Coverpage Instruction Manual Version 2.1 January 18, 2006 Powertrain Control Solutions, LLC. Phone: (804) 227-3023 10511 Old Ridge Rd. Fax (804) 227-3005 Ashland, VA 23005 www.powertraincontrolsolutions.com TCU Manual rev 2.1 - Page 1 - ©2006 Powertrain Control Solutions, LLC. Table of Contents Coverpage.....................................................................................................................................................................1 Table of Contents.........................................................................................................................................................2 1. Introduction to Electronic Automatic Transmission Control..............................................................................4 2. How the TCU Works..............................................................................................................................................5 3. Chapter 1 – Installation...........................................................................................................................................6 3.1 Planning & Research...........................................................................................................................................6 3.2 Connectors ..........................................................................................................................................................7 3.3 Inputs ..................................................................................................................................................................9 3.3.1 Digital Inputs...............................................................................................................................................9 3.3.2 Analog Inputs............................................................................................................................................10 3.3.3 Speed Inputs..............................................................................................................................................11 3.3.4 Power and Ground Connections................................................................................................................12 3.4 Outputs..............................................................................................................................................................12 3.4.1 Digital Outputs..........................................................................................................................................12 3.4.2 PWM Outputs ...........................................................................................................................................13 3.4.3 Speed Output.............................................................................................................................................13 3.5 Extra Features ...................................................................................................................................................13 3.6 Communication.................................................................................................................................................14 3.7 TCU Location and Wire Routing......................................................................................................................14 3.7.1 General Wiring Hints ................................................................................................................................14 3.8 Final Steps ........................................................................................................................................................15 3.8.1 Find and wire necessary sensors ...............................................................................................................15 3.8.2 Wire power and ground connections.........................................................................................................15 3.8.3 Install the TCU and route the wiring harness............................................................................................15 3.8.4 Double check your installation..................................................................................................................16 3.8.5 Communication.........................................................................................................................................16 3.8.6 Start it up!..................................................................................................................................................16 4. Chapter 2 – Software.............................................................................................................................................17 4.1 Planning & Research.........................................................................................................................................17 4.2 Background.......................................................................................................................................................17 4.3 Overview...........................................................................................................................................................18 4.4 Software Installation .........................................................................................................................................18 4.5 Communication.................................................................................................................................................19 4.6 File Management ..............................................................................................................................................20 4.7 Software Walkthrough......................................................................................................................................20 4.7.1 Working with calibration files...................................................................................................................20 4.7.2 Online Mode vs. Offline Mode .................................................................................................................20 4.7.3 Transmission Setup ...................................................................................................................................21 4.7.5 Calibration/Tuning ....................................................................................................................................27 4.8 Additional Features...........................................................................................................................................34 4.8.1 Stepper Motor Setup .................................................................................................................................34 4.8.2 Datalogging...............................................................................................................................................34 4.8.3 Flash Upgrade Procedure ..........................................................................................................................36 4.8.4 Com Port Manual Configuration (for Flash Upgrading Only) ..................................................................36 TCU Manual rev 2.1 - Page 2 - ©2006 Powertrain Control Solutions, LLC. 4.8.5 Diagnostic Trouble Codes.........................................................................................................................37 4.8.6 Password Protection..................................................................................................................................37 4.8.7 Monitor Screen..........................................................................................................................................38 4.8.8 Lightweight Monitor Screen .....................................................................................................................38 4.8.9 Test Mode .................................................................................................................................................38 4.8.10 Toolbar Setup..........................................................................................................................................38 4.8.11 Units Selection ........................................................................................................................................39 4.8.12 Tire Diameter Wizard .............................................................................................................................39 4.8.13 Sensor Calibration Wizard ......................................................................................................................39 5. Chapter 3 – Software Function List.....................................................................................................................40 5.1 Overview...........................................................................................................................................................40 5.2 Inputs ................................................................................................................................................................40 5.2.1 Analog Inputs............................................................................................................................................40 5.2.2 Digital Inputs.............................................................................................................................................48