Maintenance . . . . . . . . . . . . . . . . . . . . . . . . ..............................

2-3-11

Removal . . . . . . . . . . . . . . . . . . . . . . . . . ..............................2-3-

11Installation . . . . . . . . . . . . . . . . . . . . . . . . ..............................2-3-

11AUTOMATIC POWERSHIFT CONTROL (APC 100) . . ...............................2-3-13

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............................2-3-13

Direct Engagement Protection . . . . . . . . . . . . . ..............................2-3-13

Downshift Protection . . . . . . . . . . . . . . . . . . . ..............................2-3-13

Low Clutch Pressure Warning . . . . . . . . . . . . . ..............................2-3-13O

verride System . . . . . . . . . . . . . . . . . . . . . . ..............................2-3-13

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............................2-3-13

Automatic/Manual . . . . . . . . . . . . . . . . . . . ..............................2-3-13

Clutch Pressure . . . . . . . . . . . . . . . . . . . . ..............................2-3-13

Engine Speed . . . . . . . . . . . . .

AUTOMATIC POWERSHIFT CONTROL (APC 100)

DESCRIPTION
GENERAL
LOW CLUTCH PRESSURE WARNING
NOTE

The APC 100 monitors transmission clutch pressure.

If clutch pressure becomes critically low, the APC
The automatic powershift control is only
100 will cause the TRANS RPM/PRESS indicator to
applicable
to
the
carrier
cab.
light as a blinking warning, until normal clutch
Transmission control from the super-
pressure returns.
structure cab is manual.

OVERRIDE SYSTEM
The automatic powershift control (APC 100), located
behind the operator's seat, is a small computer
The override system allows the transmission to be
dedicated to transmission control. Information such
shifted manually. The override (automatic/manual)
as engine speed, turbine speed, gear selection, and
switch is mounted on top of the APC 100 mode
throttle position is used by the computer to determine
control fuse and relay box and energizes relays that
the proper time to shift the transmission. The APC
disconnect the shift solenoids from the computer and
100 prevents a dangerous shift if an improper gear is
connects them to the cab shift control. This allows a
selected with the shift control. Torque converter
vehicle disabled due to electronic shift failure to be
lockup is also controlled by the APC 100.
driven to the nearest maintenance point. Each time
the ignition switch is turned off and then back on, the

NOTE
override switch must be reset.
The safety
parameters set by the computer are not active in
Removing carrier cab seat will provide
system override.
easier access to the APC 100 and the
fuse and relay box.

INPUTS
DIRECT ENGAGEMENT PROTECTION
Automatic/Manual

From neutral, a forward or reverse gear cannot be

The automatic/manual mode (override) switch is on

selected if the engine speed is above 1000 rpm.

top of the APC 100 mode control fuse and relay box.
When changing direction, the engine speed must be
An open switch indicates automatic mode and a
less than 1000 rpm and the vehicle speed must be
closed switch indicates manual mode. A closed
less than one mph, or the transmission will shift into
switch inputs battery voltage. The manual mode
neutral.
must be reactivated each time the ignition switch is
turned off then back on.
If the crane is moving, drive can only be engaged
when the engine speed is less than 1200 rpm in 1st

Clutch Pressure
or 2nd, 1400 rpm in 3rd or 4th, and 1600 rpm in 5th
or 6th (both forward and reverse).
Clutch pressure is monitored by a clutch pressure
switch that closes if the clutch pressure becomes

DOWNSHIFT PROTECTION
critically low. A closed switch inputs battery voltage.
Downshifting is only allowed if there is no risk of

Engine Speed
overspeeding the transmission. If a gear is selected
that would result in an overspeeding condition, the
The engine speed input is obtained from a variable
computer will select the lowest gear that will not
reluctance speed sensor mounted in the converter
cause overspeeding and the TRANS RPM/PRESS
housing. The teeth of a ferrous target wheel pass by
indicator on the front console will be lit (steady). This
the pole of the sensor which produces a pulsed
condition will remain until the vehicle has slowed
signal. The APC 100 measures the time between
enough to make the shift into the selected gear.
the pulses to calculate the engine rpm

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Four Wheel Drive

maintenance personnel to help troubleshoot the

system. During initial power-up, the unit will self test
The DRIVE AXLE selector switch on the front
and the LEDs will light for about one second. After
console is used to select two or four wheel drive.
that they will light to reflect the following faults:
When two wheel drive is selected, there is no input.
When four wheel drive is selected, battery voltage is
RED LED - Illuminates if there is a problem
input indicating four wheel drive selection.
internal to the APC 100 control unit. In this
case the APC 100 enters the fail-safe mode

Throttle Position

and all outputs are switched off.

An idle switch inputs battery voltage when the throttle
YELLOW LED - Illuminates when engine or
is in the idle position (switch closed). When the
turbine speed reads zero. This LED will
throttle is moved from the idle position the idle switch
remain lit until the engine is started.
opens and the full throttle position switch closes
inputting battery voltage to indicate throttle position.
GREEN LED - Illuminates when an improper
gear selection pattern is input by the shift
Gear Selection
selector.
A switch matrix of five wires decodes the gear
Two Wheel Drive Solenoid
selector position. The five wires are switched
between open and battery voltage.
If four wheel drive input voltage is present, the APC
100 will automatically switch to two wheel drive when

Lockup Request

the transmission reaches F4 or R5. The four wheel

drive voltage opens the 2WD interlock relay allowing
The lockup switch closes and inputs battery voltage
the 2WD load out relay to close and battery voltage
to enable converter lockup when conditions permit.
is output to switch the vehicle to two wheel drive.
An open switch disables lockup.

Lockup Solenoid

Turbine Speed

The torque converter lockup output switches

The turbine speed is monitored by a pulsed signal
between battery voltage and zero depending on the
that is generated by a speed sensor in the same
engine and turbine speed input ratio. The output is
manner as the engine speed sensor.
connected to a solenoid and is energized when
lockup is engaged.

OUTPUTS
Overspeed and Low Clutch Pressure Indicator
Diagnostic LEDs

This output lights a LED on the front console. The

LED will illuminate (steady) if a gear is selected that
would cause an overspeed condition and will go out
when rpm drops to a speed allowing the selection.
The LED will blink rapidly should a turbine failure
occur. The APC must be reset to clear this
condition. The LED will blink slowly if low clutch
pressure is detected for more than five seconds.
LED will go out when sufficient pressure returns.

Shift Solenoids
Figure 2-3-6. Diagnostic LEDs

The shift solenoids output switch between battery

voltage and zero as associated shift speeds are
There are three diagnostic LEDs (Light Emitting
reached. The output energizes the appropriate shift
Diodes), under a cover, on the top of the APC 100
solenoid when the output is switched on

Speed Sender Input Diagnostics

2.
The TORQUE CONVERter UNLOCKED
indicator should illuminate when ignition switch is
1.
Disconnect relay box h

TM 5-3810-307-24-1-1MAINTENANCE

e.
Press and release the hold button. This
TEST PROCEDURES WITH CHECKOUT KIT
will activate the "checkout" mode and will
show the checkout screen:
Installation of Checkout Kit and Start-up Screens
1.
Ensure ignition switch is off (O)
and
transmission shift control is in neutral (N).
T = Turbine RPM
E = Engine RPM
2.
Disconnect 37 pin connector from APC 100
H = "Hold" Screen - no new data being
and connect to checkout kit.
shown
R = Speed Ratio - ratio of turbine speed
to engine speed
NOTE
C = Controller Position - gear selected
With checkout kit installed and ignition
via transmission shift control as
switch
on,
TRANS
RPM/PRESS
interpreted by checkout kit
indicator will flicker dimly.
G = Gear that checkout kit is outputting
to transmission
3.
Position ignition switch to 1 (run). Display will
quickly flash through three start-up screens. Use the
Input/Output Checks
hold button to freeze the screens. Release the hold
button to move to the next screens:
1.
Transmission Shift Control (Controller) Inputs
(01,02,20,21,22).
a.
Screen #1 will show:
a.
Move the shift control lever to each gear
CLARK-HURTH Comp
position. As this done observe the
CHECKOUT KIT 1.3
following:
(1)
The "C:xx" display should match
Also all input LEDs should be
the position selected.
yellow/orange and all output LEDs
(2)
The "G:xx" display will show only
should be green.
F1 or R1 while vehicle is
motionless.
b.
Screen #2 will show:
(3)
The indicator LEDs should
illuminate
yellow/orange
as
13.9FLHR24658
shown in Table 2-3-1.
AT400MILCRANE
NOTE
Also all input LEDs should be
yellow/orange and all output LEDs
The input to #01 (forward) is turned off if
should be red.
the shift control is in positions F3-F6 with
rear axle steering unpinned.
c.
Screen #3 will show:
(4)
If inputs are incorrect, check shift
APC100 4204409
control, wiring to and from shift
V1.0 05.11.95
control, and APC 100 mode
control fuse and relay box for
This is the program number of the
faulty
connections
and/or
EPROM which is installed in the
components.
checkout kit. Be sure it is #4204409.
d.
Screen should go blank. If checkout kit
does not function as shown above, refer
to checkout kit troubleshooting

The input LEDs will be either dark (off state) or

CHECKOUT KIT
yellow/orange (on state). The output LEDs will light
various colors depending on the condition of the
Description
output circuit:
The checkout kit is an APC 100 with a LCD display,
input/output signal LEDs, and diagnostic software to
dark = off
help determine system and/or wiring faults. Refer to
green = good
Figure 2-3-7 for identification of the parts to the
yellow = open circuit or shorted to +24v
checkout kit.
red = shorted to ground.
Figure 2-3-7. Checkout Ki

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arness (rectangular
turned on. If it does not light, check electrical circuit
connector) from APC 100 control box.
and indicator. Correct any fault(s) and proceed to
step 3.
2.
Position ignition switch to 1 (run).
3.
Disconnect relay box harness (rectangular
3.
Check resistance between sockets 28 and 29,
connector from APC 100 control box and place
and sockets 30 and 31 of relay box harness
ignition switch to 1 (run).
connector. Resistance should be 1000-1200 ohms.
4.
Check socket 25 (lockup request input) of
a.
If resistance readings are as stated,
harness connector for 24 vDC.
proceed to step 4.
a.
If voltage is absent, check fuse and relay
b.
If
resistance
readings
are
not
box for faulty wiring or loose connection.
acceptable, check appropriate circuit.
Correct any fault(s) and recheck
Correct any fault(s) and recheck
voltage.
resistance.
b.
If voltage is present, proceed to step 5.
4.
Place crane on outriggers, start engine from
carrier cab, place transmission shift lever in F1, and
5.
Measure resistance between socket 37
run at idle.
(lockup output) and socket 11 (ground). Resistance
should be 30-60 ohms.
5.
Measure AC voltage between sockets 28 and
29, and sockets 30 and 31 (turbine speed). Voltage
a.
If reading is not as stated, check
should be 5-10 vAC. If voltage reading is less than 3
harness, fuse and relay box fuse FU8
vAC, check speed sender for damage. Replace
and connections, and solenoid for faults.
sender if damaged and recheck voltage.
Correct any fault(s) and recheck
resistance.
NOTE
b.
If reading is acceptable, reconnect APC
Clearance is preset by bushings installed
100 relay box harness and proceed to
in transmission and should not be a
step 6.
problem.
6.
Attach a voltmeter to wire 448 at lockup
Torque Converter Lockup Diagnosis
solenoid modulator valve. Use a jumper wire if
necessary and secure wires away from driveshaft to
NOTE
allow taking reading safely with driveshaft rotating.
For proper lockup operation, APC 100,
7.
Place crane on outriggers, with tires off the
throttle switch inputs, gear selector
ground, and start engine from carrier cab.
inputs, and speed sender inputs must be
functioning properly, refer to appropriate
8.
Position transmission shift lever to F4, release
procedures and check functions prior to
brakes, run engine at 2200 rpm, and allow
diagnosing lockup problems.
transmission to enter F4 gear. Lockup may occur in
F3 since engine speed is below full throttle switch
1.
Lockup is allowed in gears F4 thru F6 and also
setting.
in F3 when the throttle is less than mid-throttle. The
crane will feel sluggish, fuel economy will suffer, and
9.
As turbine speed (torque converter output)
top speed will be difficult to achieve if lockup is not
surpasses minimum speed (refer to Table 2-3-7) and
functioning. The operator can usually feel lockup
approaches engine speed, TORQUE CONVERter
engaging (feels like a smooth prolonged shift to a
UNLOCKED indicator should turn off, the voltage
higher gear) about 3 seconds after TORQUE
reading at lockup solenoid should change from 0 to
CONVERter UNLOCKED indicator turns off.
24 vDC, and lockup should occu