming. See page 9.
1.1.4.3.2 PRESSURE TEST.
The pressure within the system can be measured by connecting

a pressure gauge (0-10 bar) into the quick release coupling in
the charge pump.
Crank the engine and observe the gauge, the pressure should
rise to 1.75 bar (25psi). If this pressure is not achieved the pump
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may need priming or another fault exists. The engine must crank
at it's standard speed of 220 rpm for this test to be effective.
If the engine will start run the engine at 1200 rpm with no load and
observe the pressure gauge. The gauge should show a minimum
pressure of 8.27 bar (120 psi).
Increase the engine rpm to maximum, the gauge should show

a fuel pressure of between 10.34-12.41 bar (150-180psi)
Minimum.
1.1.4.3.3 LEAKADGE TEST.
A leakadge test may be carried out by adding a length of clear

hose (1) to the fuel pipe (2) feeding the charging pump. The hose
must be to Tygon R3606 type with stratoflex number 10 hose
fittings. Start and run the engine and allow the air to purge out
of the pipe. No bubbles must appear in the pipe. Switch off the
engine and observe the fuel in the pipe. A small air space will
appear in the tube that is drawn from the fuel filter.
Observe the pipe for up to one hour, the air space should not
increase in size as fuel should not run back into the tank. If fuel
is running back to the tank with bubbles rising from the tank then
the leak is in the tank, filter or pipework. if fuel is running back to
the tank with no bubbles from the tank end then the leak is in the
system from the charge pump to the injectors.
Chapter 1
1.1.4.3.4 TESTINGTHE FUEL SOLENOID.
The fuel solenoid can be tested with a voltmeter to ensure the

correct voltage exists at the the terminal. With the ignition switched
on there should be a 12 volt feed to the solenoid. A resistance test
can be made by switching the ignition off and disconnecting the
feed cable to the solenoid, with the test meter set to the ohms scale
measure the resistance across the solenoid to earth. A reading of
between 6 and 10 ohms should be seen. A reading outside this
limit indicates a fault in the solenoid coil. A physical test can be
made by switching the ignition on and touching the end of the feed
cable to the solenoid terminal, the solenoid should be heard to
make a click as it is energised. A faulty solenoid must be replaced.
1.1.4.3.5 INSPECTING THE CHARGE PUMP.
If the pump does not perfom adequatly during any of the preceding
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tests it's operation should be inspected by removing the fuel feed
pipe and adaptor and observing the gears while the engine is being
cranked. If the gears do not rotate the pump should be removed.
1.1.4.3.6 REMOVING THE CHARGE PUMP.
In order to remove the pump (1) for further investigation remove

the screws (2) and pull the pump in the direction of the arrow (A).
Carefully inspect the coupling spider (3) for wear or damage and
replace if neccesary. Crank the engine and observe the accessory
drive shaft (4) for rotation. If the accessory drive shaft rotates the
charge pump (1) is faulty, If the accessory drive shaft does not
rotate the dive arrangement in the engine is faulty. Fitting the pump
is the reverse of the removal procedure, always ft a new gasket (5)
between the pump and hte accessory rive housing and inspect the
pump mounting face for wear or damage.
Chapter 1
1.1.4.3.6 PRIMING THE CHARGE PUMP.
When the fuel pump has been removed or replaced, or a fault has
occured that has caused the fuel to drain out of the charge pump
the unit may need to be primed with fuel prior to start up. There are
two ways to prime the pump by either introducing clean fuel into
the priming port in the top of the pump or by pouring fuel into the
inlet port.
To fill the charge pump by the priming port remove the plug in the
top of the charge pump assembly and fill the pump with clean fuel.
To fill the pump by the fuel inlet if access to the fill port is poor
remove the fuel feed pipe and adaptor and pour clean fuel into the
charge port. If the fuel pipe Tank or feed end is easily accessible
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the fuel may be poured into the pipe to charge the pump.
1.1.4.4 FUEL INJECTORS.
The fuel injectors are electronically controlled by the engine

electronic control module (ECM), they are mechanicaly operated
by an additional rocker assembly driven by the camshaft.
1 Rocker.
2 Adjuster.
3 Lash Gap area.
4 Pushrod.
5 Cam follower.
6 Camshaft
7 Injector metering plunger area.
8 Injector solenoid.
9 Injector timing plunger area.
10 Operating plunger.
Chapter 1
1.1.4.4.1 FUEL INJECTOR OPERATION.
The injector remains closed, with the plunger (25) held at it's lowest position by the operation of the engine
camshaft. As the camshaft rotates the spring (28) forces the plnger (25) upward. The solenoid (3)
is switched on by the ECM so fuel will flow through line (4) into the injector filling the timing chamber (23)
and metering barrel (8) with a precisely measured amount of fuel, excess fuel flows out through the return
line (5).
The plunger (25) now begins its downward stroke. At the appropriate time the ECM will switch the fuel
solenoid off trapping the metered amount of fuel in the Injector. The downward movement creates a
hydraulic link in the timing chamber (23) driving the metering plunger (20) downward increasing the
pressure in the metering barrel (8).
When the pressure reaches 345 bar (5000 psi) the needle valve (13) will be forced of its seat, atomising
and injecting the fuel into the combustion chamber. When the spill port in the metering plunger (20) passes
into line with the spill passage (21) injection pressure is lost and the needle valve (13) will close, abrubtly
ending the injection phase.
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Chapter 1
1.1.4.4.2 FUEL INJECTOR REMOVAL.
Remove the rocker cover and rockers (2), mark or number the
components, especially the pushrods(1) as they should go back
into their original positions. Remove and mark the bridge pieces
(3). As the rockers may be under load from the pushrods and
camshaft the tappet adjusters may be loosened and the crankshaft
can be rotated in the direction of the arrow (A) at the timing setting
pulley.
When the bridge pieces (2) have been removed and marked. the
injector can be unplugged from the ECM output (2). Remove the
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C01. Register 04
injector clamp capscrew (3) and the injector clamp (4).
The injector can be carefully prised upward using a pry bar under
the injector and levering against the cylinder head.
Replacing the injector is the reverse of this procedure. Before
fitting the injector ensure that the injector sleeve in the cylinder
head is clean and undamaged.
Always fit new O ring seals to the injector and lubricate them with
15W40 oil prior to fitting.
The O rings must be fitted in the correct order.
Top O ring Red.

Middle O ring White.
Bottom O ring Blue.
Do not twist the O rings during fitting.
Adjust the valves and injectors.

Chapter 1
1.1.4.4.3 ADJUSTING THE VAVLES AND INJECTORS.
The valve clearances and injector "lash" are adjusted at each

cylinder in turn in the same pattern as the firing order.
1 5 3 6 2 4
The crankshaft can be rotated by turning the pulley opposite the

charge pump drive. Do not attempt to rotate the crankshaft by
using the cooling fan as a lever.
Rotate the pulley until the timing mark "A" on the pulley alignes
with the timing mark on the timing chest cover and adjust each
injector and then the valves on each cylinder in turn acording to
the table to within the specified limit with the engine cold.
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C01. Register 04
Injector lash 120°
Inlet valve 0.36mm (0.014")
Exhaust valve 0.69mm (0.027")
ROTATE P U LLE Y SET INJECTOR SET CYLINDER

C R A N K S H A FT POSITION NUMBER NUMBER
1 START A 1 1
2 Advance to B 5 5
3 Advance to C 3 3
4 Advance to A 6 6
5 Advance to B 2 2
6 Advance to C 4 4
Each cylinder has three rocker levers.
The long rocker lever (N°1) is the exhaust valve lever.
The short rocker lever (N°2) is the inlet valve lever.
The centre rocker lever (N°3) is the injector lever.

Chapter 1
Ensuring the alignment of the timing mark (1) adjust the injector
first by loosening the rocker locknut on the centre adjuster (2) and
bottoming the injector by tightening the adjuster down gently until
it bottoms then loosen it again. Do this three or four times to
remove all the fuel from the injector. Tighten the injector again
until it bottoms then undo it 2 flats (120°). Tighten the locknut.
Each of the valve rockers (3) can be adjusted to the appropriate
setting.
Inlet valve 0.36mm (0.014")

Exhaust valve 0.69mm (0.027")
The crank should then be rotated to set the next cylinder in turn
according to the table on page 12.
The valve cover should be replaced, the isolators fitted and the
16 cap screws tightened to 15 Nm (130 inch/lb) in the correct
order as shown. Ensure that the breather tubes and charge air
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C01. Register 04
pipes are fitted correctly.
1.1.4.5 ENGINE COOLING SYSTEM.
The cooling system of the Cummins QSM engine is similar to

other engines, a pump (4) drives the coolant around the engine
block (5) and cylinder head (6) until the engine attains normal
operating temperature, at this temperature the the thermostat (1)
opens to direct the coolant through the radiator (3) where it is
cooled by the fan (2) to maintain the engine temperature within
an optimum range (82-93°c). As with all pressurised cooling
systems the water must have 50% antifreeze added at all times
and must be pressure tight (0.5bar) to prevent the coolant boiling.
Additionally the Cummins engine has a water filter that contains
soluble crystals (SCA, supplemental cooling additive), these
dissolve in the coolant over time and prevent damage to the
engine liners and cylinder head caused by hydrogen implosion.
Correct maintenance of this filter at the specified intervals is
important, failure to replace this filter could lead to early engine
failure.
Chapter 1
1.1.4.5.1 REPLACING THE WATER FILTER.
Replacement of the water filter should be carried out at the

normal service interval at the same time as the fuel and oil
filters are changed. Before removing the filter ensure that the
system is cool and that the pressure is relieved by removing
the radiator filler cap. Switch the valve on the filter head (1) to
the off position.
Caution
Ensure that the engine is cool before working on the
cooling system. Danger of burning or scalding.
Ensure that the filter valve (1) is switched to the "OFF"

position. Use a filter wrench (2) to remove the cannister (3).
Before fitting the new filter clean the filter head and smear the
rubber seal on the cannister with clean engine oil. Screw the
new filter on until the rubber seal is in contact with the filter
head then tighten the cannister by a further ½ to ¾ turn.
Note
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C01. Register 04
Do not overtighten the filter cannister, damage or
leakadge may occur.
1.1.4.5.2 REMOVING AND INSPECTING THE

THERMOSTAT.
The alternator must be removed to gain access to the

thermostat housing (1). Drain the coolant into a clean
receptacle for re-use.
Caution
The coolant is toxic, exercise care at all times.
Remove the four bolts (2) securing the thermostat housing (1)
to the engine and remove the thermostat housing.
Inspect the thermostat seal (2) and the thermostat (1) for
damage and replace if faulty. Note the nominal temperature
stamped on the body of the thermostat at (4). Test the
thermostat by suspending it in hot water and raising the
temperature of the water. The thermostat must begin to open
within 1°c of the nominal temperature and must be fully open
at the nominal temperature +12°c. It is advisable to fit new
seals to the thermostat housing (3) if possible before re-
assembly. Refit the unit and tighten the screws to 54Nm (40
lb/ft). Refill the system with the saved coolant. If new coolant
is used it must be a 50/50 mix of water and anti freeze.
Chapter 1
1.1.4.5.2 REMOVING THE WATER PUMP.
Removal of the alternator and thermostat housing will facilitate

access to the water pump. Remove the hose connections to the
water pump. Remove the two water pump transfer tube screws
(1) and the three water pump mounting screws (2).
The body of the water pump (3) can then be rotated to bring the
transfer tube (1) away from the cylinder block. The water pump
can then be removed for inspection, repair or replacement as
required. Fitting the water pump is the reverse of this procedure.
Fit and rotate the pump into position, fit and tighten the mounting
screws (2) to 47Nm (35 Lb/ft). Fit the transfer tube screws (1) and
tighten them to 24Nm (18 Lb/ft).
Caution
Ensure that the engine is cool before working on the
cooling system. Danger of burning or scalding.
Caution
The coolant is toxic, exercise care at all times.
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C01. Register 04
1.1.4.5.3 REMOVAL OF THE PULLEY BELT.
The pulley belt (1) drives the cooling fan and alternator. It is self
adjusting between set limits by an automatic tensioner (2) and
requires only periodic inspection.
To remove the belt fit a square drive bar into one of the holes in
the tensioner (3) and lever the tensioner away to free the belt.
Hold the tensioner in the loose position and remove the belt.
Inspect the belt and the pulleys for damage and replace as
necessary.
1.1.4.6 OIL FILTER REPLACEMENT.
Use a filter wrench to loosen and remove the filter. Thoroughly

clean the filter head, ensuring no particles of the old seal are
sticking to the head. Fill the new filter with clean engine oil and
aplly a light film of oil to the filter seal, screw the filter onto the head
until the seal makes contact and tighten the cannister a further ½
turn approximatly. Start and run the engine ensuring that the oil
pressure is correct and there are no leaks.
Chapter 1
1.1.4.7 ELECTRICAL SYSTEM.
The Cummins QSM engine uses an advanced electronic monitoring and fuel injection system controlled
by the ECM (electronic control module)(4). This unit will indicate faults or potential problems within the
engine by illuminating one of three warning lights in the cabin. There is also the facility for plug in analysis
with an appropriate laptop computer into the test port (1). The plugs on the end of the unit (2) and (3) are
the connections to the Linde harness.
In the front face of the ECM are three double plugs these are from left to right, Linde fault analysis plug
in. The centre plug is the actuator outputs to provide and recieve signals to various optional devices. The
third plug is the engine sensor inputs.
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C01. Register 04
When any fault or error is detected in any part of the system the ECM will detect it and respond by either
shutting the engine down or lighting a warning lamp in the cabin.
The nature of the fault can be analysed by reference to the three warning lights in the cabin mounted in
the right hand instrument pod, see page 17. One of these lights will illuminate to indicate the the fault.
The fault can then be analysed by switching the engine off, wait a few moments and switch the ignition
back on (do not start the engine). Fully press and release the accelerator pedal three times while observing
the warning lights.
The light will flash a "fault code", the number of times the light comes on in a pattern and the colour of the
light illuminated indicates the type or seriousness of the fault.
CAUTION
Failure to observe the warning codes could lead to serious engine damage.
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Service training
Transmission
Incorporating
BOOSTER
VALVE
Service Training
The Transmission
DANA TE 27 / TE 32
AP HM 1
Service Training
Content
Introduction Page 3
APC 200 Page 4
APC 200 Information Menu Page 5- 8
Dana Alarm and Warning Codes Page 9
How the system indicates an Alarm / Error Code Page 10
Problems & Failure codes during calibration Page 11-12
The Transmission Speed Sensors Page 13
The solenoid valve arrangement Page 14-16
The most common Dana Alarm Codes Page 17-22
Self diagnostic functions APC200 controller Page 23-34
Transmission Calibration Page 35-36
How to heat up the transmission Page 37
Pressure Check Points Page 38
Procedure How to Change the Trans Control Valve Page 39-41
How to perform a stall test Page 42
AP HM 2
Service Training
Dana TE 27 & TE 32 Transmission
- Type: Electronic controlled power shift transmission
- Max. input speed: 2550 RPM

- Max Turbine stall torque: 2700Nm // 3200 Nm
- Input horsepower range: Max 275 kW // 300 Kw
- Gearshift: Electronic control
- Number of gears: 4 forward & reverse
- Dual pump
75.8 l/min @ 2000 rpm - lubrication and cooling
92.8 l/min @ 2000 rpm - clutch filling, lube & cooling
Always with 2 remote filters.
Features of the TE 27 / 32 transmission:
Manual / automatic shifting

Electronic modulation
Overlap control
Electronic inching
Start 1st / 2nd
Limit vehicle speed
Reduce vehicle speed (by use of an input)
Limit engine speed
Direction change protection (speed and engine RPM)
Declutch (inching / none inching)
Engine control
Extended Oil change intervall 1000 Hrs
AP HM 3
Service Training
The APC 200
The Transmission Information-Diagnostic is a part of the APC 200
programming .
SPICER OFF-HIGHWAY D
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APC200
On the APC 200 we have a 4 digit display , indicating the current gear and direction , failure or alarm
codes , system information's like temperature , speeds ….
We also have 3 LED status lights

D Yellow indicates that the APC 200 is in Test Mode
E Yellow indicates that we have a fault in the system ( the fault number will be displayed on
the display )
F Indicates that the APC 200 is in Reset Mode
We have two operating buttons

M button is selecting the different modes and function groups
S button is scrolling in the different modes and groups
AP HM 4
Service Training
How to get the APC 200 Information menues .
To select the different Info menues select first by pressing the the M button the required Sub
menue ( Engine has to Run )
The Information menu is splitted in 3 info blocks ,
Block 1
1x M Gpos = Gear lever Position

After 1-2 seconds the display
indicates the actual position of
the gear lever
F3 = Forward 3
1x S VSPd = Vehicle Speed in Km/h or m/h

indicates the actual drive speed
20,5 km/h
1x S DiSt = DiStance travelled in Miles or Kilometer

indicates the travelled distance
in miles or kilometer ( 180,5 )
1x S oPEr = Actual oPerating hours
By pressing the M button we change to the next info block ( next page ) , by using
the S button we start again with Gpos
AP HM 5
Service Training
Block 2
1xM cPos = current Position Shiftlever
After 1-2 Sec. the display

indicates the engaged gear and
direction r 2 = neutral
1xS ESPd = Engine SPeed

indicates the actual
engine speed
1805 Rpm
1xS tSPd = turbine SPeed

indicates the actual turbine
speed 800 Rpm
1xS oSPd = outputshaft Speed

indicates the actual output shaft
speed 0050
50 Rpm
1xS SrAt = Speed rAtio

indicates the actual speed ratio
between input and output shaft
AP HM 6
Service Training
1xS tQ 1= turbine torque inputshaft

indicates the actual torque on the
inputshaft in Nm ( 80 Nm )
1xS Ttmp= Tansmission sump temperature

indicates the actual oil
temperature in the transmission
sump (87 °)
1xS cTmp = Converter out temperature or Cooler input temperature

indicates the actual oil
temperature on the converter out
,50 = below 120 ° , 150 = above
120 °
By pressing the M button we change to the next info block ( next page ) , by using
the S button we start again with c pos
AP HM 7
Service Training
Block 3
Error Code Display – ERR-
1xM Err = Error code display
1xS 42.04 = active fault 42.04 (pls rever to Alarm / Fault code list )
If there are more then 1 active

failures we can select them by
pressing the S button ,
1xS 82.01 = Blinking = inactive ( Stored ) failure / failures

Inactive failures are blinking /
flashing
1xS end of faults
AP HM 8
Service Training
The Dana Alarm and Warning Codes
As the APC 200 is checking all parameters during the operation of the machine the system is able to
create Alarm codes in case that a relevant system part (Speed , Pressure sensors , Temp . sensors
…) is out of the default parameters .
The APC 200 is displaying the Alarm codes on the APC display as a 4 digit code.
At the same time the Iqan system will send a SMS (see Iqan Alarms ) and lock the failure code also
into the event / error log.
The alarms are coming up in 5 priority levels.
Type Priority Level Description

S High Serious Failure is displayed on the APC 200 , SMS is created by
Iqan ,Transmission goes in neutral , loss of all primary
functions, transmission is in Limp Home mode
Loss of all drive comfort
A Medium Warning Failure is displayed on the APC 200 , SMS is created by
Iqan , On some failures Limp Home is Active
Loss of some of the comfort features
B Low Info Failure is displayed on the APC 200 ,SMS is created by
the Iqan , driver can feel some comfort losses
H Very Low Dana Info Failure is displayed on the APC 200 , SMS is created by
the Iqan ,
Problem is not causing any discomfort
E None Eceed Failure is displayed on the APC 200
Parameter Driver is requesting an action which is protected by
the APC 200
AP HM 9
Service Training
How the system indicates an Alarm / Error Code
As soon as the APC 200 get a wrong / no signal of the various sensors a message will send to the
MDM unit , the MDM unit will create and send a SMS message with the failure code
( see also Iqan Alarm / Error codes ) .
At the same time the E ( error ) LED on the APC 200 is illuminated and the error code is displayed on
the APC 200 display .
If we have for some reasons more then 1 error in the system we can do a read out of all the errors
by pressing the buttons on the APC 200 in the following sequence .
1) Press the M button several times until the display shows up
SPICER OFF-HIGHWAY D
M
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F
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APC200
2) Now press the S button to scroll to get all the errors displayed ( one by one )
AP HM 10
APC200 ECM/ECI ERROR CODES & DESCRIPTION Firmware version 6.3
Revision : 2.8 - 6 Feb 2009
Fault code Type Explanation Controller's action Driver action Fault cause Troubleshooting
00.50 S There is a problem related to the internal RAM (in Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Hardware related fault - related to in the internal Contact Spicer Off-Highway and inform the fault code and the time that is was
CPU). 0 RAM. active.
00.51 S There is a problem related to the system RAM (in Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Hardware related fault - related to in the system Contact Spicer Off-Highway and inform the fault code and the time that is was
00.52 S There is a problem related to the external RAM. Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Hardware related fault - related to in the external Contact Spicer Off-Highway and inform the fault code and the time that is was
0 RAM. active.
00.53 S There is a problem related to the Flash program Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Hardware related fault - related to in the flash Contact Spicer Off-Highway and inform the fault code and the time that is was
memory. 0 program memory. active.
20.60 S Pressure feed-back line is indicating there is no Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting The analog input ANI0 is in the 1500 - 4000 ohm Check the wiring between the controller and the pressure feedback sensor. Check
system pressure present, allthough pressure should 0 range, while it should be in the 500 - 1500 ohm the pressure feedback sensor (engine running / stopped).
be there range
20.61 S Pressure feed-back line is indicating there is system Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting The analog input ANI0 is in the 500 - 1500 ohm Check the wiring between the controller and the pressure feedback sensor. Check
pressure present, allthough pressure should NOT be 0 range, while it should be in the 1500 - 4000 ohm the pressure feedback sensor (engine running / stopped).
there range
30.04 S Power supply out of range -> below minimum Controller will save all logged information to flash, will Stop machine & Contact maintenance for troubleshooting Power supply to the controller too low: Check power supply cables to the controller. Check alternator, check the connection
powerdown, and force all outputs off APC200 12V supply version: < 9 V cables between the battery and the alternator, check the battery.
APC200 24V supply version: < 16V
30.05 A Power supply out of range -> above maximum The controller will have reduced proportional control accuracy Contact maintenance for troubleshooting Power supply to the controller too high: Check power supply, check if a jump start setup is still connected.
due to reduced PWM duty cycle APC200 12V supply version: > 18 V
APC200 24V supply version: > 32 V
31.00 A Voltage supply for the sensors : Vsense (8V) is out The controller will have reduced sensor signals Contact maintenance for troubleshooting Voltage supply for the sensors : Vsense (8V) is Check power supply. Check the controller.
of range -> below minimum below 7,2 V
of range -> above maximum above 8,8 V
34.00 S/A Speed sensor related fault The controller reverts to a "limp home" mode. Stop machine & Contact maintenance for troubleshooting One or more speed channel failures Check the wiring between the controller and the speed sensors. Check the speed
sensors,
34.01 S/A Measured turbine speed is to low during Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Speed sensor failure, Check the wiring between the controller and the speed sensors. Check the speed
initialisation 0 Supply pressure to transmission too low sensors, Check the speed sensor positions. Check supply pressure to the
transmission
34.02 S/A Measured drum speed is to high during initialisation Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Speed sensor failure, Check the wiring between the controller and the speed sensors. Check the speed
0 Too much drag because of thick oil, sensors, Check the speed sensor positions.
Sticking or burnt clutch
34.03 S/A Internal transmission speeds are indicating there is Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Speed sensor failure, RSP drive solenoid failure. Check the wiring between the controller and the speed sensors. Check the speed
no system pressure present, allthough pressure 0 Supply pressure to transmission too low sensors, Check the speed sensor positions.Check supply pressure to the
should be there transmission, Check the RSP drive solenoid.
34.04 S/A Internal transmission speeds are indicating there is Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Speed sensor failure, RSP drive solenoid failure. Check the wiring between the controller and the speed sensors. Check the speed
system pressure present, allthough pressure should 0 Too much drag because of thick oil, sensors, Check the speed sensor positions. Check the RSP drive solenoid.
NOT be there Sticking or burnt clutch
17/12/2009 APC200 ECM-ECI VFS Booster Error Codes ver2.8 Page : 1 of 16

40.06 A Invalid shift lever direction detected The controller will force neutral. Contact maintenance for troubleshooting The controller receives from the shiftlever a request Check the wiring between the controller and the shiftlever concerning the forward
to engage forward and reverse at the same time. and the reverse signal.
40.08 B Seat orientation input was changed while the parking The controller will force neutral. Stop the vehicle, put the shift lever in neutral and put the Seat orientation input was changed while the parking Check the seat orientation switch or train the driver to change the seat orientation
brake was not active, or/and the shiftlever was not in parking brake on until the fault disappears. brake was not active, or/and the shiftlever was not in according to the correct procedure.
neutral, or/and the machine was not at standstill. neutral, or/and the machine was not at standstill
41.06 A Invalid shift lever position detected The controller will not allow range shifting, however driving is Contact maintenance for troubleshooting The controller receives from the shiftlever an Check the wiring between the controller and the shiftlever concerning the range
still possible. unknown range shift pattern. signals.
42.04 S/A The actual transmission ratio is too low. Controller will flag the fault - this fault is indicating that one or Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
more clutches are slipping. The controller will revert to shut more than 5% below the value of what is should be. Check the transmission ratio settings of the controller.
down mode.
42.05 S/A The actual transmission ratio is too high. Controller will flag the fault - this fault is indicating that one or Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
more clutches are slipping. The controller will revert to shut more than 5% above the value of what is should be. Check the transmission ratio settings of the controller.
down mode
43.03 A The transmission converter out temperature sensor Controller will flag the fault. Contact maintenance for troubleshooting The converter out temperature sensor is not Check the wiring between the controller and the converter out temperature sensor.
is out of range. connected or shorted. Check the converter out temperature sensor.
43.07 A The transmission converter out temperature sensor Controller will flag the fault - in order to indicate the driver of Take notice of the fault, and try to bring the converter The controller measured a converter out temperature Check the converter out temperature and the converter out temperature sensor.
> 100° C. the warning level. temperature to a lower level. between 100° C and the allowed limit.
43.08 A The transmission converter out temperature sensor The controller is protecting the transmission and does not allow Stop machine, select neutral and apply full throttle (limited to The controller measured a converter out temperature Check the converter out temperature and the converter out temperature sensor.
> 120° C. that the converter out temperature exceeds its limit. The 50 %) in order to cool the transmission oil below 100° C above the allowed limit.
controller will force the transmission to neutral, and if engine is (until the fault 43.03 is gone). Once the converter out
controlled, the engine will be limited 50 % of its maximum temperature is below 100° C, continue driving the machine.
speed.
44.10 A No EEC2 message (throttle position from the The controller will flag the fault and the TSC1 message will Contact maintenance for troubleshooting No EEC2 message on the CAN bus when expected. Check engine controller and CAN connection to the APC200
engine controller) on the CAN bus when expected. send the idle possition to the engine controller.
45.06 B Invalid pattern for the reduced vehicle speed The controller will limit the vehicle speed to the reduced speed. Contact maintenance for troubleshooting Invalid pattern for the reduced vehicle speed Check the redundant reduced vehicle speed switches and the wiring connected
redundant digital inputs (2 inputs used). redundant digital inputs (2 inputs used) from these switches to the APC200.
46.05 A The transmission has exceeded the maximum torque The controller will open or close the inching clutch depending Release the inching pedal and cycle the shiftlever via neutral The transmission has exceeded the maximum torque Release the inching pedal and cycle the shiftlever via neutral back in the selected
during inching. of the GDE parameter selection. back in the selected direction in order to get drive again. during inching. direction.
47.00 B disengaged 4WD/2WD selector is stuck engaged, or Controller will flag the fault Contact maintenance for troubleshooting The mechanical actuator is stuck Check if digital output has its expected value and if the mechanical actuator has
feedback line is faulty made the switch. Also check if the digital feedback is switched and still connected
to the controller.
47.01 B engaged 4WD/2WD selector is stuck disengaged, or Controller will flag the fault Contact maintenance for troubleshooting The mechanical actuator is stuck Check if digital output has its expected value and if the mechanical actuator has
to the controller.

48.00 B disengaged Low/High selector is stuck engaged, or Controller will flag the fault Contact maintenance for troubleshooting The mechanical actuator is stuck Check if digital output has its expected value and if the mechanical actuator has
the feedback line is faulty made the switch. Also check if the digital feedback is switched and still connected
to the controller.
48.01 B engaged Low/High selector is stuck disengaged, or Controller will flag the fault Contact maintenance for troubleshooting The mechanical actuator is stuck Check if digital output has its expected value and if the mechanical actuator has
to the controller.
50.00 S Analog input 0 (wire A11) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI0 is shorted to ground, or Check the wiring between the controller and the device connected to this analog
input is shorted to ground. - temperature sensor: controller will use the lowest clipped measured input value is below the minimum value input. Check this device connected. Check if the calibration is done correctly -
value in its settings (which results in bad temperature (corresponding with 0 %). recalibration of this analog input.
compensation
- pressure feedback: the controller will revert to limp home
mode
- other: the controller will use the lowest clipped value
50.01 S Analog input 0 (wire A11) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI0 is not connected, or Check the wiring between the controller and the device connected to this analog
input is not connected. - temperature sensor: controller will use the highest clipped measured input value is above the maximum value input. Check this device connected. Check if the calibration is done correctly -
compensation
mode
50.04 B Analog input 0 (wire A11) related fault : analog Controller will flag the fault, and will use the lowest clipped Contact maintenance for troubleshooting The analog input ANI0 measured input value is Check the wiring between the controller and the device connected to this analog
input value is below the minimum value calibrated. value in its settings. below the minimum value (corresponding with 0 %). input. Check this device connected. Check if the calibration is done correctly -
recalibration of this analog input.
50.05 B Analog input 0 (wire A11) related fault : analog Controller will flag the fault, and will use the highest clipped Contact maintenance for troubleshooting The analog input ANI0 measured input value is Check the wiring between the controller and the device connected to this analog
input value is above the maximum value calibrated. value in its settings. above the maximum value (corresponding with 100 input. Check this device connected. Check if the calibration is done correctly -
%). recalibration of this analog input.
51.00 A Analog input 1 (wire A28) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI1 is shorted to ground, or Check the wiring between the controller and the device connected to this analog
compensation
mode
51.01 A Analog input 1 (wire A28) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI1 is not connected, or Check the wiring between the controller and the device connected to this analog
compensation
mode

52.00 B Analog input 2 (wire A29) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI2 is shorted to ground, or Check the wiring between the controller and the device connected to this analog
compensation
mode
52.01 B Analog input 2 (wire A29) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI2 is not connected, or Check the wiring between the controller and the device connected to this analog
compensation
mode
53.00 B Analog input 3 (wire B17) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI3 is shorted to ground, or Check the wiring between the controller and the device connected to this analog
compensation
mode
53.01 B Analog input 3 (wire B17) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI3 is not connected, or Check the wiring between the controller and the device connected to this analog
compensation
mode
53.04 B Analog input 3 (wire B17) related fault : analog Controller will flag the fault, and will use the lowest clipped Contact maintenance for troubleshooting The analog input ANI3 measured input value is Check the wiring between the controller and the device connected to this analog
input value is below the minimum value calibrated. value in its settings. below the minimum value (corresponding with 0 % - input. Check this device connected. Check if the calibration is done correctly -
100 mV). recalibration of this analog input.
53.05 B Analog input 3 (wire B17) related fault : analog Controller will flag the fault, and will use the highest clipped Contact maintenance for troubleshooting The analog input ANI3 measured input value is Check the wiring between the controller and the device connected to this analog
% + 100 mV). recalibration of this analog input.
54.00 A Analog input 4 (wire B02) related fault : analog Controller will flag the fault. The controller uses the analog Contact maintenance for troubleshooting The reference power supply (5 V ref.) for the analog Check the refence power supply of the analog inputs ANI0, ANI2, ANI3, ANI5 and
input is shorted to ground. input ANI4 to have a reference power supply for the analog inputs ANI0, ANI2, ANI3, ANI5 & ANI6 is below ANI6.
inputs ANI0, ANI2, ANI3, ANI5 and ANI6. 4,8 V.
54.01 A Analog input 4 (wire B02) related fault : analog Controller will flag the fault. The controller uses the analog Contact maintenance for troubleshooting The reference power supply (5 V ref.) for the analog Check the refence power supply of the analog inputs ANI0, ANI2, ANI3, ANI5 and
input is shorted to battery plus. input ANI4 to have a reference power supply for the analog inputs ANI0, ANI2, ANI3, ANI5 & ANI6 is above ANI6.
inputs ANI0, ANI2, ANI3, ANI5 and ANI6. 5,2 V.

compensation
mode
compensation
mode
compensation
mode
compensation
mode
60.00 S/A Speed channel 0 (wire A22) related fault : speed When only 1 speed channel has a failiure, and which is not the Contact maintenance for troubleshooting Speed channel SPC0 is shorted to ground. Check the wiring between the controller and the speed sensor connected to speed
channel is shorted to ground. engine speed channel, the controller will calculate what the channel 0. Check the speed sensor connected to speed channel 0.
missing speed should be. If several speed channels have a
failiure, of the engine speed channel has a failiure, the
controller reverts to a "limp home" mode.

60.01 S/A Speed channel 0 (wire A22) related fault : speed When only 1 speed channel has a failiure, and which is not the Contact maintenance for troubleshooting Speed channel SPC0 is not connected. Check the wiring between the controller and the speed sensor connected to speed
channel is not connected. engine speed channel, the controller will calculate what the channel 0. Check the speed sensor connected to speed channel 0.
60.03 S/A Speed channel 0 (wire A22) related fault : speed The controlller flags the error code. Contact maintenance for troubleshooting Speed channel SPC0 is not connected, or Check the wiring between the controller and the speed sensor connected to speed
measurement out of range measurement out of range channel 0. Check the speed sensor connected to speed channel 0.
60.04 S/A Speed channel 0 (wire A22) pulse count too low. This message is given as additional information for Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
transmission ratio faults. more than 5% below the value of what is should be. Check the transmission ratio settings of the controller.
60.05 S/A Speed channel 0 (wire A22) pulse count too high This message is given as additional information for Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
transmission ratio faults. more than 5% above the value of what is should be. Check the transmission ratio settings of the controller.
61.05 S/A Speed channel 1 (wire A24) pulse count too high. This message is given as additional information for Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
controller
reverts to a "limp home" mode.

62.03 S/A No engine speed information available. Controller reverts to a "limp home" mode Contact maintenance for troubleshooting No EEC1 message on the CAN bus for 200 ms. Check engine controller and CAN connection to the controller
J1939_SIGNAL_ERROR or
J1939_SIGNAL_NOT_AVAILABLE reported in
EEC1.
62.06 S/A No engine speed detected while turbine speed is Controller reverts to a "limp home" mode Contact maintenance for troubleshooting Speed sensor damaged, bad alignment between Check the transmission and speed sensor. Check speed sensor position.
measured sensor and measuring gear.
63.00 S/A Speed channel 3 (wire B11) related fault : speed When only 1 speed channel has a failiure, and which is not the Contact maintenance for troubleshooting Speed channel SPC3 is shorted to ground. Check the wiring between the controller and the speed sensor connected to speed
63.01 S/A Speed channel 3 (wire B11) related fault : speed When only 1 speed channel has a failiure, and which is not the Contact maintenance for troubleshooting Speed channel SPC3 is not connected. Check the wiring between the controller and the speed sensor connected to speed
63.03 S/A Speed channel 3 (wire B11) related fault : speed The controlller flags the error code. Contact maintenance for troubleshooting Speed channel SPC3 is not connected, or Check the wiring between the controller and the speed sensor connected to speed
63.04 S/A Speed channel 3 (wire B11) pulse count too low This message is given as additional information for Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
63.05 S/A Speed channel 3 (wire B11) pulse count too high This message is given as additional information for Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
70.00 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the The output wires of the analog output 0 are shorted Check the wiring between the controller and the VFS solenoid 0 Check the VFS
output wires are shorted to each other, or the sense controller can control that drive direction the machine will to each other, or the sense line is shorted to battery +, solenoid 0.
line is shorted to battery +, or the plus line is shorted drive, but in a "limp home" mode. If not, the opposite drive or the plus line is shorted to ground
to ground direction has to be selected to move the machine & Contact
maintenance for troubleshooting
70.01 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the An output wire of the analog output 0 is not Check the wiring between the controller and the VFS solenoid 0 Check the VFS
the output wire is not connected, or its plus line is controller can control that drive direction the machine will connected, or its plus line is shorted to battery +, or solenoid 0.
shorted to battery + drive, but in a "limp home" mode. If not, the opposite drive the VFS 0 is defect.
direction has to be selected to move the machine & Contact
70.02 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting The currecnt of the analog output 0 is exceeding Check the wiring between the controller and the VFS solenoid 0 Check the VFS
the output current exceeds 1400 mA or/and the 0 1400 mA. solenoid 0.
output plus line is shorted to battery +.

70.03 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the The current of the analog output 0 is out of range. Check the wiring between the controller and the VFS solenoid 0 Check the VFS
the output current is out of range, occurs when the controller can control that drive direction the machine will solenoid 0.
load has the incorrect impedance drive, but in a "limp home" mode. If not, the opposite drive
70.09 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "limp home" mode Stop machine & Contact maintenance for troubleshooting The wire of the analog output 0 is not connected Check the wiring between the controller and the proportional valve 0 Check the
the output is not connected proportional valve 0.
output wires are shorted to each other, or the sense controller can control that range selection the machine will to each other, or the sense line is shorted to battery +, solenoid 1.
line is shorted to battery +, or the plus line is shorted drive, but in a "limp home" mode. If not, an other range gear or the plus line is shorted to ground
to ground will be used & Contact maintenance for troubleshooting
the output wire is not connected, or its plus line is controller can control that range selection the machine will connected, or its plus line is shorted to battery +, or solenoid 1.
shorted to battery + drive, but in a "limp home" mode. If not, an other range gear the VFS 1 is defect.
will be used & Contact maintenance for troubleshooting
the output current is out of range, occurs when the controller can control that range selection the machine will solenoid 1.
load has the incorrect impedance drive, but in a "limp home" mode. If not, an other range gear
71.09 S Analog output 1 (wires A04 & A05) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the The wire of the analog output 1 is not connected Check the wiring between the controller and the proportional valve 1 Check the
the output is not connected controller can control that range selection the machine will proportional valve 1.
drive, but in a "limp home" mode. If not, an other range gear
output wires are shorted to each other, or the sense controller can control that drive direction the machine will to each other, or the sense line is shorted to battery +, solenoid 2.
line is shorted to battery +, or the plus line is shorted drive, but in a "limp home" mode. If not, the opposite drive or the plus line is shorted to ground
to ground direction has to be selected to move the machine & Contact
the output wire is not connected, or its plus line is controller can control that drive direction the machine will connected, or its plus line is shorted to battery +, or solenoid 2.
shorted to battery + drive, but in a "limp home" mode. If not, the opposite drive the VFS 2 is defect.

the output current is out of range, occurs when the controller can control that drive direction the machine will solenoid 2.
load has the incorrect impedance drive, but in a "limp home" mode. If not, the opposite drive
output wires are shorted to each other, or the sense controller can control that range selection the machine will to each other, or the sense line is shorted to battery +, solenoid 3.
the output wire is not connected, or its plus line is controller can control that range selection the machine will connected, or its plus line is shorted to battery +, or solenoid 3.
shorted to battery + drive, but in a "limp home" mode. If not, an other range gear the VFS 3 is defect.
the output current is out of range, occurs when the controller can control that range selection the machine will solenoid 3.
73.09 S Analog output 3 (wires A08 & A09) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the The output wire of analog output 3 is not connected Check the wiring between the controller and the proportional valve 3 Check the
74.00 A Analog output 4 (wires B01) related fault : output Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 4 is shorted to Check the wiring between the controller and the device connected on the analog
wire is shorted to ground. ground. output 4.
wire is shorted to battery +, or not connected. battery +, or not connected. output 4.
74.02 A Analog output 4 (wires B01) related fault : the Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 4 is exceeding Check the wiring between the controller and the device connected on the analog
output current exceeds 1400 mA. 1400 mA. output 4.
74.03 A Analog output 4 (wires B01) related fault : the Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 4 is out of range. Check the wiring between the controller and the device connected on the analog
output current is out of range, occurs when the load output 4. Check the device connected.
has the incorrect impedance.
74.09 A Analog output 4 (wires B01) related fault : the Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 4 is not connected Check the wiring between the controller and the device connected on the analog
output is not connected output 4. Check the device connected.

76.00 S Analog output 6 (wires B05) related fault : output Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 6 is shorted to Check the wiring between the controller and the device connected on the analog
76.02 S Analog output 6 (wires B05) related fault : the Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 6 is exceeding Check the wiring between the controller and the device connected on the analog
76.03 S Analog output 6 (wires B05) related fault : the Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 6 is out of range. Check the wiring between the controller and the device connected on the analog
76.09 S Analog output 6 (wires B05) related fault : the Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 6 is not connected Check the wiring between the controller and the device connected on the analog
77.02 S All VFS grounds are switched off due to an over Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting One or more VFS's have an ove current, not that this Check the combined fault, and see the troubleshooting for that fault.
current on one or more VFS's. 0 fault will be combined with a 70.02 and/or 71.02
and/or 72.02 and/or 73.02.
80.00 S Digital output 0 (wire A10) related fault : output is Controller reverts to a "shut down" mode. and will force Stop machine & Contact maintenance for troubleshooting Digital output DIG0 is shorted to ground. Check the wiring between the controller and the RSP drive solenoid + line. Check
shorted to ground neutral 0 the RSP drive solenoid.
80.01 S Digital output 0 (wire A10) related fault : output is Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Digital output DIG0 is not connected or shorted to Check the wiring between the controller and the RSP drive solenoid + line. Check
not connected, or shorted to battery + 0 batter +. the RSP drive solenoid.
80.09 S Digital output 0 (wire A10) related fault : output is Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Digital output DIG0 is not connected. Check the wiring between the controller and the RSP drive solenoid + line. Check
not connected 0 the RSP drive solenoid.
81.00 S Digital output 1 (wire A15) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG1 is shorted to ground. Check the wiring between the controller and the 2/4 selector solenoid + line. Check
shorted to ground controller can control that range selection the machine will the 2/4 selector solenoid.

81.01 S Digital output 1 (wire A15) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG1 is not connected or shorted to Check the wiring between the controller and the 2/4 selector solenoid + line. Check
not connected, or shorted to battery + controller can control that range selection the machine will batter +. the 2/4 selector solenoid.
81.09 S Digital output 1 (wire A15) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG1 is not connected Check the wiring between the controller and the 2/4 selector solenoid + line. Check
not connected controller can control that direction selection the machine will the 2/4 selector solenoid.
not connected, or shorted to battery + controller can control that range selection the machine will batter +. the 1/3 selector solenoid.
not connected controller can control that range selection the machine will the 1/3 selector solenoid.
83.00 S Digital output 3 (wire A20) related fault : output is The controller reverts to a "shut down" mode and will force Stop machine & Contact maintenance for troubleshooting Digital output DIG3 is shorted to battery +. Check the wiring between the controller and the RSP drive solenoid - line. Check
shorted to battery + neutral 0 the RSP drive solenoid.
83.01 S Digital output 3 (wire A20) related fault : output is The controller reverts to a "shut down" mode and will force Stop machine & Contact maintenance for troubleshooting Digital output DIG3 is not connected or shorted to Check the wiring between the controller and the RSP drive solenoid - line. Check
not connected, or shorted to ground neutral 0 ground. the RSP drive solenoid.
90.xx - 99.xx S/B/H System Error. Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.01 S Gearpattern doesn't contain a direction Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.02 S duplicate direction pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.03 S duplicate gear pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.04 S duplicate bump pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.06 S digital input pattern faulty Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.07 S digital input pattern interferes with cab pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.

92.08 S digital input: Neutral lock definition faulty Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.09 S duplicate digital input assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.10 S duplicate digital output assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.11 S Digital output selected on unsupported wire Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.12 S digital output pattern faulty Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.13 S digital output selected on transmission wire Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.14 S error in speed sensor 1-2 assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.15 S error in speed sensor 3 assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.16 S duplicate speed sensor assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.17 S invalid supply voltage selected Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.18 S duplicate analog input pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.19 S pressure sensor wires interfere with analog input Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
wires 0 active.
92.20 S wrong configuration regarding servo motor or brake Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
valve (on analog outputs 4-5-6) 0 active.
92.30 S wrong configuration regarding full flow selection Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
and past digital error treatment 0 active.
95.71 S Data in the APC200 is not compatible with the data The controller reverts to a "shut down" mode and will force Download an APT file compatible with the active firmware Wrong APT file (data file) is in the APC200 Download an APT file compatible with the active firmware into the APC200
expected by the APC200 firmware neutral 0 into the APC200 (typically after APC200 firmware upgrade) If the error code still persists, the data flash may be corrupt (contact Spicer Off-
Highway)
90.90 S Wrong firmware is flashed into the APC200. The controller reverts to a "shut down" mode and will force Flash the correct firmware into the APC200 Wrong firmware is flashed into the APC200 Flash the correct firmware into the APC200
neutral 0

99.95 B CAN peak load detected : APC200 temporarily Controller will reply on the CAN messages which are available No action requested Overload of incomming CAN messages to the No action requested
could not process all incoming messages, due to an in its buffer. APC200
excessive peak of CAN requests.
93.10 S Initialisation of statistical data in flash memory, Controller will flag the fault, but no actions will be taken. Stop machine, restart controller Memory conflict in flash memory Reset controller
caused by firmware upgrade or memory conflict
93.11 S Initialisation of logged error data in flash memory, Controller will flag the fault, but no actions will be taken. Stop machine, restart controller Memory conflict in flash memory Reset controller
xx.49 S Fault with undefined cause. Controller will flag the fault - action will depend on the fault. Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
active.
The codes listed below are Error codes that can only appear during autocalibration
Calibration code Explanation
E.1.XX Touch pressure Calibration
E.2.XX Optimise fill time
XX Type Explanation Controller's action Driver action Fault cause Troubleshooting
1->5, 7->9, 11->13, Unexpected Algorithm response during calibration. Stop calibration of clutch xx. Wait for continue request. List reported fault for clutch xx and request continue Engine does not respond to target engine speed. Continue calibration to identify if all clutches experience same problem. Download
15, 17-> 24 calibration. Vehicle started moving. Bad parameter correct parameter file and restart calibration. Check if vehicle starts moving during
configuration. calibration. Check engine speed response.
06 During calibration the turbine speed signal does not Controller will flag the fault and will abort calibration of clutch Driver can push S-button on APC200 to continue calibration Turbine speed does not reach minimum value during Measure clutch pressure to detect clutch leakage
rach a minimum value with error code shifting iteration process cuased by slipping clutch or Check speed sensor signal (can be in relation with 42.04 and/or 42.05 during
bad turbine speed signal. normal operation and with E1.26 during touch pressure calibration)
Check stall speed to detect slipping clutch
10 Transmission failure during calibration calibration is stopped Exit calibration Caused by shutdown error code during calibration Resolve cause of shutdown error code during calibration
Example: 20.60 error code during calibration
14 During calibration the turbine speed signal does not Controller will flag the fault and will abort calibration of clutch Driver can push S-button on APC200 to continue calibration Turbine speed does not decrause caused by too high Measure clutch pressure to detect clutch leakage
decrease with error code internal leakage and/or slipping clutch Check speed sensor signal ( must be in relation with 42.04 and/or 42.05 during
Bad turbine speed signal normal operation and with E1.26 during touch pressure calibration)

16 during calibration the turbine speed signal is too low Controller will flag the fault and will abort calibration of clutch Driver can push S-button on APC200 to continue calibration Faulty turbine speed sensor Check speed sensor signal ( must be in relation with 42.04 and/or 42.05 during
to start calibration with error code Sticking or burnt clutch with causes turbine drop normal operation and with E1.25 during touch pressure calibration)
before pressure is applied
25 Early touch detection during touch pressure Controller will flag the fault and will abort touch pressure Driver can push S-button on APC200 to continue calibration Too much drag because of thick oil Perform autocalibration at higher temperature (90-100°C)
calibration. Too much drag calibration of clutch with error code Sticking or burnt clutch with causes turbine drop Check speed sensor signal (must be in relation with 42.04 and/or 42.05 during
before pressure is applied normal operation)
Speed sensor problem Check and if necessary change VFS
Faulty VFS
26 No touch detection during touch pressure Controller will flag the fault and will abort touch pressure Driver can push S-button on APC200 to continue calibration Slipping clutch or too high internal leakage Measure clutch pressure to detect clutch leakage
calibration. calibration of clutch with error code Speed sensor problem Check speed sensor signal ( must be in relation with 42.04 and/or 42.05 during
Faulty VFS normal operation)
Check and if necessary change VFS
28 Turbine speed does not reach value = 0 rpm at end Controller will flag the fault and will abort release pressure Driver can push S-button on APC200 to continue calibration Slipping clutch or too high internal leakage Measure clutch pressure to detect clutch leakage
of closing phase of the touch pressure calibration calibration of clutch with error code Speed sensor problem Check speed sensor signal ( must be in relation with 42.04 and/or 42.05 during
Faulty VFS normal operation)
Check and if necessary change VFS
29 Turbine speed signal does not reach a high enough Controller will flag the fault and will abort release pressure Driver can push S-button on APC200 to continue calibration Too much drag because of thick oil Perform autocalibration at higher temperature (90-100°C)
value during release phase of the touch pressure calibration of clutch with error code Sticking or burnt clutch which causes turbine drop, Check speed sensor signal (must be in relation with 42.04 and/or 42.05 during
calibration. before pressure is applied. normal operation)
Speed sensor problem Check and if necessary change VFS
Faulty VFS
Exceed code Type Explanation Controller's action Driver action
E0.01 E The vehicle speed is too high to make the requested The controller will disable the downshift in order to protrect the The driver should slow down the vehicle, in order that the
downshift. transmission, until the vehicle speed comes below the requested downshiflt can be made.
downshift limit.
E1.01 E The vehicle speed is too high to make the requested The controller will not allow the direction change to protect the The driver should slow down the vehicle, in order that the
direction change. transmission and will place the transmission in neutral, until requested direction change can be made.
the vehicle speed comes below the direction change vehicle
speed limit.
E2.01 E The engine speed is too high to make the requested The controller will not allow the direction change or re- The driver should slow down the engine, in order that the
direction change or the requested re-engagement of engagement of the direction, until the engine speed comes requested direction change or direction re-engagement can be
the direction. below the direction change or the direction re-engagement made.
engine speed limit.
E3.00 E The reduced vehicle speed limitation is active. The controller is limiting the vehicle speed to the reduced No action is requested, the vehicle speed is limited due to
vehicle speed limit. request.
E3.01 E The reduced vehicle speed limitation is active, The controller is limiting the vehicle speed to the reduced The driver should slow down the vehicle, in order that the
however the vehicle speed is above the limit. vehicle speed limit, but detects a higher vehicle speed. vehicle speed comes below the reduced vehicle speed limit.
E3.02 E The vehicle speed is above the maximum vehicle The controller is limiting the vehicle speed to the maximum The driver should slow down the vehicle, in order that the
speed limit. vehicle speed limit, but detects a higher vehicle speed. vehicle speed comes below the maximum vehicle speed limit.

E4.00 E An abnormal decelleration is detected. The controller detected an abnormal decelleration, and will The driver should slow down, in order that the wheels can not
disable the automatiic shifting for a certain time. slip any more.
E4.01 E An abnormal accelleration is detected. The controller detected an abnormal accelleration, and will The driver should slow down the engine, in order that the
disable the automatiic shifting for a certain time. wheels can not spin any more.
E5.01 E Time in gear exceeded the time to recalibrate the The controller detected that the time in gear exceeded the time The driver should contact maintenance to recalibrate the
transmisson. to recalibrate the transmisson. transmission,
E6.00 E Operator is not seated with shiftlever not in neutral The controller detected that the operator is not seated with the The driver should take place in the operator seat and confirm
and/or the parking brake not activated. shiftlever not in neutral and/or the parking brake not activated. his presence (cycle the shiftlever through neutral and/or
release the throttle pedal)
E7.00 E Turbine speed exceeds the limit The controller detects that the turbine speed is above its limit. The driver should slow down the vehicle, in order that the
The controller will force engine idle to prevent damage. turbine speed comes below the maximum turbine speed limit.
E8.01 E Condition to change low high range selector not The controller detected that the machine is still driving. The driver should stop the machine
furfilled. Machine has to stand still.
E9.01 E Condition to change from 4wd to 2wd or visa versa The controller detected that the machine is still driving. The driver should stop the machine
not furfilled. Machine has to stand still.
Type Severity of Effect Level Discription
S High Severe warning Vehicle inoperable, with loss of primary function / Vehicle operable, but at reduced level of performance - customer dissatisfied.
A Moderate Warning Vehicle operable, but comfort / convenience item(s) inoperable - customer experiences discomfort.
B Low Info Vehicle operable, but comfort / convenience item(s) operable at reduced level - customer experiences some dissatisfaction.
H Very low Dana info Vehicle operable, defect not noticed by customer.
E None Exceed parameter info Driver is requesting an action, which is protected by the controller
Limp Home Mode
The GPOS / CPOS display indicates the letters ‘LH’ left of the direction/position indication
Defaulted to if either of following conditions occurs:
• a single fault on a transmission control output is detected
• a fault related to the engine speed sensor is detected
• two out of three vehicle speed sensors are in fault
If one of the above conditions is present, the transmission is put in neutral. In order to continue driving, neutral must first be selected on the shift lever. Once the shift lever has been put in neutral, the driver can re-engage a direction.
In this mode, the user can operate the transmission in either direction in 1st and 2nd only. If the fault occurs at a higher gear position, the user is allowed to shift down manually.
Note: On some transmissions, ratios normally not selectable are used to substitute those that can no longer be selected.
The controller uses default limits; all shifts use a default modulation curve.
Inching is disabled.

Shut Down Mode
The GPOS / CPOS display indicates the letters ‘Sd’ left of the direction/position indication
The ECM transmission control valve has a built-in redundant shutdown solenoid and a pressure switch that monitors the pressure controlled by that solenoid.
This solenoid is controlled by the APC200 using both a high side and a low side switch (again redundant logic).
When the APC200 enters shut down mode, all four pressure modulators are put at zero pressure AND both controlling outputs of the redundant shutdown solenoid are switched off
This mode is activated when a severe internal or external problem is detected.
In this mode, the transmission is forced in Neutral because the redundant shutdown path cuts off the hydraulic power to the clutches.
This mode is selected only if an intolerable combination of faults exists. In case of an intermitting problem, SHUTDOWN mode is exited and the controller enters the LIMP HOME mode.
However, in case the error is related to the pressure feedback signal, SHUTDOWN mode remains selected until the controller is switched off.
Also when a fault related to the parameter settings located n FLASH memory s detected, the controller reverts to shutdown mode
Pressure feedback sensor

If present, the pressure feedback signal is evaluated as an ON/OFF pressure switch, with internal resistance
of 2K ohm when open and 1K ohm when pressurized.
If resistance is substantially lower than 1K0, a SC condition is assumed.
If it's higher than 2K0, an OL condition is assumed

Service Training
To get the best possible gear change behaviour the transmission
must be calibrated from time to time
Problems during Calibration
During the calibration , all clutches
C1 Forward
C2 Reverse
C3 1st Gear
C4 2nd Gear
C5 3 rd Gear
C6 4 th Gear
Going to the 2 different calibration Modes N 1 & N 2
C1- 6 N1 = Pressurisation
Here the APC 200 need to find the pressure where we have touch pressure ( start of transferring
torque ) we start with a pressure of 0,5 bar and go ins steps of o,5 higher until we have found the
touching point/pressure
NOTE :
The max is 5,5 Bar for the calibration , if the APC can not see the start of torque transfer within the
limit we get the alarm code E1.26
E1.26 indicates No touch detection during touch pressure calibration !
C1- 6 N 2 = Filling
Here the APC 200 will measure the amount of oil we need to close the clutch.
NOTE :
A failure or a wrong amount of oil will cause the Alarm Code E1.25
NOTE :
A problem on the can connection can create the code PbOn ( = parking brake is NOT on ) when the
command press S to start the calibration ! In this case please check the Iqan system
( Xs 2 Box rear cab digital in Parking brake switch , Xt 2 box chass. LHS digital out handbrake
solenoid , also check J1939 analog out Handbrake On )
AP HM 11
Service Training
Failure codes during calibration
E indicates that one or more parameters / sensors exceeds the time to get calibrated
E1.25 Early touch detection during touch pressure calibration. Too much drag
a) this can indicating a sticking clutch
c) bad Solenoid
E1.26 No touch detection during touch pressure calibration.

This can mean
a) leaking clutch
b) internal leak in the Valve
c) bad Solenoid
d) faulty /bad speed sensor ( see page 6 for speed sensor test * )
E1.10 During calibration, shift inhibit

( can be caused by the driver , moving the direction lever or by a faulty pressure
switch 20.60/20.61)
E2.14 Fill time out Slipping clutch ,

a) Turbine speed does not decrause caused by too high internal leakage and/or
slipping clutch
b) Bad turbine speed signal
E2.16 Calibration failed. Because turbine pull down too early

a) Faulty turbine speed sensor
b) Sticking or burnt clutch with causes turbine drop before pressure is applied
*
Code 34.03 indicate a speed sensor problem , the engine ,turbine and output speeds can be
checked on the APC but NOT the drum speed sensor .
A failed drum speed sensor will only be flagged out when you put the APC into calibration mode
because the drum speed signal is only in use during calibration
AP HM 12
Service Training
The Speed and Temperatur Sensors on the Transmission
Engine speed & transmission temperature sensor
Drum speed sensor
Turbine speed sensor
Output speed sensor
357.360.89.11 Engine Speed /Temperatur Sensor

357.360.89.14 Turbine Speed Sensor
357.360.89.13 Drum Speed Sensor
357.360.89.12 Trans Output shaft Speed Sensor
AP HM 13
Service Training
The Solenoid Valve arrangement on the Dana TE27 – TE 32
The 4 Valve from top are the VFS ( Variable Force Solenoids = Proportional Valves ) Valves
for the following functions :
Speed range VFS 2nd / 4th Speed ( gear )

Drive direction VFS Forward
Drive direction VFS Reverse
Speed range VFS 1st /3rd Speed (gear )
Dana 4207160 Solenoid' VFS - ( Linde Part Number 0009702003 )

VFS Coil resistance 4.35 ± 0.35 OHMS. at 25° C
The 3 standard on / off solenoid valves are the
Total neutral Safety Valve

The Speed range Solenoid for 2nd / 4th
The Speed range Solenoid for 1st/ 3rd
Dana 4205795 Solenoid' on/off 12v - 0009702002

On/Off Coil resistance 12V - 28 ± 2 . OHMS at 20° C
(from Transmission Version 15.7TE27418 -25 )
AP HM 14
Service Training
NOTE :
Dana 4205794 Solenoid' on/off 24v - 0009702001
(old Version Transmission Version 15.7TE27418 13-19 )
On/Off Coil resistance 24V - 87 ± 2 . OHMS at 20° C
The easiest way to identify the voltage on the TE 27 transmission is by the box number on the APC
200. The 24 volt box number is 4502926 and the 12 volt is box number 4503764. These numbers
can be found on the right hand label on the APC unit underneath the serial number (See below)
Dana 4502926 24 Volt Linde Part Number 357 360 63 00

Dana 4503764 12 Volt Linde Part Number 357 360 63 01
A complete Control Valve Repair Kit is available

( The kit consists all Springs ,seals, and a pressure switch )
Part Number 357 260 9900
AP HM 15
Service Training
The Solenoid valve arrangement :
Connector R3-P3
VFS Valve 2nd - 4th
VFS Valve Reverse
VFS Valve Forward
VFS Valve 1st – 3rd
On / Off Valve Drive

(Total Neutral )
On /Off Valve 2nd / 4th

Range
On /Off Valve 1st / 3rd

Range
TIP:
Make sure that all solenoid valve are turning free by hand after tightening the clamps !
A non turning solenoid valve can cause various alarm codes
For the full list of Alarmcodes refer to the Exel file

APC 200 ECM – ECI code
on the training CD-rom
AP HM 16
Service Training
The most common Dana Alarm Codes
20.60 / 20.61
20.60 Pressure feed-back line is indicating there is no system pressure
present, although pressure should be there (2200 Ohm)
20.61 Pressure feed-back line is indicating there is system pressure present,

although pressure should NOT be there (1100 Ohm )
20.60
Check the oil level in the
transmission
Measure the pressure
If it is not possible to measure the

pressure ,
a)
Start the engine and give full
throttle immediately , if the alarm
does not come up we may have a
suction problem
b)
Start the engine , select
immediately a drive direction , if
the machine starts to drive ,(for
20.61 the delay until the alarm comes ~
5 sec) we have pressure .
Linde Part number

3573811000 Pressure Switch Kit
Note :
Check also the Engine speed sensor reading , compare the Dana engine speed reading ( Page 4
, Espd ) with the Cummins ( Gem Display in Cab ) reading , check on different speeds !
Check all cables and connectors before changing the pressure switch !
AP HM 17
Service Training
43.03 / 43.07 / 43.08
43.03 The transmission converter out temperature sensor is out of

range.
43.07 The transmission converter out temperature sensor > 100° C.
43.08 The transmission converter out temperature sensor > 125° C.
The Converter Out temperature

SWITCH
is connected to the Analog
Input 2 .
Temperature below 120° C =

2500 mV
Temperature above 120° C =

0 mV
AP HM 18
Service Training
70.00 / 70.01 / 70.02 / 70.03
70.00 Analogue output 0 (wires A02 & A03) related fault : output wires are
shorted to each other, or the sense line is shorted to battery +, or the
plus line is shorted to ground
70.01 Analogue output 0 (wires A02 & A03) related fault : the output wire is
not connected, or its plus line is shorted to battery +
70.02 Analogue output 0 (wires A02 & A03) related fault : the output
current exceeds 1400 mA
70.03 Analogue output 0 (wires A02 & A03) related fault : the output
current is out of range, occurs when the load has the incorrect
impedance
Before the change of a Solenoid valve , check the cables and connectors
AP HM 19
Service Training
71.00 / 71.01 / 71.02 / 71.03
71.00: Analogue output 1 (wires A04 & A05) related fault : output wires are
71.01: Analogue output 1 (wires A04 & A05) related fault : the output wire is
71.02: Analogue output 1 (wires A04 & A05) related fault : the output current
exceeds 1400 mA
71.03 Analogue output 1 (wires A04 & A05) related fault : the output current is
out of range, occurs when the load has the incorrect impedance
AP HM 20
Service Training
Code 72.00 / 72.01 / 72.02 / 72.03

72.00 : Analogue output 2 (wires A06 & A07) related fault : output wires are
exceeds 1400 mA
AP HM 21
Service Training
Code 73.00 / 73.01 / 73.02 / 73.03

73.00 : Analogue output 3 (wires A08 & A09) related fault : output wires are
exceeds 1400 mA
AP HM 22
Service Training
Self diagnostic functions APC200 controller
Principally there are no specific devices required for first level troubleshooting as the APC 200
incorporates several self-test features assisting in this process.
Nevertheless, use of digital multi-meters & simple tools such as an indicator light will be required to
pinpoint exact causes of problems.
The APC200 has special circuits to help verifying its operation.
Six self-test groups are build into the APC200 control program:
• Display test & version ( page 3 )
• Digital input test ( page 4 )
• Analogue input test ( Page 6)
• Speed sensor test ( page 8 )
• Output test ( page 10 )
• Voltage test ( page 12)
The “D” LED is on while operating the APC200 diagnostic mode.
SPICER OFF-HIGHWAY
D M
E
S
F
APC20
Self-test operation
Self-test mode is activated by pressing the “S” button on the APC200 front panel while powering up
theAPC200.
Switching off the power of the APC200 is the only way to leave the self-test mode.
The available information is organised as groups of related displays.

Generally, each mode’s start provides an overview of the status of all members of the group.
For instance, the start display of the input test mode cryptically shows the level of each input & the
speed sensor test mode shows the frequency of each sensor channel in kHz.
Pressing the “M”-button select, the next group in the order listed.
By pressing the “S”-button a list of modes with more detailed information about the selected group
can be looked through.
When a new group is selected with the “M”-button, the display always reverts to the overview
display (i.e. the beginning of the mode-list).
Pressing a button (S or M) shortly reselects the current group or mode. This feature is applicable in
all diagnostic groups.
AP HM 23
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Service Training
Display test & version
After the initial start up procedure of the APC200 diagnostic program, the display will illuminate all
LED’s in the display for test purposes as shown below:
When pressing the S-button again, the display changes to “VEr” followed by the APC200 software
version as a scrolling text display:
After releasing the S-button, the display again will illuminate all LED’s.
To return to the function group display, press the M-button on the APC200.
AP HM 24
Service Training
Digital Input test
When selecting this group the display shows -dinP- :
The display shows which inputs are active or deactivated by pressing the S-button. Each segment of
the display indicates a specific logical input. Different segments can be switched on simultaneously
if different inputs are activated simultaneously. In total there are 14 inputs: 10 digital & 4 analogue
inputs. (In this group the inputs are treated as if they were digital pull to ground inputs)
Digital inputs numbered 0 – 9 on the segments as shown below.

Analogue inputs numbered 10 – 13 as shown below.
0 2 4 68 1 1
0 2
1 3 5 79 1 1
1 3
Below example indicates that input 1,4 & 5 are on. All the other LED’s are off.
Note: In the Linde Reach Stacker application all LED’s are off inside the digital input test.
By pressing the S-button repeatedly, each individual input is shown in more detail.
While pressing the S-button, the display shows the logic-input number with the matching harness
wire.
AP HM 25
Service Training
- e.g. below display correspondence with input 1 connected to wire A13.
Releasing the S-button, the display will indicate the input status (hi or lo).
Note: The analogue inputs return to ‘high’ (hi) when pulled to ground
Wiring connections:
Digital input Display No. / Description Value

No. (Wire No.)
0 12 (A12) Not used Lo
Digital inputs
6 43 (B13) Not used Lo
10 11 (A11) Pressure feedback switch Lo
11 28 (A28) Transmission temperature Lo Analogue
12 29 (A29) Converter out temp. Lo inputs
(Display No’s which are higher the 30 are corresponding with wire No’s which start with “B” at the
beginning; e.g. display 06.43 = digital input No. 6 / wire No.B13)
AP HM 26
Service Training
Analogue input test
The APC200 has 4 analogue resistance inputs. They measure the single-ended resistance of a
sensor connected between the input & signal ground B18.
When selecting this group the display shows -AinP-:
Releasing the S-button brings an overview of the 4 analogue inputs on the display. The values,
displayed in kΩ, are separated by a dot.
Above display corresponds with the first input of 1 kΩ, the second & third input of 2 kΩ & the last
input of 5 kΩ. Values that are more accurate can be found while running through the input specific
displays (“S”-button).
While pressing the S-button, similar to the digital inputs, the left side of the display gives
information about which input is tested; the right side gives the matching wire. The displayed value
when the S-buttons is released is the resistance in Ω or in Volt (values with a dot in the display).
AP HM 27
Service Training
Wiring connections:
Analogue Display No. / Description Value

input No. (Wire No.)
0 11 (A11) Pressure feedback switch No pressure = 2238 Ω
Pressure = 1123 Ω
1 28 (A28) Transmission temperature 20°C = 2120 Ω
47°C = 2334 Ω
2 29 (A29) Converter out temperature 2.56 V
3 47 (B17) Not used 5.028 V
4 32 (B12) Switched battery plus 5.0 V
(Ignition key signal)
5 34 (B14) Not used 5.0 V
6 36 (B16) Not used 5.0 V
(Display No’s which are higher the 30 corresponding with wire No’s which start with “B” at the
beginning; e.g. display 03.47 = analogue input No. 3 / wire No.B17)
AP HM 28
Service Training
Speed sensor test
When selected this mode the display shows -SPd- :
When releasing the M-button, again an overview appears on the display. The 4 values, displayed in
thousand of Hertz, are separated by a dot. Speeds below 1000 Hz are shown as 0.
Using the S-button, more detailed information concerning the speeds is available. While pressing
the S-button, the display shows the speed channel number on the left side of the display while the
matching wire is shown right.
Once released the S-button, the left digit indicates what type of speed sensor should be connected
to this channel:
• c for a current sensor (Magneto resistive sensor)
• i for an inductive speed sensor
The three other digits & the dot represent the matching speed in kHz.
For instance, in below example the left display indicates a current speed sensor & a frequency of
265 Hz. The right one indicates an inductive sensor generating about 1330 Hz.
After the last channel is shown, another press on the S-button re-selects the speed sensor
overview.
AP HM 29
Service Training
Wiring connections:
Speed Display No. / Description Value

sensor (Wire No.)
0 22 (A22) Drum speed sensor c. 000 Hz = 0 km/h
c 2.20kHz = 23 km/h
1 24 (A24) Output speed c. 000 Hz = 0 km/h
sensor c 2.20kHz = 23 km/h
2 26 (A26) Engine speed c 1.05 kHz = 700 RPM
sensor c 3.08 kHz = 2050 RPM
3 41 (B11) Turbine speed c. 442 Hz = 700 RPM
sensor c 1.48 kHz = 2050 RPM
(Display No’s which are higher the 30 are corresponding with wire No’s which start with “B” at the
beginning; e.g. display 03.41 = speed input No. 3 / wire No.B11)
AP HM 30
Service Training
Output test
When selected this mode the display shows -outP- :
The display shows which outputs are active. Similar to the digital input test overview screen, each
segment of the display indicates a specific output.
Different segments can be switched on simultaneously if different outputs are activated
simultaneously.
0 2 4 68 1
0
1 3 5 79
A blinking segment indicates a fault at a certain output.
In total, there are 11 outputs

• Outputs 0 - 6 are analogue
• Outputs 7 - 9 are STP (switched to plus) digital outputs
• Output 10 is a STG (switched to ground) digital output
Above example indicates that output 0, 2, 3,7,8,9 & 10 are on. All the other LED’s are off.
Information that is more specific can be found while running through the different modes (S-
button). While pressing the S-button, the left side of the display gives information about which
output channel is tested; the right side gives the matching wire number.
When the S-button has been released, the display shows either the actual current in mA, or the
logic state of the output (“hi” or “lo”).
If an output is currently in fault, its respective segment in the overview screen blinks slowly. On the
output specific screen, the display alternates between the actual state (current value or logic state)
& the fault type (open / short / curr / oor).
AP HM 31
Service Training
Output Display Description Value

No. No. /
Wire
No.)
0 02 (A02) Reverse VFS 997mA = FORWARD
0005mA = REVERSE
1 04 (A04) 2nd / 4th VFS 997mA = 1st gear start
0011mA = 2nd gear start
2 06 (A06) Forward VFS 997mA = REVERSE
Analogue
0005mA = FORWARD
outputs
3 08 (A08) 1st / 3rd VFS 998mA = 2nd gear start
0007mA = 1st gear start
4 31 (B11) Turbine speed sensor “+” 0000
5 33 (B13) Not used 0000
6 35 (B15) Not used /
7 10 (A10) Total Neutral solenoid “+” hi = every gear STP digital
side lo = transmission fault outputs
detected
8 15 (A15) 2nd / 4th solenoid hi = 2nd gear
lo = 1st ; 3rd ; 4th gear
9 16 (A16) 1st / 3rd solenoid hi = 1st gear
lo = 2nd ; 3rd ; 4th gear
10 20 (A20) Total Neutral solenoid “--” hi = every gear
STG digital
side lo = transmission fault
outputs
detected
Wiring connections:
STP= switched to plus; STG= switched to ground; VFS= variable force solenoid)
AP HM 32
Service Training
Voltage test
When selecting this mode the display shows -Volt- :
The display value after the “M”-buttons is released is the PERMANENT VOLTAGE -vP- in Volts as
measured on wire A01.
The other 2 modes of this group are switched voltage (vS) & sensor voltage (vSEn), also expressed
in Volts.
vS is measured on wire B12. This power supply input is used to allow the APC200 to control the
power down process- allowing it to save statistical information in FLASH before actually shutting
down.
vSEn is measured off an internally generated voltage regulator & should be near 8.0V. It can be
measured on any unloaded analogue input channel (e.g. AN10 on A11). The vSEn voltage is used as
a reference for the analogue inputs.
AP HM 33
Service Training
Wiring connections:
Description Value
vP Permanent Voltage 26V-

26,5
vS Switched Voltage 26 V-
26,5
vSEn Sensor Voltage 8.0V -

8,5
AP HM 34
Service Training
Transmission Calibration
To get maximum performance and comfort out of the system all components have
to by aligned to each other, this will be done with the Automatic Calibration
An automatic calibration has to be done :

When the vehicle is built at the OEM.
After each 2000 hours driving in gear (forward or reverse selected).
When an overhaul of the transmission is done.
When the transmission is repaired.
When the APC200 is replaced.
When the control valve is replaced.
When the driver complains bad gear shifting.
How to do an automatic calibration:

Before we start the calibration we have to make sure the all involved systems are in
specification.
The gear shift lever has to be in Neutral.
Mechanical function of the parking brake.
1 Function Parameter in the MDM has to be set against the Factory default
Parameter 26 Low Fuel consumption Default is = 0 Must =1
( how to set Function Parameters ,refer to 357/03 Calibration Booklet )
The Transmission Oil Temperature should be above 70 ° (see how to use the calibration
mode to heat the transmission page 14 ) as closer the oil temp is to the normal operation
temperature as better the calibration result will be
To start the calibration we have to push the buttons on the APC 200 in a specific sequence.
FOR ERROR FAILURE INDICATION DURING CALIBRATION PLEASE SEE PAGE 11 + 12
AP HM 35
Service Training
How to do the Auto Calibration
Start the engine , during power up of the
APC 200
D M
E press the S button for at least 15 second
S
F
The display will show up
TRAN ( transmission calibration mode)

D M Press the S button one more time
E
S
F The display will indicate
GO F ( select on the gear lever Forward)
D This will start the auto calibration if the oil

M temp is above 60 ° ,
E Note : See Heat mode
S
F
The APC 200 is now calibrating all direction
and speed clutches indicated by the display
D c1.M1 ( clutch 1 mode 1 )

M
E NOTE : If something goes wrong ( f.e. if you
S have to move the machine ) just select
F
reverse , this will interrupt the calibration .
After the interrupt you have to do again a
complete Calibration .
D M c2.M2 ( clutch 2 .mode 2 ……)

E The calibration takes around 15 minutes
S If something goes wrong the calibration will
F be stopped and an error code comes up on
the display ( see error / alarm list )
If the calibration is done the display change

D to
M Done
E
S Now switch the engine off and wait for 5 sec,
F start the engine again and the new
calibration is stored to the memory and the
AP HM machine is ready for work again 36
Service Training
How to use the calibration mode to heat up the transmission
Start the engine , during power up of the APC

D M 200
E
S press the S button for at least 15 second
F
The display will show up
TRAN ( transmission calibration mode)

D M
E Press the M button one time
S
F
The display will indicate
Heat
D M ( indicate the transmission is in heat mode)
E
S
F
To start the heat up press the button

D M S
E
S The diplay will change and indicates now the
F
transmission oil temperature
c° 20 ( Oil temp.20 ° Celsius )
Make sure that the parking brake is on !

D M
E Select forward,
S Bring the engine to max speed for 15 Sec ,
F select neutral ,
keep engine on full throttle for 15 sec.
Bring engine back to idle .start again
Select forward ………
D M When the temperature is above 60 ° C ,
E The temp display starts to flash , from here we
S can start the calibration!
F
Press
the M button several times ,until the display
AP HM shows Trans again , start the calibration . 37
Service Training
Pressure Checkpoints on the ECM Control valve for the TE27Transmission
CHECKPORT 4/4 SPEED (TE27)

A VFS 4TH/2ND
B VFS FWD
C VFS 3RD/1ST
D VFS REV
E Booster REV
F Booster FWD
G G Booster 4TH/2ND
A H Booster 3RD/1ST
System pressure (after
J
Total Neutral) 22Bar
F System pressure
B K
(before Total Neutral)
N Pilot pressure =
H L 12 Bar
Pressure check range
C M
clutches
Pressure check
N
direction clutches
D
E
L
J
M
Note:
Check pressure on different engine speeds min ( 750 Rpm , max 2080 Rpm )
AP HM 38
Service Training
Procedure to replace TE 27 transmission control valve.

Insure hand brake is on, wheels are chocked and master electric isolator switch is turned off.
1. Remove transmission belly plates, to gain sufficient access to control valve.
2. Remove electric plug, connected to control valve.
3. Remove ‘forward’ transmission, support bracket, bolt. (24,mm).
4. Place a tray under the control valve, to collect oil spillage.
5. Unscrew the 16 cap head bolts (6,mm key). Note! If possible and during this procedure, fit 2
support type bolts (these should be without heads, but slotted to accept a screw driver). SEE
NEXT PAGE
6. Remove valve from transmission-advised to the rear of the machine.
7. Remove gasket and clean surfaces.
8. Fit a new gasket (Dana part number:-4207514).
9. Fit the new control valve to the transmission, using 16 hex bolts. Tighten finger tight at this
stage.
10. Unscrew the 4 hex bolts (13,mm)-see attached illustration, marked 14, 19, 20 & 21.
11. Tighten all bolts to a torque of 20 to 25 Nm.-see attached illustration, following order of
sequence.
12. Refit the previously removed transmission, support bracket bolt.
13. Reconnect the electric plug to the control valve.
14. Start the engine. Check for oil leaks. Check oil levels and refill if necessary.
15. Replace belly plates.
16. Test run machine and confirm selection of all gears.
AP HM 39
Service Training
Procedure to replace TE 27 transmission control valve.
Removing the valve
Make sure that the area around the valve is clean and that no dirt can fall into the valve during the
disassembly procedure.
Unscrew the 4 hex bolts (marked RED on drawing) until you feel that the tension is out of the bolt.
Do not remove them!!!
Unscrew the 17 other bolts (with internal hex) some turns. When all bolts are loose, you should be
able to move the valve a bit. Now take the bolts off and remove the valve .
Installing the valve

First you fasten all bolts (21 pieces hand tight) according to the numbers you find on the drawing.
Redo the same procedure but now with a torque wrench. Settings of the torque wrench 20 to 25
Nm.
AP HM 40
Service Training
How to Perform a Stall Test on a TE 27 Transmission
The so called Stall test is a quick way to get an indication if lack of power is caused by the
engine or the transmission.
During the design / engineering work a lot of calculations are done, with the information of
maximum engine power and maximum brake force of the transmission the so called stall
speed is calculated.
The stall speed on the MK3 Reachstacker is 1800 RPM
This means if the engine power output and the brake force of the transmission is in spec, the
maximum engine RPM (2080) will drop to 1800 RPM!
If the engine speed drops more down we have a problem on the engine!
If the engine speed is higher we have a problem on the Transmission!
The stall test has to be done in both drive direction clutches as well as in every speed clutch.
Before we can do the stall test we have to bring the machine into the test condition mode.
For this we have to change the following Parameter in the IQAN MDM .
26 Accelerator in fuel save mode or always on from 0 to 1
Please also check the following parameter
31 Drive speed adjustment should be 28 Km/h
How to do changes in the MDM for stall test ,pls go to
How to calibrate a new sensor / how to do changes in Menu Properties Others
Then we select Forward 4st gear ( Parking brake on ) and press the accelerator pedal fully
down , check on the engine display the engine RPM ( should 1800 RPM )
If the RPM are much higher we have a Transmission Problem (Clutch slipping )
See how to do pressure tests on the TE 27 transmission .
If the RPM are lower, we have a engine problem !
Note :
The test for each direction and speed clutch should not excide 15 seconds , please let the
system run in Neutral for at least 30 seconds between the different clutch tests !
Note :
After the stall test you have to reset the function parameters back to factory setting
AP HM 41
Service training
Transmission
Incorporating
FULL
FLOW
VALVE
Maintenance & Service Manual
TE27 / TE32
Powershift Transmission
4 Speed
Short Drop
SPICER OFF-HIGHWAY COMPONENTS
CD-ROM: 8100101
03/2010
MANUAL: 8100102
Table of Contents
11/2009 1
TOWING OR PUSHING............................................................................................................5
FOREWORD.............................................................................................................................6
1 SAFETY PRECAUTIONS.......................................................................................................7
2 Cleaning, Inspection and Legend symbols ........................................................9
2.1 CLEANING................................................................................................................................... 9
2.1.1 BEARINGS........................................................................................................................... 9
2.1.2 HOUSINGS........................................................................................................................... 9
2.2 Inspection................................................................................................................................ 9
2.2.1 BEARINGS........................................................................................................................... 9
2.2.2 OIL SEALS, GASKETS, etc............................................................................................... 10
2.2.3 GEARS & SHAFTS............................................................................................................ 10
2.2.4 HOUSINGS, COVERS, etc................................................................................................. 10
2.3 LEGEND SYMBOLS.................................................................................................................. 10
3 TECHNICAL SPECIFICATIONS.......................................................................................... 11
3.1. IDENTIFICATION OF THE UNIT............................................................................................... 12
3.2. WEIGHT, DIMENSIONS, OIL CAPACITY.................................................................................. 12
3.3 TIGHTENING TORQUEs.......................................................................................................... 13
3.3.1 Torque specifications for lubricated or plated screw threads...................................... 13
3.3.2 Elastic stop nut torque..................................................................................................... 15
3.3.3 Torque tables for plugs (“o”-ring ports)......................................................................... 15
3.3.4 Torque tables for pipe plugs............................................................................................ 15
3.3.5 Permanent metric plug torque chart .............................................................................. 15
3.4 PRESSURE & TEMPERATURE SPECIFICATIONS.................................................................. 16
3.5 Electrical specifications............................................................................................... 17
3.6 Hydraulic cooler lines specifications.................................................................... 17
4 MAINTENANCE...................................................................................................................18
4.1. Oil specification................................................................................................................. 19
4.1.1 Recommended lubricants................................................................................................ 19
4.1.2 Normal oil change interval............................................................................................... 19
4.2 MAINTENANCE INTERVALS..................................................................................................... 19
4.2.1 Daily.................................................................................................................................... 19
4.2.2Clutch calibration............................................................................................................... 19
4.3 Servicing machine after components overhaul.................................................. 20
4.4 Procedure for performing automatic calibration............................................ 21
4.4.1 Introduction....................................................................................................................... 21
4.4.2 running the automatic calibration................................................................................... 21
4.4.2.1 How to enter the calibration mode.......................................................................... 21
4.4.3 PERFORMING AN AUTOMATIC CALIBRATION.............................................................. 22
4.4.4 HEATING UP THE TRANSMISSION BY USING THE ‘HEAT’-MODE.............................. 23
4.4.5 CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS...................... 25
TE27/32 4 SD 03/2010
4.4.5.1 Calibration condition messages.............................................................................. 25
4.4.5.2 Calibration errors...................................................................................................... 25
4.4.6 PERFORMING A STALL TEST.......................................................................................... 26
5 Installation details....................................................................................................28
5.1 Converter drive coupling . ......................................................................................... 28
5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE............................................. 29
5.3 External plumbing............................................................................................................ 30
5.3.1 Cooler & filter lines specifications.................................................................................. 30
5.4 speed sensor installation............................................................................................. 31
6 Transmission Operation............................................................................................34
6.1 The transmission assembly............................................................................................ 34
6.1.1 The converter, pump drive section and pressure regulating valve.............................. 35
6.1.2 The input shaft and directional clutches........................................................................ 36
6.1.3 The range clutches .......................................................................................................... 37
6.1.4The output section............................................................................................................. 37
6.2 The transmission controls (refer to hydraulic diagram)............................ 38
6.3 Electric solenoid controls......................................................................................... 39
6.4 Powerflows, activated solenoids and hydraulic circuit.............................. 40
6.4.1 Neutral-1 Selected............................................................................................................. 40
6.4.2 Forward 1st speed............................................................................................................ 42
6.4.3 Forward 2nd speed........................................................................................................... 44
6.4.4 Forward 3rd speed............................................................................................................ 46
6.4.5 Forward 4TH speed........................................................................................................... 48
6.4.6 Reverse 1st speed............................................................................................................. 51
6.4.8 Reverse 3rd speed............................................................................................................ 54
6.4.9 Reverse 4TH speed........................................................................................................... 56
7 Troubleshooting guide.............................................................................................60
7.1 The Transmission................................................................................................................ 60
7.2 The input shaft and directional clutches............................................................. 60
7.2.1 Stall test............................................................................................................................. 60
7.2.2 Transmission pressure checks........................................................................................ 61
7.2.3 Mechanical and electrical checks.................................................................................... 61
7.2.4 Hydraulic checks............................................................................................................... 61
7.2.5 Controller (APC200): Please refer to functional description........................................ 61
7.3 TROUBLESHOOTING GUIDE................................................................................................... 62
7.3.1 Low clutch pressure........................................................................................................ 62
7.3.2 Low charging pump output flow..................................................................................... 62
7.3.3 Overheating..................................................................................................................... 62
7.3.4 Noisy converter............................................................................................................... 62
7.3.5 Lack of power.................................................................................................................. 62
7.4 CHECK POINTS....................................................................................................................... 63
7.5 SPEED SENSOR - STATIC STANDALONE TEST.................................................................... 67
7.6 Full flow valve components...................................................................................... 68
8 SECTIONAL VIEWS & PARTS IDENTIFICATION..............................................................69
TE27/32 4 SD 03/2010
TORQUE CONVERTER GROUP..................................................................................................... 70
TRANSMISSION CASE & REAR COVER GROUP......................................................................... 72
TURBINE SHAFT GROUP............................................................................................................... 74
PUMP DRIVE GROUP...................................................................................................................... 76
Adaptor sleeve group........................................................................................................... 78
Wheel group............................................................................................................................... 80
FLEX PLATE group...................................................................................................................... 82
FWD & REV/2nd and 3th or 4th clutch shaft assy........................................................ 84
forward clutch shaft GROUP............................................................................................. 86
3rd speed clucth shaft GROUP........................................................................................... 88
3rd speed gear.......................................................................................................................... 90
REV / 2nd schaft GROUP........................................................................................................... 92
1st speed clutch shaft GROUP............................................................................................ 94
4th speed clutch shaft GROUP........................................................................................... 96
1st shaft gear GROUP............................................................................................................. 98
Output shaft GROUP.............................................................................................................. 100
Regulator valve group....................................................................................................... 102
control valve GROUP............................................................................................................ 104
remote filter adapter GROUP........................................................................................... 106
9 assembly instructions............................................................................................109
10 Disassembly of transmission (under construction)............................... 116
11 SPECIAL TOOL................................................................................................................190
TE27/32 4 SD 03/2010
TOWING OR PUSHING
Before towing the vehicle, be sure to disconnect the driveline to avoid damage to the transmission during towing.
Note:
Because of the design of the hydraulic system, the engine cannot be started by pushing or towing.
©
Copyright DANA CORPORATION 1990. Unpublished material.
All rights reserved. Limited Distribution.
No part of this work may be reproduced in any form under any means without direct written permission of the DANA CORPORATION
TE27/32 4 SD 03/2010 5
FOREWORD
This manual has been prepared to provide the customer and the maintenance personnel with information and
instructions on the maintenance and repair of the SPICER OFF-HIGWAY PRODUCTS product.
Extreme care has been exercised in the design, selection of materials, and manufacturing of these units. The
slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated
intervals, and such adjustments as may be indicated, will be reimbursed many times in low cost operation and
trouble-free service.
In order to become familiar with the various parts of the product, its principle of operation, troubleshooting and
adjustments, it is urged that the mechanic studies the instructions in this manual carefully and uses it as a refer-
ence when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only SPICER OFF-HIGHWAY PRODUCTS ap-
proved parts as listed in the applicable parts manual should be used. Use of “will-fit” or non-approved parts may
endanger proper operation and performance of the equipment. SPICER OFF-HIGHWAY PRODUCTS does not
warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied or ap-
proved by SPICER OFF-HIGHWAY PRODUCTS.
IMPORTANT
ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN
ORDERING PARTS.
TE27/32 4 SD 03/2010 6
1 SAFETY PRECAUTIONS
To reduce the chance of personal injury and/or property damage, the following instructions must be carefully
observed.
Proper service and repair are important to the safety of the service technician and the safe reliable operation of
the machine. if replacement parts are required, the parts must be replaced by spare parts which have the same
part number or with equivalent parts. DO NOT USE A SPARE PART OF LESSER QUALITY.
The service procedures recommended in this manual are effective methods for performing service and repair.
Some of these procedures require the use of tools specifically designed for the purpose.
Accordingly, anyone who intends to use a spare part, service procedure or tool, which is not recommended by
SPICER OFF-HIGHWAY PRODUCTS, must first determine that neither his safety nor the safe operation of the
machine will be jeopardised by the spare part, service procedure or tool selected.
IMPORTANT
IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS ‘CAUTIONS AND NOTICES’ THAT
MUST BE CAREFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSONAL INJURY DURING
SERVICE OR REPAIR, OR THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE
UNIT OR RENDER IT UNSAFE.
IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE ‘ CAUTIONS AND NOTICES’ ARE NOT EXHAUS-
TIVE, BECAUSE IT IS IMPOSSIBLE TO WARN ABOUT ALL POSSIBLE HAZARDOUS CONSEQUENCES
THAT MIGHT RESULT FROM FAILURE TO FOLLOW THESE INSTRUCTIONS.
TE27/32 4 SD 03/2010 1-7

2 CLEANING and inspection
TE27/32 4 SD 03/2010 2-8

2 Cleaning, Inspection and Legend symbols
2.1 CLEANING
Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in clean-
ing fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are
thoroughly cleaned.
CAUTION
CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE HAZARDS, AND INHALATION OF
VAPOURS WHEN USING SOLVENT TYPE CLEANERS.
2.1.1 BEARINGS
Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of
lubricant. Immerse again in cleaning fluid to flush out particles. repeat above operation until bearings are thor-
oughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air stream across bearing to
avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate
drying process.
2.1.2 HOUSINGS
Clean interior and exterior of housings, bearing caps, etc... thoroughly. Cast parts may be cleaned in hot solution
tanks with mild alkali solutions providing these parts do not have ground or polished surfaces.
Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation
of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean
water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaner.
CAUTION
CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPOURS AND SKIN RASHES WHEN
USING ALKALI CLEANERS.
All parts cleaned must be thoroughly dried immediately by using moistere-free compressed air or soft lintless
absorbant wiping rags, free of abrasive materials such as metal fillings, contaminated oil or lapping compound.
2.2 Inspection
The importance of careful and thorough inspection of all parts cannot be overstressed. replacement of all parts
showing indication of wear or stress will eliminate costly and avoidable failures at a later date.
2.2.1 BEARINGS
Carefully inspect all rollers: cages and cups for wear, chipping, or nicks to determine fitness of bearings for fur-
ther use. DO NOT REPLACE A BEARING CONE OR CUP INDIVIDUALLY without replacing the mating cup or
cone at the same time. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless
cloth or paper to protect them until installed.
TE27/32 4 SD 03/2010 2-9

Cleaning and Inspection & Legend symbols
2.2.2 OIL SEALS, GASKETS, etc.

Replacement of spring load oils seals, “O” rings, metal sealing rings, gaskets and snap rings is more economical
when the unit is disassembled than premature overhaul to replace these parts at a future time.
Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly.
Sealing members should be handled carefully, particularly when being installed. Cutting, scratching or curling
under of lips of seals seriously impairs its efficiency.
When assembling new metal type sealing rings, these should be lubricated with a coat of chassis grease to
stabilise rings in their grooves for ease of assembly of mating members. Lubricate all “O” rings and seals with
recommended type Automatic Transmission Fluid before assembly.
2.2.3 GEARS & SHAFTS

If Magna-Flux process is available, use process to check parts. Examine teeth on all gears carefully for wear,
pitting, chipping, nicks, cracks or scores. If gear teeth show spots where case hardening is worn through or
cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to
make certain they are not sprung, bent or spline-twisted, and that shafts are true.
2.2.4 HOUSINGS, COVERS, etc.

Inspect housings, covers and bearing caps to ensure that they are thoroughly clean and that mating surfaces,
bearing bores, etc... are free from nicks or burrs. Check all parts carefully for evidence of cracks or conditions
which would cause subsequent oil leaks or failures.
2.3 LEGEND SYMBOLS
Smontaggio di sottogruppi Sostituire con ogni montaggio

Disassembly of assembly groups Renew at each reassembly
Montaggio di sottogruppi Togliere - mettere la sicura

Reassemble to from assembly group Unlock - lock e.g. split pin, locking plate, etc.
Smontaggio di particollari ingombranti Mettere la sicura, incollare (mastice liquido)

Remove obstruction parts Lock - adhere (liquid sealant)
Montaggio di particollari ingombranti Evitare danni ai materiali, danni ai pezzi

Reinstall - remount parts which had obstructed disassembly Guard against material damage, damage to parts
Attenzione, indicazione importante Marchiari prima dello smontaggio (per il montaggio)

Attention! important notice Mark before disassembly, observe marks when reasembl.
Controllare regolare p.e. coppie, misure, pressione etc. Carricare riempire (olio - lubrificante)
Check - adjust e.g. torque, dimensions, pressures etc. Filling - topping up - refilling e.g. oil, cooling water, etc.
T = Attrezzature speciali P = Pagina Scarricare olio, lubrificante

T = Special tool P = Page Drain off oil, lubricant
Rispettare direzione di montaggio Tendere

Note direction of installation Tighten - clamp ; tightening a clamping device
Controllare esaminare controllo visuale Insere pressione nel circuito idraulico

Visual inspection Apply pressure into hydraulic circuit
Eventualimente riutilizzable (sostituire se necessario) Pulire

Possibly still serviceable, renew if necessary To clean
TE27/32 4 SD 03/2010 2-10

3 TECHNICAL SPECIFICATIONS
TE27/32 4 SD 03/2010 3-11

Technical specifications
SPICER OFF-HIGHWAY
TEN BRIELE 3
B-8200
BELGIUM
MODEL
SERIAL
3.1. IDENTIFICATION OF THE UNIT
1. Model and type of the unit

2. Serial number.
3.2. WEIGHT, DIMENSIONS, OIL CAPACITY
Weight (dry): 865 Kg [1903 lb]

Max. Length: 1011 mm [39.8”]
Max. With: 703 mm [27.7”]
Max. Heigth: 982 mm [38.7”]
Oil capacity
60 liter [15.9 US Gallon] without cooler and hydraulic lines.

Consult Operator’s manual on applicable machine for system capacity.
TE27/32 4 SD 03/2010 3-12

3.3 TIGHTENING TORQUEs

3.3.1 Torque specifications for lubricated or plated screw threads
GRADE 5 GRADE 5
NOM. THD FINE THREAD COARSE THREAD
SIZE TORQUE Lbs.ft [Nm] TORQUE Lbs.ft [Nm]
.2500 9-11 [12.2-14.9] 8-10 [10.8-13.6]
.3125 16-20 [21.7-27.1] 12-16 [16.3-21.7]
.3750 26-29 [35.2-39.3] 23-25 [31.2-33.9]
.4375 41-45 [56-61] 37-41 [50.2-55.6]
.5000 64-70 [87-95] 57-63 [77-85]
.6525 91-100 [123-136] 82-90 [111-122]
.6250 128-141 [174-191] 113-124 [153-168]
.7500 223-245 [302-332] 200-220 [271-298]
Partnumber 2C 1C
prefix
GRADE 8 GRADE 8
NOM. THD FINE THREAD COARSE THREAD
SIZE TORQUE Lbs.ft [Nm] TORQUE Lbs.ft [Nm]
.2500 11-13 [14.9-17.6] 9-11 [12.2-14.9]
.3125 28-32 [38-43.4] 26-30 [35.2-40.7]
.3750 37-41 [50.2-55.6] 33-36 [44.7-48.8]
.4375 58-64 [79-87] 52-57 [70.5-77.3]
.5000 90-99 122-134] 80-88 [108-119]
.6525 128-141 [174-191] 115-127 [156-172]
.6250 180-198 [224-268] 159-175 [216-237]
.7500 315-347 [427-470] 282-310 [382-420]
Partnumber
prefix 18C-94G-96G 17C-93G-95G
TE27/32 4 SD 03/2010 3-13

3.3.1 Torque specifications for lubricated or plated screw threads (continued)
NOM. THD SIZE GRADE 8.8 GRADE 10.9 GRADE 12.9

COARSE THREAD TORQUE Lbs.ft [Nm] TORQUE Lbs.ft [Nm] TORQUE Lbs.ft [Nm]
M5 x 0,8 3.7-4.4 [5-6] 5.2-5.9 [7-8] 5.9-7.4 [8-10]
M6 x 1 5.9-7.4 [8-10] 8.9-11.1 [12-15] 9.6-11.8 [13-16]
M8 x 1,25 14.8-18.4 [20-25] 22.1-25.8 [30-35] 25.8-29.5 [35-40]
M10 x 1,5 29.5-36.9 [40-50] 44.3-47.9 [60-65] 47.9-55.3 [65-75]
M12 x 1,75 50-55 [68-75] 74-81 [100-110] 85-96 [115-130]
M14 x 2 81-92 [110-125] 111-129 [150-175] 133-155 [180-210]
M16 x 2 125-140 [170-190] 177-203 [240-275] 207-236 [280-320]
M20 x 2,5 236-266 [320-360] 332-369 [450-500] 387-443 [525-600]
M24 x 3 420-479 [570-650] 590-664 [800-900] 664-774 [900-1050]
M30 x 3,5 848-959 [1150-1300] 1180-1328 [1600-1800] 1364-1549 [1850-2100]
M36 x 4 1475-1660 [2000-2250] 2028-2323 [2749-3149] 2397-2729 [3249-3699]
Partnumber prefix 1CM -1GM 7CM-10CM-4GM 3GM
NOM. THD SIZE GRADE 8.8 GRADE 10.9 GRADE 12.9

FINE THREAD TORQUE Lbs.ft [Nm] TORQUE Lbs.ft [Nm] TORQUE Lbs.ft [Nm]
M8 x 1 17-20 [23-28] 25-28 [34-39] 30-34 [41-46]
M10 x 1 35-42 [47-57] 52-60 [71-81] 62-69 [84-94]
M10 x 1,25 32-40 [44-54] 49-57 [67-77] 58-66 [79-89]
M12 x 1,25 60-68 [82-92] 89-96 [120-130] 105-116 [143-158]
M12 x 1,5 58-65 [78-88] 86-94 [117-127] 101-112 [138-153]
M14 x 1,5 94-105 [128-143] 142-153 [193-208] 162-184 [220-250]
M16 x 1,5 159-169 [215-228] 216-227 [293-308] 258-273 [350-370]
M18 x 1,5 221-236 [300-320] 319-330 [433-448] 369-398 [500-540]
M18 x 2 207-221 [280-300] 304-315 [413-428] 347-376 [470-510]
M20 x 1,5 302-332 [410-450] 439-476 [595-645] 503-559 [683-758]
M22 x 1,5 413-443 [560-600] 586-623 [795-845] 681-736 [923-998]
M24 x 1,5 531-590 [720-800] 767-841 [1040-1140] 882-992 [1195-1345]
M24 x 2 509-568 [690-770] 730-804 [990-1090] 845-955 [1145-1295]
M27 x 1,5 789-848 [1070-1150] 1129-1202 [1530-1630] 1308-1420 [1175-1925]
Partnumber prefix 2CM -5GM
TE27/32 4 SD 03/2010 3-14

3.3.2 Elastic stop nut torque
THREAD SIZE TORQUE

M10 x 1 6-7 [8-10]
M14 x 1.5 7-9 [10-12]
M18 x 1.5 25-30 [34-41]
M22 x 1.5 35-44 [48-60]
M33 x 2 83-103 [112-140]
3.3.3 Torque tables for plugs (“o”-ring ports)
THREAD SIZE TORQUE Lbs.ft [Nm] Partnumber prefix

5/16-24 3-5 [4-7]
3/8-24 5-8 [7-11]
7/16-20 7-10 [9-14]
1/2-20 10-13 [14-18]
9/16-18 12-15[16-20]
124K-47K
3/4-16 20-25 [27-34]
7/8-14 30-35 [41-47]
11/16-12 45-50 [61-68]
15/16-12 65-75 [88-102]
15/8-12 75-85 [102-115]
17/8-12 75-85 [102-115]
3.3.4 Torque tables for pipe plugs
THREAD SIZE TORQUE Lbs.ft [Nm] Partnumber prefix

1/16-27 5-7 [7-9] 16F-40K-41K-1
1/8-27 7-10 [9-14] 10F-16F-40K-41K-2
1/4-18 15-20 [20-27] 11F-16F-40K-41K-4
3/8-18 25-30 [34-41] 11F-16F-40K-41K-6
1/2-14 30-35 [41-47] 11F-16F-40K-41K-8
3/4-10 or 14 40-45 [54-61] 11F-16F-40K-41K-12
1-11 1/2 50-55 [68-75] 11F-16F-40K-41K-16
1 1/4-11 1/2 60-65 [81-88] 11F-16F-40K-41K-20
3.3.5 Permanent metric plug torque chart
Plugs (Permanent plugs)

Nominal Size Torque Nm [Lbs.ft]
M18 x 1.5 6H 34-41 [25-30]
M26 x 1.5 6H 61-68 [45-50]
TE27/32 4 SD 03/2010 3-15

3.4 PRESSURE & TEMPERATURE SPECIFICATIONS
• Normal operating temperature 70 - 120°C [158 - 248F] measured at temperature check port to cooler
(port 71 or port 32 **).
• Maximum allowed transmission temperature 120°C [248 F].
• Transmission regulator pressure (*) - (neutral) - port 31 (**).

- at 600 RPM: 22.5 bar [326.3 PSI] minimum.
- at 2650 RPM: 25.5 bar [369.8 PSI] maximum.
•Pump flow (*)

- System pump flow: 100.7 l/min minimum [26.60 GPM] at 2170 RPM.
- Lube pump flow: 52.4 l/min [13.84 GPM] minimum at 2170 RPM selective lube
84.6 l/min [22.35 GPM] maximum at 2910 RPM.
• Clutch pressures (*)

- 1st clutch: port 41 (**).
- 2nd clutch: port 42 (**).
- 3rd clutch: port 43 (**).
- 4th clutch: port 44 (**).
- forward clutch: port 45 (**).
- reverse clutch: port 46 (**).
at 2200 RPM :
- 20.5bar [297.3PSI] minimum with 1st clutch activated.
• Filter bypass valve set at 4.1 to 4.5 bar(*) [59.4 to 65.2 PSI].
• Lube pressure (*) (port 34) - 4.0-5.5 bar [58 - 80 PSI] at 2200RPM.
• Internal total leakage at 1000 engine RPM

Fwd/Rev: 4l/min. [1 GPM] maximum
1st: 9.2l/min [2.43 GPM] maximum
2nd-3rd-4th: 4l/min [1 GPM] maximum
Converter: 5-12 l/min [1.3-3.2 GPM] at 1000RPM
• Safety valve : cracking pressure (*) 8.8-9.6 bar [127.6-139.2 PSI].
• To cooler (converter out) pressure (*) (port 33) 5 bar [72.5PSI] min at 2000RPM engine speed
and a max of 8.5 bar [123.3 PSI] pressure at no load governed speed.
(*) All pressures and flows to be measured with oil temperature of 82 - 93° C ( 180 - 200F).
(**) Refer to section troubleshooting for check port identification.
TE27/32 4 SD 03/2010 3-16

3.5 Electrical specifications
• Proportional valves:
FWD/REV - 1st/3rd - 2nd/4th:
coil resistance : 7.25 Ω at 20°C [68°F].
• Selection valves:
FWD/N/REV - 1st/3rd - 2nd/4th:
coil resistance : 12V - 7.1 Ω at 20°C [68°F].
coil resistance : 24V - 28.5 Ω at 20°C [68°F].
• Speed sensor :
- type: magneto resistive sensor.
- sensing distance: 0 - 1,8 mm [0” - 0.07”].
- Sensor signal: generates a square current with a fixed amplitude changing between 7-14 mA.
• Temp sensor:
-Material: silicon
-Resistance at 25°C [77°F] = 2000 Ω ± 1%
• Pressure sensor:
-Supply voltage 4.5-5.5V
-Maximum current: 10mA
-Pressure range: 1 to 31 bar [14.5-450PSI]
-±1.2% full scale (31bar [450PSI]) range 1 to 25 bar [14.5-363 PSI]
-±2.5% full scale (31bar [450PSI]) range 25 to 31 bar [363-450PSI]

3.6 Hydraulic cooler lines specifications
• Minimum 25.4mm [1”] internal diameter for lines and fittings.

• Suitable for operation from ambient to 120° C [248° F] continuous operating temperature.
• Must withstand 28 bar [406PSI] continuous pressure and with 41 bar [595PSI] intermittent surges.
• Conform SAE J1019 and SAE J517,100RI
TE27/32 4 SD 03/2010 3-17

4 MAINTENANCE
T27/32 4 SD 03/2010 4-18

Maintenance
4.1. Oil specification
4.1.1 Recommended lubricants
• Dexron* III, viscosity at 40° C [104° F]: 33 - 38 cSt
100° C [212° F]: 7 - 8 cSt
Sump preheaters
Preheat the transmission fluid to the mimimum temperature for the oil viscosity used before engine startup.
4.1.2 Normal oil change interval

Drain and refill system every 1000 hrs for average environmental and duty cycle conditions. Severe or sus-
tained high operating temperature or very dusty atmospheric conditions will result in accelerated detioration or
contamination. Judgement must be used to determine the required change intervals for extreme conditions.
Drain and refill system as follows (drain with oil at 65 - 93° C [150 - 200 F°])
1. Drain transmission.
2. Remove and discard filter. Install new filter.
3. Refill transmission to FULL mark.
4. Run engine at 500 - 600 RPM to prime convertor and lines.
5. Recheck level with engine running at 500 - 600 RPM and add oil to bring level to LOW mark.
When oil temperature is hot 82.2 - 93.3 °C (180- 200 F) make final oil level check and adjust if
necessary to bring oil level to FULL mark.
Note
It is recommended that oil filter be changed after 100 hours of operation on new, rebuilt or
repaired unit.
EXTENDED OIL CHANGE INTERVAL
Extended oil service life may result when using synthetic fluids. Appropriate change intervals should be deter-
mined for each transmission by measuring oil oxidation and wear metals over time, to determine a baseline.
Wear metals analysis can provide useful inforamtion but a transmission should not be removed from service
based solely on this analysis.
filters
Service oil filter element intervals

100hrs first time
Then every 1000 hrs under normal envirronmental and duty cycle conditions.
4.2 MAINTENANCE INTERVALS

4.2.1 Daily
Check oil level daily with engine running at idle (600 RPM) and oil at 82 - 93 °C (180-200 F).
Maintain oil level at full mark.
4.2.2Clutch calibration
Every 2000hrs perform automatic clutch calibration
* DEXRON is a registered trademark of GENERAL MOTORS CORPORATION

T27/32 4 SD 03/2010 4-19
Maintenance
4.3 Servicing machine after components overhaul

The transmission, torque converter, and its allied hydraulic system are important links in the driveline between
the engine and the wheels. The proper operation of either unit depends greatly on the condition and operation
of the other. Therefore, whenever repair or overhaul of one unit is performed, the balance of the system must
be considered before the job can be considered complete.
After the overhauled or repaired transmission has been installed in the machine, the oil cooler, and connecting
hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a degree of
judgement must be exercised as to the method employed.
The following are considered the minimum steps to be taken:

1. Drain entire system thoroughly.
2. Disconnect and clean all hydraulic lines. Where feasible hydraulic lines should be removed from
machine for cleaning.
3. Replace oil filter element.
4. The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” with oil and
compressed air until all foreign material has been removed. Flushing in direction of normal oil
flow will not adequately clean the cooler. If necessary, cooler assembly should be removed from
machine for cleaning, using oil, compressed air, and steam cleaner for that purpose.
IMPORTANT
DO NOT use flushing compounds for cleaning purposes.
5. Reassemble all components and use only type oil recommended from lubrication section.
Fill transmission through filler opening until fluid comes up to the oil level check port.
Run engine 2 minutes at 500+600 R.P.M. to prime torque converter and hydraulic lines.
Recheck level of fluid in transmission with engine running at idle (500-600 R.P.M.).
Add quantity necessary to bring fluid level to oil level check port.
Recheck with hot oil (180-200 F) 82-93° C.
6. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary.
T27/32 4 SD 03/2010 4-20

Maintenance
4.4 Procedure for performing automatic calibration
4.4.1 Introduction
The APC200 firmware contains an automatic transmission calibration procedure, which is able to optimize the
shift quality of the transmission.
An automatic calibration has to be done:
- When the vehicle is build at the OEM
- Every 2000 hrs of transmission operation
- When an overhaul of the transmission is done
- When the transmission is repaired
- When the APC200 is replaced
4.4.2 running the automatic calibration

4.4.2.1 How to enter the calibration mode
S
S
M S
S
M
M M
The automatic calibration mode is entered by pressing the S-button on the APC200 <display for 15 seconds dur-
ing POWER-UP of the APC200 (See above figure)
T27/32 4 SD 03/2010 4-21

Maintenance
4.4.3 PERFORMING AN AUTOMATIC CALIBRATION
Before the automatic calibration can be started, a number of conditions need to be fulfi lled :
- The parking brake on the vehicle has to be activated.
- The transmission temperature needs to be above 60° C. See the next paragraph how to use the
‘HEAT’-mode to do this in a time effective way.
- The engine speed has to be kept at around 800 rpm (± 200 rpm) during the complete calibration. If
the APC200 has control over the engine, the engine speed will be adapted automatically.
If all the conditions mentioned above are met, the actual automatic calibration can be performed starting from
the following display on the APC200 :
To trigger the automatic calibration procedure, push the S-button once. You will get this APC200-display readout:
The APC200 asks you to put the shift lever in FORWARD.

The automatic transmission calibration procedure starts. This is indicated on the APC200-display :
the fisrt 2 characters indicates which clutch is calibrated (clutch 1 to clutch 6)

the last 2 characters indicates the calibration phase inwhich this clutch is (mode 1 or mode2)
When all clutches have been calibrated, the APC200 displays :
At this point, the automatic calibration has completed successfully. The normal duration of a complete
transmission calibration is around 15 minutes.
To exit the automatic calibration mode, you should need to switch off the ignition key the vehicle. Make sure that
the APC200 has powered down – wait for 2 seconds. Now restart the vehicle and the new tuning results will be
activated automatically.
REMARK 1 :
If you get any different information on the APC200 display as described above, there can be two possible
reasons:
• the calibration conditions are not fulfi lled (temperature is too low, parking brake switched off, the
vehicle is moving, engine rpm is too high or too low)
• a calibration error has occurred during the calibration (message starting with an ‘E’).
For possible messages see chapter 4.4.5
T27/32 4 SD 03/2010 4-22

Maintenance
REMARK 2 :
By selecting REVERSE on the shift lever, while the automatic calibration is performing, the procedure will abort
the automatic calibration immediately and restart the APC200. You can use this as an emergency procedure
when something goes wrong during the calibration procedure.
Note : by aborting the automatic calibration, the calibration is not finalized and needs to be done from the
beginning.
4.4.4 HEATING UP THE TRANSMISSION BY USING THE ‘HEAT’-MODE
The ‘HEAT’-mode allows to select forward / reverse while the parking brake is activated, without forcing neutral
and will disable the inching and declutch function. During the heat 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.
The paragraph how to enter the calibration mode (see 1st paragraph), also displays how the ‘HEAT’-mode can be
activated. Once you see on the display “tran”, you can press the M-button once to go into the “heat”-mode. The
APC200 will display :
To trigger the ‘HEAT’-mode, push the S-button. The APC200 will display the sump temperature :
This means the actual sump temperature of the transmission is 20°C.
T27/32 4 SD 03/2010 4-23

Maintenance
Perform the following steps in order to heat up the transmission :

1. Make sure the parking brake is active and works properly.
2. Put the transmission in forward by selecting forward with the shift lever and then accelerates the
engine to full throttle.
3. Keep the engine at full throttle for about 15 seconds and then put the gearbox in neutral by selecting
neutral with the shift lever. Keep the engine at full throttle!
4. Keep the gearbox in neutral at full engine throttle for about 15 seconds again.
5. Release the throttle pedal and decelerate the engine to idle.
6. Go back to point 2 and repeat until the APC200 display shows a temperature above 60°C. When the
temperature is above 60° C, the temperature indication on the display starts blinking. Now you can
switch to the automatic calibration, by pressing the M-button for several times – until the APC200
displays “tran”.
FULL
IDLE
forward
neutral
15 Sec. 15 Sec.
REMARK :
During this warm up procedure, it is possible that the converter out temperature of the transmission exceeds the
maximum limit. This is a consequence of heating up the transmission using this quick procedure.
When this occurs, the engine speed will be limiting 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 yet.
T27/32 4 SD 03/2010 4-24

Maintenance
4.4.5 CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS
This chapter gives an overview of the most common calibration condition messages. Normally, you will be able
to repair the cause of a calibration condition message yourself. However, you will have to contact the OEM of the
machine when a calibration error appears.
4.4.5.1 Calibration condition messages
The APC200 expects the shift lever Put the shift jever back in NEUTRAL
to be in NEUTRAL, but finds it in
another position.
(FORWARD or REVERSE)
THE APC200 expects the partking Put the parking brake ON
brake to be ON while it is OFF
The APC200 has detected output Verify that the parkiing brake is ON and working prop-
speed erly. If this is already the case, you will be obliged to
keep the machine at standstill by using the footbrake.
Once the machine has been stopped, the APC200
will ask the driver to shift to FORWARD before con-
tinuing the calibration.
Engine RPM is to low according If the vehicle is equiped with throttle-by-wire, the
to the limit that is necessary for engine RPM will be automatically adapted. In the
calibration. other case, the driver has to change the throttle pedal
position until the display looks as follows:
Engine RPM is to high according
to the limit that is necessary for
calibration.
After being to low or to high, the

engine RPM is coming back into
the correct bounderies for calibra-
tion
When during the automatic trans- Use the M-button on the APC200 to go back to the
mission calibration the temperature 'HEAT' mode and the S-button to trigger this mode.
becomes to low, the APC200 dis- Now you have to warm-up the transmission again un-
play indicates the actual transmis- til the temperature is above 60° C [140° F]. Then go
sion temperature. back to the automatic tuning mode by the M-button
and trigger this one again to continue calibration.
4.4.5.2 Calibration errors

Calibration errors have the form ‘E1.xx’ or ‘E2.xx’ (example : E1.25). Please contact the OEM of the
machine if an error of this form appears on the display.
T27/32 4 SD 03/2010 4-25

4.4.6 PERFORMING A STALL TEST
With a stall test it is possible to test clutch pack slippage or test the converter/engine stall speed in each gear.
How to Preform a stall test
1 Activate parking brake
2 Activate calibration mode during power up and holding the S button for 15 seconds
3 select "STAL" using the M button
FULL
IDLE
forward
neutral
15 Sec. 15 Sec.
4 Select the requested range gear with the S button
ENGINE SPEED
S
ENGINE SPEED
ENGINE SPEED
ENGINE SPEED
5 Select FWD or REV in the selected range gear

6 request full throttle and read the engine speed at the APC display
7 All speeds should reach approximately the same value when the transmission in ok
8 Leave the stall mode with the M button or switch-off the ignition
T27/32 4 SD 03/2010 4-26

5 INSTALLATION DETAILS
TE27/32 4 SD 03/2010 5-27

5 Installation details
5.1 Converter drive coupling
Measure the “A” dimension (bolt circle diameter) and order drive plate kit listed below.
Note three (3) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly.
Three (3) kits with three intermediate drive plates.
(1) DRIVE PLATE AND

WELD NUT ASSEMBLY
A
A
BOLT CIRCLE DIA. BOLT CIRCLE DIA.
BACKING RING (2) INTERMEDIATE DRIVE PLATES BACKING RING (3) INTERMEDIATE DRIVE PLATES
“A” Dimension (Bolt circle diameter) “A” Dimension (Bolt circle diameter)
• 15” (381.0 mm) diameter • 15” (381.0 mm) diameter
Each kit will include the following parts: Each kit will include the following parts:
• 2 Intermediate drive plates • 3 Intermediate drive plates
• 1 Drive plate and weld nut assembly • 1 Backing ring
• 1 Backing ring • 6 Mounting screws
• 6 Mounting screws • 6 Lock washers
• 6 Lock washers • 1 Instruction sheet
• 1 Instruction sheet
Position drive plate and weld nut assembly on torque converter assembly with welded nuts toward converter.
Align intermediate drive plates and backing ring with holes in torque converter assembly.
Note:
Two dimples 180° apart in backing ring must be out (Toward the engine flywheel).
Install cap screws and washers. Tighten 40 - 50 Nm [30 to 37 lbft] torque.
TE27/32 4 SD 03/2010 5-28

Installation details
5.2 TRANSMISSION TO ENGINE INSTALLATION FLYWHEEL H OUSING MOUNT

PROCEDURE DIAL INDICATOR
HERE
1. Remove all burrs from flywheel mounting face and nose

pilot bore. Clean drive plate surface with solvent.
ENGINE
2. Check engine flywheel & housing for conformance to
standard SAE No. 3 per SAE J927 and J1033 tolerance FLYWHEEL
specifications for pilot bore size, pilot bore runout and PILOT BORE
mounting face flatness. Measure and record engine
crankshaft end play (Fig. 1).
FLYWHEEL
3. Install two 63,50 mm (2.50”) long transmission to
flywheel housing guide studs in the engine flywheel
housing as shown. Rotate the engine flywheel to align a FIG. 1
drive plate mounting screw hole with the flywheel housing
access hole (Fig. 2).
FLYWHEEL HOUSING CONVERTER HOUSING
*4. Install a 101,60 mm (4.00”) long drive plate locating
stud .3750-24 fine thread in a drive plate nut. Align the
locating stud in the drive plate with the flywheel drive plate
mounting screw hole positioned in step No. 3. 4"STUD
5. Rotate the transmission torque converter to align the

locating stud in the drive plate with the flywheel drive plate
mounting screw hole positioned in step No. 3. Locate 21/2"ALIGNING
STUDS
transmission on flywheel housing.
DRIVE
Aligning drive plate to flywheel and transmission to FLYWHEEL
PLATE
flywheel housing guide studs. Install transmission to
flywheel housing screws. Tighten screws to specified
FIG. 2
torque. Remove transmission to engine guide studs.
Install remaining screws and tighten to specified torque. SPECIAL STUD, WASHER AND
SELF LOCK NUT FURNISHED
*6. Remove drive plate locating stud. FLYWHEEL HOUSING BY ENGINE MANUFACTURER.
7. Install drive plate attaching screw and washer. Snug

screw but do not tighten. Some engine flywheel
housings have a hole located on the flywheel housing FLYWHEEL
circumference in line with the drive plate screw access
hole. A screwdriver or pry bar used to hold the drive
IMPELLER
plate against the flywheel will facilitate installation of COVER
the drive plate screws. Rotate the engine flywheel and
install the remaining seven (7) flywheel to drive plate INTERMEDIATE
attaching screws. Snug screws but do not tighten. DRIVE PLATES
After all eight (8) screws are installed.
Torque each one according to torque specifications. This
will require tightening each screw and rotating the engine FIG. 3 FIG.4
flywheel until the full amount of eight (8) screws have been
tightened to specified torque.
PLATES TO BE INSTALLED
8. Measure engine crankshaft end play after transmission WITH CONCAVE SIDE
has been completely installed on engine flywheel. This TOWARD ENGINE FLYWHEEL.
value must be within 0,025 mm (0.001”) of the end play

recorded in step No. 2.
* Does not apply to units having 3 intermediate drive plates.
See Fig.4.
FIG. 5
TE27/32 4 SD 03/2010 5-29

5.3 External plumbing
to remote filter 1
remote filter 1
from remote filter 1

from transmission to cooler
from pump 1
remote filter 2
cooler
from cooler to
transmission
from remote filter 2
5.3.1 Cooler & filter lines specifications

• Minimum 25.4 mm [1.0 inch] internal diameter for lines and fittings.
• Suitable for operation from ambient to 120° C [248° F] continuous operating temperature.
• Must withstand 30 bar [435psi] continuous pressure and with 40 bar [652 psi] intermittent surges.
• Conform SAE J1019 and SAE J517,100RI.
TE27/32 4 SD 03/2010 5-30

- +
TE27/32 4 SD
INSTALL CLIP UNDER ANGLE X

5.4 speed sensor installation
(SEE TABLE)
03/2010
TRANSMISSION ASSY Partnr CONNECTOR TYPE X POSITION
MODEL
TE27/32 4209752 AMP 2 Pins Engine Speed 180 Degrees INSTALLATION INSTRUCTIONS
4209752 AMP 2 Pins Drum Speed 180 Degrees
5-31
4209750 AMP 2 pins Output Speed 180 Degrees
4209751 AMP 2 Pins Turbine Speed -90 Degrees
5.4 speed sensor installation (Continued)
Pin 2 Pin 1
The magneto resistive sensor generates a square wave current with a fixed amplitude changing between 7 mA
and 14 mA. The sensor has an integrated AMP superseal 2 pin connector. The two pins are numbered 1 and 2.
Following table shows the relation between wire colour, pin number and connection.
COLOUR PIN NUMBER FUNCTION CONNECTION
BROWN 1 Current input Hot wire

BLUE 2 Current output Ground wire
Note
The sensor wires have a polarity.

Be sure to correctly observe sensor polarities, as wrong connections will deactivate the sensor !
5.5 Temperature sensor installation
TE27/32 4 SD 03/2010 5-32

6 TRANSMISSION OPERATION
TE27/32 4 SD 03/2010 6-33

6 Transmission Operation
6.1 The transmission assembly
Basically the transmission is composed of five main assemblies:

1. The converter, pump drive section and pressure regulating valve.
2. The input shaft and directional clutches.
3. The range clutches.
4. The output section.
5. The transmission control valve.
FWD 3RD
REV 2ND 1ST
4TH
The converter, pump drive section and pressure regulator valve
The input shaft and directional clutches
The range clutches
TE27/32 4 SD The output section

03/2010 6-34
layout 32
Transmission Operation
6.1.1 The converter, pump drive section and pressure regulating valve
Engine power is transmitted from the engine flywheel to the impeller through the impeller cover.
This element is the pump portion of the hydraulic torque converter and is the primary component which starts
the oil flowing to the other components which results in torque multiplication. This element can be compared to a
centrifugal pump, that picks up fluid at its centre and discharges it at the outer diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque
converter. This element receives fluid at its outer diameter and discharges it at its centre.
The reaction member of the torque converter is located between and at the centre of the inner diameters of the
impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the
turbine and change its direction to allow correct entry for recirculation into the impeller element.
This recirculation will make the converter to multiply torque.

The torque multiplication is function of the blading (impeller, turbine and reaction member) and the converter out-
put speed (turbine speed). The converter will multiply engine torque to its designed maximum multiplication ratio
when the turbine shaft is at zero RPM (stall).
Therefore we can say that as the turbine shaft is decreasing in speed, the torque multiplication is increasing.
The hydraulic pump is connected with the pump drive gear. This pump drive gear is driven by the impeller hub
gear. Since the impeller hub gear is connected with the impeller cover, the pump speed is in direct relation with
the engine speed.
FWD 3RD
REV 2ND 1ST
4TH
CONVERTER SECTION CONTROL VALVE
left
TE27/32 4 SD 03/2010 6-35
6.1.2 The input shaft and directional clutches
The turbine shaft driven from the turbine transmits power to the directional clutches (fwd/rev.).
These clutches consist of a drum with internal splines and a bore to receive a hydraulic actuated piston.
The piston is oil tight by the use of sealing rings. The steel discs with internal splines, and friction discs with
external splines, are alternated until the required total is achieved.
A back-up plate is then inserted and secured with a retainer ring. A hub with outer diameter splines is inserted
into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in speed or
rotate in the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, the solenoid will direct oil under pressure through tubes and passages to the selected
clutch shafts.
Oil sealing rings are located on the clutch shafts. These rings direct the oil through a drilled passage in the shaft
to the desired clutch.
Pressure of the oil forces the piston and discs against the back-up plate. The discs with splines on the outer
diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked
together and allows them to drive as one unit.
When the clutch is released, a return spring will push the piston back and oil will drain back via the shift spool,
the bleed hole or holes in the clutch piston into the transmission sump.
These bleed holes will only allow quick escape of oil when the pressure to the piston is released.
The engagement of all range and directional clutches is modulated and electronically controlled. This means that
clutch pressure is built up gradually. This will enable the unit to make forward, reverse shifts while the vehicle is
still moving and will allow smooth engagement of drive.
3RD
FWD
REV 2ND 1ST
4TH
INPUT SECTION
TE27/32 4 SD 03/2010 6-36

6.1.3 The range clutches
Once a directional clutch is engaged power is transmitted to the range clutches.
Operation and actuation of the directional clutches is similar to the range clutches.
The engagement of the directional clutches is modulated.
For the 1st clutch assembly there is an extra bleed hole to allow full drain when the pressure
to the piston is released.
3RD
FWD
REV 2ND 1ST
4TH
6.1.4The output section RANGE CLUTCH-

With a range clutch engaged, power is finally transmitted to the output shaft.
Output rotation is the opposite to input rotation when the forward clutch is engaged.
3RD
FWD
REV 2ND 1ST
4TH
OUTPUT SECTION
TE27/32 4 SD 03/2010 6-37

6.2 The transmission controls (refer to hydraulic diagram)
The transmission is controlled by a TCON ECU. This unit has a microprocessor that receives certain inputs (gear
selector position, speed senors,...), which are processed and will give output signals to the control valve.
Operation of the valve

Regulated pressure 22 - 26 bar [319 - 377 PSI] is directed to the proportional valve and selector valves to acti-
vate the clutches required.
When activated the proportional valve will give an output pressure curve from 0 to 26 bar [0-87PSI] proportional
to a current from 0 mA to 1000mA. Dampers are used to dampen any hydraulic vibration.
Directional selection
When a direction (forward or reverse) is selected, the required selector valve is activated for forward or
reverse and the proportional valve will provide a pressure rise from 0 to 26 bar feeding the directional clutch with
modulated pressure.
Range selection
When 1st clutch is selected, the 1st/3rd selector valve is actevated and the 1st/3rd proportional valve will provide
a pressure rise from 0 to 26 bar feeding the 1st clutch with modulated pressure.
When 2nd clutch is selected, the 2nd/4th selector valve is activated, the 1st/3rd proportional valve will decrease
pressure from 26 to 0 bar, thus releasing the 1st clutch in a controlled manner. At the same time the 2nd/4th pro-
portional valve is activated and will provide a pressure curve from 0 to 26 bar, which will provide clutch overlap.
When the shift is finalized the 1st/3rd selector valve is deactivated.
When 3rd clutch is selected the 3rd/1st selector valve is not activated. The 2nd/4th proportional valve will
decrease pressure from 26 to 0 bar, thus releasing the 2nd clutch in a controlled manner. At the same time the
1st/3rd proportional valve is activated and will provide a pressure curve from 0 to 26 bar, which will provide
clutch overlap.
When the shift is finalized the 2nd/4th selector valve is deactivated.
When 4th clutch is selected, the 2nd/4th selector valve is not activated. The 1st/3rd proportional valve will
decrease pressure from 26 to 0 bar, thus releasing the 3rd clutch in a controlled manner. At the same time the
2nd/4th proportional valve is activated and will provide a pressure curve from 0 to 26 bar, which will provide
clutch overlap.

Restriction plug
The pressure line is connected to the drain line via a restricted hole. This ensures the drain line to remain air free
at all times and guarantees the reliable functioning of the proportional valves.
TE27/32 4 SD 03/2010 6-38

Pressure sensor
The control valve also has a pressure sensor installed to monitor overlap on range clutches
6.3 Electric solenoid controls
selected gear Activated Activated Activated

Selector valve Proportional valve clutches
Forward 4 FWD FWD/REV - 2nd/4th Forward, 4th
Forward 3 FWD FWD/REV -1st/3rd Forward, 3rd
Forward 2 FWD - 2nd/4th FWD/REV - 2nd/4th Forward, 2nd
Forward 1 FWD - 1st/3rd FWD/REV -1st/3rd Forward, 1st
Neutral 4 2nd/4th 4th

Neutral 3 1st/3rd 3rd
Neutral 2 2nd/4th 2nd/4th 2nd
Neutral 1 1st/3rd 1st/3rd 1st
Reverse 4 REV FWD/REV - 2nd/4th Reverse, 4th

Reverse 3 REV FWD/REV -1st/3rd Reverse, 3nd
Reverse 2 REV - 2nd/4th FWD/REV - 2nd/4th Reverse, 2nd
Reverse 1 REV - 1st/3rd FWD/REV -1st/3rd Reverse, 1st
TE27/32 4 SD 03/2010 6-39

A ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar
TE27/TE32 TRANSMISSION FULL FLOW VALVE - HYDRAULIC DIAGRAM
B PRESSURE INTENSIFIER 0-6 TO 0-20 bar
NEUTRAL SELECTED
OPERATOR COMPARTMENT
PRESSURE
TEMPERATURE
GAUGE
GAUGE
TE27/32 4 SD
TORQUE
32 CONVERTER 37 41
6.4.1 Neutral-1 Selected
HOSE 31
71
PRESSURE
Ø0.8
REGULATOR
VALVE 22 bar
COOLER FWD/REV 1ST/3RD PRESSURE 2ND/4TH PRESSURE

SENSOR SENSOR
SAFTY VALVE
CRACKING
9 bar
34
HOSE
FWD/N/REV
1ST/3RD 2ND/4TH
03/2010
LUBRICATION
HOSE RANGE HOSE
CLUTCHES
34A 31A
FILTER 2 BY-PASS VALVE FILTER 1 BY-PASS VALVE

4,1-4,5 bar 4,1-4,5 bar
35A 34A 46 45 41 43 42 44
6.4 Powerflows, activated solenoids and hydraulic circuit
HOSE HOSE
46 45 41 43 42 44
PUMP 1
PUMP 2 100,7 L/min @ 2170 rpm Ø0.9 Ø0.9 Ø0.9 Ø0.9 Ø0.9 Ø0.9
52,4 L/min @ 2170 rpm
Lubrucation REV FWD 1ST 3RD 2ND 4TH

CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
Low pressure
AIR
BREATHER
SCREEN High pressure
OIL SUMP
Drain
6-40
6.4.1 Neutral-1 (Continued)
FWD 3RD
REV 2ND 1ST
4TH
TE27/32 4 SD 03/2010 6-41

FORWARD FIRST SELECTED
PRESSURE
TEMPERATURE
GAUGE
GAUGE
TE27/32 4 SD
TORQUE
CONVERTER
6.4.2 Forward 1st speed
32 37 41
HOSE 31
71
PRESSURE Ø0.8
REGULATOR
VALVE 22 bar
PRESSURE
SENSOR
COOLER FWD/REV 1ST/3RD PRESSURE

2ND/4TH
SENSOR
SAFTY VALVE
CRACKING
9 bar
34
HOSE
03/2010
FWD/N/REV
LUBRICATION 1ST/3RD 2ND/4TH
HOSE RANGE HOSE
CLUTCHES
34A 31A

4,1-4,5 bar 4,1-4,5 bar
35A 34A 46 45 41 43 42 44
HOSE HOSE
46 45 41 43 42 44
PUMP 1
52,4 L/min @ 2170 rpm

Low pressure
AIR
6-42
BREATHER
OIL SUMP
Drain
Powerflow FWD 1st
6.4.2 Forward 1st speed (continued)
FWD
3RD
1ST
REV 2ND
4TH
TE27/32 4 SD 03/2010 6-43

FORWARD SECOND SELECTED
PRESSURE
TEMPERATURE
GAUGE
GAUGE
TE27/32 4 SD
TORQUE
32 CONVERTER 37 41
6.4.3 Forward 2nd speed
HOSE 31
71
PRESSURE Ø0.8
REGULATOR
VALVE 22 bar
PRESSURE PRESSURE
SENSOR SENSOR
COOLER FWD/REV 1ST/3RD 2ND/4TH

SAFTY VALVE
CRACKING
9 bar
34
HOSE
03/2010
FWD/N/REV
HOSE RANGE HOSE
CLUTCHES
34A 31A

4,1-4,5 bar 4,1-4,5 bar
35A 34A 46 45 41 43 42 44
HOSE HOSE
46 45 41 43 42 44
PUMP 1
52,4 L/min @ 2170 rpm

Low pressure
AIR
6-44
BREATHER
OIL SUMP
Drain
Powerflow FWD 2nd
6.4.3 Forward 2nd speed (continued)
FWD
3RD
2ND
REV 1ST
4TH
TE27/32 4 SD 03/2010 6-45

FORWARD 3rd SELECTED
PRESSURE
TEMPERATURE
GAUGE
GAUGE
TE27/32 4 SD
TORQUE
32 CONVERTER 37 41
6.4.4 Forward 3rd speed
HOSE 31
71
PRESSURE Ø0.8
REGULATOR
VALVE 22 bar
PRESSURE
SENSOR

2ND/4TH
SENSOR
SAFTY VALVE
CRACKING
9 bar
34
HOSE
03/2010
FWD/N/REV
HOSE RANGE HOSE
CLUTCHES
34A 31A

4,1-4,5 bar 4,1-4,5 bar
35A 34A 46 45 41 43 42 44
HOSE HOSE
46 45 41 43 42 44
PUMP 1
52,4 L/min @ 2170 rpm

Low pressure
AIR
6-46
BREATHER
OIL SUMP
Drain
Powerflow FWD 3rd
6.4.4 Forward 3rd speed (continued)
FWD
3RD
REV 2ND 1ST
4TH
TE27/32 4 SD 03/2010 6-47

FORWARD 4TH SELECTED
PRESSURE
TEMPERATURE
GAUGE
GAUGE
TE27/32 4 SD
TORQUE
32 CONVERTER 37 41
6.4.5 Forward 4TH speed
HOSE 31
71
PRESSURE Ø0.8
REGULATOR
VALVE 22 bar
PRESSURE PRESSURE
SENSOR SENSOR

SAFTY VALVE
CRACKING
9 bar
34
HOSE
03/2010
FWD/N/REV
HOSE RANGE HOSE
CLUTCHES
34A 31A

4,1-4,5 bar 4,1-4,5 bar
35A 34A 46 45 41 43 42 44
HOSE HOSE
46 45 41 43 42 44
PUMP 1
52,4 L/min @ 2170 rpm

Low pressure
AIR
6-48
BREATHER
OIL SUMP
Drain
Powerflow FWD 4rd
6.4.5 Forward 4th speed (continued)
FWD
3RD
REV 2ND 1ST
4TH
layout 32
TE27/32 4 SD 03/2010 6-49

A ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar .
REVERSE FIRST SELECTED
PRESSURE
TEMPERATURE
GAUGE
GAUGE
TE27/32 4 SD
TORQUE
32 CONVERTER 37 41
HOSE 31
71
PRESSURE Ø0.8
REGULATOR
VALVE 22 bar
PRESSURE
SENSOR

2ND/4TH
SENSOR
SAFTY VALVE
CRACKING
9 bar
34
HOSE
03/2010
FWD/N/REV
HOSE RANGE HOSE
CLUTCHES
34A 31A

4,1-4,5 bar 4,1-4,5 bar
35A 34A 46 45 41 43 42 44
HOSE HOSE
46 45 41 43 42 44
PUMP 1
52,4 L/min @ 2170 rpm

Low pressure
AIR
6-50
BREATHER
OIL SUMP
Drain
Powerflow REV 1st
6.4.6 Reverse 1st speed
3RD
FWD
REV 1ST
2ND
4TH
TE27/32 4 SD 03/2010 6-51

REVERSE SECOND SELECTED
PRESSURE
TEMPERATURE
GAUGE
GAUGE
TE27/32 4 SD
TORQUE
6.4.7 Reverse 2nd speed
32 CONVERTER 37 41
HOSE 31
71
PRESSURE Ø0.8
REGULATOR
VALVE 22 bar
PRESSURE PRESSURE
SENSOR SENSOR

SAFTY VALVE
CRACKING
9 bar
34
HOSE
03/2010
FWD/N/REV
HOSE RANGE HOSE
CLUTCHES
34A 31A

4,1-4,5 bar 4,1-4,5 bar
35A 34A 46 45 41 43 42 44
HOSE HOSE
46 45 41 43 42 44
PUMP 1
52,4 L/min @ 2170 rpm

Low pressure
AIR
6-52
BREATHER
OIL SUMP
Drain
Powerflow REV 2nd
6.4.7 Reverse 2nd speed (continued)
3RD
FWD
REV 2ND
1ST
4TH
TE27/32 4 SD 03/2010 6-53

REVERSE 3rd SELECTED
PRESSURE
TEMPERATURE
GAUGE
GAUGE
TE27/32 4 SD
TORQUE
32 CONVERTER 37 41
6.4.8 Reverse 3rd speed
HOSE 31
71
PRESSURE Ø0.8
REGULATOR
VALVE 22 bar
PRESSURE
SENSOR

2ND/4TH
SENSOR
SAFTY VALVE
CRACKING
9 bar
34
HOSE
03/2010
FWD/N/REV
HOSE RANGE HOSE
CLUTCHES
34A 31A

4,1-4,5 bar 4,1-4,5 bar
35A 34A 46 45 41 43 42 44
HOSE HOSE
46 45 41 43 42 44
PUMP 1
52,4 L/min @ 2170 rpm

Low pressure
AIR
6-54
BREATHER
OIL SUMP
Drain
Powerflow REV 3rd
6.4.8 Reverse 3rd speed (continued)
FWD 3RD
REV 2ND 1ST
4Th
TE27/32 4 SD 03/2010 6-55

REVERSE 4TH SELECTED
PRESSURE
TEMPERATURE
GAUGE
GAUGE
TE27/32 4 SD
TORQUE
32 CONVERTER 37 41
6.4.9 Reverse 4TH speed
HOSE 31
71
PRESSURE Ø0.8
REGULATOR
VALVE 22 bar
PRESSURE PRESSURE
SENSOR SENSOR

SAFTY VALVE
CRACKING
9 bar
34
HOSE
03/2010
FWD/N/REV
HOSE RANGE HOSE
CLUTCHES
34A 31A

4,1-4,5 bar 4,1-4,5 bar
35A 34A 46 45 41 43 42 44
HOSE HOSE
46 45 41 43 42 44
PUMP 1
52,4 L/min @ 2170 rpm

Low pressure
AIR
6-56
BREATHER
OIL SUMP
Drain
Powerflow REV 4rd
6.4.9 Reverse 4TH speed (continued)
FWD
3RD
REV 2ND 1ST
4Th
TE27/32 4 SD 03/2010 6-57

6.5 GEAR AND CLUTCH LAYOUT
ut
Inp
ut
Outp
TE27/32 4 SD 03/2010 6-58

TE27/32 4 SD 03/2010 7-59
7 Troubleshooting guide
The following information is presented as an aid to isolate and determine the specific problem area in a
transmission that is not functioning correctly.
When troubleshooting a “transmission” problem, it should be kept in mind that the transmission is only the
central unit of a group of related powertrain components. Proper operation of the transmission depends on the
condition and correct functioning of the other components of the group.
Therfore, to properly diagnose a suspected problem in the transmission, it is necessary to consider the
transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connecting lines
and controls, including the engine as a complete system.
By analysing the principles of operation together with the information in this section, it should be possible to
identify and correct any malfunction which may occur in the system.
7.1 The Transmission

TE27/32 powershift transmission with torque converter troubles fall into four general categories:
1. Mechanical problems
2. Hydraulical problems
3. Electrical problems
4. Controller problems
In addition to the mechanical and electrical components, all of which must be in proper condition and functioning
correctly, the correct functioning of the hydraulic circuit is most important. Transmission fluid is the “life blood”
of the transmission. It must be supplied in an adequate quantity and delivered to the system at the correct
pressures to ensure converter operation, to engage and hold the clutches from slipping, and to cool and
lubricate the working components.
7.2 The input shaft and directional clutches
7.2.1 PERFORMING A STALL TEST
A stall test identifies transmission, converter or engine problems.
Use the following procedure:
With a stall test it is possible to test clutch packslippage or test the converter/engine stall speed in each gear.
How to perform the stall test
1 Put the vehicle against a solid barrier, such as a wall and/or apply the parking brake, block the
wheels.
2 Activate calibration mode during power up end holding the S button for 15 seconds
3 Select "STAL" using the M buttom
Full
Idle
forward
neutral
15 Sec 15 Sec
TE27/32 4 SD 03/2010 7-60

Maintenance
ENGINE SPEED
S
ENGINE SPEED
ENGINE SPEED
ENGINE SPEED
5 Select FWD or REV in the selected range gear

6 Once the oil temperature reaches 70° C [158° F] check max. stall speed at full throttle in all gears.
7 The figure obtained should be within 50 RPM as mentioned in the vehicle handbook and should be
equal in all gears. Between gears allow the converter outlet temperature to cool down
to 70° C [158° F] by selecting neutral.
8 Leave the stall mode with the M button or switch-off the ignition
If max. stall speed measured is below specifications, it could indicate an engine or converter problem.
If max. stall speed measured is above specifications, it could indicate slipping clutches.
CAUTION
Do not operate the converter at stall condition longer than 30 seconds at one time, shift to
neutral for 15 seconds and repeat the procedure until desired temperature is reached.
Excessive temperature 120° C [250° F] maximum will cause damage to transmission clutches,
fluid, converter and seals.
TE27/32 4 SD 03/2010 7-61

7.2.2 Transmission pressure checks

Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping
clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch
plate friction material failure.
In addition, converter charging pressure and transmission lubrication pressure can also be measured.
7.2.3 Mechanical and electrical checks

Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical
and electrical checks should be made:
• Check the parking brake and inching pedal for correct adjustment.
• Be sure all lever linkage is properly connected and adjusted in each segment and at all connect-
ing points.
• The controls are actuated electrically. Check the wiring and electrical components.
• Be sure that all components of the cooling system are in good condition and operating correctly.
The radiator must be clean to maintain proper cooling and operating temperatures for the engine and
transmission. Air clean the radiator, if necessary.
7.2.4 Hydraulic checks

Also, before checking the transmission clutches, torque converter, charging pump and hydraulic circuit for
pressure and rate of flow, it is imporatant to make the following transmission fluid check:
• Check oil level in the transmission. The transmission fluid must be at the correct (full level).
• All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times.
Note:
the transmission fluid must be at operating temperature of 82 - 93° C [180 - 200° F] to

obtain correct fluid level and pressure readings.
Do not attempt to make these checks with cold oil.
To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run
the engine with converter at “stall” (refer to 6.2.1 “stall test”).
Caution:
Be carefull that the vehicle does not move unexpectedly when operating the engine and
converter at stall RPM.
7.2.5 Controller (APC200): Please refer to functional description
TE27/32 4 SD 03/2010 7-62

7.3 TROUBLESHOOTING GUIDE

Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles
7.3.1 Low clutch pressure
Cause Remedy
1. Low oil level. 1. Fill to proper level.

2. Clutch pressure regulating valve stuck open. 2. Clean valve spool and housing.
3. Faulty charging pump. 3. Replace pump.
4. Broken or worn clutch shaft or piston sealing rings. 4. Replace sealing rings.

7.3.2 Low charging pump output flow
Cause Remedy
1. Low oil level. 1. Fill to proper oil level.

2. Suction screen clogged. 2. Clean suction screen.
3. Defective charging pump. 3. Replace charging pump.
7.3.3 Overheating
Cause Remedy
1. Worn oil sealing rings 1. Remove, disassemble and rebuild converter

assy.
2. Worn charging pump. 2. Replace charging pump.
3. Low oil level. 3. Fill to proper level.
4. Dirty oil cooler. 4. Clean cooler.
5. Restriction in cooler lines. 5. Change cooler lines.
7.3.4 Noisy converter
Cause Remedy
1. Worn charging pump. 1. Replace charging pump.

2. Worn or damaged bearings. 2. A complete disassembly will be necassary to
determine which bearing is faulty.
7.3.5 Lack of power
Cause Remedy
1. Low engine RPM at converter stall. 1. Tune engine, check governor.

2. See “Overheating” and make same checks. 2. Make corrections as explained in “Overheating”.
TE27/32 4 SD 03/2010 7-63

7.4 CHECK POINTS
Port 42
Pressure check port
2nd clutch
Port 46
Pressure check port
Rev. clutch
Port 34 Port 44
Pressure check port Pressure check port
Lube 4th. clutch
FRONT VIEW Plug - Magnetic drain

M22 x 1.5 UNI
Port 16b
From remote filter 1
Port 32
Pressure check port
To cooler
Temperature switch
Temperature sensor
Port 43
Pressure check port
3rd clutch
REAR VIEW
TE27/32 4 SD 03/2010 7-64

7.4 CHECK POINTS (continued)
Port 11
Port 31
To cooler
Pressure check port
Regulator
Port 37
Pressure check port
Convertor in Engine speed
sensor
Port 45
Pressure check port
Fwd clutch
Drum speed sensor
Port 12
Output speed sensor From cooler
Port 16A
From remote filter
Turbine speed sensor
Metric flange for dip-
stick dia 25.4mm 4 Mounting holes
M20 x 2.5 THD
RIGHT VIEW 30mm DEEP
right
Port 41
Pressure check port
1st clutch
Oil level check port

¼ NPT
LEFT VIEW
TE27/32 4 SD 03/2010 7-65

left
Port 13b Port 13a

To remote filter To remote filter
from pump 2 from pump 1
Oil fill hole

¾-14NPTF
TOP VIEW
top
TE27/32 4 SD 03/2010 7-66

Checkpoint 31A.............. System pressure

Checkpoint 41................ 1st clutch pressure
Checkpoint 42................ 2nd clutch pressure
Checkpoint 43................ 3rd clutch pressure
Checkpoint 44................ 4th clutch pressure
Checkpoint 45................ FWD clutch pressure
Checkpoint 46................ REV clutch pressure
Checkpoint 66................ FWD/REV regulated pressure
Checkpoint 67................ 1st/3rd regulated pressure
Checkpoint 68................ 2nd/4th requlated pressure
31A
45
66
46
68
67 43
44
41
42
TE27/32 4 SD 03/2010 7-67

7.5 SPEED SENSOR - STATIC STANDALONE TEST
In order to be able to sense the currents, a series resistor of e.g. 200 Ω must be used. This resistor is integrated
in the controller, but when the sensor is to be used, it must be connected externally.
The idea is to connect the sensor to an external power source and measure the DC voltage across the series
resistor.
The voltage reading should be either 1.2V (from the 7mA ± 1mA current level) or 2.6 - 3.0V (for the 14mA ± 1mA
current level).
If the teeth can be moved slowly, distinct toggling between the two levels should be noticed.
TE27/32 4 SD 03/2010 7-68

7.6 Full flow valve components
FWD/REV
SELECTOR
VALVE A
FWD/REV
PROPORTIONAL
VALVE
2ND/4TH
PROPORTIONAL
VALVE
3RD/1ST
PROPORTIONAL
VALVE
1ST/3RD
4TH/2ND SELECTOR
SELECTOR VALVE
VALVE
4TH/2ND
PRESSURE
SENSOR
3RD/1ST
PRESSURE
SENSOR
TE27/32 4 SD 03/2010 7-69

8 SECTIONAL VIEWS & PARTS IDENTIFICATION
TE27/32 4SD 03/2010 8-70

TORQUE CONVERTER GROUP
TE32
CONVERTER HOUSING GROUP
13
7 33
8 32
38 37 30
29
42 34
43 35
40 31
19
41 21
14 18
1 17
15 19
20
42 18
43
40 19
41 3 20
18
16
35 13
36 23
22 44
37 45
38
10 21
6
9
12 3
11
39
39
7
5
4
10 3
41
8 27 40
12 9
11 25
43
42
27
26
28
24
GRP-32011 rev.092002
TE27/32 4 SD 03/2010 8-71
TORQUE CONVERTER GROUP
Item Description Qty
1 Torque Converter...................................................................................................................... 1
2 Not Illustrated............................................................................................................................ 1
3 Plug - Expansion...................................................................................................................... 3
4 Plug ......................................................................................................................................... 1
5 “O” Ring.................................................................................................................................... 1
6 Tube.......................................................................................................................................... 1
7 Tube.......................................................................................................................................... 1
8 Tube.......................................................................................................................................... 1
9 Clip............................................................................................................................................ 2
10 “O” Ring.................................................................................................................................... 2
11 Capscrew.................................................................................................................................. 2
12 Lockwasher............................................................................................................................... 2
13 Tube.......................................................................................................................................... 1
14 Sleeve....................................................................................................................................... 1
15 Sleeve....................................................................................................................................... 1
16 Sleeve....................................................................................................................................... 1
17 Sleeve....................................................................................................................................... 1
18 Washer..................................................................................................................................... 3
19 Capscreww............................................................................................................................... 3
20 Lockwasher............................................................................................................................... 3
21 Plug........................................................................................................................................... 1
22 Plug........................................................................................................................................... 2
23 “O” Ring.................................................................................................................................... 2
24 Pin - Dowel............................................................................................................................... 2
25 Capscrew................................................................................................................................ 14
26 Capscrew.................................................................................................................................. 9
27 Lockwasher............................................................................................................................. 23
28 gasket - Converter to transmission case.................................................................................. 1
29 Bushing..................................................................................................................................... 1
30 Breather - Air............................................................................................................................. 1
31 Plug........................................................................................................................................... 1
32 Switch - Temperature................................................................................................................ 1
33 Adaptor - Temperature switch................................................................................................... 1
34 Sensor - Speed......................................................................................................................... 1
35 “O” Ring.................................................................................................................................... 1
36 Sensor - Speed 60mm.............................................................................................................. 1
37 Support - Speed sensor............................................................................................................ 2
38 Capscrew.................................................................................................................................. 2
39 Plug........................................................................................................................................... 2
40 Cover - Split flange................................................................................................................... 3
41 “O” ring...................................................................................................................................... 3
42 Capscrew................................................................................................................................ 12
43 Lockwasher............................................................................................................................. 12
44 Plug........................................................................................................................................... 1
45 “O” Ring.................................................................................................................................... 1
TE27/32 4 SD 03/2010 8-72

TRANSMISSION CASE & REAR COVER GROUPTE32
TRANSMISSION CASE GROUP
10
12
22 11
12
23 8
25
24 27
30
29
21 20 26
9
18 6
19 5
28
W
20 16 17 Y 6
21 5
34
X 6
5
5
35 6 W 14
32 33
29
31
5 W
6 X
1 Y
Y
4
5
6 15
W 3
2 X
Y
GRP-32021 rev. 092002
TE27/32 4 SD 03/2010 8-73

TRANSMISSION CASE & REAR COVER GROUP

1 Case - Transmission................................................................................................................. 1
2 Tube - 1st speed clutch pressure............................................................................................. 1
3 Tube - Low shaft rear bearing lube........................................................................................... 1
4 Tube - 3rd speed clutch pressure............................................................................................. 1
5 Sleeve - Pressure & lubr tube................................................................................................... 1
6 “O” ring...................................................................................................................................... 6
7 Cover - Rear............................................................................................................................. 1
8 Plug - Expansion...................................................................................................................... 1
9 Pin - Dowel............................................................................................................................... 2
10 Capscrew................................................................................................................................ 37
11 Capscrew.................................................................................................................................. 7
12 Lockwasher............................................................................................................................. 44
13 Gasket - Rear cover to transmission case................................................................................ 1
14 Plug........................................................................................................................................... 2
15 Plug - Magnetic drain................................................................................................................ 1
16 Sensor - Speed assy................................................................................................................ 1
17 “O” ring...................................................................................................................................... 1
18 Sensor - Speed assy................................................................................................................ 1
19 ‘O” ring...................................................................................................................................... 1
20 Support - Speed sensor............................................................................................................ 2
21 Capscrew.................................................................................................................................. 2
22 Tube - Suction.......................................................................................................................... 1
23 “O” ring...................................................................................................................................... 1
24 Lockwasher............................................................................................................................... 2
25 Capscrew.................................................................................................................................. 2
26 Baffle - Oil................................................................................................................................. 1
27 Cover - Oil baffle....................................................................................................................... 1
28 Tube - Oil baffle........................................................................................................................ 3
29 Lockwasher............................................................................................................................... 6
30 Capscrew.................................................................................................................................. 3
31 Screw........................................................................................................................................ 3
32 Cover - Split flange................................................................................................................... 1
33 “O” ring...................................................................................................................................... 1
34 Capscrew.................................................................................................................................. 4
35 Lockwasher............................................................................................................................... 4
TE27/32 4 SD 03/2010 8-74

TURBINE SHAFT GROUP
TE32
TURbINE SHAFT GROUP
2
15
16
14
9
6
8
7
11
12
10
13
1
3
4
5
GRP-TE32031 rev 230902
TE27/32 4 SD 03/2010 8-75

TURBINE SHAFT GROUP

1 Bearing - Turbine shaft front..................................................................................................... 1
2 Bearing - Turbine shaft rear...................................................................................................... 1
3 Spacer - Front bearing.............................................................................................................. 1
4 Snapring................................................................................................................................... 1
5 Ring - Piston............................................................................................................................. 1
6 Stator support assy................................................................................................................... 1
7 Screw - Stator support.............................................................................................................. 7
8 Lockwasher............................................................................................................................... 7
9 Ring - Piston............................................................................................................................. 1
10 Baffle - Oil................................................................................................................................. 1
11 Seal - Oil baffle......................................................................................................................... 1
12 Ring - Oil baffle seal................................................................................................................. 1
13 Ring - Oil baffle retaining.......................................................................................................... 1
14 “O” Ring.................................................................................................................................... 1
15 Snapring................................................................................................................................... 1
16 Turbine shaft............................................................................................................................. 1
TE27/32 4 SD 03/2010 8-76

TE32
PUMP DRIVE GROUP
PUMP DRIVE GROUP
3
4
2
7
1
8
7
1 10
5
11
8
6
12
7
1 9
GRP-TE32051 rev 290802
TE27/32 4 SD 03/2010 8-77

PUMP DRIVE GROUP

1 Support - Pump drive bearing................................................................................................... 3
2 Screw - Bearing support........................................................................................................... 4
3 “O” Ring.................................................................................................................................... 4
4 Washer..................................................................................................................................... 4
5 Lockwasher............................................................................................................................... 2
6 Screw - Bearing support........................................................................................................... 2
7 Bearing - Pump drive gear........................................................................................................ 3
8 Snapring................................................................................................................................... 3
9 Gear - Aux. pump drive............................................................................................................. 2
10 Gear - Charging pump.............................................................................................................. 1
11 Gear - Impeller hub................................................................................................................... 1
12 Snapring................................................................................................................................... 1
TE27/32 4 SD 03/2010 8-78

Adaptor sleeve group
GRP-TE32201 rev.290502
TE27/32 4 SD 03/2010 8-79

Adaptor sleeve group

1 Sleeve - Pump drive................................................................................................................. 1
2 Snapring................................................................................................................................... 1
TE27/32 4 SD 03/2010 8-80

Wheel group
16
17
10
15
14
18
19
3
9
2 1 8
6
5
4
11
20
21
22 13
23 12
24
7
25
GRP-32061 rev.092002
TE27/32 4 SD 03/2010 8-81

Wheel group
1 Member - Reaction................................................................................................................... 1
2 Snapring................................................................................................................................... 1
3 Spacer - Reaction member....................................................................................................... 1
4 Turbine...................................................................................................................................... 1
5 Hub - Turbine............................................................................................................................ 1
6 Snapring................................................................................................................................... 1
7 Snapring................................................................................................................................... 1
8 Screw - Turbine hub............................................................................................................... 10
9 Locktab..................................................................................................................................... 5
10 Impeller..................................................................................................................................... 1
11 “O” Ring.................................................................................................................................... 1
12 Screw...................................................................................................................................... 32
13 Lockwasher............................................................................................................................. 32
14 Hub - Impeller........................................................................................................................... 1
15 “O” Ring.................................................................................................................................... 1
16 Screw........................................................................................................................................ 8
17 Ring - Impeller hub dcrew backing........................................................................................... 1
18 Bearing..................................................................................................................................... 1
19 Snapring................................................................................................................................... 1
20 Cover - Impeller........................................................................................................................ 1
21 Bearing - Turbine hub............................................................................................................... 1
22 “O” Ring.................................................................................................................................... 1
23 Spacer...................................................................................................................................... 1
24 Snapring................................................................................................................................... 1
25 Hub - Impeller cover................................................................................................................. 1
TE27/32 4 SD 03/2010 8-82

VARIOUS MODELS
FLEx PLATE GROUP
FLEX PLATE group
3
4
GRP-T40041 rev290802
TE27/32 4 SD 03/2010 8-83

DRIVE PLATE group

1 Assembly - Drive plate and (when used) welded nuts.............................................................. 1
2 Plate - Drive.............................................................................................................................. 5
3 Ring - Backing.......................................................................................................................... 1
4 Capscrew................................................................................................................................ 14
TE27/32 4 SD 03/2010 8-84

TE32
FWD & REV/2nd and 3th orFWD,
4thREV/2nd
clutch shaft
& 3rd assy SHAFT ASSY GROUP
or 4th CLUTCH
d
2n
&
V
RE
D
FW
4th
or
d
3r
gRP-TE32071 (rev 15nov02)
TE27/32 4 SD 03/2010 8-85

FWD & REV/2nd and 3th or 4th clutch shaft assy
1 Fwd shaft drum assy................................................................................................................. 1

2 Rev/2nd shaft drum assy.......................................................................................................... 1
3 3rd shaft drum assy on 3 speed............................................................................................... 1
3 4th shaft drum shaft assy on 4 speed....................................................................................... 1
TE27/32 4 SD 03/2010 8-86

forward clutch shaft GROUP
TE32
FORWARD CLUTCH SHAFT GROUP
12
10
24
24
14
16
13
2
18
15 3
4
18 1
17
6
5
7
8
9
22
21
20
19
23
25
GRP-TE32091 rev240902
TE27/32 4 SD 03/2010 8-87

forward clutch shaft GROUP

1 Piston........................................................................................................................................ 1
2 Seal - Piston outer.................................................................................................................... 1
3 Seal - Piston inner.................................................................................................................... 1
4 Screen (not sold seperate........................................................................................................ 1
5 Disc - Clutch inner...................................................................................................................11
6 Disc - Clutch outer...................................................................................................................11
7 Plate - End................................................................................................................................ 1
8 Seal ......................................................................................................................................... 1
9 Snapring................................................................................................................................... 1
10 Washer - Belleville.................................................................................................................. 15
11 Ring - Retaining........................................................................................................................ 1
12 Spacer - Clutch piston.............................................................................................................. 1
13 Bearing - Clutch driven gear..................................................................................................... 1
14 Bearing..................................................................................................................................... 1
15 Bearing..................................................................................................................................... 1
16 Ring - Retaining........................................................................................................................ 1
17 Ring - Piston............................................................................................................................. 2
18 Ring - Retaining........................................................................................................................ 2
19 Bearing..................................................................................................................................... 1
20 Spacer...................................................................................................................................... 1
21 Snapring................................................................................................................................... 1
22 Retainer - Oil............................................................................................................................. 1
23 Snapring................................................................................................................................... 1
TE27/32 4 SD 03/2010 8-88

TE32
3rd speed clucth shaft GROUP
3RD SPEED CLUTCH SHAFT GROUP
12
10
11
13
16
14
17
15 2
18 3
19 4
1
27
6 28
5
7 21
8
9
24
19
23
26
22 29 25
20
GRP-TE32101 rev290802
TE27/32 4 SD 03/2010 8-89

3rd speed clucth shaft GROUP
1 Piston........................................................................................................................................ 1
4 Screen (not sold seperate)....................................................................................................... 1
7 Disc - Clutch outer half............................................................................................................. 2
8 Plate - End................................................................................................................................ 1
9 Snapring................................................................................................................................... 1
10 Washer - Belleville.................................................................................................................. 15
12 Retainer - Spring...................................................................................................................... 1
13 Ring - Retainer.......................................................................................................................... 1
14 Bearing..................................................................................................................................... 1
15 Bearing..................................................................................................................................... 1
16 Washer..................................................................................................................................... 1
17 Snapring................................................................................................................................... 2
18 Snapring................................................................................................................................... 1
19 Ring - Piston............................................................................................................................. 2
20 Bearing..................................................................................................................................... 1
21 Cap - 3rd speed shaft rear bearing........................................................................................... 1
22 Spacer...................................................................................................................................... 1
23 Snapring................................................................................................................................... 1
24 “O” Ring.................................................................................................................................... 1
25 Plug........................................................................................................................................... 1
26 “O” Ring.................................................................................................................................... 1
27 Capscrew.................................................................................................................................. 4
28 Lockwasher............................................................................................................................... 4
29 “O” RIng.................................................................................................................................... 1
TE27/32 4 SD 03/2010 8-90

3rd speed gear
GRP-TE32111 rev290802
TE27/32 4 SD 03/2010 8-91

3rd speed gear
1 Gear - 3rd speed...................................................................................................................... 1

2 Gear - 3rd speed driven............................................................................................................ 1
TE27/32 4 SD 03/2010 8-92

REV / 2nd schaft GROUP
TE32
REV/2ND CLUTCH SHAFT GROUP
25
26
24
27
30 31
28
29
36
18
17
19
20
21
1
4
2
37
3
N D
V &2
RE
13
38
15 14
12
23
32
22 35
34
11 33
10
16
8
9
GRP-TE32121 rev. 240902
TE27/32 4 SD 03/2010 8-93

REV / 2nd schaft GROUP

1 Piston........................................................................................................................................ 1
2 Seal - Clutch piston outer......................................................................................................... 1
3 Seal - Clutch piston inner......................................................................................................... 1
4 Screen (Not Sold Separate)..................................................................................................... 1
5 Washer - Belleville.................................................................................................................... 7
7 Ring - Retaining........................................................................................................................ 1
8 Disc - Clutch inner.................................................................................................................... 7
9 Disc - Clutch outer.................................................................................................................... 7
10 Plate - End................................................................................................................................ 1
11 Snapring................................................................................................................................... 1
12 Piston........................................................................................................................................ 1
13 Seal - Clutch piston outer......................................................................................................... 1
14 Seal - Clutch piston inner......................................................................................................... 1
15 Screen (Not Sold Separate)..................................................................................................... 1
16 Ring - Retaining........................................................................................................................ 1
19 Plate - End................................................................................................................................ 1
20 Seal........................................................................................................................................... 1
21 Snapring................................................................................................................................... 1
22 Washer - Bellevile................................................................................................................... 15
24 Bearing..................................................................................................................................... 1
25 Bearing..................................................................................................................................... 1
26 Ring - Retaining........................................................................................................................ 1
27 Ring - Retaining........................................................................................................................ 1
28 Bearing..................................................................................................................................... 1
29 Ring - Retaining........................................................................................................................ 1
30 Ring.......................................................................................................................................... 1
31 Washer - Bearing thrust............................................................................................................ 1
32 Hub - 2nd Clutch disc............................................................................................................... 1
33 Snapring................................................................................................................................... 1
34 Retainer.................................................................................................................................... 1
35 Snapring................................................................................................................................... 1
36 Ring - Piston............................................................................................................................. 3
TE27/32 4 SD 03/2010 8-94

1st speed clutch shaft GROUP
TE32
1ST SPEED CLUTCH SHAFT GROUP
1
4
2
15
8
27 7
26
25
16
28
5
6
12
11
23
10 24
22 21
17
32 18
31 20
19
30
29
14
13
GRP-TE32131 rev290802
TE27/32 4 SD 03/2010 8-95

1st speed clutch shaft GROUP

1 Piston........................................................................................................................................ 1
7 Plate - End................................................................................................................................ 1
8 Snapring................................................................................................................................... 1
9 Washer - Belleville.................................................................................................................... 9
11 Retainer - Spring...................................................................................................................... 1
12 Ring - Retainer.......................................................................................................................... 1
13 Bearing..................................................................................................................................... 1
14 Washer..................................................................................................................................... 1
15 Bearing..................................................................................................................................... 1
16 Retainer - Oil............................................................................................................................. 1
17 Ring - Piston............................................................................................................................. 2
18 Cap - Bearing........................................................................................................................... 1
19 “O” Ring.................................................................................................................................... 2
20 Plug........................................................................................................................................... 2
21 “O” Ring.................................................................................................................................... 2
22 “O” Ring.................................................................................................................................... 1
23 Capscrew.................................................................................................................................. 4
24 Lockwasher............................................................................................................................... 4
25 Bearing..................................................................................................................................... 1
26 Spacer - Bearing....................................................................................................................... 1
27 Snapring................................................................................................................................... 1
28 Snapring................................................................................................................................... 1
29 Bearing..................................................................................................................................... 1
30 Bearing..................................................................................................................................... 1
31 Spring - Disc............................................................................................................................. 1
32 Nut............................................................................................................................................ 1
TE27/32 4 SD 03/2010 8-96

4th speed clutch shaft GROUP TE32
4TH SPEED CLUTCH SHAFT GROUP
1
4
2
15 17
14
16 18
13
19 11
12
10
9
5
7
GRP-TE32141 rev 290802
TE27/32 4 SD 03/2010 8-97

4th speed clutch shaft GROUP
1 Piston........................................................................................................................................ 1
6 Disc - Clutch outer half............................................................................................................. 2
8 Plate - End................................................................................................................................ 1
9 Snapring................................................................................................................................... 1
11 Retainer - Spring...................................................................................................................... 1
12 Spring....................................................................................................................................... 1
13 Ring - Retainer.......................................................................................................................... 1
14 Bearing..................................................................................................................................... 1
15 Snapring................................................................................................................................... 1
16 Snapring................................................................................................................................... 1
17 Hub........................................................................................................................................... 1
18 Snapring................................................................................................................................... 1
19 Ring - Piston............................................................................................................................. 2
TE27/32 4 SD 03/2010 8-98

1st shaft gear GROUP TE32
1ST SHAFT AND GEAR GROUP
1
t
1s
GRP-TE32151 rev. 290502
TE27/32 4 SD 03/2010 8-99

1st shaft gear GROUP

1 Gear - Idler................................................................................................................................ 1
2 Assy - 1st speed clutch............................................................................................................. 1
TE27/32 4 SD 03/2010 8-100

TE32
OUTPUT SHAFT GROUP
Output shaft GROUP
3
4 19
6 18
17
20
16
8
14 10
13 11
9
12
15
7
GRP-TE32161 rev.290502
TE27/32 4 SD 03/2010 8-101

output shaft group
1 Shaft - Output........................................................................................................................... 1
2 Bearing..................................................................................................................................... 1
3 Bearing..................................................................................................................................... 1
4 Retainer - Oil............................................................................................................................. 1
5 Snapring................................................................................................................................... 1
6 Snapring................................................................................................................................... 1
7 “O” Ring.................................................................................................................................... 1
8 Seal - Output oil........................................................................................................................ 1
9 Cap - Bearing........................................................................................................................... 1
10 Plug........................................................................................................................................... 1
11 “O” Ring.................................................................................................................................... 1
12 Stud.......................................................................................................................................... 4
13 Lockwasher............................................................................................................................... 4
14 Nut............................................................................................................................................ 4
15 “O” Ring.................................................................................................................................... 1
16 Bearing..................................................................................................................................... 1
17 “O” Ring.................................................................................................................................... 1
18 Washer - Flange....................................................................................................................... 1
19 Locknut..................................................................................................................................... 1
20 Flange....................................................................................................................................... 1
TE27/32 4 SD 03/2010 8-102

Regulator valve group
TE32
REGULATOR VALVE GROUP
18
19
16
14
15
17
2
3
4 7
13
12
11
12
10
GRP-TE32171 rev. 240902
TE27/32 4 SD 03/2010 8-103

Regulator valve group

1 Assy - Valve regulator............................................................................................................... 1
2 Gasket - Valve to converter housing......................................................................................... 1
3 “O” Ring.................................................................................................................................... 1
4 Pump - Hydraulic...................................................................................................................... 1
5 Shaft - Gear to pump................................................................................................................ 1
6 Snapring................................................................................................................................... 1
7 Screw........................................................................................................................................ 2
8 Adaptor - Suction tube side...................................................................................................... 1
9 Adaptor - Suction transmission case side................................................................................ 1
10 Capscrew.................................................................................................................................. 8
11 Hose - Suction.......................................................................................................................... 1
12 Clamp - suction......................................................................................................................... 2
13 “O” Ring.................................................................................................................................... 2
14 Screw........................................................................................................................................ 8
15 Lockwasher............................................................................................................................... 8
16 Cap - Flange............................................................................................................................. 1
17 “O” Ring.................................................................................................................................... 1
18 Capscrew.................................................................................................................................. 4
19 Lockwasher............................................................................................................................... 4
TE27/32 4 SD 03/2010 8-104

control valve GROUP
TE32
GROUP-CONTROL VALVE
31
30
28
29
15A
6B
6A
9
16
1817
19
15B
2
2
25 6C
7
2 8
1 10
2
2
21
20A 12 11
13
14
20B
2
4 4
20C
22
24
23 5
27
3 26
32
GRPTE32184
TE27/32 4 SD 03/2010 8-105

control valve GROUP
1 control valve housing................................................................................................................ 1

2 Plug-expansion....................................................................................................................... 22
3 Plug-expansion......................................................................................................................... 3
4 Plug - Restriction...................................................................................................................... 4
5 Plug - orifice.............................................................................................................................. 1
6A Proportional valve forward/reverse........................................................................................... 1
6B Proportional valve 2nd/4th........................................................................................................ 1
6C Propottional valve 3rd/1st......................................................................................................... 1
7 O-ring........................................................................................................................................ 3
8 O-ring........................................................................................................................................ 6
9 Capscrew.................................................................................................................................. 6
10 Selector valve forward/reverse................................................................................................. 1
11 O-ring........................................................................................................................................ 1
12 O-ring........................................................................................................................................ 1
13 O-ring........................................................................................................................................ 1
14 O-ring........................................................................................................................................ 1
15A Selector valve 1st/3rd............................................................................................................... 1
15B Selector valve 4th/2nd.............................................................................................................. 1
16 O-ring........................................................................................................................................ 2
17 O-ring........................................................................................................................................ 2
18 O-ring........................................................................................................................................ 2
19 O-ring........................................................................................................................................ 2
20A accumulator spool forward/reverse.......................................................................................... 1
20B accumulator spool 2nd/4th ...................................................................................................... 1
20C accumulator spool 3rd/1st ....................................................................................................... 1
21 Pin-accumulator stop................................................................................................................ 3
22 Spring....................................................................................................................................... 3
23 Plug........................................................................................................................................... 3
24 O-ring........................................................................................................................................ 3
25 Sensor-valve pressure.............................................................................................................. 2
26 Plug........................................................................................................................................... 2
27 O-ring........................................................................................................................................ 2
28 Plug......................................................................................................................................... 10
29 O-ring...................................................................................................................................... 10
30 Lockwasher............................................................................................................................. 16
31 Capscrew................................................................................................................................ 16
32 Gasket...................................................................................................................................... 1
TE27/32 4 SD 03/2010 8-106

remote filter adapter GROUP
TE32
REMOTE FILTER ADAPTOR GROUP
13 11
4
14
12 9
10
3
8
4 7
6
2 10
9 11
14
12 13
GRP-TE32191 rev.290502
TE27/32 4 SD 03/2010 8-107

remote filter adaptor GROUP

1 Filter.......................................................................................................................................... 1
2 Adapter - Filter.......................................................................................................................... 1
3 Assy - Filter adapter body......................................................................................................... 1
4 Plug........................................................................................................................................... 1
5 Spool - Safety valve.................................................................................................................. 1
6 Plug........................................................................................................................................... 1
7 “O” Ring.................................................................................................................................... 1
8 Spring....................................................................................................................................... 1
9 Plug........................................................................................................................................... 2
10 “O” Ring.................................................................................................................................... 2
11 Cap - Flange............................................................................................................................. 2
12 “O” Ring.................................................................................................................................... 2
13 Capscrew.................................................................................................................................. 8
14 Lockwasher............................................................................................................................... 8
Note: 2 sets required
TE27/32 4 SD 03/2010 8-108

9 assembly instructions
TE27/32 4SD 03/2010 9-109

9 assembly instructions
10
3RD 4
3 FWD
11
3 REV 2ND 1ST
12
4TH
7
9
TE27/32 4 SD 03/2010 layout 32 9-110

assembly instructions
All lead-in chamfers for oil seals, pistonrings and 0-rings must be smooth and free from burrs. Inspect at as-
sembly.
Add some grease to 0-rings before assembly.
Add some grease to piston rings before assembly.
Apply a thin coating of grease between seal lips on lip type seals prior to assembly.
Use only precoated pipe plugs. On uncoated pipe plugs apply a light coat of Loctite© 592
Pump must be filled up with oil prior to assembly.
After assembly of parts using Loctite© there must not be any free or excess material which might enter the oil
circuit.
1 Apply a light coat of Loctite© 262 or 270 to all thru hole stud holes.
2 Teflon seals must be sized prior to assembly. Add some grease to seal diameter of clutch hub before
assembly.
3 Fwd and Rev Clutch

TE32 11 seperator plates with outer splines.
11 friction plates (friction material on both sides) with inner splines
Clearance Min 6.0mm [0.23in]

Max 6.4mm [0.25in]

8 friction plates (friction material on both sides) with inner splines.

Max 6.4mm [0.25in]
Choose an end plate with suitable thickness to obtain this clearance.

Caution
The seperator plates for Fwd and Rev and 1st and 2nd are not the same.
DO NOT MIX PLATES WITH PLATES FROM OTHER CLUTCHES.
4 1st Clutch

Max 4.75mm [0.19in]


Max 4.75mm [0.19in]
TE27/32 4 SD 03/2010 9-111

ASSEMBLY INSTRUCTIONS
5 2nd Clutch

Max 3.15mm [0.12in]


Max 3.15mm [0.12in]

6 3rd Clutch
TE32 12 seperator plates with inner splines.
11 friction plates (friction material on both sides) with outer splines
2 1-sided friction plates (friction material on one (1) side) with outer splines.

Max 3.9mm [0.16in]

8 friction plates (friction material on both sides) with outer splines.

Max 3.9mm [0.16in]

7 4th Clutch
10 friction plates (friction material on both sides) with outer splines

Max 3.5mm [0.14in]

10 friction plates (friction material on both sides) with outer splines.

Max 3.5mm [0.14in]

TE27/32 4 SD 03/2010 9-112

8 Be sure that shielded and sealed bearings are mounted as shown.
9 Seals must be pressed in perpendicular upon shaft axis from bearing side.
10 Tighten air breather to 31-41 Nm [25-30 Lbs.ft]
11 Tighten nut to 145-160 Nm [107-118 Lbs.ft]
12 Tighten nut to 339-407 Nm [250-300 Lbs.ft]
13 Tighten 2 coil nuts to 6.8-9.5 Nm [250-300 Lbs.ft]
14 Tighten 1 valve to 53-73 Nm [39-54 Lbs.ft]
15 Tighten 6 screws to 5-6 Nm [3.7-4.4 Lbs.ft]
16 Tighten 2 coil nuts to 6.8-9.5 Nm [5-7 Lbs.ft]
17 Tighten 2 pressure sensors to 7-11 Nm [5-8 Lbs.ft]
18 Tighten 2 valves to 34-36 Nm [25-27 Lbs.ft]
13 14
15
16 18
17
TE27/32 4 SD 03/2010 9-113

INSTALLATION INSTRUCTIONS FOR TE27/32 VALVE
Remove the valve
Refer to “Cleaning & Inspection” pages. The area around the valve must be clean and free of any foreign
material.
Unscrew 16 bolts (marked with hexagonals on the drawing) some turns. When all bolts are loose, you should
be able to move the valve. Replace 2 bolts by aligning studs. Remove the remaining 14 hex bolts and valve
from the transmission case.
Install the valve
Install 2 aligning studs. install new gasket and valve body.

Install 14 bolts and handtighten according to the number sequence on the drawing, replace the studs by bolts.
Now torque all bolts twice to 20-25 Nm [15-18Lbs.ft] in the correct sequence.
Recalibrate the transmission.
16 15
14 13
2 1 3
5 4
7
6
10 8 9
12 11
TE27/32 4 SD 03/2010 9-114

TE27/32 4 SD 03/2010 9-115

11 SPECIAL TOOLS
TE27/32 4 SD 05/2004 11-190

11 SPECIAL TOOLS
TE27/32 4 SD 05/2004 11-191

SPECIAL TOOLS
Bolt M10 x 40 Eyebolt M16
TE27/32 4 SD 05/2004 11-192

SPECIAL TOOLS
Bolt .4375-14 UNC-3B X 20

both sides
TE27/32 4 SD 05/2004 11-193

SPECIAL TOOLS
TYP
TYP
TE27/32 4 SD 05/2004 11-194

APPLICATION POLICY
Capability ratings, features and specifications vary depending upon the model type of service. Applications approvals must
be obtained from Spicer Off-Highway Products Division. We reserve the right to change or modify our product specifications,
configurations, or dimensions at any time without notice.
SPICER OFF-HIGHWAY PRODUCTS

Ten Briele 3
B-8200 Sint-Michiels
Brugge, Belgium
Revision : 2.8 - 6 feb 2009
00.50 S There is a problem related to the internal RAM (in Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Hardware related fault - related to in the internal Contact Spicer Off-Highway and inform the fault code and the time that is was
00.51 S There is a problem related to the system RAM (in Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Hardware related fault - related to in the system Contact Spicer Off-Highway and inform the fault code and the time that is was
00.52 S There is a problem related to the external RAM. Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Hardware related fault - related to in the external Contact Spicer Off-Highway and inform the fault code and the time that is was
0 RAM. active.
00.53 S There is a problem related to the Flash program Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Hardware related fault - related to in the flash Contact Spicer Off-Highway and inform the fault code and the time that is was
memory. 0 program memory. active.
21.00 S Pressure on sensor 1 too low for command. Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Supply pressure to transmission too low. Check supply pressure to the transmission. Log pressure when problem occurs.
0 Proportional solenoid stuck.
21.01 S Pressure on sensor 1 too high for command. Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting Supply pressure to transmission too high. Check supply pressure to the transmission. Log pressure when problem occurs.
30.04 S Power supply out of range -> below minimum Controller will save all logged information to flash, will Stop machine & Contact maintenance for troubleshooting Power supply to the controller too low: Check power supply cables to the controller. Check alternator, check the connection
powerdown, and force all outputs off APC200 12V supply version: < 9 V cables between the battery and the alternator, check the battery.
APC200 24V supply version: < 16V
30.05 A Power supply out of range -> above maximum The controller will have reduced proportional control accuracy Contact maintenance for troubleshooting Power supply to the controller too high: Check power supply, check if a jump start setup is still connected.
due to reduced PWM duty cycle APC200 12V supply version: > 18 V
APC200 24V supply version: > 32 V
of range -> below minimum below 7,2 V
of range -> above maximum above 8,8 V
01/04/2011 APC200 ECM-ECI Full Flow Error Codes ver2.8.xls Page : 1 of 16

40.06 A Invalid shift lever direction detected The controller will force neutral. Contact maintenance for troubleshooting The controller receives from the shiftlever a request Check the wiring between the controller and the shiftlever concerning the forward
to engage forward and reverse at the same time. and the reverse signal.
40.08 B Seat orientation input was changed while the The controller will force neutral. Stop the vehicle, put the shift lever in neutral and put the Seat orientation input was changed while the parking Check the seat orientation switch or train the driver to change the seat orientation
parking brake was not active, or/and the shiftlever parking brake on until the fault disappears. brake was not active, or/and the shiftlever was not in according to the correct procedure.
was not in neutral, or/and the machine was not at neutral, or/and the machine was not at standstill
standstill.
41.06 A Invalid shift lever position detected The controller will not allow range shifting, however driving is Contact maintenance for troubleshooting The controller receives from the shiftlever an Check the wiring between the controller and the shiftlever concerning the range
still possible. unknown range shift pattern. signals.
42.04 S/A The actual transmission ratio is too low. Controller will flag the fault - this fault is indicating that one or Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
more clutches are slipping. The controller will revert to shut more than 5% below the value of what is should be. Check the transmission ratio settings of the controller.
down mode
42.05 S/A The actual transmission ratio is too high. Controller will flag the fault - this fault is indicating that one or Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
more clutches are slipping. The controller will revert to shut more than 5% above the value of what is should be. Check the transmission ratio settings of the controller.
down mode
43.03 A The transmission converter out temperature sensor Controller will flag the fault. Contact maintenance for troubleshooting The converter out temperature sensor is not Check the wiring between the controller and the converter out temperature sensor.
is out of range. connected or shorted. Check the converter out temperature sensor.
43.07 A The transmission converter out temperature sensor Controller will flag the fault - in order to indicate the driver of Take notice of the fault, and try to bring the converter The controller measured a converter out temperature Check the converter out temperature and the converter out temperature sensor.
> 100° C. the warning level. temperature to a lower level. between 100° C and the allowed limit.
43.08 A The transmission converter out temperature sensor The controller is protecting the transmission and does not allow Stop machine, select neutral and apply full throttle (limited to The controller measured a converter out temperature Check the converter out temperature and the converter out temperature sensor.
> 120° C. that the converter out temperature exceeds its limit. The 50 %) in order to cool the transmission oil below 100° C above the allowed limit.
controller will force the transmission to neutral, and if engine is (until the fault 43.03 is gone). Once the converter out
controlled, the engine will be limited 50 % of its maximum temperature is below 100° C, continue driving the machine.
speed.
44.10 A No EEC2 message (throttle position from the The controller will flag the fault and the TSC1 message will Contact maintenance for troubleshooting No EEC2 message on the CAN bus when expected. Check engine controller and CAN connection to the APC200
engine controller) on the CAN bus when expected. send the idle possition to the engine controller.
45.06 B Invalid pattern for the reduced vehicle speed The controller will limit the vehicle speed to the reduced speed. Contact maintenance for troubleshooting Invalid pattern for the reduced vehicle speed Check the redundant reduced vehicle speed switches and the wiring connected
redundant digital inputs (2 inputs used). redundant digital inputs (2 inputs used) from these switches to the APC200.
46.05 A The transmission has exceeded the maximum torque The controller will open or close the inching clutch depending Release the inching pedal and cycle the shiftlever via neutral The transmission has exceeded the maximum torque Release the inching pedal and cycle the shiftlever via neutral back in the selected
during inching. of the GDE parameter selection. back in the selected direction in order to get drive again. during inching. direction.
47.00 B disengaged 4WD/2WD selector is stuck engaged, or Controller will flag the fault Contact maintenance for troubleshooting The mechanical actuator is stuck Check if digital output has its expected value and if the mechanical actuator has
to the controller.
47.01 B engaged 4WD/2WD selector is stuck disengaged, or Controller will flag the fault Contact maintenance for troubleshooting The mechanical actuator is stuck Check if digital output has its expected value and if the mechanical actuator has
to the controller.
48.00 B disengaged Low/High selector is stuck engaged, or Controller will flag the fault Contact maintenance for troubleshooting The mechanical actuator is stuck Check if digital output has its expected value and if the mechanical actuator has
to the controller.

48.01 B engaged Low/High selector is stuck disengaged, or Controller will flag the fault Contact maintenance for troubleshooting The mechanical actuator is stuck Check if digital output has its expected value and if the mechanical actuator has
to the controller.
50.00 S Analog input 0 (wire A11) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI0 is shorted to ground, or Check the wiring between the controller and the device connected to this analog
compensation
- pressure sensor: the controller will revert to shut down mode
50.01 S Analog input 0 (wire A11) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI0 is not connected, or Check the wiring between the controller and the device connected to this analog
compensation
51.00 A Analog input 1 (wire A28) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI1 is shorted to ground, or Check the wiring between the controller and the device connected to this analog
compensation
51.01 A Analog input 1 (wire A28) related fault : analog Depending on the function that is assigned to this pin: Contact maintenance for troubleshooting The analog input ANI1 is not connected, or Check the wiring between the controller and the device connected to this analog
compensation
compensation

compensation
compensation
compensation
54.00 A Analog input 4 (wire B02) related fault: analog input Controller will revert to shutdown. The controller uses the Contact maintenance for troubleshooting The reference power supply (5 V ref.) for the analog Check the refence power supply of the analog inputs ANI0, ANI2, ANI3, ANI5,
is shorted to ground. analog input ANI4 to have a reference power supply for the inputs ANI0, ANI2, ANI3, ANI5, ANI6 and ANI8 is ANI6 and ANI8.
analog inputs ANI0, ANI2, ANI3, ANI5, ANI6 and ANI8 below 4,8 V.
54.01 A Analog input 4 (wire B02) related fault: analog input Controller will revert to shutdown. The controller uses the Contact maintenance for troubleshooting The reference power supply (5 V ref.) for the analog Check the refence power supply of the analog inputs ANI0, ANI2, ANI3, ANI5,
is shorted to battery + analog input ANI4 to have a reference power supply for the inputs ANI0, ANI2, ANI3, ANI5, ANI6 & ANI8 is ANI6 and ANI8.
analog inputs ANI0, ANI2, ANI3, ANI5, ANI6 and ANI8 above 5,2 V.
compensation

compensation
compensation
compensation
compensation
compensation

compensation
compensation
failiure, or the engine speed channel has a failiure, the

61.05 S/A Speed channel 1 (wire A24) pulse count too high. This message is given as additional information for Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
62.03 S/A No engine speed information available. Controller reverts to a "limp home" mode Contact maintenance for troubleshooting No EEC1 message on the CAN bus for 200 ms. Check engine controller and CAN connection to the controller
J1939_SIGNAL_ERROR or
J1939_SIGNAL_NOT_AVAILABLE reported in
EEC1.
62.06 S/A No engine speed detected while turbine speed is Controller reverts to a "limp home" mode Contact maintenance for troubleshooting Speed sensor damaged, bad alignment between Check the transmission and speed sensor. Check speed sensor position.
measured sensor and measuring gear.
63.00 S/A Speed channel 3 (wire B11* or A27*) related fault: When only 1 speed channel has a failiure, and which is not the Contact maintenance for troubleshooting Speed channel SPC3 is shorted to ground. Check the wiring between the controller and the speed sensor connected to speed
speed channel is shorted to ground. engine speed channel, the controller will calculate what the channel 3. Check the speed sensor connected to speed channel 3.
* please refer to hardware technical leaflet of your missing speed should be. If several speed channels have a
APC platform failiure, or the engine speed channel has a failiure, the
63.01 S/A Speed channel 3 (wire B11* or A27*) related fault: When only 1 speed channel has a failiure, and which is not the Contact maintenance for troubleshooting Speed channel SPC3 is not connected. Check the wiring between the controller and the speed sensor connected to speed
speed channel is not connected. engine speed channel, the controller will calculate what the channel 3. Check the speed sensor connected to speed channel 3.
* please refer to hardware technical leaflet of your missing speed should be. If several speed channels have a
APC platform failiure, or the engine speed channel has a failiure, the

63.03 S/A Speed channel 3 (wire B11* or A27*) related fault: The controlller flags the error code. Contact maintenance for troubleshooting Speed channel SPC3 is not connected, or Check the wiring between the controller and the speed sensor connected to speed
speed measurement out of range measurement out of range channel 3. Check the speed sensor connected to speed channel 3.
* please refer to hardware technical leaflet of your
APC platform
63.04 S/A Speed channel 3 (wire B11* or A27*) pulse count This message is given as additional information for Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
too low transmission ratio faults. more than 5% below the value of what is should be. Check the transmission ratio settings of the controller.
APC platform
63.05 S/A Speed channel 3 (wire B11* or A27*) pulse count This message is given as additional information for Contact maintenance for troubleshooting The transmission ratio measured by the controller is Check the transmission, in order to understand if and which clutch is slipping.
too high transmission ratio faults. more than 5% above the value of what is should be. Check the transmission ratio settings of the controller.
APC platform
70.00 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "limp home" mode Stop machine & Contact maintenance for troubleshooting The output wires of the analog output 0 are shorted Check the wiring between the controller and the proportional valve 0 Check the
output wires are shorted to each other, or the sense to each other, or the sense line is shorted to battery +, proportional valve 0.
line is shorted to battery +, or the plus line is shorted or the plus line is shorted to ground
to ground
70.01 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "limp home" mode Stop machine & Contact maintenance for troubleshooting An output wire of the analog output 0 is not Check the wiring between the controller and the proportional valve 0 Check the
the output plus line is shorted to battery + connected, or its plus line is shorted to battery +, or proportional valve 0.
the proportional valve 0 is defect.
70.02 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting The currecnt of the analog output 0 is exceeding Check the wiring between the controller and the proportional valve 0 Check the
the output current exceeds 1400 mA or/and the 0 1400 mA. proportional valve 0.
70.03 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting The current of the analog output 0 is out of range. Check the wiring between the controller and the proportional valve 0 Check the
the output current is out of range, occurs when the 0 proportional valve 0.
load has the incorrect impedance
70.09 S Analog output 0 (wires A02 & A03) related fault : Controller reverts to a "limp home" mode Stop machine & Contact maintenance for troubleshooting The wire of the analog output 0 is not connected Check the wiring between the controller and the proportional valve 0 Check the
the output is not connected proportional valve 0.
71.00 S Analog output 1 (wires A04 & A05) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the The output wires of the analog output 1 are shorted Check the wiring between the controller and the proportional valve 1 Check the
output wires are shorted to each other, or the sense controller can control that range selection the machine will to each other, or the sense line is shorted to battery +, proportional valve 1.
71.01 S Analog output 1 (wires A04 & A05) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the An output wire of the analog output 1 is not Check the wiring between the controller and the proportional valve 1 Check the
the output plus line is shorted to battery + controller can control that range selection the machine will connected, or its plus line is shorted to battery +, or proportional valve 1.
drive, but in a "limp home" mode. If not, an other range gear the proportional valve 1 is defect.

71.03 S Analog output 1 (wires A04 & A05) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the The current of the analog output 1 is out of range. Check the wiring between the controller and the proportional valve 1 Check the
the output current is out of range, occurs when the controller can control that range selection the machine will proportional valve 1.
72.01 S Analog output 2 (wires A06 & A07) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the An output wire of the analog output 2 is not Check the wiring between the controller and the proportional valve 2 Check the
the output plus line is shorted to battery + controller can control that range selection the machine will connected, or its plus line is shorted to battery +, or proportional valve 2.
drive, but in a "limp home" mode. If not, an other range gear the proportional valve 2 is defect.
73.01 S Analog output 3 (wires A08 & A09) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the The +line output wire of the analog output 3 is Check the wiring between the controller and the proportional valve 3 Check the
the output wire plus line is shorted to battery + controller can control that range selection the machine will shorted to battery +, or the proportional valve 3 is proportional valve 3.
drive, but in a "limp home" mode. If not, an other range gear defect.

73.09 S Analog output 3 (wires A08 & A09) related fault : Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the The output wire of analog output 3 is not connected Check the wiring between the controller and the proportional valve 3 Check the
76.02 S Analog output 6 (wires B05) related fault : the Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 6 is exceeding Check the wiring between the controller and the device connected on the analog

76.03 S Analog output 6 (wires B05) related fault : the Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 6 is out of range. Check the wiring between the controller and the device connected on the analog
76.09 S Analog output 6 (wires B05) related fault : the Controller will flag the fault, but no actions will be taken. Contact maintenance for troubleshooting The output wire of analog output 6 is not connected Check the wiring between the controller and the device connected on the analog
77.02 S All proportional valve grounds are switched off due Controller reverts to a "shut down" mode and will force neutral Stop machine & Contact maintenance for troubleshooting One or more proportional valves have an ove current, Check the combined fault, and see the troubleshooting for that fault.
to an over current on one or more proportional 0 not that this fault will be combined with a 70.02
valves. and/or 71.02 and/or 72.02 and/or 73.02.
80.00 S Digital output 0 (wire A10) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG0 is shorted to ground. Check the wiring between the controller and the forward valve selector. Check the
shorted to ground controller can control that direction selection the machine will forward valve selector.
80.01 S Digital output 0 (wire A10) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG0 is shorted to battery +. Check the wiring between the controller and the forward valve selector. Check the
shorted to battery + controller can control that direction selection the machine will forward valve selector.
80.09 S Digital output 0 (wire A10) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG0 is not connected. Check the wiring between the controller and the forward valve selector. Check the
not connected controller can control that direction selection the machine will forward valve selector.
81.00 S Digital output 1 (wire A15) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG1 is shorted to ground. Check the wiring between the controller and the reverse valve selector. Check the
shorted to ground controller can control that direction selection the machine will reverse valve selector.
81.01 S Digital output 1 (wire A15) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG1 is shorted to battery +. Check the wiring between the controller and the reverse valve selector. Check the
shorted to battery + controller can control that direction selection the machine will reverse valve selector.
81.09 S Digital output 1 (wire A15) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG1 is not connected Check the wiring between the controller and the reverse valve selector. Check the
not connected controller can control that direction selection the machine will reverse valve selector.
82.01 S Digital output 2 (wire A16) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG2 is shorted to battery +. Check the wiring between the controller and the 1/3 selector solenoid + line. Check
shorted to battery + controller can control that range selection the machine will the 1/3 selector solenoid.

not connected controller can control that range selection the machine will the 1/3 selector solenoid.
83.00 S Digital output 3 (wire A20) related fault : output is Controller reverts to a "limp home" mode Stop machine, goto neutral and select back drive. If the Digital output DIG3 is shorted to battery +. Check the wiring between the controller and the 2/4 selector solenoid + line. Check
shorted to battery + controller can control that range selection the machine will the 2/4 selector solenoid.
not connected, or shorted to ground controller can control that range selection the machine will ground. the 2/4 selector solenoid.
90.xx - 99.xx S/B/H System Error. Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.01 S Gearpattern doesn't contain a direction Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.02 S duplicate direction pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.03 S duplicate gear pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.04 S duplicate bump pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.06 S digital input pattern faulty Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.07 S digital input pattern interferes with cab pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.08 S digital input: Neutral lock definition faulty Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.09 S duplicate digital input assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.10 S duplicate digital output assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.11 S Digital output selected on unsupported wire Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.12 S digital output pattern faulty Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.

92.13 S digital output selected on transmission wire Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.14 S error in speed sensor 1-2 assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.15 S error in speed sensor 3 assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.16 S duplicate speed sensor assignment Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.17 S invalid supply voltage selected Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.18 S duplicate analog input pattern Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
0 active.
92.19 S pressure sensor wires interfere with analog input Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
wires 0 active.
92.20 S wrong configuration regarding servo motor or brake Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
valve (on analog outputs 4-5-6) 0 active.
92.30 S wrong configuration regarding full flow selection Controller reverts to a "shut down" mode and will force neutral Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
and past digital error treatment 0 active.
95.71 S Data in the APC200 is not compatible with the data The controller reverts to a "shut down" mode and will force Download an APT file compatible with the active firmware Wrong APT file (data file) is in the APC200 Download an APT file compatible with the active firmware into the APC200
expected by the APC200 firmware neutral 0 into the APC200 (typically after APC200 firmware upgrade) If the error code still persists, the data flash may be corrupt (contact Spicer Off-
Highway)
90.90 S Wrong firmware is flashed into the APC200. The controller reverts to a "shut down" mode and will force Flash the correct firmware into the APC200 Wrong firmware is flashed into the APC200 Flash the correct firmware into the APC200
neutral 0
99.95 B CAN peak load detected : APC200 temporarily Controller will reply on the CAN messages which are available No action requested Overload of incomming CAN messages to the No action requested
could not process all incoming messages, due to an in its buffer. APC200
excessive peak of CAN requests.
93.10 S Initialisation of statistical data in flash memory, Controller will flag the fault, but no actions will be taken. Stop machine, restart controller Memory conflict in flash memory Reset controller
93.11 S Initialisation of logged error data in flash memory, Controller will flag the fault, but no actions will be taken. Stop machine, restart controller Memory conflict in flash memory Reset controller
xx.49 S Fault with undefined cause. Controller will flag the fault - action will depend on the fault. Contact maintenance for troubleshooting Software related fault. Contact Spicer Off-Highway and inform the fault code and the time that is was
active.
The codes listed below are Error codes that can only appear during autocalibration

Calibration code Explanation
E.1.XX Touch pressure Calibration
E.2.XX Optimise fill time
XX Type Explanation Controller's action Driver action Fault cause Troubleshooting
1->5, 7->9, 11->13, Unexpected Algorithm response during calibration. Stop calibration of clutch xx. Wait for continue request. List reported fault for clutch xx and request continue Engine does not respond to target engine speed. Continue calibration to identify if all clutches experience same problem. Download
15, 17-> 24 calibration. Vehicle started moving. Bad parameter correct parameter file and restart calibration. Check if vehicle starts moving during
configuration. calibration. Check engine speed response.
06 During calibration the turbine speed signal does not Controller will flag the fault and will abort calibration of clutch Driver can push S-button on APC200 to continue calibration Turbine speed does not reach minimum value during Measure clutch pressure to detect clutch leakage
rach a minimum value with error code shifting iteration process cuased by slipping clutch or Check speed sensor signal (can be in relation with 42.04 and/or 42.05 during
bad turbine speed signal. normal operation and with E1.26 during touch pressure calibration)
Check stall speed to detect slipping clutch
10 Transmission failure during calibration calibration is stopped Exit calibration Caused by shutdown error code during calibration Resolve cause of shutdown error code during calibration
Example: 20.60 error code during calibration
14 During calibration the turbine speed signal does not Controller will flag the fault and will abort calibration of clutch Driver can push S-button on APC200 to continue calibration Turbine speed does not decrause caused by too high Measure clutch pressure to detect clutch leakage
decrease with error code internal leakage and/or slipping clutch Check speed sensor signal ( must be in relation with 42.04 and/or 42.05 during
Bad turbine speed signal normal operation and with E1.26 during touch pressure calibration)
16 during calibration the turbine speed signal is too low Controller will flag the fault and will abort calibration of clutch Driver can push S-button on APC200 to continue calibration Faulty turbine speed sensor Check speed sensor signal ( must be in relation with 42.04 and/or 42.05 during
to start calibration with error code Sticking or burnt clutch with causes turbine drop normal operation and with E1.25 during touch pressure calibration)
before pressure is applied
25 Early touch detection during touch pressure Controller will flag the fault and will abort touch pressure Driver can push S-button on APC200 to continue calibration Too much drag because of thick oil Perform autocalibration at higher temperature (90-100°C)
calibration. Too much drag calibration of clutch with error code Sticking or burnt clutch with causes turbine drop Check speed sensor signal (must be in relation with 42.04 and/or 42.05 during
before pressure is applied normal operation)
Speed sensor problem Check and if necessary change proportional valve
Faulty proportional valve
26 No touch detection during touch pressure Controller will flag the fault and will abort touch pressure Driver can push S-button on APC200 to continue calibration Slipping clutch or too high internal leakage Measure clutch pressure to detect clutch leakage
calibration. calibration of clutch with error code Speed sensor problem Check speed sensor signal ( must be in relation with 42.04 and/or 42.05 during
Faulty proportional valve normal operation)
Check and if necessary change proportional valve

28 Turbine speed does not reach value = 0 rpm at end Controller will flag the fault and will abort release pressure Driver can push S-button on APC200 to continue calibration Slipping clutch or too high internal leakage Measure clutch pressure to detect clutch leakage
of closing phase of the touch pressure calibration calibration of clutch with error code Speed sensor problem Check speed sensor signal ( must be in relation with 42.04 and/or 42.05 during
Faulty proportional valve normal operation)
Check and if necessary change proportional valve
29 Turbine speed signal does not reach a high enough Controller will flag the fault and will abort release pressure Driver can push S-button on APC200 to continue calibration Too much drag because of thick oil Perform autocalibration at higher temperature (90-100°C)
value during release phase of the touch pressure calibration of clutch with error code Sticking or burnt clutch which causes turbine drop, Check speed sensor signal (must be in relation with 42.04 and/or 42.05 during
calibration. before pressure is applied. normal operation)
Speed sensor problem Check and if necessary change proportional valve
Faulty proportional valve
Exceed code Type Explanation Controller's action Driver action
E0.01 E The vehicle speed is too high to make the requested The controller will disable the downshift in order to protrect the The driver should slow down the vehicle, in order that the
downshift. transmission, until the vehicle speed comes below the requested downshiflt can be made.
downshift limit.
E1.01 E The vehicle speed is too high to make the requested The controller will not allow the direction change to protect the The driver should slow down the vehicle, in order that the
direction change. transmission and will place the transmission in neutral, until requested direction change can be made.
the vehicle speed comes below the direction change vehicle
speed limit.
E2.01 E The engine speed is too high to make the requested The controller will not allow the direction change or re- The driver should slow down the engine, in order that the
direction change or the requested re-engagement of engagement of the direction, until the engine speed comes requested direction change or direction re-engagement can be
the direction. below the direction change or the direction re-engagement made.
engine speed limit.
E3.00 E The reduced vehicle speed limitation is active. The controller is limiting the vehicle speed to the reduced No action is requested, the vehicle speed is limited due to
vehicle speed limit. request.
E3.01 E The reduced vehicle speed limitation is active, The controller is limiting the vehicle speed to the reduced The driver should slow down the vehicle, in order that the
however the vehicle speed is above the limit. vehicle speed limit, but detects a higher vehicle speed. vehicle speed comes below the reduced vehicle speed limit.
E3.02 E The vehicle speed is above the maximum vehicle The controller is limiting the vehicle speed to the maximum The driver should slow down the vehicle, in order that the
speed limit. vehicle speed limit, but detects a higher vehicle speed. vehicle speed comes below the maximum vehicle speed limit.
E4.00 E An abnormal decelleration is detected. The controller detected an abnormal decelleration, and will The driver should slow down, in order that the wheels can not
disable the automatiic shifting for a certain time. slip any more.
E4.01 E An abnormal accelleration is detected. The controller detected an abnormal accelleration, and will The driver should slow down the engine, in order that the
disable the automatiic shifting for a certain time. wheels can not spin any more.
E5.01 E Time in gear exceeded the time to recalibrate the The controller detected that the time in gear exceeded the time The driver should contact maintenance to recalibrate the
transmisson. to recalibrate the transmisson. transmission,
E6.00 E Operator is not seated with shiftlever not in neutral The controller detected that the operator is not seated with the The driver should take place in the operator seat and confirm
and/or the parking brake not activated. shiftlever not in neutral and/or the parking brake not activated. his presence (cycle the shiftlever through neutral and/or
release the throttle pedal)
E8.01 E Condition to change low high range selector not The controller detected that the machine is still driving. The driver should stop the machine
furfilled. Machine has to stand still.

E9.01 E Condition to change from 4wd to 2wd or visa versa The controller detected that the machine is still driving. The driver should stop the machine
not furfilled. Machine has to stand still.
Type Severity of Effect Level Discription
S High Severe warning Vehicle inoperable, with loss of primary function / Vehicle operable, but at reduced level of performance - customer dissatisfied.
A Moderate Warning Vehicle operable, but comfort / convenience item(s) inoperable - customer experiences discomfort.
B Low Info Vehicle operable, but comfort / convenience item(s) operable at reduced level - customer experiences some dissatisfaction.
H Very low Dana info Vehicle operable, defect not noticed by customer.
E None Exceed parameter info Driver is requesting an action, which is protected by the controller
Limp Home Mode
The GPOS / CPOS display indicates the letters ‘LH’ left of the direction/position indication
Defaulted to if either of following conditions occurs:
 a single fault on a transmission control output is detected
 a fault related to the engine speed sensor is detected
 two out of three vehicle speed sensors are in fault
If one of the above conditions is present, the transmission is put in neutral. In order to continue driving, neutral must first be selected on the shift lever. Once the shift lever has been put in neutral, the driver can re-engage a direction.
In this mode, the user can operate the transmission in either direction in 1st and 2nd only. If the fault occurs at a higher gear position, the user is allowed to shift down manually.
Note: On some transmissions, ratios normally not selectable are used to substitute those that can no longer be selected.
The controller uses default limits; all shifts use a default modulation curve.
Inching is disabled.
Shut Down Mode
The GPOS / CPOS display indicates the letters ‘Sd’ left of the direction/position indication
The ECM transmission control valve has a built-in redundant shutdown solenoid and a pressure switch that monitors the pressure controlled by that solenoid.
This solenoid is controlled by the APC200 using both a high side and a low side switch (again redundant logic).
When the APC200 enters shut down mode, all four pressure modulators are put at zero pressure AND both controlling outputs of the redundant shutdown solenoid are switched off
This mode is activated when a severe internal or external problem is detected.
In this mode, the transmission is forced in Neutral because the redundant shutdown path cuts off the hydraulic power to the clutches.
This mode is selected only if an intolerable combination of faults exists. In case of an intermitting problem, SHUTDOWN mode is exited and the controller enters the LIMP HOME mode.
However, in case the error is related to the pressure feedback signal, SHUTDOWN mode remains selected until the controller is switched off.
Also when a fault related to the parameter settings located n FLASH memory s detected, the controller reverts to shutdown mode
Pressure feedback sensor

If present, the pressure feedback signal is evaluated as an ON/OFF pressure switch, with internal resistance
of 2K ohm when open and 1K ohm when pressurized.
If resistance is substantially lower than 1K0, a SC condition is assumed.
If it's higher than 2K0, an OL condition is assumed

Service training
AXLE
Chapter 3
Ser vice Training
Service Page 1
3 TRUCK BOD
TRUCK Y
BODY
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Chapter 3
Page 2 Ser vice Training
Service
3.1 CHASSIS ASSEMBLY
The chassis assembly is of welded construction and has a number of sub assembly parts and covers
attached that provide access as illustrated.
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1 Access in chassis for main electrical power switch.

2 Access to batteries and central greasing pump (if fitted).
3 Access to electrical boxes including 3B6, CB14 (engine) and central greasing programer (if fitted).
4 Access to brake oil tank.
5 Access to the brake oil cooler unit.
6 Grill covering the brake oil cooler.
7 Grill covering the hydraulic oil cooler.
8 Access to the hydraulic oil cooler.
9 Demountable hydraulic tank assembly.
10 Sealed access cover to the hydraulic tank.
11 Access cover to the hydraulic tank and filters.
Chapter 3
Ser vice Training
Service Page 3
3.1.1 HYDRAULIC TANK ASSEMBLY.
The Hydraulic tank is removable and is height adjusted to match the chassis during manufacture. The tank
is a matched unit to the chassis and is not readily interchangeable between trucks.
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1 Hydraulic tank assembly. 12 Return from cooler motor and proportional valves.
2 Tank filler cap. 13 Temperature switch.
3 Tank to chassis mounting holes (6). 14 Switch, thermostatic cooler valve.
4 Height adjustment bracket (2) on chassis. 15 Low oil level switch.
5 Tank securing screws (2). 16 Hydraulic filter assy (2).
6 Height adjusting screws (2). 17 Low pressure return filter (1).
7 Feed outlet to working pump 1. 18 Breather Filter (1).
8 Drain plug. 19 Hydraulic tank mounting bolts (6).
9 Feed outlet to steer supply pump. 20 Sealed cover.
10 Feed outlet to working pump 2. 21 Oil level sight glass.
11 Return feed from control valve.
Chapter 3
Service
3.2 CABIN GLASS.
Removal and replacement of damaged cabin glass is often left to professional glazing service companies
but if circumstances force individual service organisations to complete this work themselves then it is
important that proper procedures are followed.
The next pages show the different types of glazing techniques in use and describe any special procedures
that may be advised when removing broken or cracked glass and fitting new.
Glass that is adhered to the cabin using silicon adhesive, as for example in the front screen of the cabin
is illustrated below.
1 Cabin front screen.

2 Silicon rubber adhesive.
3 Cabin Frame.
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This glass can be removed using the following procedure. C01. Register 05
Drill or cut a small hole or slot in the silicon adhesive (2).

Pass a cheesewire saw through the hole.
Saw around the outside of the glass(1) through the silicon (2).
Use a sharp utility knife to cut excess silicon off the cabin frame.
Clean the area using a proprietry cleaner.
It is not necesary to remove all trace of the existing silicon as the new silicon will adhere to the old without
difficulty.
Chapter 3
Ser vice Training
Service Page 5
3.2.1REPAIRING THE CABIN GLASS PANE
With adhesive tape With polyurethane glue

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Prepare and clean the new glass pane (1 ) and pane channel (2).
Remove any dust and other dirt in the bonding area of the window opening with a dry cloth. Do not use
solvents.
Cut the new window pane channel and drill a 3 mm hole for metal screw (3) 25 mm from each corner of
the channel.
Fit the channel to the glass pane.
Affix double-sided tape (5) (2 x 20 mm) or apply Purflex glue (5a) or a similar material 5 - 6 mm thick
continuously to the channel (2).
Remove the protective strip on the back of the tape, install the lower channel first in the frame (4) and press
the glass pane firmly against the frame.
Fasten the channels with metal screws (3).
Seal the inside and outside of the mitre sections, the outside of the channels on (6) with black Purflex
polyurethane. Apply transparent Purflex polyurethane or a similar sealant at (7).
The sealant is firm after 1 hour and completely dry after 12 hours.
Chapter 3
Service
3.2.2 REPAIRING THE CABIN WINDOW PANE (GLASS-TO-GLASS)
Affix crepe tape to the outside and inside of the new glass panes on both sides (not the edges).
Install the glass pane so that there is a gap of 1 - 4 mm at the inner edges.
Press transparent silicone sealant continuously into the joint from the top down, making sure that both joint
edges are fully covered. The silicone bead (1 ) should be about 8 - 10 mm thick.
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Smoothen the silicone bead within 10 minutes and eliminate any faults (commercial silicone remover).
After complete hardening of the silicone sealant (approx. 12 hours), remove the crepe tape.
Chapter 3
Ser vice Training
Service Page 7
3.2.3 REPAIRING THE CABIN WINDOW PANE WITH ALUMINIUM FRAME (SLIDING WINDOW)
NOTE:
Windows for direct bonding are provided with channels without fastening holes.
Prepare and clean the new glass pane (3) and channel (2).
solvents.
Install channel (2) to glass pane (3).
Affix double-sided tape (4) (2 x 20 mm) to the flange surface (4) of the channel.
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Remove the protective strip on the back of the tape and insert the glass pane into the door frame with the
lower side first.
Press the glass pane firmly against the door frame.
Seal the channel on the outside of the door frame with Purflex polyurethane sealant or a similar material.
Chapter 3
Service
3.2.4 REPAIRING THE ROOF WINDOW WITHOUT FRAME OR CHANNELS
solvents.
Affix a continuous piece of tape (diameter 6 mm) to the roof channel (3).
Remove the protective strip and position the roof pane above the opening and press on firmly.
The remaining joints can be sealed with silicone, if desired. Hardening time about 12 hours.
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Chapter 4
Ser vice Training
Service Page 1
4 STEERING SYSTEM
4.1 STEER AXLE TYPE L 101

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L 101
Axle type
Steer axle
Description
The rear wheels are steered by the action of a single double-ended, balanced hydraulic cylinder connected
to two fixed length track rods and the two stub axles.
Movement of the steering wheel actuates the steering control valve, which regulates the flow of oil to the
steering cylinder.
The oil is supplied via an engine-driven gear pump.
The axle housing is supported in the chassis by spherelastic bearings, which allow full articulation of the
axle when operating on uneven ground.
The steering cylinder is attached to the housing by four bolts.
The track rod link arms have bearings with seals pressed on each end and are connected to the piston
rod and stub axles with pressed-in bolts and roll pins.
These links have a fixed length and do not require adjustment to maintain correct tracking.
Chapter 4
Service
4.2 REMOVING AND INSTALLING THE STEER AXLE
STEER AXLE REMOVAL
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- Before removing the wheels, reduce tyre inflation pressure to under 5 bar.
- Loosen the wheel nuts (1) and clamps (2).
- Jack up the truck at the rear and support it securely.
(Use a jack with a minimum lifting capacity of 25 000 kg).
- Remove the rear wheels (3).
- Support the steer axle.
- Loosen and remove the fastening nuts, and drive out the bolts.
- Disconnect the oil lines at the shock valve or steering cylinder. (Place an oil pan underneath.)
- Lower the steer axle (4) slowly.
Replacing the rubber mount (5)
- Remove the circlips (6).

- Drive out the rubber mount bushings (5).
- Insert and drive in new rubber mount bushings (5).
- Install the circlips (6).
Chapter 4
Ser vice Training
Service Page 3
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steer axle installation
- Position the steer axle (4) on the truck frame and insert the bolts (7).
- Install the washers and nuts and torque them to 1050 Nm.
- Connect the oil line on each side.
- Bleed the steering system by turning the steering wheel several times through the full cycle.
- Mount the wheels.
- Lower the truck to the ground.
- Tighten opposite wheel nuts and clamps to 350 Nm.
- Inflate the tyres to 10 bar.
Chapter 4
Service
4.3 REPAIRING THE STEER AXLE - TO 09/99
NOTE:
The following services can be carried out without dismantling the steer axle from the truck.
This axle was fitted with preloaded king pin bearings and grease filled hubs.
4.3.1 RENEWING THE WHEEL BEARINGS
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1 Wheel hub 7 Seal

2 External tapered roller bearing 8 Thrust washer (curved washer)
3 Internal tapered roller bearing 9 Wheel hub nut
4 Ring 10 Wheel bearing dust cap
5 Stub axle 11 Locking screw
6 Spacer 12 Bushing
Chapter 4
Ser vice Training
Service Page 5
- Before removing the wheels, reduce the tyre inflation pressure to under 5 bar.
- Loosen the wheel nuts.
- Jack up the truck at the rear and support securely.
- Remove the rear wheels.
- Remove the cap (10).
- Wipe off any grease and remove the locking screw (11) and bushing (12).
- Loosen and remove the wheel hub nut (9) with special spanner 001 941 10 03.
- Drive out the wheel hub (1) from the inside out with a plastic mallet.
- Remove and renew the outer ring of the tapered roller bearings (2) and (3). (Press in the outer rings,
do not drive them in).
- Pull the tapered roller bearing (3) from the stub axle (5) and renew it.
- Drive out the radial seal ring (7) and clean the ring (4).
- If the ring (4) and the spacer (6) are damaged or worn, replace them as follows.
- Heat the ring (4) and drive it out of the wheel hub from the inside out.
- Remove any remnants of Loctite and clean the wheel hub (1).
- Coat the seat of the new rings (4) with Loctite 270 and press them into the wheel hub (1).
- Heat the spacer (6) and pull it off the stub axle.
- Remove any remnants of Loctite and clean the stub axle (5).
- Coat the seat of the spacer (6) on the stub axle with Loctite 572.
- Heat the spacer (6) to approx. 100 °C and drive it against the stub axle with light blows.
- Coat the radial seal ring size 180x215x15 (7) with Loctite 270 and press it into the ring (4) with tool
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000 941 10 03.

- Pack the radial seal ring (7) and wheel bearings 2 and 3 with roller bearing grease.
- Fit the wheel hub (1) on the stub axle (5) and drive in the bearing (2), install the thrust washer (8)
and screw in the wheel hub nut (9).
4.3.2 ADJUSTING THE WHEEL BEARINGS - TO 09/99
- Tighten the castellated nut (9) to approx. 1000 Nm.

- Hit the wheel hub (1) with a plastic mallet while turning it.
- Retighten the castellated nut, repeat the procedure until no further tightening is possible, then loosen
the nut by approx. 30° until the threaded hole in the thrust washer (8) is in line with the cut-out of
the nut (9).
- Coat the locking screw (11) with Loctite 270 and install it along with the bushing (12).
- Apply sealing compound to the wheel bearing dust cap and screw it tight.
Chapter 4
Service
4.4 STUB AXLE - TO 09/99
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1 Bolt 10 Stub axle

2 Cover 11 Tensioning element
3 O-ring 12 Set screw
4 Bearing 13 Self-aligning ring
5 Spacer 14 Spacer
6 Seal 15 Thrust washer
7 Thrust roller bearing 16 Bolt
8 Self-aligning ring 17 Cover
9 King pin 18 M20 bolt
Chapter 4
Ser vice Training
Service Page 7
4.4.1 REMOVING THE STUB AXLE - TO 09/99
- The truck must be jacked up and the wheel removed.

- Drive out the track rod pin and detach the track rod.
- Remove the two M6 socket head screws (12) at the self-aligning ring (13).
- Remove the silicone sealant and turn back the self-aligning ring.
- Remove the covers (2) and (17) and wipe away any grease.
- Drive out the bolt (16) and extract the thrust washer (15).
- Attach the wheel hub and stub axle (10) to a crane.
- Screw the M27 threaded spindle into the king pin and using threaded spindle 001 941 80 09 pull the
king pin (9) out with hydraulic puller 000 941 91 00.
- Pull the stub axle (10) out of the axle housing to the side.
- Take out the thrust roller bearing (7), spacer (14) and clamping ring (11).
- Drive out the top and bottom bearing (4) and spacer (5) from the inside out and remove them.
- Remove the seal (6) in the self-aligning rings (8) and (13).
- Clean all parts and inspect for wear and damage.
4.4.2 INSTALLING THE STUB AXLE - TO 09/99
- Place the seals (6) in the groove for the self-aligning rings (8) and (13) and coat with grease.
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- Install the bottom bearing shell and the cage of the thrust roller bearing (7) on the stub axle and pack
with grease.
- Press the top bearing shell (inside diameter is larger than the bottom bearing shell) of the thrust roller
bearing (7) into the axle housing (drive in).
- Insert the stub axle (10) into the axle housing and press or drive in the king pin (9).
- Pressing tool 001 941 80 18
- Driving tool 001 941 80 08
- NOTE: Before pressing in the pin, grease the holes and pins with Molykote paste or grease.
- Insert the spacer (5) and drive in the top bearing (4).
- Place the O-ring (3) into the groove of the cover (2), put the cover in place and fasten it with screws.
Torque the M20 screws (1) to 610 Nm.
- Slide the tensioning element (11) and spacer (14) onto the king pin from below and drive in the
bottom bearing (4).
- Using a jack, press the stub axle (10) upward until the thrust roller bearing (7) is free of play.
- Install the thrust washer (15) and clamp it by tightening the screws (16) of the tensioning element
(11).
- Torque the three M16 x 70 screws (16) to 310 Nm.
- Adjust the lower self-aligning ring (13) to a gap of 0.5 mm.
- Coat the 2 set screws (12) with Loctite 262 and screw them in to clamp the self-aligning ring in this
position.
- Remove the jack. Move the stub axle back and forth and hit on the stub axle with a plastic mallet
to seat the bearing, pin and tensioning element.
- Torque the screws to 310 Nm again.
- Place the O-ring (3) into the groove of the cover (17), put the cover in place and fasten it with screws.
- Torque the screws (18) to 610 Nm.
- Seal the self-aligning rings (8) and (13) with silicone.
- Lubricate the stub axle bearing with grease.
Chapter 4
Service
4.3.1 RENEWING THE WHEEL BEARINGS - FROM 09/99
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1 Adjusting ring 10 Grease nipple

2 Seal 11 Grub screw
3 Stub axle 12 Hub nut
4 B ush 13 Cover plate
5 Axle beam 14 Bolt
6 Thrust bearing 15 Lock screw
7 King pin 16 Lock washer
8 Bush 17 outer bearing
9 Plate 18 inner bearing
19 Seal
Chapter 4
Ser vice Training
Service Page 9
- Before removing the wheels, reduce the tyre pressure to under 5 bar.
- Loosen the wheel nuts.
- Jack up the truck at the rear and support securely.
- Remove the rear wheels.
- Remove the bolts (14) and cap (13).
- Wipe off any grease and remove the locking screw (15) and lock washer (16).
- Loosen and remove the wheel hub nut (12).
- Drive the wheel hub off from the with a plastic mallet.
- Remove the outer tapered roller bearings (17).
- Remove the seal (19).
- Remove the inner tapered roller bearing (18).
- Inspect the abutment ring under the seal for wear or damage, if it needs replacing proceed as follows.
- Split the ring with a cold chisel and remove it from the stub axle shaft.
- Clean any loctite residue from all area's.
- Apply loctite 570 to the srea of the stub axle where the abutment ring fits.
- Heat the abutment ring to 100°C and fit to the stub axle.
- Fit a new inner taper roller bearing (18) and seal (19).
- Fit the outer shell of the outer taper roller bearing(17) to the hub.
- Fit the hub to the stub axle, pack the bearing area with grease.
- Fit the outer bearing roller cage (17), the lock washer (16) and the nut (12).
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4.3.2 ADJUSTING THE WHEEL BEARINGS - FROM 09/99
- Tighten the nut (12) to approx. 1000 Nm.

- Hit the wheel hub with a plastic mallet while turning it to settle the bearings.
- Loosen the nut by approx. 30° until the threaded hole in the lock washer (16) is in line with the cut-
out of the nut (12).
- Coat the locking screw (15) with Loctite 270 and fit and tighten it.
- Apply sealing compound to the wheel bearing cover and screw it tight.
Chapter 4
Service
4.4 STUB AXLE - FROM 09/99
357 804 46 01. 0102

C01. Register 05
1 Adjusting ring 10 Grease nipple

2 Seal 11 Grub screw
3 Stub axle 12 Hub nut
4 B ush 13 Cover plate
5 Axle beam 14 Bolt
6 Thrust bearing 15 Lock screw
7 King pin 16 Lock washer
8 Bush 17 outer bearing
9 Plate 18 inner bearing
19 Seal
Chapter 4
Ser vice Training
Service Page 11
4.4.1 REMOVING THE STUB AXLE - FROM 09/99
- The truck must be jacked up and the wheel removed.

- Drive out the track rod pin and detach the track rods.
- Remove the wheel hub as described on page 5.
- Remove the covers and nipples (9) and (10) and wipe away any grease.
- Drive out the king pin (7) and extract the thrust washer (6).
- Attach the stub axle (3) to a crane or lifting device.
- Screw the M27 threaded spindle into the king pin and using threaded spindle 001 941 80 09 pull the
king pin (7) out with hydraulic puller 000 941 91 00.
- Pull the stub axle (3) out of the axle housing to the side.
- Drive out the top bush and spacer (8) and bottom bush and spacer (4).
- Remove the silicon sealant from the seal adjuster rings(1), loosen the grub screws (11) and unscrew
the rings, remove the seals (2)
- Clean all parts and inspect for wear and damage.
4.4.2 INSTALLING THE STUB AXLE - FROM 09/99
- Place new seals (2) in the groove of the adjusting rings (1).
- screw the adjusting rings (1) onto the stub axle top and bottom ensuring that the thread is good.
357 804 46 01. 0102
C01. Register 05
- Smear the outside of the top and bottom bushes and spacers (4 & 8) with Molybdenum assembly
grease and install them in position.
- Fit the bottom cover (9) and nipple (10) using loctite 270 sealant.
- Insert the stub axle (3) into the axle housing and fit the thrust bearing in position above it, press in
the king pin (7).
- NOTE: Before pressing in the pin, grease the holes and pins with Molykote paste or grease.
- Fit the top cover (9) using loctite 270 sealant and nipple (10).
- Adjust the bottom adjusting ring first to a gap of 1mm, lock it with the grub screw.
- Adjust the top adjusting ring to a gap of 1.3 mm, lock it with the grub screw.
- Seal the adjusting rings (1) silicone.
- Lubricate the stub axle bearing with grease.
Chapter 4
Service
4.5 STEERING CYLINDER
4.5.1 REMOVING AND INSTALLING THE STEERING CYLINDER
357 804 46 01. 0102

C01. Register 05
Removal
- Remove the roll pins (4) from the pins (3).

- Drive out the pins (3).
- Disconnect the hoses.
- Remove the four fastening screws (2) from the rear of the axle housing (1).
- Pull back the steering cylinder and pull both track rods (8) out at the stub axle.
- Remove the roll pins (6) from the pins.
- Press out the pins (3) with a hydraulic press and remove the track rods (8).
Chapter 4
Ser vice Training
Service Page 13
Installation
- Position the track rods (8) in the steering cylinder and press the pin (5) in with a hydraulic press.
NOTE
When pressing in the pin, ensure that the lubrication hole in the pin is in line with the lubrication
groove of the bearing.
- Drive in the roll pins (6) with a hammer.

- Put the steering cylinder (7) in position on the axle housing (1).
- Coat the four 30 x 220 - 8.8 screws (2) with Loctite 262, install them in axle housing and torque them
to 1450 Nm.
- Position the track rods (8) in the stub axle, drive in the pins (3) and secure them with roll pins (4).
NOTE
When driving in the pins, ensure that lubrication hole in the pin is in line with the lubrication
groove of the bearing.
- Connect the hydraulic hoses to the steering cylinder.

- Start the engine and bleed the system by turning the steering wheel several times through the full
cycle.
357 804 46 01. 0102
C01. Register 05
- Inspect the steering cylinder for leaks.

Chapter 4
Service
4.5.1.1 SEALING THE STEERING CYLINDER
357 804 46 01. 0102

C01. Register 05
1 Piston seal 8 Support ring
2 Guide ring 9 Eyebolt
3 Piston rod 10 Rod seal (lip seal)
4 Cylinder tube 11 O-ring
5 Cylinder head 12 Bordering
6 Guide ring 13 O-ring
7 Seal 14 Wiper
4.5.1.2 CHANGING THE STEERING CYLINDER SEALS SAH LEDUC CYLINDERS
Recognised by the end cap having "slots" for a C spanner.

- Fasten the steering cylinder on a workbench or a suitable support (clamp in a vice or fasten with
screws).
- Open the bordering (12) at the cylinder head (5).
- Using a suitable hook spanner, remove the eyebolts (9) from the cylinder tube (4).
- Withdraw the piston rod (3) and cylinder head (5) and inspect them for damage.
- Drive out the second cylinder head (5) from the inside out.
- Remove the seals from the cylinder heads (5) and clean the cylinder heads.
- Install new seals and apply a thin coat of grease.
- Renew the piston seal (1) and guide ring (2), apply a thin coat of grease and slide the piston rod into
the cylinder tube (4).
- Place the right and left cylinder heads (5) over the piston rod and into the cylinder tube (4).
- Renew the O-rings (11) at the eyebolts (9) and screw the right and left eyebolts (9) into the cylinder
tube.
- Torque the eyebolts (9) to 300 - 350 Nm and drive in the bordering (12).
Chapter 4
Ser vice Training
Service Page 15
4.5.1.3 CHANGING THE STEERING CYLINDER SEALS VAGGERYDS CYLINDERS
Recognised by the end cap having two "Flats" for a special spanner.
Disassembling
- Disassemble the bearing (head gland) from the tube. The thread is locked with Locktite and heating
to approx 175°C may be necessary to loosen the Locktite. A special spanner "A" must be used to
loosen the bearing.
- The same procedure is to be used for the second bearing.
- Disassemble the rod assembly from the tube by pulling it out, taking care not to damage the chromed
surface.
- Disassemble all seals, wipers and wear rings, take care not to damage the seal grooves.
- Clean all parts. Remove all Locktite residue.
- Inspect all parts for damage, rust or wear, especially the surface of the rod, the inner surface of the
tube and all seal grooves. Any fault must be corrected.
- If any part cannot be corrected it must be replaced.
Assembling
- Assemble new seals. Lubricate all seals with hydraulic oil before assembling.
- Assemble the rod into the tube. Taking care not to damage the piston seal.
357 804 46 01. 0102
C01. Register 05
- Assemble the bearing (head gland) onto the rod. Use the inserter tool "B" to prevent damage to the
seals.
- Apply Locktite 242 on the thread of the bearings. Make sure the thread of the bearings and the tube
are free from grease or oil before applying Locktite.
- Tighten the bearing carefully to the tube by using tool ”A”. Torque 500-1000 Nm depending on the
size of the cylinder.
Special spanner "A" Part number Tube/rod size.

0019418042 180/140
0019418043 200/160
Seal inserter "B"
0019418047 180/140
0019418048 200/160
A B
Chapter 4
Service
4.6 ADJUSTING THE STEERING STOPS
To prevent damage to the hydraulic steering cylinder, first inspect and adjust if necessary, the outer and
then the inner steering stops after repairing a stub axle, track rod or steering cylinder.
ADJUSTING THE OUTER STEERING STOPS
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C01. Register 05
1 Outer steering stop
2 Stop screw
3 Shims
X Specified dimension 609 mm
CHECKING THE STEERING STOPS
- Turn the wheels to the right or left until the outer steering stop screw (1) contacts the stub axle.
- Check dimension X at the steering cylinder (3) for 609 mm.
If dimension X is too large or too small, adjust the outer stops as follows:
- Raise the truck until the wheels of the steer axle are clear of the ground.
- Operate the steering cylinder until dimension X equals 609 mm.
- Adjust the stop screw (1) with shims so that dimension X equals 609 ± 0.5 mm when the steering
is operated (maximum pressure is reached) and the stop screw is adjusted correctly.
NOTE:
Always check and adjust both outer steering stops.
Torque loading for stop screw (1) is 180 Nm.
Chapter 4
Ser vice Training
Service Page 17
ADJUSTING THE INNER STEERING STOPS

357 804 46 01. 0102
C01. Register 05
1 Shims
2 Steering cylinder
CHECKING THE STEERING STOPS
- Turn the wheels to the right or left as far as the stop and until maximum steering pressure is reached.
- There should be no clearance between the stop screw and the inner steering stop.
- If the clearance is too large, remove the fasting nut, take out the stop screw and adjust the inner
steering stop with shims (1).
NOTE:
Always check and adjust, if necessary, both inner steering stops.
Torque loading for stop screw: 180 Nm.
Adjustment
of steer angle
stops.
Step 1. Adjust
stop until you get
dim X of the
steer cylinder. Step 2. Adjust
stop until there is
no clearance
between the
stop & the
adjuster screw.
X= 609mm.
This is different to training manual
A.P. FK3
Adjustment of steer
angle stops.
Typical examples of
steer cylinders when
the stops are not
correctly adjusted.
A.P. FK3
Chapter 4
Service
4.7 HYDRAULIC LOAD SENSING STEERING SYSTEM.
1 Linde load sensing hydraulic pump. 105 cc.

2 Danfoss proportional flow amplifier. Comprising of:-
2a Priority flow valve.
2b Combined valve flow switching unit.
2c Combined valve flow control unit.
2d Directional spool.
3 Danfoss Steer hand pump.
4 Cross line pressure relief valves.
5 Steering cylinder.
Description of operation.
Oil is supplied by the pump (1) into the flow amplifier valve (2) at the HP connection. Initial flow is into the
priority valve 2a where the oil is passed to into the steering system fully charging it to the stand by pressure
(34 bar) at this point no signal at LS is and a delta p condition at the LS valve sufficient to overcome the
pressure regulator on the pump opens a fill path at the swash piston, swashing the pump to "zero" supply.
Operation of a steering motion supplies a flow of oil to one end of the direction valve (2d), also permiting
an increase in LS system pressure operating the LS system to drain the swash piston, stroking the pump
357 804 46 01. 0102

C01. Register 05
to provide additional oil as required. Movement of the directional valve (2d) opens an oil path to the
combinaton valve (2b & C) causing the valve to open and permit a full flow of oil from the pump through
the combination valve, through the directional valve and onto the appropriate end of the steering cylinder
(5) providing the steering action.
Oil returning from the opposite end of the cylinder passes through the directional valve and back to the
hydraulic tank via the HT line.
At the end of the cylinder stroke when full pressure will exist in the system the LS signal will again destroke
the pump reducing the flow of oil to "zero". Excessive pressure spikes are unloaded by the LS safety valve
at 210 bar.
Excessive flows not required by the system are diverted at the priority valve either to assist general
hydraulic operation if required or directly back to tank if not.
The crossline pressure relief valve (4) protects the system in the case of an impact on a steering wheel,
oil pressure in excess of 260 bar will open the relief valve permiting oil to pass either to the low pressure
side of the cylinder or back to tank.
The steer hand pump (3) acts only as a directional signaling valve, little actual flow passes through the
steer valve but this is both guiding and augmenting the main pump flow through the amplifier.
Chapter 4
Ser vice Training
Service Page 19
4.7.1 STEERING HYDRAULICS CIRCUIT DIAGRAM
2d
2c
2b
357 804 46 01. 0102
C01. Register 05
3
2a
2
35 702 _0 4_0 2
Chapter 4
Service
4.7.2 FLOW AMPLIFIER VALVE
Flow detail.
Pilot flow.
Main flow.
Return to tank flow.
Description of operation.
When no steering motion is made the flow from the pump passes into the priority valve at HP and out at
EF. If no demand is being made on the pump by any other part of the complete system the pump will
destroke to the "zero" flow position.
On operation of the steer hand pump to turn right a pilot flow is input to to the direction control valve at
A. This flow feeds through the direction control valve end orifice to pressure area 13 to push the valve to
the right. The increase in pressure is seen also at the load sense port (4) to the pump, stroking the pump
to begin supplying oil to the HP port. The pilot flow also passes through the combination valve to the control
orifice 12 and 3 at each end of the valve at areas 9 and 3 and to the end of the priority valve closing the
357 804 46 01. 0102

C01. Register 05
EF port and opening the CF port to the combination valve. The balanced flow opens the combination valve
proportional to the amount the steer hand pump is being turned to allow the main flow from the pump to
enter the flow amplifier at HP passing through the combination valve and up to the directional flow valve
and out to the CR (cylinder right) flow out.
Oil returning from the CL (cylinder left) connection passes back through the open return port of the
directional control valve into the return to tank line.
When the steering motion is stopped the directional valve returns to the centre (neutral) position, the load
sense signal is lost and the pump will destroke to reduce the flow to zero. The priority steering valve will
close to provide any output from the pump to the EF port for auxiliary services.
Chapter 4
Ser vice Training
Service Page 21
O.S. Q FLOW AMPLIFIER VALVE.

357 804 46 01. 0102
C01. Register 05
Chapter 4
Service
4.7.2.1 FLOW AMPLIFIER VALVE, PRESSURE SETTING.
To adjust the steering pressure fix a gauge or pressure transducer

into the test point "1" on the flow amplifier or into the PS port on the
main control valve.
The plug on the pressure adjuster "2" must be removed to reveal

the adjuster threaded locking washer "3" and the adjuster "4".
1
To carry out the adjustment increase the engine revs to between 3

50 and 80% of maximum and operate the steering to full lock.
357 804 46 01. 0102

C01. Register 05
loosen the threaded locking washer and turn the adjuster to correct
the pressure. Adjustment of this unit is delicate and patience is
required.
4
DANFOSS FLOW AMPLIFIER VALVE
Pressure setting:
1. Fix a suitable gauge at test point.
2. Remove plug.
3. Loosen locking washer.
4. Turn adjuster to set correct pressure.
ENGINE RPM at 50 to 80% of max & operate the steering to full lock.
A.P. FK3
DANFOSS FLOW AMPLIFIER VALVE
Please note;
Do not adjust
this pressure
higher that 210
bar + standby
pressure
otherwise 260
bar valves will
open. This will
cause the pump
to remain at full
swash angle.
Resulting in
possible
overheating.
A.P. FK3
Chapter 4
Ser vice Training
Service Page 23
4.7.3 TROUBLESHOOTING THE OSQA FLOW AMPLIFIER
The following chat can be utilised to aid fault analysis.
ERROR CAUSE REMEDY
Too few steering wheel turns Dirty, leaky or missing check Renew or clean the check valve.
from stop to stop. valve (x).
Steering over reacting. Piston (x) stuck in open Dia assemble and check piston
position. movement.
Too many steering wheel

turns from stop to stop.
Piston (x) stuck in closed

Steering too slow. position. Dia assemble and check piston
movement.
357 804 46 01. 0102
C01. Register 05
Prolonged hard point when Dirty orifice in directional Clean or replace orifice.
beginning to turn the steering spool.
wheel. Dirty orifice in combined
valve.
Amplification is delayed and Dirty orifice in OSQ housing.
sets in suddenly. Dirty orifice in LS inlet port.
Blocked check valve external
PP port.
Blocked spool check valve in Clean or replace valve.
external PP port.
Spool/sleeve tight in housing.
Steering wheel can be Setting of shock valve too Adjust the setting.
turned rapidly. low.
No end stop feeling.

Chapter 4
Service
ERROR CAUSE REMEDY
Steering wheel can be Leaky or hanging suction Dismantle the suction valve and
turned rapidly. valve. renew if necessary.
No end stop feeling. Missing end stop in directional fit end stop.
valve.
Insufficient force to turn the LS relief valve set too low. Adjust pressure setting.
steer wheels when
stationary. Spool and sleeve fitted Strip and re assemble correctly.
incorrectly, no LS pressure
can be built up.
Spool and sleeve worn. Replace the assembly.
357 804 46 01. 0102

C01. Register 05
4.8 DANFOSS STEER HAND PUMP TYPE OSPB 200 LS
The steer hand pump mounted on the steering column provides both a directional flow signal to the flow
amplifier and one quarter of the eventual flow to the steer cylinder. It also provides the LS load sensing
signal to the hydraulic pump to instigate increased pump output. The unit is generally trouble free and
requires special tools to repair. The unit is also "timed" during assembly, if the timing is altered the unit
will not function correctly.
Chapter 4
Ser vice Training
Service Page 25
1 Wiper seal 13 Bolts

2 Matched components 14 Special bolt
3 Check ball 15 Aluminium washers
4 Screw insert 16 End plate
5 Special 2 piece seal 17 Gear set O rings
6 Thrust bearing 18 Gear set
7 Location ring 19 Distribution plate
8 Inner direction spool 20 Distribution plate O ring
9 Driving pin 21 Cardan shaft
10 Outer direction spool 22 Check valve
11 Centring springs 23 Valve body
12 Data plate
4.8.1 DANFOSS STEER HAND PUMP, OPERATION
There are five ports in the pump, viewed directly at the face in which the ports are located these are
Bottom left Pump feed in

Top left return to tank
Bottom right Feed to right turn
Top right Feed to left turn
357 804 46 01. 0102
C01. Register 05
Right side of body LS port
Hydraulic oil at stand by pressure is fed into the pump and passes into and through the outer and inner
spools, up the centre of the spool and out of the holes in the top of the spools adjacent to the return to tank
port and directly back to tank. When a steering motion is made, rotation of the inner spool against the
tension of the leaf spring pack will allow the inner spool to rotate off neutral in relation to the outer spool
to a limit set by the driving pin, this selects the direction of steer. An LS signal is also sent to the hydraulic
pump to increase output as required. Continued rotation of the inner spool by the steering wheel will start
to rotate the outer spool by the driving pin. The driving pin also drives the cardan shaft which drives the
inner gyrotor gear of the gear set. The path of the oil is now blocked from passing through both spools to
the tank, instead it flows through galleries to the gear set where the pressurised oil is pumped back up
through galeries in the spool that align with the turn outlet port, either left or right dependant on which way
the spool is being rotated. Oil returning from the cylinder will pass through newly aligned galleries in the
spools, into the spools centre, up the centre of the spools and out of the return to tank galleries back to
tank.
When the steering motion is stopped the leaf springs will rotate the outer spool back to neutral inrelation
to the inner spool and flow to the cylinder wil cease.
It is possible to reseal the pump should a leak occur, a seal kit is available through the parts division. A
special tool, part number K068-118-000 is available. This tool must be used to insert the special two piece
seal and wear ring into the neck of the valve body.
Caution
The steer hand pump must be timed on assembly, failure to do so could lead to serious
damage to the unit or possible injury to the user. If in doubt do not attempt disassembly.
When the steer hand pump is stripped great care must be observed, do not handle
components more than is necessary, store all components in clean hydraulic oil while the unit
is disassembled. It is advantagious to handle the components only while wearing disposable
gloves soaked in hydraulic oil. The accuracy and finish of componets is such that careless
handling with bare hands will damage them.
Chapter 4
Service
4.8.2 DANFOSS STEER HAND PUMP, ASSEMBLY TIMING.
CAUTION
The steer hand pump must be timed on assembly, failure to do so could lead to serious
damage to the unit or possible injury to the user. If in doubt do not attempt disassembly.
During assembly the alignment of the driving pin, it's relationship with the gear set gyrotor and the port
face are critical. The illustration below indicates this relationship.
The spool must be assembled and fitted with the pin (2) at 90 degrees to the port face of the pump(1) as
illustrated by the arrow (3).
The gyrotor of the gear set must then be fitted so that two of the lobes (4) are parallel with the port face
(1) as illustrated by the lines (5).
357 804 46 01. 0102

3
C01. Register 05
2
5
4
1
35702_04-06
4.8.3 DANFOSS STEER HAND PUMP,TROUBLESHOOTING.
The following chat can be utilised to aid fault analysis.
ERROR CAUSE REMEDY
No steering function Oil flows directly back to tank Manual steering ball is missing.
within the steering unit
Chapter 4
Ser vice Training
Service Page 27
ERROR CAUSE REMEDY
Short hard point when Air in the LS and PP lines. Bleed the lines.
beginning to turn the steering
wheel. Initial spring compression in Fit a stronger spring in the priority
the priority valve in OSQ set valve.
too low.
Clogged orifice in LS and/or Clean the orifices.

PP lines in OSQ unit
Short hard point when Air in the LS and PP lines. Bleed the lines.
beginning to turn the steering
wheel. Initial spring compression in Fit a stronger spring in the priority
the priority valve in OSQ set valve.
too low.
Clogged orifice in LS and/or Clean the orifices.

357 804 46 01. 0102
C01. Register 05
PP lines in OSQ unit
Heavy steering Insufficient oil or oil pressure. Attend to the hydraulic pump.
Relief valve set too low or Reset or replace the valve.

faulty.
Blocked LS orifice or tight Remove and clean all units.

spools in OSQ. Check filtration.
High auxiliary pressures Contact Technical support at

acting on EF port. Linde HTD.
Misplaced anti cavitaion ball. Re position the ball.
"Motoring" The steering Faulty, weak or brocken leaf Replace the springs.
wheel turns by itself. springs.
Tightness between spools Contact Technical support at

Linde HTD.
Temporarily lower relief valve
settings.
Chapter 4
Service
ERROR CAUSE REMEDY
Repeated steering Leaf springs weak or broken. Replace leaf springs.

corrections required.
Steering column out of Correct column alignment.
Steering will not go to neutral alignment with steering unit.
position.
Steering column lacks Increase clearance.
Steering to left or right clearance with steer unit.
without wheel movement.
Steering column binding. remove cause.
Backlash in steering Splines of the cardan shaft Replace cardan shaft.

worn or broken.
Leaf springs weak or broken. Replace leaf springs.
"shimmy" Can be caused by a course
357 804 46 01. 0102

C01. Register 05
abnormal vibration of tyre pattern.
steering wheel.
Air in system. Bleed the system.
Worn mechanical links and Replace worn parts.

wheel bearings.
Leaking dual shock valves, Repair or replace the valves.

suction valves.
The steering wheel can be No oil supply. correct cause

turned continouosly without
turning the wheels. Steer cylinder seals Repair or replace the cylinder.
bypassing.
Shock valve failure. Repair or replace the shock

valves.
Steering will turn to full lock Shock valves set to the same Adjust pressures.
position but steer wheel can pressure as the system relief
coninue being turned. valve.
Contamination of shock Clean or replace shock valves.

valves.
Chapter 4
Ser vice Training
Service Page 29
ERROR CAUSE REMEDY
Heavy impacts on steering Incorrect timing of unit. Re set the timing.

wheel in both directions.
Kick back in system. Missing external check valve Fit valve.

in P line to OSQ unit.
impact from wheels. Contamination of OSQ valve Overhaul and clean valve.
spool.
357 804 46 01. 0102
C01. Register 05
Chapter 4
Service
357 804 46 01. 0102

C01. Register 05
Service training
Electric Wiring Diagrams

24v (BAT +) :60
24v (BAT +) Isolator :30
Aircon clutch X105 pin 6 Pg10: (764)

24v (IGN +) Isolator :15
FM2
C1
24v (IQAN +) E/S :45
120A 24v (IQAN +) E/S :28
F9
X10B F1 30A S5
30A
B19
F17 F34 F21 F18 F19 K16 Pin 4 Pg1: (30) F20 F33
5A 3A 20A 10A 10A 5A 5A
X97
X4 IQAN XS2-A1 Pin 9

Pg3: (180)
IQAN XS2-A1 Pin 11 Pg3: (163)

X10B X10A
R32
K1 K8
FM1 S1 30
1A
S1
50A
S2 15/54 X10A
S1-A
XT2-A0 Pin 7 Pg4: (249)
K16 X1
10 1
11
X2A X10B Pin 5 Pg1: (64)
4
K15 X1 X4
12 14 13 9
S3
XS2-A1 Pin 6 Pg3: (196)
OEM2
Cummins engine QSM Tier3 DANA CLARK

Management System TE27 TRANS
+
-
B4
G2
B+ I+ B+ EX B3
G
+24V
M1 G1 3
X9
S4
GND GND
+
OEM1
Y37 M9
-
Chassis Ground 0v
1
F3
15A
+BAT
Non harness wiring

(D
INPUTS
O (
O D
S34
S33
R IN
-BAT OUTPUTS
SW -
T
IT )
C
H)
Cab floor ground 0v

(S
+24v Ign & E/Stop (28)
LH
RH
(D PR
E
(S O U A
P T D
X88
AR -
A ER (D
(D E) ) LO IN
C -S
(S O U (S KE )
Linde engine harness

P T D
AR - PR )
E
E) B) A
(
D D
ER
(
H9 H10
(S O U UN DI
P T -L N -
AR -
C O R
C )
(D E) ) KE
D
(S O U )
P T
AR -
(D E) D)
Chasis harness
( O
SP U (L
AR T- G
X93
E) E) S (D
(D U IN
N
( O
SP U CL -Q
AM )
AR T-
S56
F P)
(D E) ) (L (D
O
(S U G IN
P T S
AR - C -P
G )
Cab harness
LA
(D E) ) M
P)
(S O U
P T
AR -
H
(D E) )
(S O U
P T
AR -
I)
(D E) (R
EA (D
(S O U R IN
P T LG -O
AR -
(D E) J) S )
U
S57
(R P)
(S O U EA
P T
AR - R (D
K LG IN
(D E) ) S -N
DW )
(S O U N)
P T
AR -
E L) )
(F
R (D
NT
LG IN
S -M
UP )
S58
(F )
R
NT (D
LG IN
S -L
D )
W
N
)
X94
(-V
R
(+ EF
5V )
3A
RE
ILF2
F)
(S (V
R IN
EA
DE -A
R )
JS
(S )
R (V
N2
EA IN
DE -B
JS-6
R )
JS
)
B31
(S (V
R IN
EA
DE -C
Drawn
R )
(S
M.check
R (V JS)
EA IN
(D DE -D
IN R )
Auxillary dim .
Date
Inspection dim.
-G JS
16016
) (J )
S
JS-10
PB
(
1)
Confidential document
(D
Refer to protection notice ISO
IN
Name
Auth'd 24.03.09 A PAULY
-
)
HEAVY TRUCK DIVISION

20.03.09 G J REES
Checked 23.03.09 P HARLING
(D F) (
IN JS
Drawing number
Repl.
(D -H) PB
IN (JS 2)
S:
A:
-I) P
(J B 3
Date
(D S )
Title:
13.10.08
IN PB
MDL Pin 27 Pg:6 (470) (C (D -J
A IN ) (J 4)
MDL Pin 41 Pg:6 (470) (C N-H -K S
AN ) ) (J P B
S 5
(C -L) PB )
XS2-A1 Pin 27 Pg:3 (232) (S
R
P HARLING
6)
Checked
AN EA
(C -H DE
XS2-A1 Pin 41 Pg:3 (234)
IQAN-XS2-(A0) CAB FRONT Address resistor
AN ) R (V
PR IN
-L O -E
) (A (A P )
357 802 0261
R
O
DD DD
R R T)
-H -L
)
Orig.
CAN-bus
)
MK5 Re-issue
357 MK5
PB6
PB5
Alteration
PB2
PB3
PB4
ELECTRICAL SCHEMATIC
PB1
XS2-0
R21
A3
of 19
NONE
Page:
T10985
Scale:
Change No
+BAT
F4
15A
(D
(Ig IN
n
sw-B
S1
)
Pg1: (28)
( )
(S DIN
ea -
-BAT
ts M
INPUTS
w )
Non harness wiring

1
( )
(S DI
ea N
t s -N
w )
S7
2
X108
OUTPUTS
Cab floor ground 0v

(D
+24v
( U OU (P
ar (D
PA T k IN
O -E br
a
/P )
) ke -A
sw)
S8
Linde engine harness

K4
CBFB
(D
( R OU (P
ev T ri n
er -A
se ) tc (
om DI
lig
ht
N
m -G
s
X110
an
)
Chasis harness
d )
pb
)
K8
( D
I
(U N -
(D PA H)
(B O 3
r a UT )
ke -B
co )
ol
er
)
Cab harness
K9
(D
O (2 ( D
(H U 0' IN
or R -
n
T- et J
r e C) ra )
la ct
S10
y )
) (4
0' ( D
Ex IN
te -
ns I)
io
n
K10
)
(D
(
O
U U
PA T-
/p D
ro )
g
lig (3
ht O (
) '/
35 DIN
'S -
to S)
(3 p
O in
S11
(D '/
35 ( D )
(IG OU ' S IN
to -
N T p T)
SW -K ou
IT ) t)
C
H
O
FF
K16
)
X105-A
(D
(E O U
N
G T- (P ( D
R J ow I
PM ) er N -
) sl K
op )
e
S12
)
X108
(P ( D
ow IN
er -L
N3
sl )
B7
op
e
(D )
BUZZER
( W OU
ar T
ni -F
ng ) (T
bu lc
zz k s
er un
) lo
ck (
ve DI
rt N -
B8
(T lif Q
lc to )
(D k s
S13
pt
lo )
BUZZER
(A O ck (
la UT
rm - ve DIN
G
bu ) rt -
lif R
zz to )
er pt
) )
(D
Drawn
( R OU
M.check
ES T (D
ET -H (J IN
ac -
S20 Pg: (236)
P/ )
B
Auxillary dim .
k s C)
Date
Inspection dim.
LA up
S18
)
16016
M
P
) (J ( D
ac IN
(D
(
ks -
( O
R U
d w D)
E A T- n
R L )
Name
A )
Auth'd 24.03.09 A PAULY
)
U
20.03.09 G J REES
Checked 23.03.09 P HARLING
TO
/M
Drawing number (D AN
IQAN-XS2-(A1) CAB (FUSEBOX)
W
Repl.
( T OU
O T IP
S:
A:
P - ER
A I)
U O
/P
Date
TO
) (D
Title:
13.10.08
/M (C IN
A
S30 Pg:11 (842) S31 Pg:11 (864)
ab -
N
W Fw E)
IP d
)
S19
ER
XS2-A0 Pin 27 Pg: (152) (C
O
A /P
(D
) (C IN
XS2-A0 Pin 41 Pg: (152) (C N-H (S a b -F
P HARLING
Checked
AN ) pr
ea R )
ev
d )
XT2-A0 Pin 27 Pg: (312)
(C -L) er (
ov DI
X94
AN
er N
id -P
(C -H e
357 802 0261
XT2-A0 Pin 41 Pg: (314) pb)

AN ) (O
-L / ri ( )
Address resistor
) (A (A de D
I
Orig.
MK5 Re-issue
X10C
DD ke N -
y O
DD
OVERIDE
R R sw )
357 MK5
-H -L )
)
CAN-bus
)
S20
Alteration
Cab floor ground 0v
ELECTRICAL SCHEMATIC
R24
X94
XS2-1
S21
A3
of 19
NONE
Page:
T10985
Scale:
Change No
+24v Ign & E/Stop (28) +24v Ign & E/Stop (28)
+24V
Ω
F6
Ω
X51 R4 R5
20A
X10C R9 ILF3 S54 S55

R12 R8 R10 R11
3A
X11
bar bar bar bar bar R6 R7
S14 PLT
SP
SP X-SPARE
2)
)
)
)
1)
+BAT INPUTS
lt )
SU J)
F)
p)
l l -I)
U )
RE
O )
er
F)
2)
el
1)
O )
)
TO )
lf )
o i -H
2 -C
TO )
-E
-D
-B
T -G
o i -A
em
T -F
ev
M
ilt
P)
ES N-
RE
P
ue I N
P
P)
RE
IN
IN
CK IN
IN
IN
IN
IF IN
IF IN
U
TT
I
TT
( F (V
(V
(-V
(V
(V
(V
1
(V
(V
(V
(V
(V
5V
O
O
CK
ke
PR
ke
B
B
A
ra
(L
(+
(L
A
ra
T
T
(J
T
(J
(B
IF
IF
(B
O
(L
(L
IL
(P
L)
R-
IQAN-XT2-(A0)
D
N4 CHASSIS LEFT
D
Address resistor
(A
H)
)
R20
R-
ly
ly
)
pp
pp
C der+) pply
D
)
pl
id
su
su
D)
V)
D
A) up
no
)
su
ay
FW
RE
(A
op
op
T - op s
le
el
p
so
pr
pr
B
tr
ro
s)
a )
CA
N )
pr
CA
G )
e )
ar
lig )
VI -C
R er p
b
ke
-)
)
O cab
D
in -F
ht
d )
)
ke -E
in B+
g )
B)
ca
A )
A )
ea -A
B-
)
st
T-
-A
(C -L)
ea -A
in B
T-
(C N-H
(C -H
-L
G
ng T
O T
ra T
br
ov T -
T-
g
T-
U
pr T
ov T -
(E OU
(M OU
ET
pr T
U
N
(B OU
N
d
(S U
U
VI
O
(S E
U
O
E
an
(M E
A
O
O
O
R
-BAT OUTPUTS
(D
CAN-bus
(D
(D
R
(D
(C
(D
(H
(M
(M
C
C
C
C
C
XT2-0
X2A
XT2-A1 Pin 27 Pg:5 (390)
XT2-A1 Pin 41 Pg:5 (390)

SP
Pg8: (636)
XS2-A1 Pin 16 Pg: (232)
XS2-A1 Pin 30 Pg: (234)

K15 Y3 Y1 Y2 E3 E4 Y13 Y10
K1 Pg: (14)
Chassis Ground 0v Chassis Ground 0v
Inspection dim.
Auxillary dim . ( )
13.10.08 P HARLING MK5 Re-issue T10985
Date Name Date Checked Alteration Change No
Drawn 20.03.09 G J REES
Checked 23.03.09 P HARLING Title: 357 MK5
Auth'd 24.03.09 A PAULY ELECTRICAL SCHEMATIC
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 4
A: of 19
Non harness wiring Linde engine harness Chasis harness Cab harness Repl. Orig.
16016
A3
+24V
F7 R18
20A
Ω
Ω R17
X10C S16
S15
S52 S53
X11
x cm
bar bar R23 S17
LS P t x°
5 sec
°C R13 R14
X-SPARE
L)
1)
2)
+BAT INPUTS
SU J)
SU -I)
1)
)
)
LE H)
2)
)
M )
TH )
G C)
)
)
F)
TH )
)
F)
RE
-D
-F
N
NG -A
RE
TE -G
-E
VE
NG -B
N
)
LE
LE
ES N-
DW
ES IN
DW
-
RE
ANN -
RE
IN
IN
IN
IN
LE I N
LE I N
IL N
G
I
PR (V
I
AN
2
(V
O VI
(V
IL
(V
(V
(V
(-V
(V
(V
(V
K
K
5V
O
C
C
(
M
M
PR
A
A
M
K
O
O
(+
(J
(J
N
O
YD
O
O
(P
TA
S
(B
(B
(B
(L
(H
(B
YD
(H
L)
R-
IQAN-XT2-(A1T) R19
D
N5
D
Address resistor
(A
H)
CHASSIS RIGHT
E)
R-
LV
D
VA
D
e)
e)
(A
L
lv
lv
e)
O
e)
e)
e)
TS
va
va
e)
TR
lv
e)
lv
lv
lv
N)
op +)
pr +)
)
lv
va
va
lv
va
op )
DO
va )
W )
va
U
S C)
op
op )
op )
S E)
op
op )
N
pr -B-
P)
pr )
op -
O -D
W
P )
va
p r -B
p r -B
p r -A
pr B
er -A
er -A
p r -A
TP
M A
A )
O
A )
)
(C -L)
U
(C N-H
D
CK T-
(C -H
-L
CK T-
-
IL T
C
U -
XT T
ET T
T
XT T
ET T
ow T
ow T
ft T
U
(P W M
(P OU
T
N
(E U
N
(R OU
(li U
(E E
(R RE
(L RE
(li RE
(L OU
O
A
O
A
R
O
-BAT
A
CAN-bus
ft
A
(D
(D
(P
(C
(C
(C
(D
(C
(C
(C
(C
(C
(J
(J
(
XT2-A1
X-SPARE
XT2-A0 Pin 16 Pg: (314)
XT2-A0 Pin 30 Pg: (316)

Y5 Y6 Y7 Y8 Y4 Y9 Y38 Y39
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 5
A: of 19
16016
A3
24v (IQAN +) E/S :28 + 24v + 24v
+5v +5v
24v (BAT +) :60 24v (IQAN +) E/S :28
0v 0v
R1-A
F2 S22
15 15
X104 R1 R26 R3 R2
F8
15A S6 ILF1 R1-A
3A 3A
R
F 13 21
R1
1
R31 N 2
3
4 bar bar
R F 14 22 (S25 Pg:11 (830)
1 2 3 4 S22 (S25 Pg:11 (830)

KD 53B 53 31B J F R
+RTC
INPUTS
+BAT
)
IN )
T)
(DIN-D)
)
I )
( D )
E )
2)
1)
(-V EF)
F)
PO )
PO )
2)
(DIN-C)
SE )
PO )
D
)
)
VR H)
E E)
-E
W M
( B1
AK -F
C O)
PS
(D -A
-K
L -B
E -D
C P)
L -C
)
-L
(D N-B
ER -N
TE
)
C
PS
T
AB
T
(R DI )
RE
(F -
AK -
IT
B IN
C
IN
-
IN
IN
XE IN
R IN
-
XE IN
A
EV N
IN
R IN
LE
SW
NG N
VI DIN
E V
(D
AK
(D
(D
VI DI
(V
( B (V
SE
(V
(D
( B (V
NG
X102
C (
R
(+
R
S
(
O
ER
(E
(E
(H
RS232
O
O
IP
(M
(M
(W
VI
RPM
B14
ER
(S
Y )
A OU AD
X100
IQAN-MDL A
E) -H E) -G E - E - E) -D E) -C E) -B ) -A
N1
AT A RE
R T AR T AR T AR T R T R T R T R E T
T)
PA U P U P U P U PA U PA U PA U PA U
2-
(S DO (S DO (S DO (S DO (S DO (S DO (S DO (S DO
3
)
3 2 2 -D S 2
(
)
IN
T
S 2 2 3 (R
-D A
B
)
(
SPARE OUTPUTS
(R R S
(
)
(
C XS2-A0 PIN 26
)
-H -L -H -L -H
)
-D -D -C -C -B -B -A -A
) F ) E
(
XS2-A0 PIN 40
A AN AN AN AN
)
(C (C (C (C (C (C (C (C
D
)
J1939 ENG / TRANS (X90)

(
)
BU
N
J1939 ENG / TRANS (X90)
)
A
(
)
IQ
LFM CONT (X97)
)
)
93
(
J1
N
LFM CONT (X97)
)
-L -H -L
(
N
N
J1939 SPREADER / UPA
)
A
PE
_O
F1 F2 F3 F4 F5
N N
J1939 SPREADER / UPA
CAN-bus )
AN
A A
C
9
93
J1
-BAT
X-MDL
Fusebox ground 0v
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 6
A: of 19
16016
A3
N1 MDL N2 XS2-(A0) N3 XS2-(A1) N4 XT2-(A0) N5 XT2-(A1T)
(Cab) (cab front) (Cab fuse box) (Chassis LHS) (Chassis RHS)
C3 XS2 XS2 XA2 XA2
(R11) RS232 IQAN prigram / diagnostic interface plug
C1 C1 C1 C1 C1
X-MDL XS2-0 XS2-1 XT2-0 XT2-1
ADDRESS
ADDRESS
ADDRESS
ADDRESS
R21 R24 R20 R19
)
)
)
)
)
)
-H
-H
-H
-H
-L
-L
-L
-L
)
)
N-H
)
)
N-H
)
N-L
N-L
)
)
N-B
N-B
N-H
N-H
N-H
N-H
N-L
N-D
N-D
N-C
N-C
N-A
N-A
N-L
N-L
N-L
N-H
N-H
N-L
N-L
A
A
A
A
A
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
IQAN-BUS
J1939 Printer
X10-C
X100
X11
IQAN-BUS IQAN-BUS IQAN-BUS IQAN-BUS
J1939 ENGINE / TRANS BUS

R25
X90
X112
X112
J1939 ENGINE / TRANS BUS
X19
P10
CAN-L
CAN-H
(P10) DANA Transmission harness CAN interface plug

X97
DANA PRE-WIRED TRANSMISSION HARNES
X89 J1939 BUS SCREEN

GRND POINT ENGINE ECU
2 3 P1 (R11) RS232 Dana transmission controller prigram / diagnostic

R11 B3 Engine ECM unit J2
J1939 Spreader
interface plug
1
5 6 P2
4
8
9 (Connector J2)
7
J2
0
*
N8 LINDE LFM B4 Transmission controller

(DANA SPICER TE-17)
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 7
A: of 19
16016
A3
24v (Bat +) Isolator (30) 24v (Bat +) Isolator (30)
24v Ign + (:15) 24v Ign + (:15)
24v switch illumination
F41 F23 F50

F49 F22 15A 15A 10A
5A 5A
Pg8: (592)
IQAN XS2-A1 Pin 8

Pg2: (90)
15/1 56
S23
K4
K3
S24 S25
56A 56B
S25-B
H7
IQAN XT2-AO Pin 6

Pg8: (616) Pg4: (278)
S25-B
L R
K5
F43 F44 F42 F47 F48 F45 F46

3A 3A 1A 10A 10A 5A 5A E3 E4
S25 49A
X10B X10A X10B X10B

X10A
X4 X4 X4 X4 X4
X35R
X35L X35L
X35L X35L H6 K3
E20 E21 E14 E15 E1 E2 B11
E16 E17 E18 E19 E10 E11 E12 E13
Chassis Grnd 0v Chassis Ground 0v
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 8
A: of 19
16016
A3
24v Ign + (:15) 24v Ign + (:15)
24v switch illumination 24v switch illumination
F40 F51 F52 F53 F54

5A 20A 20A 10A 20A
S26 S27 S28 S32
X10A X88 X10A X10B E23:1 E23A:1
X4 X109 X4 X4A
E7 E6 E8 E9 E22 E23
E23:2 E23A:2
Chassis Ground 0v
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 9
A: of 19
16016
A3
24v Bat + (:30) 24v Bat + (:30)
24v Ign + (:15) 24v Ign + (:15)
F35
F24 F28 30A
5A 15A
X105
IQAN XS2-A1 Pin 22

Pg3: (186)
Pg1: (36) Aircon clutch

K9
X43
E5
E5
B16
E5
0
M
S46 M2
SP901-E
SP901
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 10
A: of 19
16016
A3
24v Bat + (:30) 24v Bat + (:30)
24v Ign + (:15) 24v Ign + (:15)
F37 F26 F27

15A 10A 10A
(IQAN XS2-A1)Pin 4 Pg 3 (226)

(IQAN XS2-A1)Pin 7 Pg 3 (222)
15 S25-A
S25 Pg.2 (234) Pg.2 (234)
+24v +24v +24v +24v
+24v Wash/wipe o/p
+24v Wash/wipe o/p

0
1
+24v wipe o/p
+24v wipe o/p

2
2
24v wash
24v wash
1 0 J
o/p
o/p
0v
0v
S30 S31
S25-B
53B 53 31B J 53C
(IQAN MDL Pin 35 Pg 6 (444)

D1
R30
D2
D3 K6 K7
I 86 S 31B 15
(IQAN MDL Pin 34 Pg 6 (442)
X14 X14
M5 M7
X14
M6 M5 M8 M7
M4 M3
K2
31
K2
X14 X14
M4 X14
Cab floor Ground 0v Cab floor ground 0v
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 11
A: of 19
16016
A3
24v Ign + E/stop (:45) 24v (IQAN +) E/S :45
24v Bat + (:30) 24v (BAT +) Isolator :30
24v Ign + (:15) 24v (IGN +) Isolator :15
24v Perm bat 24v (BAT +) :60
F36 F15 F59 10A 10A F25 F55 F58 F31 F39
30A 5A 1A 3A 3A 5A 5A 5A
Pg:2 (124)
X94 Pin 1
S29
P7 SP08-0 P7 SP09-0
(495) (495)
Pg:1 (26)
Pg:1 (24)
X94 Pin 2
X101
X100
B22 B25 B23
24v
B20
M B19
B26
GND
24v
B27
GND
12v
12v
X97
MDL Pin 6 Pg 6 (474)
MDL Pin 7 Pg 6 (474)

SP901-E SP900 SP900
B21
Cab floor ground 0v Cab floor Ground 0v
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 12
A: of 19
16016
A3
24v Bat + (:30) 24v Bat + (:30)
24v Ign + (:15) 24v Ign + (:15)
F38 F32 F60

5A 5A 5A
S37
S35
X10-C
X113
X91 X106 X106
X10-B
X10-C X10-C
X10-C
X103
X95 X95
X91
CABLE 1
B24
B28 B29 B30
S36
CABLE 2
X92
X91
X10-C
H16 H17 E24
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 13
A: of 19
16016
A3
24v Ign + (:15) 24v Ign + (:15)
X109
F10 F11 F12 F14 F13

10A 10A 10A 10A 3A
16 x 1.5mm core Lapp cable
X88
H9-H11 H18-H25
ELME Combi Can Bus Spreader

12 x 1.5mm multicore cable
S26 Pin 1 Pg9: (656)
S26 Pin 2 Pg9: (662)
4 x 1.5mm multicore cable 12 x 1.5mm multicore cable

X89
2 CORE 0.5 mm twisted pair cable 2 CORE 0.5 mm twisted pair cable
IQAN MDL Pin 8 Pg6: (472)
X111
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 14
A: of 19
16016
A3
24v Ign + (:15) 24v Ign + (:15)
X109
F10 F11 F12 F14 F13

10A 10A 10A 10A 3A
X88
ELME Can Bus Spreader

S26 Pin 1 Pg9: (656)
S26 Pin 2 Pg9: (662)

X89
2 CORE 0.5 mm twisted pair cable 2 CORE 0.5 mm twisted pair cable
X111
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 15
A: of 19
16016
A3
24v (Bat +) Isolator (30) 24v (Bat +) Isolator (30)
24v Ign + (:15) 24v Ign + (:15)
F56 F57 F35
X43-DOT
15A 15A 30A
0
X105
(RED) RED B
M
C
(ORANGE) ORANGE
0 SP5
I
Pg1: (36) Aircon clutch
°C
IA
(GREEN) GREEN
bar
X43 X43M
SP2
SP1
(BLACK) BLACK
X43F
BLACK
M
(BLACK)
S46
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 16
A: of 19
16016
A3
Page to be used for Eberbacher A/C
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 17
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A3
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
S: 357 802 0261 18
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A3
K3 K4 K5 K6
K2
K7 K8 K9 K10
FC1
F16
F15
F11
F14
F10
F12
F2
F4
F6
F7
F8
F3
F1 F5 F9 F13
FC2
F23
F22
F28
F24
F25
F26
F21
F17
F19
F20
F18
F27
K1
F29 F30 F31 F32
FC3
F41
F39
F38
F44
F37
F40
F42
F35
F33
F34
F36
F43
F45 F46 F47 F48
K16 FC4
F54
F55
F56
F60
F53
F57
F58
F51
F49
F50
F52
F59
F61 F62 F63 F64
ACB
FS1
K17 K19 K18 K20
FS2
FS3
FS4
FS5
FS6
Inspection dim.
Auxillary dim . ( )
M.check
Scale:
Drawing number
NONE
Page:
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Service training
IQAN
Control System Calibrations
Service Training
How to create / get a Password ( acces code )
Click TOOLS
Then Password Manager
Send the Public Key to

nick.price@linde-htd.com
Just press copy and past it into
your e-mail
He will send the key back to you !
Service Training
When you get the Key back from LHTD , just copy it from the E-mail and past it into the
Add safe password
Now you can up / down load new software or up dates to the MK 5 Reachstacker !
Service Training
Setting the Truck into Calibration Mode via the MDL Screen
1. Press the Centre of the scroll

function button once.
2. Using functions buttons A, B, C & D

to enter the Service Engineer
Access Code. Do not press the
scroll button after entering the
access code.
3. The screen automatically changes

and displays spreader / joystick
information.
Price N Page 1 6/16/2009

Service Training
4. Rotate the scroll function button

until calibration mode is displayed
in the lower left hand corner of the
display. The calibration Mode
indicator light will be illuminated
green when calibration mode is
switched off
5. Press F1 to switch Calibration

mode on. Note: The calibration
mode indicator light will change to
Amber.
6. Note: It is not possible to lift

containers or goods whilst in
calibration mode.
7. The above procedure should be

used to Exit Calibration Mode and
return the truck back to General
Service Mode.
Price N Page 2 6/16/2009

Service Training
The Safety computer system on the 357/05 Reachstacker

The computer system is a linked with a Can Bus and includes the following components
The MDL ( Master Display Large ) Unit

The MDL is the main controller of the system
IQAN can protocol
2 XS can Controller units located in the driver cab

XS 1 Front Cab RHS behind a plastic cover
XS2 Rear Cab inside the Fuse Box
2 XT can Controller located in the chassis

XT 1 Chassis RHS
XT 2 Chassis LHS
The APC 200 Transmission Controller

Located in the chassis LHS
J 1939 Can Protocol
The Cummins ECU Engine Controller

Mounted on the RHS of the engine
J 1939 Can Protocol
The Elme Spreader Can Controller mounted on the

Spreader
ELME Spreader J1939 Can Protocol
A.P.version 03 2011 1
Service Training
The MDL is operating/ controlling together with the APC 200 the Cummins ECU and the
Spreader controller all truck functions ! .
In case of a safety problem ( broken sensor …) the MDL will shut/slow down all related
systems regarding to the safety level of the problem !
The MDL is also the central display unit and displays during normal operation all system
information’s like explained in the operator handbook .
After the start up of the truck the following displays can be selected without setting a code
This displays are called the driver displays
In the following pages , we explain all Service relevant informations and functions relevant
for faultfinding and diagnostic
Load Indication as a coloured graph bar

Boom position informations ;length ,angle…
Park brake indication
Selected drive direction
Fuelgauge as coloured graph bar and Ltr
Speedmeter
Enginespeedmeter
Trip Counter
The F1 button can switch between 1st or 2nd
gear start
F3 and F4 can reset the Trip counter
F5 switch the automatic function for the top
and rear wiper on or off
By pressing the A button the display change to

the
Engine display
Indicating important engine infos like

Water Temp
Engine oil pressure
Engine oil temp
Engine torque
……..
By pressing the A button the display goes back
to the drivers start page
By pressing the B button the display goes to

the transmission page
Service Training
The transmission Page gives all important

transmission information like
Trans oil temp.
Travel speed
Drive pedal command percentage
Brake pedal command percentage
Distance travelled
Fuel used
Trip distance
Trip Fuel
By Pressing the C button the display change

to the Hydraulic Page
Here we get the system pressure readings

LS Pressure , P Pressure ; Delta Pressure ,
Pilot Pressure ,
The hydraulic oil temperature in degree and
as a coloured graph
The Joystick command for the Xand Y axes in

Milli Amp
By pressing the D button we get the

Spreader display
Here we can se the actual Twistlock position

And the Actual as well as the max possible
weight on the spreader
By Pushing the rotating/ confirm button we

can change into the Service mode
The so called
First Level Access
Service Training
How to change Language ,Time and Date
If there is an need to change the display

language or the date and time ,
Press the BOOK button below the D

button !
The diplay change to
Main Adjustment Screen
Here we have to select
F3 Preferences
By Pressing the
A Button ,
we enter the Time and date adjustment
B Button
We enter the adjustment for the display
black out
C Button
We enter the Language adjustment
menu
Service Training
After entering the language set up the

language can be selected by
turning the rotating adjuster
When the correct language is found and

highlighted ( like ENGLISCH on the
example ) the rotating adjuster must be
pressed one time to confirm the new
selection !
Service Training
Driver Adjustments
By pressing the
F1 Button Adjust
We enter the main adjustment menu
For all calibration menus marked with

the padlock we need the second
service level acces code , see page 9
The only menu accessible without

code is
DRIVER SETTINGS
By using the rotating adjuster we

scroll down and confirm the selected
Menu by pressing the adjuster
In the driver Settings we can adjust
The Page Time out

Time before the display page change
back to the start page
Lift Height Wiper Start
At what lifting height the top wiper
start if auto wipe is selected
Prop Rocker switch on
This will cange the spreader rotation
from a two speed setting to
proportional movement according to
the rocker switch n the joystick head
Joystick speed up block
Here we can switch engine speed up
on joystick on or off
Service Training
Service Display First Level Access
The code ( 4323)has to be

activated by using the buttons
A 4x
B 3x
C 2x
D 3x
Note :
After setting the correct code the
display will change automatically
to the first page of the diagnostic
pages
The display shows

LS and Pump pressures , Pilot
Pressure
And the MilliAmp command to the
spreader solenoid valve
We can see all commands from the
joystick to the spreader , also the
information is given if we have can
communication with the spreader
By using of the rotating / confirm
button we can go to the next
screen
From here we can go to the
calibration menus ( second level
access ) by using the A-B-C or D
button
see second level access Page 9
By using the F1 button we can

activate / deactivate the
Calibration (transport mode)
F2 –F5 Is access to the different
Data Loggers
A –B-C-D Access to the Calibration
for this Components
Joystick , Pedals , Length and Angle
Sensor , Hydraulic Valve
Green OK for Work
Orange , Calibration Mode
Service Training
If the Calibration Mode is Activated , the

Normal Driver Display will show this
info on the top Row
CALIBRATION MODE NO WEIGHT LIFT

POSSIBLE
By Using the A Button we can adjust ,

Automatic Gear Change or Manual
By Using
B we can get all Transmission Info like
Speeds , Current to valves …
C will get us the transmission error
codes ( if there are codes !)
D we can change the date
F1 can change between First or second

Gear Start
F2 can activate the Heat mode for a
Transmission calibration
Service Training
Service Display Second Level Access
To enter the second level acces , press
The button
The Display will change to the

Adjustment display
As soon as we select one of the menus

marked with a padlock the system
requests the second level access code
The level code 9993 has to be selected

by using the rotating button !
Service Training
How to adjust a Sensor F.E. The Boom Length Sensor 1&2
After setting the correct code we can enter

into the adjustment menus
By using the rotating button we can select
the required sensor
F.E.
Boom Length 2
1) Bring the truck into calibration mode !
The required figures are indicated on

the top row of the screen
2) By using the
A Button we can adjust the Min Value

Note :
Min means the Min Voltage not the Min
Length
B Button we can adjust the Max Value

Note :
Max means the Max Voltage not the
Max Length
Bring the boom by using the Joystick

into the full extended position
Approx 1630 cm
When the boom travels , the raw value

and the actual value will change to
F.E. Raw Value 1161 mV

Actual Value 1627 cm
Service Training
How to adjust a Sensor F.E. The Boom Length Sensor 1&2
Now by using the rotating button we select

/ adjust the min reading to the value
indicated by the raw value 1161
Confirm the new setting by PRESSING the

rotating button
The menu will changes automatically to

the max adjustment
Now bring the boom back to the complete

retract position !
When the boom travels , the raw value and

the actual value will change to
F.E. Raw Value 4821mV

Actual Value 868 cm
Now by using the rotating button we select

/ adjust the max reading to the value
indicated at raw value 4821mV
Confirm the new setting by PRESSING the

rotating button
Service Training
The menu will changes automatically to

the start menu and we can now adjust
the Boom Length 2
Or
The Angle Sensors !
The procedure is the same !
Service Training
How to calibrate the Joystick
The 357/05 Joystick is a hall effect type joystick , means there are no wearing parts on the
signal track !
The joystick signal for each direction command is for more safety a dual signal means the
MDL is receiving 2 signals ( Joystick 1 + Joystick 2 , X axes or Y axes ) , if there is a greater
difference in this 2 values then programmed in the MDL ( signal excides the tolerance ) the
system will set a alarm and stop the motions !
The current joystick signal can be

checked in the MDL ! Go to
measure and select by using the
rotating button the joystick , then
press the rotator to confirm !
Service Training
By pressing the A button we

change from scaled value to
raw value and back
NOTE :
If all axes showing 49xx Mv,
Check the glas fuse on the
-V Rev line between XS 2 cab
front and Joystick
In calibration we can only see

the raw value
Note :
To go into the calibration
menue , see page 7 , second
level acces !
Select the sensor required to
calibrate , set the acces code!
A calibration is only possible

in a specified window
F.E.
For the min calibration , the
system will only accept a
value between
800 mV and 1600 mV !
Note :
the display on the left shows
the
Joystick 1 X axes Min
calibration ,
Joystick in Neutral position ,
Raw Value = 2500 mV
Joystick movement 0,15%
Service Training
Now Move the joystick to the

dedicated position
NOTE : the raw value has to go into the
direction Min is asking for .
Joystick 1 ( then 2) X Axes MIN
Raw Value 1162 mV

Joystick Actual Value 99,7 %
NOTE : Min 1157

is the value of the previous calibration
By rotating the adjusting rotator

button
Cw or Acw we have to set the
Min value to match the Raw Value !
The scale in the middle will move with

the command of the adjusting rotator !
When the two values are matching

each other confirm the new setting by
PRESSING the rotating /confirm button
1161 Min
Joystick Actual Value 100 %
The system goes automatically to
3847 Max
Service Training
Now move the joystick to the Max

position !
Raw Value 3929

Joystick Actual Value -106%
By rotating the adjusting rotator

Cw or Acw we have to set the
Max value to match the Raw Value !
The scale in the middle will move with the

command of the adjusting rotator !
When the two values are matching each

other confirm the new setting by
PRESSING the rotating /confirm button
3929 Max
Joystick Actual Value -100 %
The display will go back to the selection

screen ,
Now we have to do the
Joystick X axes 2
Then
Joystick Y axes 1
Then
Joystick Y axes 2
In the same way !
Service Training
How to Adjust the Engine Low Idle Speed
NOTE :
On truck with software versions below 1.11 we have to switch the Accelerator pedal on
all Time
Switch the Ignition on
Press the Book Button to select the MAIN

menu
The Display Change to
Select F1 ADJUST
Search and Highlight PEDAL CALIBRATION by

using the rotating button confirm the
selection by pressing the rotating button
Set the correct code 9993 to enter into Pedal

Calibtation
Service Training
Search and Highlight
DRIVE PEDAL ENABLE NEUTRAL
By using of the rotating button and

confirm the selection by pressing the
rotating button
The Display change to
Now change the Value from

0 = Accelerator OFF in Neutral
To
1 = Accelerator on all time
Confirm the setting by pressing the
rotating button
The display changes to
Now search and highlight
ENGINE LOW IDLE ADJUST
Confirm the selection by pressing the

rotating button
The display change to
Service Training
No adjust the low idle speed
Default = 700 Rpm
Max recommended is
7% ~ 800 RPM
NOTE :
if the low idle is higher the 810 rpm , may
the auto parkbrake will not work
Software 1.11 a and higher
Engine Low Idle Adjust ( can be done on MDL direct or via Lap Top )
On MDL ,
Select adjustments , then Pedal Calibrate , then Low Idle Adjustment !
With Lap Top

Log in with the Laptop Computer , select Adjust then Pedals Calibrate then Low Idle Adjust
Default Set is 0 % = 700 Rpm
Recommendation is 8 % means 800 to 820 rpm
Note : for a Transmission Calibration this has may to be readjusted to original

0 % = 700 Rpm
Service Training
Service Hours Counter settings ( MDL and Lap Top )

On MDL ,
Select adjustments , then Service Hour Counter ,
Select adjustments ,
then Service Hour Counter
NOTE :
Service Hrs Cont Down Timer
And
Service Overdue Hrs
Can only be set with LaP Top
see page 26
Then Service Interval Hours ( as our trucks

running normally on 500 Hrs engine oil
changes this should be set to 500 , if you
offer a grease check then select 250 . this
setting means if you use the
Service hours reset button , a timer counts

down from either 500 or 250 or what ever
you set at
NOTE : After every Service you must use

this function to reset the timer ,
Switch the value one time to 1 and then

back to 0 this will restart the counter
Service Training
How to Up Date / Load a new Software
Required equipment :
Lap Top Computer ,
USB printer Cable to connect Lap Top to MDL
New Software
Start Lap Top , connect Lap top to the MDL and then Start Iqan Run
Make Sure that the correct connection is Selected Communication USB
After the communication start the

communication indicator will be green
Service Training
Now Log in to the system
If you have the required acces rights the welcome screen appears
Service Training
Now get first of all a clone file from the MDL , ( select get logs with clone )
After receiving of the clone file the following Safe window opens
Normally the file got the chassis number automatically with clon on the end like
E1X357 Axxxxx clone
Safe the file in your truck file or where ever you find it later if necessary !
Service Training
Now click the Up Date button , the following window will pop up ,
If the software ( you have received by E – Mail ) is not present in the pop up screen , search
for the file you have saved it !
Highlight the software you want to use with a mouse click
Confirm / open the software by using the open button
Service Training
The following info will pop up , if this is the correct Software confirm by using YES
Confirm the safety warning !
Now the up date starts automatically
Service Training
The MDL Display will change to blue
The up date will take approx 2 -3 minutes , after finishing the update the following pop up
window appears on the Lap Top Screen
Confirm by using OK and the job is finished ! Disconnect the Lap Top , do a full test run and
return the truck to service !
Service Training
How to do adjustment with the Iqan Run software
Note : for all adjustment blocks with the padlock in front you need the access code 9993
Service counter adjustment .
Log in with the Laptop Computer , select Adjust , Service Hrs counter
Putt the Code 9993 to open the adjustment window
Service Training
Service counter adjustment .
Service Hour Count down Timer,should be set to match up with the operator handbook
service schedule ,
Example : if we did the 50 hrs service , we want the next not on 550 hrs we want 500 hrs so
we set he timer to 450 !
Service overdue Hours , here we count the time until we reset the timer
Service symbol visible hours , here we adjust how long before the service time we can see
the service notification symbol ( spanner symbol in MDL )
Service Interval Hours should be set to the with the customer agreed service schedule , 250
Hrs or 500 hrs
Service Hrs reset , , here we start the counter ( 250 or 500 hrs ) again
Example :
the current Working hours are 9 in the MDL , we want to service the
truck at 500 Working Hours so we set the countdown timer to 491 !
Max Drive Speed Adjustment * Speed Limiter* ( Lap Top only )

Service Training
Log in with the Laptop Computer , select Adjust then Speed Limits , then Fixed Speed Limitation
Default Set is 32 Km/h
With the up down arrows or by typing in we can change the max

drive speed ( 0 to 32 Km/h )
Service Training
How to use the measure function on the MDL Display

F.E. Boom Length readings in Voltage inputs
Start the engine
From the main display screen select the
button .
The screen will change to
Main
Here select the F2 Measure button
No select by scrolling with the rotating

button VOLTAGE INPUTS
With the rotating button we can now scroll

up / down until we see the input signal we
want to see !
Here :
Boom Length 1 879 cm

Boom Length 2 879 cm
Service Training
By using the A button we can switch

between the
Raw Value indication in Milli Volt
Or the
Scalled Value in cm , bar , % ….
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Section 8
Ser vice Training
Service Page 1
8 BOOM AND SPREADER

357 804 46 01. 0102
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Section 8
Service
357 804 46 01. 0102

C01. Register 05
Section 8
Ser vice Training
Service Page 3
8.1 BOOM AND SPREADER ASSY

357 804 46 01. 0102
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GENERAL VIEW OF BOOM AND SPREADER
1 Boom pivot bearing

2 Boom
3 Energy chain with supply lines to the spreader
4 Levelling cylinder
5 Spreader bearing
6 Spreader
7 Lift cylinder
The boom (2) is mounted in the boom pivot bearing (1) on the chassis. It is raised by two lift cylinders (7).
The spreader (6) is attached at the spreader bearing (5). Swing movements of the spreader are dampened
with the levelling cylinders (4). The spreader (3) is supplied with hydraulic energy with the supply lines and
controlled with the electric functions.
Two different spreader models are in service:
- Model 817 telescopic top pick spreader with slewing gearbox and sideshift
- Model 857 telescopic top and bottom pick spreader with slewing gearbox, sideshift carriage and
blockstack cylinders.
Section 8
Service
8.2 BOOM
BOOM
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1 Lifting eyes, rear
2 Boom, outer tube
3 Lifting eyes, front
4 Boom, inner tube
5 Energy chain
6 Pivot bearing
7 Beam extension cylinder
8.2..1 DESCRIPTION
The boom consists of the outer tube (2) and the inner tube (4), which are connected by the beam extension
cylinder (7). The inner tube slides on sliding bearings mounted in the outer tube at the front and rear. The
sliding bearings are lubricated via grease nipples and are liable to wear. They must be replaced when their
thickness is down to .... mm. For the removal of the boom lifting eyes are provided at the front (3) and rear
(1) end of the outer tube. The boom is mounted on the chassis in two pivot bearings (6) at the rear end.
The hydraulic and electric cables for the boom and spreader. The electric and hydraulic lines to the
spreader are routed through the energy chain (5).
Section 8
Ser vice Training
Service Page 5
3
1 2
7
357 804 46 01. 0102
C01. Register 05
13
9
11 10
12
FEEDS TO THE BOOM AND SPREADER.
1 24 Pin plug standard electrical feeds to spreader 8 Hydraulic tank return from spreader
2 Plug connector to red, amber, green lights 9 Pilot signal to extension cylinder
3 Plug connector to additional piggy back lights 10 Feed to spreader damping cylinders
4 24 Pin plug option, piggy back spreader 11 Feed to automatic greasing on boom
5 Regeneration valve for extension cylinder 12 Plug connector to angle transducer
6 Leak to tank from spreader and extension cyl 13 Plug connector to beacon/boom lights
7 Hydraulic feed to spreader
TECHNICAL DATA
Weight of boom 13.5 tonnes Weight of standard spreader 9.25 tonnes

Weight of lift cylinder 1 tonne Weight Piggy back spreader 11 tonnes
Weight of boom extend cyl. 1.8 tonne
Section 8
Service
8.2.2 BOOM REMOVAL
Aids required:
- Crane, approx. 25 tonnes
- Fork truck with a load capacity of at least 8 tonnes
- Working platform or fork truck with working cage
DANGER
When the boom is being lifted with a
crane, do not stand within the working
range of the crane! Do not step under
the raised load. Only use a crane and
lifting gear with sufficient lifting capac-
ity. After the slings are attached to the
crane hook (2), close the hook safety
(1).
NOTE: Dismantle the spreader before remov-

ing the boom.
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C01. Register 05
- Support the boom as shown (1) (weight of the
boom: 13.5 tonnes).
- Support the lift cylinder as shown (2) (weight of the
lift cylinder: 1 tonne).
- Disconnect the hydraulic hoses from the lift cylin-
der and plug them.
- Remove the pin (3) at the lift cylinder.
- Lower the lift cylinder onto the chassis.
NOTE
NOTE:: To avoid damage, place wooden
blocks between the chassis and lift
cylinder.
- Refit the pin (3) on the boom.

- Fasten the lift cylinder.
- Remove the second lift cylinder as described
above.
- Disconnect the electric cables on the boom.
- Disconnect the hydraulic hoses from the boom
and plug them.
- Remove the pin (4) from the boom pivot bearing.
- Lift the boom to the rear away from the pivot
bearing.
- Deposit the boom on wooden blocks as shown
(5) to prevent damage.
- Refit the pin (4) in the boom pivot bearing at the
rear.
Section 8
Ser vice Training
Service Page 7
8.2.3 BOOM ASSEMBLY
BEFORE ASSEMBLY
- With the engine shut off and the ignition turned on,
depress the buttons on the central control lever to
release any residual pressure in the hydraulic
system.
- Turn off the ignition and remove the ignition key.
- Apply the parking brake and block the wheels with
chocks.
- Lift the boom as shown (3) and position it at the

chassis for the installation of the pin (4) at the pivot
bearing (weight of the boom: 13.5 tonnes).
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MOUNTING THE BOOM IN THE PIVOT BEARING
- Position the boom (B) to the vehicle frame bearing (A) so that the drilled holes are in line.
- Insert the pin (1) with the shims (2) through the drilled holes (with nose on pin pointing downwards) and
drive it in with light blows of the hammer.
ATTENTION
Position the lubricating hole (arrow) vertically so that the bearing is greased sufficiently.
- Position the plate (3) at the pin and fasten it with four M16x55 screws (4).
- Tighten the screws (4) to 180 Nm.
Section 8
Service
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C01. Register 05
MOUNTING THE BOOM IN THE PIVOT BEARING

1 Pin
AVehicle frame bearing 2 Shims
BBoom bearing 3 Plate
4 M16x55 screws
Section 8
Ser vice Training
Service Page 9
MOUNTING THE LIFT CYLINDER IN THE BOOM

BEARING
- Lift the lift cylinder (7) as shown (5) and position it

so that the cylinder can be installed with the lift
cylinder mounting pin (6) (weight of the lift cylin-
der: 1 tonne).
- Insert the lift cylinder mounting pin (6) into the
boom bearing (D), position the tab of the pin in the
cut-out and drive the pin in with light blows of the
hammer.
ATTENTION
Position the lubricating hole (arrow)
vertically so that the bearing is greased
sufficiently.
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- Position the plate (8) at the pin and fasten it with

screws (9) and washers (10).
- Tighten the screws (9) to a torque of 180 Nm (?).
- Reconnect all hydraulic hoses and electric ca-
bles (see figure with connections at the rear of the
boom).
Section 8
Service
8.2.4 BOOM REPAIRS
8.2.4.1 BOOM EXTENSION CYLINDER
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INSTALLATION OF BOOM EXTENSION CYLINDER
1 Screw
2 Washer
3 Cover
4 Screw
5 Washer
6 Pin
7 Cylinder tube
Section 8
Ser vice Training
Service Page 11
BOOM EXTENSION CYLINDER
1 Piston seal
2 Extension tube
3 Piston
4 Wear ring
5 Locking screw
6 Wear ring
7 Seal
8 O ring with back up ring
9 Feed tube
10 Rod
11 O ring with back up ring
12 Trunion
13 Rod seal
14 Rod seal
15 wiper seal
16 Head gland
17 Rod end
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Section 8
Service
REPLACING THE BOOM EXTENSION CYLINDER SEALS
ATTENTION
Observe the precautions for handling fluids and lubricants.
CAUTION
The hydraulic oil and tank are very hot when the operating temperature is reached. Danger
of scalds and burns!
This machine is equipped with accumulators in the brake and control circuits. Before starting
maintenance work on the circuits, the stored energy must be released. This is done with the
engine shut off and the ignition turned on by repeatedly operating the brake pedal, the parking
brake and the central control lever.
Work on the truck on level ground. Shut off the engine, apply the parking brake and remove
the ignition key during servicing.
With the engine shut off and ignition turned on

operate the central control lever (joystick) to
release any pressure in the system.
357 804 46 01. 0102

Turn off the ignition.
C01. Register 05
Chock the wheels of the truck.
Disconnect the battery (1).
NOTE
This work requires two fork trucks with a lifting capac-
ity of 3.5 tonnes and a lifting height up to 5 metres.
Disconnect the hose connections to the extension 1

cylinder. 2
The extend feed hose (1) with it's sae coupling and
block (2), the leak off hose (5), the pilot signal hose (6)
ant the retract feed hose (7).
The lowering valve screws (3) can be removed and
the lowering valve (4) can be lift away from the extend
cylinder. 4
7
6 5 3
Section 8
Ser vice Training
Service Page 13
Loosen the 3B6 system extension measuring cable

(2) from it's securing bolt (1) and allow the cable to 1
retract slowly into the housing (3).
2
3
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Carefully position one fork (1) under the boom

extension cylinder (2) and take up the weight.
Remove the lifting eye nut (1) and washer (2); pull
the screws (3) out of the boom (4).
NOTE
Pull the screw out from the other side of the boom.
Section 8
Service
Remove the four screws (1) and the cover plate (2)
from the boom (3)
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C01. Register 05
Pull the six screws (1) out and remove the pin (2)
from the boom (3).
Repeat the above procedure for the pin on the other
side of the boom.
Lift the rear end of the cylinder (1) about 50 mm.

Support the cylinder as shown (2).
Section 8
Ser vice Training
Service Page 15
Carefully reverse the fork truck until the shoe weld (2)
is about 100 cm from the boom end.
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Lift the cylinder with the second fork truck as shown

(1). Raise the cylinder about 50 mm.
Carefully reverse both fork trucks until the cylinder is
out of the boom.
Lower the cylinder onto wooden pallets placed on level
ground.
Section 8
Service
Pull the piston assembly (8) about 600 mm out of
the cylinder.
Remove the screws (5) from the end cap (6) and
pull the pston assembly out of the tube (1).
Secure the end of the piston assembly (8)
Remove the front piston retaining screw (4) from
the piston rod and unscrew the piston from the
tube using the special tool (A).
Clean the threads.
Remove and discard all seals (2), and wear rings
(3).
Install new wear rings (3) and seals (2). The seal
(2a) fitted between the piston and the feed tube (7)
must be heated to 70°C and folded into a heart
shape to permit fitting as must the PTFE seal (2b)
Fit the feed tube (7) into the piston using the special
tool (B).
Fit the piston into the tube and tighten using the
special tool (A) to 2000Nm.
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A
C01. Register 05
Drill and tap two new grub screw holes M8 at 90°
to the existing holes and fit the grub screw (4),
secure the grubscrew with Loctite 243 and caulk
on completion.
Assemble the piston assembly into the tube with B
the ring item (6) in position. Fit and tighten the
screws (5)
Bleed the cylinder at low pressure before fitting into
the boom, bleed screw in piston head (8).
NOTE
This cylinder cannot be resealed without
using the special tools as illustrated.
Support the cylinder with two trucks as shown.

Carefully align the cylinder with the boom.
Drive the fork truck forward at creep speed
until the shoe weld (1) is about 100 cm in the
boom.
Remove the front sling (2).
Section 8
Ser vice Training
Service Page 17
Drive the fork truck slowly forward until the

holes in the piston (2) are in line with the holes
in the boom.
Drive the fork truck slowly forward until the
holes in the piston (2) are in line with the holes
in the
Remove the rear sling (3).
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C01. Register 05
Refit the pin (2) in the boom (3) and secure it with six
screws (1). Torque the screws to 110 Nm.
Repeat the above procedure for the pin on the
opposite side of the boom.
Using the four screws (1), refit the cover plate (2) on
the boom (3). Torque the screws to 23 Nm.
Repeat the above procedure for the cover plate on the
opposite side of the boom.
Section 8
Service
Install the screw (3) in the boom (4).
Secure the screw (3) with the washer (2) and lifting
eye nut (1).
Carefully lower the fork (1) and back the fork truck
away from the shutoff valve (2).
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C01. Register 05
Reconnect the valve block and hoses to the extension
cylinder. Check the hydraulic oil level and top up if
necessary, reconnect the battery.
Reconnect the 3B6 measuring cable, check the boom
length measurement and slow down are operating
correctly. See programme map section 6, pages 19-
24
Section 8
Ser vice Training
Service Page 19
8.2.4.2 LIFT CYLINDER
1 Removable head 1
2 Gland seal
3 Gland
4 O-ring
5 Piston
6 Wear rings
7 Cylinder tube 11
2
8 Piston seal
9 Lower chamber feed tube
10 Upper chamber feed tube 3
11 Wiper seal
4
10
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8 7
Section 8
Service
SEALING THE LIFT CYLINDER, SERIES 357
Attention
Observe the precautions for the handling of hydraulic fluids and lubricants.
Caution
The hydraulic oil and oil tank may be at operating temperature. Risk of scalding and burns!
Work on the truck only on level ground; shut off the engine, apply the parking brake and remove
the key from the ignition switch.
Place one container on top of another.

Apply the parking brake.
Disconnect the connector (1) at the rear of the fork
truck on the boom mount.
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C01. Register 05
Press the escape function key once on the MDM ,
Using the up/down botton scroll through menu
Until measure is displayed. Select voltage in (F1)
Using the up/down button scroll through sub menu

and check values for Low Pressure and High
pressure, on pressure transducer at the top and
bottom of the lift cylnders. Release the park brake
and Lower the handler onto the top container until
the pressure values for top and bottom cylinder
pressure equals zero
It may be necessary to adjust the boom

Position (up or down) in order to achieve
The zero indication.
Shut off the engine and apply the park

brake.
Section 8
Ser vice Training
Service Page 21
Caution
This procedure must be carried out at
heights of over 2 metres. Use the
appropriate access equipment. Danger
of fall injuries.
Support the lift cylinder (1) (weight of the lift cylinder:

1 tonne).
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C01. Register 05
Remove the screws (1), washers (2) and retaining

plate (3) of the boom mounting pin (4).
Screw two Ø 12 mm and 150 mm long full-thread
screws into the extraction holes in the pin (4).
Turn the screws clockwise in equal steps until the
pin (4) can be removed easily.
Remove the pin (4).
The cylinder spherical bearing (5) is installed in the
the cylinder rod end with circlips (6).
Lower the cylinder on the chassis.

NOTE:
To prevent damage, place wooden 1
blocks (1) between chassis and lift
cylinder.
Turn the ignition key to the ON position, but do not

start the engine.
Wait 10 seconds until the computer has performed
its selftest.
Operate the lift/lower control lever to release any
existing hydraulic pressure.
Turn off the ignition and remove the ignition key.
Section 8
Service
Place a container with a capacity of 50 litres on the
chassis under the pilot valve (1).
Disconnect the four hydraulic hoses (3) at the
shutoff valve (1). Protect the hose ends against
debris.
Carefully remove the four screws (2) from the 1
shutoff valve (1).
Remove the shutoff valve (1).
Do not re-use any O-ring on the shutoff valve (1).
2
NOTE:
If a central greasing system is installed,
remove the greasing system fuse (cf. 3
operating instructions) and remove the
hose from the shutoff valve.
Sling and support the lift cylinder (1).
357 804 46 01. 0102

Remove the screws (1), washers (2) and retaining C01. Register 05
plate (3) of the chassis mounting pin (6).

Remove the screws and washers (7 & 8) in the lock
plate (9).
Use a dummy plate similar to item 9 to manufacture
a simple extractor as shown on page 21to pull the
pin Item (6).
Carefully take the lift cylinder from the chassis and
deposit it on wooden pallets placed on level ground.
Retain the bush Item (5) in the chassis for re-use.
Remove the second lift cylinder as described above.

Section 8
Ser vice Training
Service Page 23
Manufacture a special tool from steel as shown.

357 804 46 01. 0102
C01. Register 05
Section 8
Service
Remove the 16 Allen screws (6).
Remove the piston rod from the cylinder tube (1).
Remove the head Item (5).
remove the gland (4) ffrom the piston.
Remove all the seals (2a - 2F) and the wear rings
(3)
Clean the threads.
Install new seals (2) and wear rings (3).
Install the piston into the tube (1).
Fit the gland (4) and the screws (6) and tighten.
Fit the head (5).
Repeat the above procedure for the second lift

cylinder.
Fit the cylinders into the truck, fitting is the reverse
of the removal procedure.
357 804 46 01. 0102

C01. Register 05
The cylinder must be bled to ensure correct
operation, the bleed screw is located in the top of
the piston (1) adjacent to the removable head (2).
Remove the bleed screw (1), operate the lift very

slowly until oil is ejected from the vent area.
Note.
observe safe working procedures while
bleeding the cylinder. Ensure that
ejecected oil will not contaminate nearby
objects or personel.
Start the engine.

Remove the handler from the container.
Back off the truck from the stack.
Lower the boom and retract it.
Stop the engine.
Check the hydraulic oil level (1). If necessary, add
hydraulic oil.
Perform a comprehensive functional check on the

lifting system.
Check for leaks and eliminate them, if necessary.
Recheck the oil level.
Return the truck into operation.
Section 8
Ser vice Training
Service Page 25
8.2.4.3 SLIDING BEARINGS
RENEWING THE SLIDING BEARINGS
NOTE
NOTE:: Lubricate all sliding bearings with general grease immediately after installation.
357 804 46 01. 0102
C01. Register 05
REAR SLIDING BEARINGS
1 Guide
2 Screw
3 Washer
4 Stop plate
5 Sliding bearing
REAR OF BOOM
Remove the screws (2) and washers (3).

Take off the stop plate (4), pull out the sliding bearing (5) and guide (1) and renew them.
Install new guides and sliding bearings (6 items) and secure them with stop plates and screws.
Section 8
Service
FRONT SLIDING BEARINGS
1 Intermediate plate
2 Screw
3 Washer
4 Plate
5 Sliding bearing
6 Screw
7 Bushing
8 Washer
9 Stop plate
10 Pin
357 804 46 01. 0102

C01. Register 05
FRONT OF BOOM
Remove the screws (6), washers (8) and bushing (7) (2 bushings each per side).
Take the sliding bearing (5) out of the bushing and renew it (4 items).
Refit the bushing and secure it with screws.
FRONT TOP OF BOOM
Remove the screws (2) and washers (3) on the top of the boom.
Remove the plate (4) and renew it (2 items).
FRONT BOTTOM OF BOOM
Remove the screws (10) and washers (3) at the stop plate (9).
Remove the sliding bearing and renew it (2 items).
Fasten the new sliding bearing with the stop plate and screws.
Section 8
Ser vice Training
Service Page 27
8.2 SPREADER MODEL 817

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GENERAL VIEW OF SPREADER MODEL 817
1 Front levelling cylinder 7 Twistlocks

2 Slewing motor 8 Beam extension cylinder (in extension beam)
3 Spreader bearing 9 Sideshift cylinder
4 Rear levelling cylinder 10 Control box L4 on slewing gearbox
5 Spreader beam 11 Control box L1 on spreader
6 Right extension beam 12 Slewing brake
8.2.1 OPERATION AND CONSTRUCTION
The spreader (handler) is used to pick up containers with a maximum load of 45 tonnes and of different
lengths: IE. 20', 30', 35' and 40' ISO containers.
SUSPENSION
The spreader is attached to the boom at the spreader bearing (3). The rear (1) and front (4) levelling
cylinders dampen swing movements occurring between the boom and spreader when a container is
picked up. The rear levelling cylinder is continously supplied with a low hydraulic pressure, approx. 30 bar,
while the front cylinder is supplied is supplied with about 20 bar of pressure. This makes the spreader
assembly assume a "front higher" aspect to assist operation.
Section 8
Service
HYDRAULIC FUNCTIONS
The right (6) and left side of the spreader beam contains beam extensions which are moved by the two
extension cylinders (8). The movement is controlled with the joystick via a solenoid valve for each cylinder.
The beam extensions adjust the spreader length (2 hydraulic stops) to the container length. They run on
renewable sliding bearings (wear pads).
The spreader can be rotated horizontally with the slewing motor (3); two slewing brakes (12) brake the
rotation of the handler. Rotation is controlled by solenoid valves operated by the joystick in the driver's
cabin. The spreader is positioned accurately over the container with the aid of two sideshift cylinders (9),
one each for right and left side shifting. All spreader functions are controlled electrically through the joystick
via solenoid valves. The oil for the operation of the hydraulic functions is supplied by the hydraulic system
in the chassis via the energy chain on the right side of the boom.
TWISTLOCKS
Two pendulum twistlocks (7) are installed at each end of the beam extensions, with which the container
is seized from above and lifted. The twistlocks are rotated into the corner castings by the twistlock
357 804 46 01. 0102

C01. Register 05
cylinders. One double-acting twistlock cylinder per side actuates two twistlocks through a cross shaft;
the three different positions (not locked - seated - locked) are monitored by sensors (proximity switches).
The twistlocks are subject to wear and are renewable. The twistlock cylinders are controlled by solenoid
valves from the joystick in the driver's cabin.
ELECTRICAL SYSTEM
The spreader is connected electrically to the controlling joystick via the sistemi 3B6 load safety computer.
The cables are routed to the spreader through the energy chain on the right-hand side of the boom.
The twistlock positions
- not locked ........................................................ red

- seated .............................................................. yellow + red
- locked .............................................................. green + yellow
- locked and lifted ............................................... green
are indicated on the boom with indicator box L6 and in the driver's cabin with indicator lights.
Section 8
Ser vice Training
Service Page 29
8.2.2 TECHNICAL DATA AND SCHEMATIC DIAGRAMS
8.2.2.1 OPERATING AND PERFORMANCE DATA
Operating voltage 24 VDC

Operating pressure of hydraulic system 170 bar
Operating pressure of levelling cylinders (approx) 30 bar at rear, 20 bar at front
Weight 9.25 tonnes
Capacities:
- Slewing gear (rotator) up to bottom of filler opening
- Slewing brake up to bottom of filler opening
357 804 46 01. 0102
C01. Register 05
Oil types and lubricants:

- General lubrication points general purpose grease
- Turntable bearing Linde lithium-based, heavy-duty grease
with EP additives and MoS2
- Slewing gear transmission oil to ISO 2448
G 150-220
- Slewing brake hydraulic oil to ISO VG 46
Torque loadings:
- Fastening screws: slewing gear to turntable bottom plate:

M12 (10.9) Torque loading 90 Nm
- Ring rear fastening screws (without locking devices):

M24 (10.9) torque loading 740 Nm
Section 8
Service
8.2.3 SPREADER REMOVAL
DANGER
Do not stand within the working range
of the crane when hoisting the spreader
with a crane! Do not step under the
raised load. Only use a crane and
lifting gear with sufficient capacity. The
safety (1) must close after the slings
are attached to the crane hooks (2).
BEFORE REMOVAL
- Retract the boom.
357 804 46 01. 0102

C01. Register 05
- Lower the boom.
- Retract the spreader to the 20' position.
- Centre the spreader.
- With the engine shut down and the ignition turned
on, operate the push-buttons on the central con-
trol lever in order to release any residual pressure
in the hydraulic system.
- Turn off the ignition and remove the ignition key.
- Apply the parking brake and chock the wheels.
REMOVAL
- Support the spreader (3) as illustrated (weight of

the spreader: 8.5 tonnes).
- Disconnect the electric cables.
- Disconnect the hydraulic hoses.
- Plug the hydraulic hoses.
- Remove the levelling cylinder (4) from the spreader
by pulling out the pin (5).
- Fasten the levelling cylinder (4) to the boom.
- Refit the pin (5) on the spreader.
- Pull the pin (6) out of the spreader bearing.
- Remove the spreader from the boom and lower
onto wooden blocks (7) to prevent damage to the
twistlocks.
- Refit the pin (6) on the spreader.
Section 8
Ser vice Training
Service Page 41
8.2.4 SPREADER ASSEMBLY
- Attach 4 ropes to the lifting eyes on the spreader,

pick the spreader up with the crane and place it on
a ready 20' container.
- With the boom in the horizontal position, position
the spreader as shown (1) so that the pins (4) can
be installed at the spreader pivot bearing (7).
- Align the drilled holes and drive the pins (4) in with
light hammer blows.
- Position the plate (3) on the pin and fasten with
four M16 x 55 screws (2).
- Torque to 180 Nm.
357 804 46 01. 0102
C01. Register 05
- First position the rear, then the front levelling

cylinder (5) in line with the drilled hole (6), insert
the screws, install and tighten the nuts.
- Install and tighten the hydraulic hoses for the
spreader.
- Connect the electric cables at the spreader.
NOTE: The hoses are colour-coded.
AFTER ASSEMBLY
- Carry out a complete functional check of the

boom and spreader.
- Inspect all hydraulic connections for leaks.
Section 8
Service
8.2.5 SPREADER REPAIRS
8.2.5.1 SLIDING BEARINGS
357 804 46 01. 0102

C01. Register 05
SLIDING BEARINGS
1 Sliding bearing 6 Nylon wear pad

2 Roll pin 7 Stop plate
3 Stop plate 8 Stop plate
4 Washer 9 Spreader frame
5 Screw 10 Beam extension, rear bearing
The sliding bearings (1) and nylon wear pads (6) are secured with stop plates (3), (7) and (8), which are
fastened with screws (5) and washers (4). The sliding bearings and nylon wear pads must be lubricated
regularly every 500 service hours with general grease and inspected for wear and security. When the pad
thickness is down to 8 mm, the plates must be renewed.
RENEWING THE SLIDING BEARINGS
CAUTION
Lower the spreader. This work must be performed at heights of over 2 metres. Use suitable
tools (working platform) to gain safe access. Danger of fall injuries!
- Remove the screws (5) and washers (4).

- Take off the stop plates (3), (7) and (8).
- Slide the sliding bearings (1) and nylon wear pads (6) out of the guides and renew them.
- Secure the new sliding bearings and nylon wear pads with stop plates.
- Lubricate the plates with a general grease.
Section 8
Ser vice Training
Service Page 43
.8.2.5.2 REPAIRING THE TWISTLOCKS
TWISTLOCK CROSS SHAFT

357 804 46 01. 0102
C01. Register 05
1 tie rod 3 carriers(1 sensor, 2 adjusters for twistlocks)

2 end piece 4 adjusting bolts
REMOVAL, INSTALLATION AND ADJUSTMENT OF TWISTLOCK CROSS SHAFT
- Remove all fastening screws from the carriers (3) and end pieces (2) and screw a setscrew into the
centre hole of each part.
- Rotate the tie rod (1) about 90° and install the three carriers and the two end pieces in roughly the correct
position on the cross shaft.
- Insert the tie rod in the end pieces and fit the end pieces to the yokes on the top nuts of the twistlocks.
- Turn the twistlocks and position them accurately in the "not locked" position.
- Fix the end pieces in this position with the setscrews.
- Ensure that the twistlock cylinder is in the correct position corresponding to the "not locked“ position of
the twistlocks.
- Adjust the two adjusting bolts (4) on the two carriers to the midway position.
- Move these two carriers to the correct position so that the screw heads just touch the piston rod and are
in line with the cylinder.
- Lock both carriers in place with the setscrews.
- Determine the correct position for the bracket of the "locked" and "not locked" proximity switches.
- Fix the bracket at the determined place with the setscrew.
- Remove the cross shaft assembly making sure not to change the position of the components.
- Drill two 10 mm holes through each of the five parts and fasten each item on the cross shaft with M10x70
screws and nylock nuts.
- Mount the cross shaft in the beam extension, allowing about 0.5 mm play between the screws (4) and
the piston rod ends.
- Operate the twistlocks hydraulically and carefully check that the twistlock heads are in line with the
twistlock bushings. If necessary, adjust with the screws (4).
Secure the screws (4) with locknuts.
- Check the operation of the "locked“ and "not locked“ indicator lights and adjust the proximity switches,
if necessary.
Section 8
Service
8.2.5.3 TWISTLOCK REMOVAL
Remove the plastic housing that supports the

locked/not locked sensors from the end beam and
loosen the twistlock adjusting bolt to give some
free play. Remove the end piece from the twistlock
cross shaft. see section 8, page 41.
- Remove the M8 x 80 bolts (15).
- using two of the bolts as an extractor pull the
crank (14) from the twistlock,note the key in the
twistlock held in place by a roll pin, remove the
key.
- Support the twistlock (5) from below.
- Use a screwdriver to lever out the collets (13).
- The twistlock can now be lowered out of the
housing.
- The sleeve (8) and the lower bearing set will
usually come out with the twistlock.
- Remove all other components.
357 804 46 01. 0102

C01. Register 05
8.2.5.4 TWISTLOCK INSPECTION.
As the twistlock is a lifting device and must support

heavy loads it is critical that it is properly inspected
and any components that are not in perfect
condition are replaced.
TWISTLOCK CYLINDER
1 Piston rod 8 Cylinder tube

2 Allen screw, washer 9 O-ring
3 Wiper ring 10 Seal
4 Washer 11 Piston
5 Seal 12 Allen screw
6 Plate 13 Plate
7 O-ring
Section 8
Ser vice Training
Service Page 45
SEALING THE TWISTLOCK CYLINDER
NOTE
NOTE:
A seal kit (3, 5, 7, 9, 10) containing all the seals is available. The twistlock cylindermust be
removed for repair.
- Remove the twistlock cylinder.

- Clamp the cylinder tube (8) in a vice with protective jaws.
- Unscrew the Allen screws (2) from the plate (6) and (13) and remove it along with washer.
- Pull plates (6) and (13) from the cylinder tube (8).
- Renew the wiper ring (3), seal (5) and O-ring (7) of the plates.
- Clean the inside of the cylinder tube (8) and examine for damage such as grooves and traces of scoring
and corrosion.
- Draw the piston (11) out of the cylinder tube (8).
ATTENTION
Do not damage the grooves and recesses on the piston rod with sharp-edged tools.
357 804 46 01. 0102
C01. Register 05
- Renew the seal (10) and O-ring (9) on the piston.

- Examine the piston rod for damage such as grooves and traces of scoring and corrosion.
- Refit the components on piston rod using new seals.
- Slide the piston rod into the cylinder tube, position the plates and fasten them with Allen screw and
washers.
- Reinstall the twistlock cylinder in the beam extension.
8.2.5.3 BEAM EXTENSION CYLINDERS
BEAM EXTENSION CYLINDERS

1 RH beam extension 6 Pin
2 Service access opening 7 LH beam extension
3 Hose take-up reel/energy chain 8 Service access opening
4 Hose take-up reel/energy chain 9 RH beam extension cylinder
5 LH beam extension cylinder 10 Pin
Section 8
Service
REMOVING THE BEAM EXTENSION CYLINDER
- Retract the spreader to a length of 20' and lower it.
NOTE: The following text below describes the removal of the left beam extension cylinder (5). The
procedure also applies for the right beam extension cylinder (9).
- Support the left beam extension cylinder (5) safely with a suitable automotive jack.
- Disconnect the hydraulic hose and electric cables at the piston head end of the cylinder.
- Remove the pin at the end of the cylinder (piston head end).
- Loosen mounting of the energy chain (4) on the guide at the underside of the beam extension.
- Using a crane or fork truck, pull out the end of the beam (1) about 50 cm to gain access to the service
opening (2) at the top of the beam extension.
- Remove the cylinder pin (6) on the piston rod end.
- Attach the beam extension to a suitable lifting gear.
ATTENTION
The used lifting gear must have a load capacity of approx. 150 kg.
357 804 46 01. 0102

C01. Register 05
- Pull the beam extension cylinder horizontally out of the spreader with the lifting gear, until the sliding
bearings guiding the cylinder foot come out of the guide.
- Install a new cylinder in the reverse order of removal.
BEAM EXTENSION CYLINDER
1 Adjusting screw 9 Washer

2 Nut 10 Piston rod
3 Seal from seal kit 11 Screw
4 Piston 12 Guide ring
5 O-ring 13 Bushing
6 Spacer 14 Guide bushing
7 Allen screw 15 Cylinder
8 Ring
Section 8
Ser vice Training
Service Page 47
RENEWING THE BEAM EXTENSION CYLINDER SEALS
NOTE: A seal kit (3) containing all the seals is available.
- Clamp the cylinder (15) in a vice with protective jaws.

- Remove the 4 screws (11) from the ring (8).
- Pull out the piston rod (10) with ring (8), washer (9), guide ring (13), spacer (6) and piston (4). Deposit
the piston rod in a safe place.
- Clean the inside of the cylinder (15) and examine it for damage such as grooves, traces of scoring and
corrosion.
- Clamp the piston rod in a vice with protective jaws.
ATTENTION
Do not damage the grooves and recesses on the piston rod with a sharp-edged tool.
- Loosen the adjusting screw (1) on the nut (2), remove the nut on the piston, withdraw the piston (4).
- Renew the seals on the piston (4) using seals from the seal kit (3).
- Remove the spacer (6) from the piston rod and renew the two O-rings (5).
- Remove bushing (13) from the piston rod and renew the seal on the bushing with one from the seal kit
357 804 46 01. 0102
C01. Register 05
(3).
- Extract the ring (8) and washer (9).
- Renew the seals on the ring and washer with ones from the seal kit (3).
- Inspect the piston rod for damage such as grooves and traces of scoring and corrosion..
- Refit the components on piston rod using new seals.
- Secure the nut (2) of the piston with the adjusting screw (1).
- Install the piston rod in the cylinder and secure it with screws (11).
Section 8
Service
8.2.5.4 SIDESHIFT CYLINDER
357 804 46 01. 0102

C01. Register 05
SIDESHIFT CYLINDER
1 Pin 7 Cylinder tube

2 Nut 8 Piston rod
3 Washer 9 Piston
4 Yoke 10 Nut
5 Seal kit part 11 Adjusting screw
6 Guide bushing
RENEWING THE SIDESHIFT CYLINDER SEALS
NOTE: A seal kit (5) containing all the seals is available. To renew the seals, the sideshift cylinder
does not have to be removed.
- Remove the nut (2) and washer (3).

- Drive the pin (1) out of the yoke (4).
- Pull the guide bushing (6) and piston rod (8) out of the cylinder tube (7).
ATTENTION
- Loosen the adjusting screw (11) on nut (10), remove the nut at the piston and withdraw the piston (9).
- Renew seal kit part (5) on the piston.
- Unscrew the guide bushing (6) from the piston rod (8) and renew seal kit parts (5).
- Inspect the piston rod for damage such as grooves and traces of scoring and corrosion.
- Refit the components with new seals on the piston rod.
- Fasten the piston rod with nut (10) and secure the nut with adjusting screw (11).
- Slide the piston rod into the cylinder tube, screw in the guide bushing.
- Position the yoke (4) at the piston rod bearing and secure the pin (1) with washer (3) and nut (2).
Section 8
Ser vice Training
Service Page 49
8.2.5.5 LEVELLING CYLINDER

357 804 46 01. 0102
C01. Register 05
LEVELLING CYLINDER
1 Cylinder tube
2 Adjusting screw
3 Piston
4 Seal kit part
5 Piston rod
6 Guide bushing
RENEWING THE LEVELLING CYLINDER SEALS
NOTE: A seal kit (4) containing all the seals is available. The levelling cylinder does not have to be
removed to renew the seals.
- Screw the guide bushing (6) and piston rod (5) out of the cylinder tube (1).
ATTENTION
- Loosen the adjusting screw (2) on the piston (3) and remove the piston.
- Renew seal kit part (4) on the piston.
- Unscrew the guide bushing (6) from the piston rod (5) and renew seal kit parts (4).
- Examine the piston rod for damage such as grooves and traces of scoring and corrosion.
- Refit the components on the piston rod with new seals.
- Fasten the piston on the piston rod and secure it with adjusting screw (2).
- Slide the piston rod into the cylinder tube.
- Refit the levelling cylinder to the spreader bearing and boom bearing.
Section 8
Service
LEVELLING CYLINDER VALVE BLOCK
357 804 46 01. 0102

C01. Register 05
LEVELLING CYLINDER VALVE BLOCK
1 Flow valve
2 Pressure relief valve 80 bar
3 Levelling cylinder port
4 Tank return line port
5 Flow valve
7 Levelling cylinder port
ADJUSTING THE LEVELLING CYLINDER POWER
NOTE: Each levelling (=damping) cylinder is controlled by its own valve block. Both levelling
cylinders (rear and front) must be adjusted. The damping power can be set for both directions.
The piston must be in the end position for the adjustment.
Section 8
Ser vice Training
Service Page 51
- Lower the spreader so that the levelling cylinder piston is retracted.
- To increase the damping power:

Turn the adjusting screw at the flow valve (1) in.
- To reduce the damping power:

Turn the adjusting screw at the flow valve (1) out.
- Lower the spreader so that the piston of the levelling cylinders is extended.
- To increase the damping power:

Turn the adjusting screw at the flow valve (5) in.
- To the reduce the damping power:

Turn the adjusting screw at the flow valve (5) out.
357 804 46 01. 0102
C01. Register 05
Section 8
Service
8.2.5.7 SLEWING GEAR
357 804 46 01. 0102

C01. Register 05
VALVE BLOCK FOR SLEWING GEAR
1 Solenoid valve for left-right rotation

2 Flow valve - fast rotation
3 Flow valve - slow rotation
4 Solenoid valve for changing slewing speed
5 Solenoid valve for releasing slewing brake
6 Return line port
7 Brake port 1
8 Brake port 2
11 Slewing motor port 1
12 Slewing motor port 2
13 Pressure port
15 Tank port
Section 8
Ser vice Training
Service Page 53
ADJUSTING THE SLEWING MOTOR
NOTE: The slewing speeds (fast and slow rotation) and the motor torque can be set at the slewing
gear valve block.
ADJUSTING SLOW ROTATION SPEED
- To reduce the slewing speed:

Turn the adjusting screw of the flow valves (3) in (clockwise).
- To increase the slewing speed:

Turn the adjusting screw of the flow valves (3) out (anticlockwise).
ADJUSTING FAST ROTATION SPEED
- To reduce the slewing speed:

Turn the adjusting screw of the flow valves (2) in (clockwise).
357 804 46 01. 0102
C01. Register 05
- To increase the slewing speed:

Turn the adjusting screw of the flow valves (2) out (anticlockwise).
ADJUSTING SLEWING MOTOR POWER
- To increase the slewing motor power:

Turn the adjusting screw of pressure-relief valves (9) and (10) in (clockwise).
- To reduce the slewing motor power:

Turn the adjusting screw of pressure-relief valves (9) and (10) out (anticlockwise).
TIGHTENING THE FASTENING SCREWS
NOTE: The fastening screws at the slewing gear and turntable bearing must be tightened twice a year
or every 1000 service hours.
-Fastening screws slewing gear to turntable bottom plate

-Ring gear fastening screws (without securing devices)

SERVICE MANUAL
Section A User instruction
Section B Service manual
Section C Diagrams
.
MODEL: 857 BUILD INDEX NO. 1-1821
.
SECTION A USER INSTRUCTION
A100-001 Driver instruction
SECTION B SERVICE MANUAL
B110-185 Lubrication chart

B110-017 Maintenance instruction
B110-068 Servicing pendular twistlock
B110-081 Extension cylinder service inst.
B110-251 Twistlock indication and endbeam adjustment
B9-106 Description folding and clamping
B9-107 Description folding block
B9-110 Description tilt block
B9-134 Description rotation block
B9-136 Description and adjustment of foot assy.
SECTION C DIAGRAMS
C120-001 Hydraulic symbols

786 299 Hydraulic schematic
804 078 Wiring diagram
804 077 Electric schematic
804 079 Electric bill of material
2008
SECTION
A
USER INSTRUCTION
USER INSTRUCTIONS Page no A
100-001-1
KEEP IT SIMPLE
ELME CONTAINER / TRAILER HANDLER

Model Nos.852 / 858 / 872 / 875 / 876
DRIVER INSTRUCTIONS
The ELME Models 852 / 858 / 872 / 875 / 876 trailer handlers are technically advan-
ced pieces of equipment which, if they are carefully used and maintained will serve
their purpose for many years.
Initial check.
Each work shift should be started by making a visual check of the unit ( this must be
part of the daily routine. ) Possible damage will in this way be discovered at an early
stage thus enabeling repairs to be carried out at much lower cost.
NEVER USE THE UNIT UNLESS ALL SAFETY DEVICES FUNCTION CORREC-
TLY !!!
CONTAINER HANDLING
1 Starting work with the spreader.

First of all the length of the spreader must be adjusted to the size of container that is
required to be lifted. This is done by retracting the stops ( if fitted ) and then activa-
ting the extention lever or button in order to extend or retract the spreader beams to
the desired length.
NOTE ! it is important to remember that loads should only be lifted at the spe-
cified lengths for which the spreader is designed ie. 20ft. 30ft. 35ft.40ft and in
some cases 45ft. Where stops are fitted the stops should be used to position
the beams accuratly at one of the above mentioned positions. If the spreader is
not equipped with stops then the spreader may only be used for lifting 20 and
40ft. containers. Lifting outside the specified positions can result in serious
damage to the spreader.
When the required length has been reached , lift the spreader high enough to give
good visibility under it. This serves two purposes, 1 it gives good visibility for tra-
velling and 2 it positions the spreader ready for picking up the first container. The
spreader should now be side shifted to the center position and the reach function
operated to the fully retracted position. This will be termed ”THE BASIC POSITION”
in the rest of the instruction.
07-97(08-92,06-92)(05-92)
USER INSTRUCTIONS Page no
A100-001-2
KEEP IT SIMPLE
2. Picking up a container.
If necessary raise the spreader in order to have plenty of space between it and the con-
tainer. Always attempt to position the spreader centrally over the container.
The final adjustments for lining up the twist locks with the corner castings of the contai-
ner can now be made.
By using the controls for shift and reach, position the spreader accurately over the
corner castings and then lower the spreader into them. If the twist locks or some of the
twist locks do not fit into the corner castings properly, CAREFULLY lift the spreader just
free of the container, readjust its position and the try again. NEVER PUSH OR SIDE
SHIFT while any of the twist locks are still engaged in the corner castings of the contai-
ner. When all the twist locks are correctly engaged in the corner castings the spreader
should be lowered until it rests unsupported on the container, this is termed as the
spreader being correctly SEATED, and this will be indicated by the SEATED LIGHT be-
ing switched on. As soon as this happens the twist locks can be activated to the locked
position and the LOCKED LIGHT will be switched on.
CHECK THAT THE ”LOCKED” LIGHT HAS BEEN SWITCHED ON and then lift the
container to the required height for loading and / or travelling. Before moving the con-
tainer, return the spreader to the ”BASIC POSITION”. The container is now ready to be
transported to a new location. When travelling always keep the load at the lowest pos-
sible height and drive carefully.
3. Depositing a container.
When approaching the new location for the container ( this could be a chassis or a stack
etc. ) lower the container to the required height and adjust the position of the corner
castings so that they are accuratly situated above the corner locks of the chassis. Lower
the container ensuring that its corner castings locate on the corner locks.
NEVER USE MORE TILT THAN NECESSARY AND NEVER PUSH !!!
WARNING !!! A heavy container and the weight of a spreader will do serious da-
mage to a trailer or chassis if not handled with care.
The twist locks may now be activated to the ”UNLOCKED” position, the spreader lifted
free of the container and the truck backed away.
TRAILER HANDLING
07-97(08-92,06-92)(05-92)
USER INSTRUCTIONS Page no
A100-001-3
KEEP IT SIMPLE
4. Picking up a trailer.
The spreader should be brought to the "BASIC POSITION" and raised to a suitable
height. The rear legs (the legs closest to the truck) should be folded down and MUST be
activated to the unclamped position. Drive up to the container carefully and stop when the
gap between the trailer is approx. 10cm (4 inch). Line the spreader up with the trailer as
accuratly as possible by using the slew (See page 100-013 for operation of FLOAT func-
tion.) reach and side shift controls. Fold the front legs down. CAUTION make sure that
there is sufficient space in front of the trailer to allow free movement of the legs ! Adjust
the tilt of the mast so that all four legs engage and lift equally on either side of the trailer.
Visually check that the legs are firmly clamped onto the trailer before lifting it. Lift the trai-
ler to the correct height for travelling.
WARNING !!! Cornering at high speed and travelling over uneven terrain can cause
excessive swing, with the risk that the feet could lose contact with the trailer and
cause an accident.
When travelling over longer distances it is advisable to travel in reverse with the trailer as
low as possible.
5. Depositing a trailer.
Lower the trailer until the wheels touch the ground. Continue to lower the spreader until
the indicator lights for foot engagment are switched off. Unclamp the legs from the trailer
(the clamp indicator lights will switch off.) and raise the spreader approx. 1meter . Fold
the front legs up and make sure that they are completely up BEFORE backing away from
the trailer.
6. General advice
- CAUTION !!! Never move the truck or use the slew, reach or side shift functions
as long as any of the feet/legs are in contact with the ground.
- Always adjust the spreader back to the ”BASIC POSITION” after every handling
cycle.
- When parking the truck and spreader or when they are not in use for longer periods of
time, always make a habit of folding the legs up and lowering the spreader to its lowest
position.
- Read all instruction books carefully and be sure that you understand them.
- Should there be anything you do not understand, then contact your local dealer who will
ensure that all your questions are answered.
07-97(08-92,06-92)(05-92)
SECTION
B
SERVICE MANUAL
PAGE NO
MAINTENANCE INSTRUCTIONS B110-185-1
LUBRICATION CHART
for Model 857
3 6
1 3 1
9 9
2 10 11 2
5 7 5 11 10 7
2 4 10 5 5 10 4 2
1 Slider pads extention 7 Side shift cylinders.

2 Twist locks 8 Slew gear box
3 Extension cylinder 9 Tilt cylinders
4 Stops 10 Folding group
5 Slider pads side shift 11 Feet
6 Slewing ring bearing and gear
(See individual description of each lubrication point.)
WHERE GREASE IS RECOMMENDED USE MULTI PURPOSE GREASE

WITH 2-4 % MOLYBDENEM DISULFIDE ADDITIVE.
12-02(02-02)
PAGE NO
POSITION 1
WEAR PADS FOR MAIN BEAMS AND EXTENDING BEAMS
NO. OF GREASE POINTS 24.
INTERVAL - EVERY 500 HOURS OR 3 MONTHS. A B

6 TRACKS ON EACH EXTENDING BEAM.
6 TRACKS ON THE INSIDE OF EACH MAIN BEAM.
( SEE ARROWS "A" AND "B" )
POSITION 2
END BEAMS AND TWIST LOCKS.
INTERVAL - EVERY 100 HOURS OR MONTHLY.
2 GREASE NIPPLES IN EACH END BOX.
LUBRICANT - MULTI PURPOSE GREASE
POSITION 3.
EXTENTION CYLINDER SUPPORT WEAR PADS
AND TRACKS.
INTERVAL - EVERY 1000 HOURS OR 6 MONTHS
2 TRACKS IN EACH EXTENTION BEAM.
LUBRICANT - MULTI PURPOSE GREASE.
POSITION 4
STOP CYLINDERS.
INTERVAL - EVERY 500 HOURS OR 3 MONTHS.
POINTS. 1 GREASE NIPPLE ON EACH STOP CYLINDER.
12-02(02-02)
PAGE NO
POSITION 5
SIDE SHIFT SLIDER PADS
NO. OF GREASE POINTS 4
INTERVAL - EVERY 500 HOURS OR 3 MONTHS A

POINTS. 2 TRACKS ON EACH SIDE OF THE SPREADER
LUBRICANT - MULTI PURPOSE GREASE.

B
POSITION 6
SLEWING RING BEARING AND GEAR.
INTERVAL - EVERY 100 HOURS OR MONTHLY
NO. OF LUBRICATION POINTS 6.
4 GREASE NIPPLES POSITION "A" MOUNTED AT

ONE CENTRAL POINT ON THE UPPER ROTATOR
FRAME PLATE FOR GREASING THE BEARING.
2 HOLES AT POSITION "B" IN THE STOP BLOCKS

FOR LUBRICATING THE GEAR RING.
LUBRICANT. - "A" MULTI PURPOSE GREASE. B A

"B" EXPOSED GEAR LUBRICANT
WITH ADHESIV AND EP ADDITIVE
POSITION 7
A
SIDE SHIFT CYLINDER BEARINGS.
2 GREASE NIPPELS ON EACH CYLINDER TUBE BEARING. POSI-

TION "A".
LUBRICANT. - MULTI PURPOSE GREASE
POSITION 8
A
SLEWING GEARBOX (2 off) B
NO. OF POINTS - 2.
INTERVAL - CHECK OIL LEVEL EVERY 100 HOURS OR MONTHLY.

CHANGE OIL AFTER THE FIRST 50 HOURS OF
OPERATION AND THEN EVERY 2000 HOURS OR YEARLY.
POINTS. - PLUG "A" IN ELBOW AT TOP OF GEARBOX = FILLER

AND LEVEL PLUG.
PLUG "B" IN THE BOTTOM OF THE BOX = DRAIN PLUG.
LUBRICANT. - SAE 90 GEAR OIL.

12-02(02-02)
PAGE NO
POSITION 9
TILT CYLINDERS
NO OF LUBRICATION POINTS 8
A
POINTS - ONE GREASE NIPPLE AT EACH END OF EACH

CYLINDER,POSITION "A".
POSITION 10
LEG FOLDING GROUP
NO. OF GREASING POINTS 7 (FOR EACH LEG) C B

"A" FOLD/CLAMP CYLINDER - 2 NIPPLES ON EACH BEARING
"B" LEG RAISE CYLINDER - 1 NIPPLE ON TOP BEARING
"C" LEG PIVOT PIN - 1 NIPPLE IN BOSS AT TOP OF LEG
"D" SHOULDER PIVOT PIN - 1 NIPPLE IN BOSS OF SHOULDER A D

("C" & "D" GREASE NIPPLES ARE ACCESABLE WHEN LEGS ARE
IN THE FOLDED POSITION)
LEGS ARE IN THE FOLDED POSITION
( SEE ARROWS "A" "B" "C" & "D" )
POSITION 11
FOOT AT BOTTOM OF EACH LEG
NO. OF GREASE POINTS 4 (ON EACH LEG)

B A
"A" 1 NIPPLE IN THE CENTER SHAFT
"B" 3 NIPPLES AT THE REAR OF EACH FOOT
12-02(02-02)
PAGE NO
MAINTENANCE INSTRUCTIONS B 110-017-1
KEEP IT SIMPLE
GENERAL MAINTENANCE INSTRUCTIONS.
1. - The nylon wear pads should be inspected for wear at the same time
as their tracks are lubricated. The pads should be replaced when their
thickness is reduced to minimum 18 mm.
Replacing the wear pads can be done with ordinary hand tools and
without removing the beams.
Minimum thickness 18 mm
2. - Twist locks are wearing parts and need inspecting on a regular

basis. Lubrication of the twist locks is recommended at monthly
intervals and it is also recommended that they are inspected for
wear and damage at the same time.
Should be replaced if this

dim. is less than 25mm
The drawing above shows where the heads of the twist locks
wear. When the worn part exceeds the area indicated by cross-
hatching the twist locks should be replaced.
Generally it is recommended that twist locks be replaced after a

max. use of 5000 working hours.
3. - The extension cylinder support has wear pads under it. These should also
05-03(11-92)
PAGE NO
KEEP IT SIMPLE
be inspected on a regular basis and replaced when their thickness is

reduced to minimum 18 mm. See item 1.
4. Maintenance of the stop cylinders if fitted, consists of checking all

mounting bolts for tightness and inspection for leakage from the cylinder.
5 The side shift wear pads should be inspected for wear at the same time
as lubrication is carried out. The wear pads should be replaced when their
thickness is reduced to minimum 18 mm. See item 1.
6. Other recommended spreader maintenance is:
a- Inspect the main spreader components for damage, cracks and

distortion.
b- Check the signal and safety systems for correct operation.
c- Check the hydraulic pressures periodically.
d- Check all hydraulic cylinders for leakage and reseal if necessary.
e- Inspect all hydraulic hoses for damage and leakage. Replace if

faulty.
05-03(11-92)
PAGE NO
KEEP IT SIMPLE
SERVICING THE PENDULAR TWISTLOCK

13
12
The tie-rod is a fixed unit and is not adjustable.
8
11
10
1 4
3
7
To remove the tie-rod proceed as follows:
1 Remove the Locked / Not locked sensor bracket (item 1).
2 Loosen one of the adjuster bolts at the twistlock cylinder, enough to give some
play.
3 Loosen and remove the M8 x 80 bolts (item 2) in the top of both twistlocks
in the same end beam.
4 Use two of the M8 x 80 bolts (item 2) as pullers by inserting them in the

two threaded holes (item 3) in each of the cranks (item 4) and tighten them
alternatly until they lift the cranks (item 4) off the top of the twistlock shaft (item 5).
5 The tie-rod (item 6) including both cranks (item 4) can now be removed from the
end beam.
To remove the twistlock and sleeve proceed as follows:
6 The key (item 7) that locates the crank (item 4) to the twistlock (item 5) is held in
place on the twistlock by a roll pin so that it will remain in place on the twistlock
after the crank is removed.
05-02
MAINTENANCE INSTRUCTIONS PAGE NO
B 110-068-2
KEEP IT SIMPLE
By lightly knocking the key away from the twistlock it can be removed.
7 Support the twistlock (item 5) from below so that it does not drop out.
Using a screwdriver prise the collets (item 8) out of the recess in the twistlock (item 5). It is
now possible to lower the twistlock out of the end beam. The sleeve (item 9) and lower
bearing set (item 10) will in most cases accompany the twist lock as it is removed, this is
quite normal.
INSPECTION PRIOR TO REASSEMBLY
8 After removal of all twistlock parts remove all grease and dirt from the parts and also from
the corner of the end beam. Steam clean or clean with some form of solvent.
9 Check the twistlock (item 5) for wear at the head and also for wear at the bushing
surfaces. Inspect the lower (item 10) and upper (item 11) bearing sets for wear and
damage, if badly worn or damaged they should be replaced. The collets (item 8) and the
crank (item 4) should be inspected for possible wear or damage and replaced if necessary.
It should be noted that the state of the collets (item 8) and the recess in the twist
lock (item 5) is very important as these parts are carrying the load when a container
is lifted.
REPLACING / FITTING TWISTLOCKS
10 Replacing the twistlock is the revers order of removal, however the best way to start
assembly is to assemble the sleeve (item 9) including bushes, onto the twistlock (item
5) and then grease the the lower bearing set (item 10) and place in position on top of the
sleeve. Fit the four centering springs in the sides of the sleeve.
11 Grease the upper bearing set (item 11) and place in position on the top surface of the
corner plate (in the end beam) with the convex half uppermost (threaded holes up)
12 Lift the twistlock assy. as assembled in point 10 and position up through the corner plate in
the end beam, ensuring that the upper bearing set (item 11) is positioned correctly around
the twistlock. Support the assembly with a jack or other means and then go to the next
point.
13 Fit the collets (item 8) with the pointed part upwards.
14 Fit the key (item 7) incl. roll pin to the keyway of the twistlock (item 5)
15 In order to fit the tie-rod (item 6) it is necessary to mount both cranks (item 4) to the tie-rod
before placing it in the end beam. Fit the ball joints, O rings, and plastic washers to the tie-
rod ends and then fit the fork of the crank (item 4) over the tie-rod end. Ensure that the
countersunk ends of the securing holes in the crank are uppermost. Secure the crank to
the tie-rod end by fitting the pin (item 12) and then the ring pin and allen screw.
16 In order to simplify assembly of the crank to the twistlock it is advisable to fit two alignment
pins to the assy. The pins can be made from two M8 x 75 bolts or allen screws with the
heads removed and slightly chamfered.
These pins should be screwed into the top plate of the upper bearing (item 11) diagonally
so that each pin guides one half of the collets (item 8).
05-02
MAINTENANCE INSTRUCTIONS PAGE NO
B 110-068-3
KEEP IT SIMPLE
17 Insert the tie-rod (item 6) into the end beam and the fit the cranks (item 4) onto the
alignment pins and ensure that the key and keyway line up. Fit two of the allen securing
(item 2) in the remaining two holes and screw in and tighten lightly. Remove the alignment
pins and fit the other two securing screws. The securing screws can now be tightened to
approx. 25 Nm.
18 Activate the twistlocks to the NOT LOCKED position and then adjust the twistlock cylinder
adjuster bolts so that the twistlocks are positioned accuratly in the NOT LOCKED posi
tion. Ensure that there is Zero play between the adjuster bolts and the twistlock cylinder
rod ends.
19 Grease the complete assembly with a high-pressure grease gun.
In order to test the operation it is necessary to land the spreader on a container so that the seated
pins are activated.
05-02
TWISTLOCK INDICATION AND ENDBEAM ADJUSTMENT PAGE NO
B 110-251-2
2a
2b
3
5a 4 4 5b
TWISTLOCK ANGLE ADJUSTMENT
1. Turn the twistlocks (pos1) to the fully UNLOCKED position (as shown).
2. If the twistlock heads do not line up with the twistlock sleeve, they can be adjusted by
loosening the lock nuts (pos 5) for the adjuster bolts (pos 2)
3. Turn the twistlocks at each end of the end beam so that they line up with the sleeves, if it is
found difficult to line up the twistlocks and sleeves accurately distribute the
misalignment equally on both sides of the sleeve. Make sure that the twistlock heads
DO NOT protrude outside the the theoretical line between twistlocks. If the twistlocks do
protrude outside the previously mentioned line between the twistlocks it can cause jamming
in corner castings as the spreader is lifted off the container.
4. Run both adjuster bolts (pos 2) up to the piston rod (pos 4) ends of the twistlock cylinder
(pos 3) by hand making sure that neither the twistlocks nor the cylinder are moved.
Tighten the lock nut (pos 5a) of the inside adjuster (pos 2a) first.
5. Unscrew / back off the outer adjuster bolt (pos 2b) no more than 2 flats of the hexagan head
(60°) so that there is only just enough play to allow the tie rod (pos 6) to slide back and forth
across the adjuster bolts when the twistlock cylinder (pos 3) is activated.
CAUTION if the gap between the twistlock cylinder rod ends is too large the rod ends will
hammer against the adjusters and subsequent damage will occur to the piston rod ends.
6. Tighten the lock nut (pos 5b) securely while at the same time ensuring that the adjuster bolt
(pos 2b) does not move.
7. Activate the twistlocks to the LOCKED position and check that the twistlock heads are
900+/- 100 to the twistlock sleeve.
02-05(03-04,09-03,05-03)
TWISTLOCK INDICATION AND ENDBEAM ADJUSTMENT PAGE NO
B 110-251-1
Proximity switch / Sensor
Proximity switch / Sensor

bracket
7 to 8mm Mounting surface
8-10 mm
Distance from landing surface
to underside of seated pin
Seated pin
Landing surface of end
SEATED / LANDED signal adjustment
1. Check that the SEATED PIN can move up and down freely. The force needed to lift the
pin is approx. 10 kg (20 lbs).
2. The SEATED signal should switch on with the pin protruding approx. 9mm below the
landing surface of the end beam.
3. If adjustment of the proximity switch / sensor is necessary, remove the seated sensor
mounting bracket incl. sensor from the top of the seated tower, and adjust the proximity
switch / sensor so that the end surface is 7-8 mm above the lower mounting surface of the
bracket. This adjustment will result in the seated pin indication being switched on when the
underside of the seated pin is approx. 8 to10mm lower than the end beams landing surface.
This adjustment also ensures that the mechanical and electrical lockout is released so that
the twistlocks can be turned.
02-05(03-04,09-03,05-03)
INSTRUCTION FOLDING AND CLAMPING BLOCK PAGE NO
FOR SPREADERS MODEL 872-875 B 9-106
3 4 5 6 7 8
1 2 9 10 11 12
13 14 15 20 21 22
2 13
16 17 18 19
To adjust the leg raising sequence

The leg must be fully up (horisontal) before the shoul- 1 12
der starts to rotate inwards. If the shoulder starts to 3 15
11
move before the leg is horisontal adjust the cartridge
no 16. Turning the adjuster clockwise will delay the 4 16
shoulder movement. 17
If the shoulder does not rotate inwards after the leg
has reached the horisontal position or if it moves too 6 19
slowly then turn the adjuster anticlockwise.
7 8
To adjust the leg lowering sequence
The shoulder must rotate to the fully out position be- 18 5 20 14 9 21 22 10
fore the leg starts to lower.
If the leg does not move down or moves too slowly
turn the adjuster of cartridge No. 4 anticlockwise
Note! Never alter the adjustment of cartridge No17.

This is factory set and cannot be adjusted in field.
Item list
To adjust the clamping speed 1 Electro valve Leg folding
Turn the adjuster on cartridges nos 6 and 19 clockwise 2 Tank port
in order to reduce clamping and unclamp speed and 3 Check valve
turn the adjusters anticlockwise in order to increase 4 Sequence valve Leg folding down
the speed. 5 Cylinder port
6 Flow control valve Clamping speed
To adjust damping force on legs 7-8 Flow control valve Damping force
Turn the adjuster on cartridges nos 7 and 8 clockwise 9-10 Cylinder ports
in order to increase the damping force on the forward 11 Pilot operated checkvalve
and backward movement of the legs and turn the 12 Electro valve Clamping
adjusters anticlockwise in order 13 Pressure port
to decrease the damping force. 14 Cylinder port
15 Check valve
16 Sequence valve Leg folding up
17 Counter balance valve (Do not adjust)
18 Cylinder port
19 Flow control valve Clampng speed
20-22 Cylinder ports
12-01(11-91)
PAGE NO
INSTRUCTION FOLDING BLOCK FOR SPREADERS MODEL 872-875
B 9-107
3 4 5
1 2
6 7 8
9 10 11 12
2 6
To adjust the leg raising sequence
The leg must be fully up (horizontal) before the shoulder
starts to rotate inwards. If the shoulder starts to move
before the leg is horisontal adjust the cartridge no 9.
Turning the adjuster clockwise will delay the shoulder 1
movement. 3 8
If the shoulder does not rotate after the leg has reached
the horizontal position or if it moves slowly then turn 9 4
adjuster anticlockwise.
10
To adjust the leg lowering sequence
The shoulder must rotate to the fully out position before
the leg starts to lower.
If the leg does not move down or only moves slowly turn
7 12 5 11
the adjuster of cartridge No. 4 anticlockwise
Note! Do not alter the adjustment of cartridge No. 10.

This is factory set and cannot be adjusted in field.
Item list
1 Electro valve Leg folding
2 Tank port
3 Check valve
4 Sequence valve Leg folding down
5 Cylinder port
6 Pressure port
7 Cylinder port
8 Check valve
9 Sequence valve Leg folding up
10 Counter balance valve (Do not adjust)
11-12 Cylinder port
05-93
DESCRIPTION FOR SIDE TILT BLOCK FOR SPREADERS MODEL 817, 857 PAGE NO
B 9-110
7
8
2 9
3 10
4 11
5 12
6 13
7 8
1
Item list
1 Electro valve
2 Counter balance (Do not adjust)
3-4 Cylinder ports
5-6 Cylinder ports 2 9
7 Tank port
8 Pressure port
9 Counter balance (Do not adjust)
10-11 Cylinder ports
12-13 Cylinder ports 3 4 12 13
5 6 11 10
Note! Do not alter adjustment on cartridge No. 2 and 9.

These are set in factory and can not be reset in field.
DESCRIPTION OF DUAL SPEED ROTATION BLOCK PAGE NO
B 9-134
2
15
3
14
4
5
13
6
7
12 8
11
9
10
Adjustment of the initial low speed rotation

To alter the initial speed of rotation, turn the adjuster on cartridge no 3,
clockwise to decrease speed and anti-clockwise to increase speed.
Adjustment of high speed rotation

To alter the high speed of rotation, turn the adjuster on cartridge no 2,
clockwise to decrease speed and anti-clockwise to increase speed.
Adjustment of rotation motor pressure

To alter the rotation motor pressure, turn the adjusters on cartridge nos 9 and 10 clockwise to
increase the pressure and anti-clockwise to decrease the pressure.
ITEM LIST
1 Solenoid valve Rotation direction D
2 High speed Flow control valve 6 15 13
3 Low speed Flow control valve
4 Solenoid valve Rotation speed 4
5 Solenoid valve Brake release
6 Drain port 14
7 Brake port 1
2 3
8 Brake port 2 5 T P
9 Relief valve Setting (80 bar)
10 Relief valve Setting (80 bar) B A 1
11 Motor port 1
12 Motor port 2
10
13 Pressure line
14 Relief valve Setting (40 bar) 9
15 Tank port 8 7
11 12
DESCRIPTION AND ADJUSTMENT INSTRUCTIONS FOR THE PAGE NO
EUROPEAN TYPE FOOT FOR BOTTOM PICK SPREADERS B 9-136-1
KEEP IT SIMPLE
DESCRIPTION
The foot consists of the following components: ( See Fig 1 )
1 -The weldment at the bottom of the leg.

2 -The foot, which pivots on the spigot that is part of the leg weldment.
3 -The spring-loaded indicator for "CLAMPED" which slides in and out in
the foot.
4 -The spring-loaded indicator for "SEATED".
5 -3 Proximity switches (sensors).
The thin profile of the foot has been designed to ensure that the driver always has
good visibility to the twist locks or location points of a trailer or rail car when a contai-
ner or swap body is being deposited.
3 1 Leg
Cross bar Spigot 5a (CLAMPED)

of indicator
5b (CLAMPED)
2
5 (SEATED)
4
Fig 1
The foot (pos. 2) is mounted on a spigot, which is part of the leg weldment. This al-
lows the foot to pivot around the spigot so that it is capable of lining up with lifting
points on containers and swap bodies.
The indicator (pos. 3), which is situated between the foot and the leg weldment ac-
tivates two sensors (pos. 5a and 5b) which advise the operator that the foot is firmly
"CLAMPED" onto the lifting point of the container or swap body.
When lifting the container, the spring loaded indicator for "SEATED" activates a
sensor (pos. 5), which advises the driver that the feet are correctly engaged with
the small rim on the pick-up point on the container or swap body. See the diagrams
below for details.
10-03(04-99)
HANDLING OPERATION
Position 1 Position 2 Position 3 Position 4

Fig 2
INITIAL POSITION (Position 1)
The foot is in the unclamped position. In this position, the clamped light for each leg
pair will be off.
APPROACHING "CLAMP" POSITION (Position 2)
The foot is in the lower clamp position. In this position, the upper sensor (pos. 5a) is
energized. As the foot is raised, the lower part of the indicator is pushed towards the
leg and the lower sensor (pos. 5b) becomes energized. Sensors (pos. 5a & 5b) are
connected in parallel.
"CLAMP" POSITION (Position 3)
The foot is in the position where sensors (pos.5a &5b) are both activated. As soon as
both feet are clamped on one side, the corresponding "CLAMPED" light will switch on.
"SEATED" POSITION (Position 4)
The foot has been lifted so that it has located on the rim of the lifting point on the
container or swap body. This pushes the spring of indicator (pos. 4) down and de-en-
ergizes the sensor (pos. 5 Fig 1) which causes the "SEATED" light to be switched on.
At this point the driver will see the "CLAMPED" & "SEATED" lights switched on at the
same time.
10-03(04-99)
ADJUSTMENT PROCEDURE
1. Apply two G-cramps to either side of the foot or fit the ELME tool in order to
compress the indicator (pos.3 Fig.1) to it's maximum. (It is important that both
sides of the indicator are tightened up equally)
2. a - Start by adjusting sensor 5b (pos.5b Fig. 3). This sensor monitors the upper
clamp position. Disconnect the plug of sensor (pos. 5b Fig. 3) and adjust the
sensor by screwing the sensor in or out to give a dimension of approx. 2 mm
between the indicator cross bar and the sensing face of the sensor (see Fig. 3)
then tighten the lock nut and reconnect the sensor plug. At this point the LED
on sensor 5b should be switched on.
b - Next, adjust the sensor 5a (pos. 5a Fig. 3). This sensor monitors the lower
clamp position. Disconnect the plug for sensor (pos. 5a Fig. 3) and adjust the
sensor as previously explained, by screwing the sensor in or out to give a
dimension of 2mm between the indicator finger and the sensing face of the sensor
(see Fig. 3) then tighten the lock nut and reconnect the plug to the sensor again:
the LED on the sensor should be switched on.
CLAMPED sensor 5a
(for lower clamp pos.)
2mm
CLAMPED sensor 5b
(for upper clamp pos.)
Cross bar
SEATED sensor 5
2mm
Fig 3 (Foot in clamped position)

10-03(04-99)
c - Adjust "SEATED" sensor 5 (pos. 5 Fig. 3).

Loosen the 4 screws that secure the seating sensor bracket at the bottom
of the foot and remove it. Disconnect the plug of sensor (pos. 5 Fig. 3)
and adjust the sensor by screwing the sensor in or out to give a dimen
sion of approx 2mm between the spring indicator and the sensing face of
the sensor (see Fig. 3) then tighten the lock nut and reconnect the
sensor plug. At this point the LED on sensor 5 should be switched on.
Tighten the four screws, which secure the seated sensor bracket.
The LEDs on all 3 sensors should now be illuminated/switched on.
d - Remove the G cramps or the ELME tool. After removing the clamps the
LEDs on both "CLAMPED" sensors will switch off, and the LED on the
"SEATED" sensor will remain on.
NOTE: It should be noted that the "SEATED" sensors function is opposite that of
the "CLAMPED" sensor, in that when the LED on the sensor is switched
on, the indicator lamp on the spreader and in the cab is switched off. In
the case of the "CLAMPED" sensors, when the LED's on the sensors are
switched on then the indicator lights will also be on.
3. After proceeding as above the indicator lights in the cab and on the spreader
for "CLAMPED" should be switched off and the indicator light for "SEATED"
should be switched off. If the "CLAMPED" light is not switched off, then the as
sembly must be removed again and the clamped sensor readjusted.
4. Repeat the adjustment on all four feet
5. Test the spreader on a container or swap - body. The indicator lights should
react as follows:
- With the legs in the unclamped mode the "CLAMPED" & "SEATED" lights
should be switched off.
- Clamp the feet onto a swap - body and check that the "CLAMPED" light
comes on. This should be repeated at various heights to check that both
clamped sensors in each foot are operating correctly.
- When the clamped sensors are considered to be working correctly lift the
spreader so that the feet engage the lifting points. This will push the spring
indicator down and activate the "SEATED" light.
The "SEATED" light must stay on all the time while the spreader is lifting a
load. The "CLAMPED" light / lights should stay on except if the container
or swap body is moving.
If the spreader is as described above then the spreader can be returned

to work.
10-03(04-99)
SECTION
C
DIAGRAMS
HYDRAULIC SYMBOLS PAGE NO
ISO STANDARD
ACCORDING TO C 120-001
1. Pump 13. Directional valve

(variable displacement) (single solenoid, 2 positions)
Motor Directional valve

2. 14.
(fixed displacement) (single solenoid, 2 positions)
Pressure relief valve 15. Directional valve

3.
(normally closed) (single solenoid, 2 positions)
RPEC-FAN
Directional valve
Sequence valve 16.
4. (double solenoid, 2 positions,
(normally closed) without spring)
RSDC-LAN
Directional valve
Pressure reducing valve 17. (double solenoid, 3 positions,
5.
(normally open) spring centred)
PBDB-LAN
PRH 102 S 50 Directional valve
18. (double solenoid, 3 positions,
spring centred)
6. Load control valve Directional valve

(counterbalance) 19. (double solenoid, 3 positions,
spring centred)
CBCA-LHN
7. Check valve Directional valve
CXDA-XCN 20. (double solenoid, 3 positions,
9C600S spring centred)
CVH 103 P
Check valve 21. Main line
8. (pilot operated)
CKCB-XCN
9. Check valve 22. Pilot line

(pilot operated)
CPOM2
Flow control valve 23. Closed connection

10.
(fully adjustable)
NFCC-LCN
NV 101 S 24. Connection point
Flow control valve

11.
(fully adjustable with 25. Crossing point without connection
reverse free flow check)
NCCB-LCN
9F600S
FM2DDKN 26. Filter
12. Flow control valve 27. Double acting cylinder

(fully adjustable,
FDCB-LAN pressure-compensated
with reverse free flow check) 28. Pressure
29. Tank
30. Components range

05-03

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Service Training

Container handling truck

Engine type Cummins. QSM11-c

356 804 46 01. 10/01

1.1.2 ENGINE SERIAL NUMBER

10.1.2.1 LOCATION OF ENGINE DATA PLATE

1.1.2.2 INFORMATION ON DATA PLATE

This information indicates the following:-

1 Engine serial number.

1.1.3.1 FUEL SYSTEM LAYOUT

356 804 46 01. 10/01

1 Fuel return to tank. 6 Fuel solenoid.

1.1.4 FUEL SYSTEM COMPONENTRY.

1.1.4.1 FUEL FILTER AND WATER TRAP.

The fuel filter and water trap assembly is mounted on the

1.1.4.2 FUEL CHARGE PUMP AND SOLENOID.

Inlet line restricton (maximum) 254 mm HG. (10" HG)

356 804 46 01. 10/01

1 Fuel shut down solenoid.

1.1.4.3 TESTING THECHARGE PUMP AND SOLENOID.

1.1.4.3.1 FLOW TEST.

A series of checks can be made to test the operation of the fuel

1.1.4.3.2 PRESSURE TEST.

The pressure within the system can be measured by connecting

Increase the engine rpm to maximum, the gauge should show

1.1.4.3.3 LEAKADGE TEST.

A leakadge test may be carried out by adding a length of clear

The fuel solenoid can be tested with a voltmeter to ensure the

1.1.4.3.5 INSPECTING THE CHARGE PUMP.

356 804 46 01. 10/01

1.1.4.3.6 REMOVING THE CHARGE PUMP.

In order to remove the pump (1) for further investigation remove

1.1.4.3.6 PRIMING THE CHARGE PUMP.

1.1.4.4 FUEL INJECTORS.

The fuel injectors are electronically controlled by the engine

356 804 46 01. 10/01

1.1.4.4.2 FUEL INJECTOR REMOVAL.

injector clamp capscrew (3) and the injector clamp (4).

Top O ring Red.

Do not twist the O rings during fitting.

Adjust the valves and injectors.

The valve clearances and injector "lash" are adjusted at each

The crankshaft can be rotated by turning the pulley opposite the

356 804 46 01. 10/01

ROTATE P U LLE Y SET INJECTOR SET CYLINDER

Each cylinder has three rocker levers.

The long rocker lever (N°1) is the exhaust valve lever.

The short rocker lever (N°2) is the inlet valve lever.

The centre rocker lever (N°3) is the injector lever.

Inlet valve 0.36mm (0.014")

pipes are fitted correctly.

1.1.4.5 ENGINE COOLING SYSTEM.

The cooling system of the Cummins QSM engine is similar to

Replacement of the water filter should be carried out at the

Ensure that the filter valve (1) is switched to the "OFF"

356 804 46 01. 10/01

1.1.4.5.2 REMOVING AND INSPECTING THE

The alternator must be removed to gain access to the

1.1.4.5.2 REMOVING THE WATER PUMP.

Removal of the alternator and thermostat housing will facilitate

1.1.4.5.3 REMOVAL OF THE PULLEY BELT.

1.1.4.6 OIL FILTER REPLACEMENT.

Use a filter wrench to loosen and remove the filter. Thoroughly

356 804 46 01. 10/01