PCS TCM2800 User manual

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PCS TCM2800 QUICK START GUIDE

Table of Contents
Section 1: Installation Instruction Contents ......................................................................................................................................................... 1 - 5
Section 1.1 Introduction ................................................................................................................................................................................... 1
Section 1.2 Check TCM and Harness ............................................................................................................................................................. 1
Section 1.3 TCM and Harness Guidelines ...................................................................................................................................................... 1
Section 1.4 Connections ................................................................................................................................................................................. 2
Section 1.4.1 Inputs .................................................................................................................................................................. 2 - 5
Section 1.4.2 Outputs .......................................................................................................................................................................5
Section 2. Installation Instruction Contents ........................................................................................................................................................ 6 - 7
Section 2.1 System Overview ......................................................................................................................................................................... 6
Section 2.2 System Requirements .................................................................................................................................................................. 6
Section 2.3 Congurable Tuning Software Installation .................................................................................................................................... 6
Section 2.4 Connecting the Communication Cable ................................................................................................................................... 6 - 7
Section 3. Save Calibration File ................................................................................................................................................................................... 8
Section 4. Initial Setup .................................................................................................................................................................................................. 9
Section 4.1 Tire Size and Axle Ration Setup ................................................................................................................................................... 9
Section 4.2 Throttle Position Setup ................................................................................................................................................................ 10
Section 5. Verify Operation of Initial Setup ............................................................................................................................................................... 10
Section 6. Calibrating the Transmission ............................................................................................................................................................ 11 - 14
Section 6.1 Shifting into Gear Pressure ........................................................................................................................................................ 11
Section 6.2 Steady State Pressure ................................................................................................................................................................ 11
Section 6.3 Manual Range Pressure .............................................................................................................................................................. 12
Section 6.4 Upshift/Downshift Tables ............................................................................................................................................................. 13
Section 6.5 Wide Open Throttle (WOT) Upshift RPM A ................................................................................................................................. 13
Section 6.6 Wide Open Throttle (WOT) Downshift Speeds A ........................................................................................................................ 14
Section 6.7 TCC Lockup Settings .................................................................................................................................................................. 14
Section 7. Datalogging ........................................................................................................................................................................................ 15 - 16
Section 7.1 Datalogging Menu ...................................................................................................................................................................... 15
Section 7.2 View Datalogs ............................................................................................................................................................................. 16
03-04-2020 - REV 2.1: Instuctions on how to enter “Basic + Setup” mode added to Section 4.
Revision History

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PCS TCM2800 Quick Start Guide
1 Installation Instruction Components
1.1 Introduction
Please check your new transmission control system contents. These transmissions are fully electronic and will not
shift automatically without a transmission control system connected to it. Powertrain Control Solution’s TCM, computer
software and wiring harness. The programmable TCM has many features such as; fully tunable part throttle and WOT
shift points, shift rmness for various throttle/torque level, Sport/Tow Haul calibration tables. The torque converter lock-up
vehicle speeds are fully adjustable as well as the lock up on rate. All of the wiring harness connectors are clearly labeled.
You should have received the following items:
• TCM-2800 Transmission Control Unit (TCM)
• Complete wiring harness with labeled connectors
• USB Drive with Software
• 5ft communications cable for TCM to laptop
1.2 Check TCM and Harness
Your TCM should come preloaded with a starting calibration le. Check the sticker on the bottom of the controller to
see what calibration le has been preloaded. If the sticker has “Cal to be loaded by OEM/Dealer” contact the dealer
the controller was purchased from to see if a calibration has been loaded or to acquire the initial calibration. If using the
controller on an unsupported transmission, a more in depth setup is required and is beyond the scope of this document.
Verify the connectors on the harness match the ones on your transmission and sensors. The Wiring harness schematics
have views of all the connectors and should be matched to your applications prior to any installation.
1.3 TCM and Harness Guidelines
The TCM itself is weatherproof, but there are some basic rules to follow when you are deciding a location to mount it
Mounting it in the engine compartment is acceptable or under the vehicle is acceptable. Also verify the wiring harness
has ample length to reach the other connections before permanently mounting it. The TCM requires an 12v power,12V
Switched, ground connection, Throttle Position input to operate correctly. The power connection to the TCM is prewired
to an unterminated wire.
Function Wire Color
12V Power Red
12V Switched Yellow
Ground Black
TPS Yellow/Black
TPS Ground Black/White
Engine RPM Orange/Black
Engine RPM Ground Black/White

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1.4 Connections
1.4.1 Inputs
Transmission Control Module (TCM) Connector
The main transmission connector varies depending on the transmission model you are working with. Verify the
connector and wiring diagram match your transmission prior to beginning the installation. PCS harnesses connect
all of the internal transmission solenoids, sensor switches that the TCM requires to control the transmission.
Simply plug it into the connector of the transmission. Reference Figure 1.
Laptop Calibration Connector
This connector allows the TCM to interface with your laptop. The laptop calibration connector plugs into the
supplied communication cable. Reference Figure 2.
Throttle Position Sensor (TPS)
Throttle position is required for all transmissions to function properly.. There is a three wire connector used for
the throttle position sensor. Typically, the mating connector has 2 wires, Yellow and Black for the TPS reference
signal and black and white for the analog sensor ground. This is typically the AD1 input under the Digital Input
setup. Reference Figure 3.
Figure 3: Throttle Position Sensor (TPS)
Figure 2: Laptop Calibration Connector
Figure 1: TCM Connector

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RPM Wires (unterminated)
There are 2 wires in the harness that are used for the RPM input. There Orange and Black for the RPM signal and the
Black and White for RPM Ground. This signal will need to be congured. This wire is not required for operation of your
TCM-2800 unit but it is recommended to offer comprehensive diagnostic capabilities. To utilize the full diagnostic function
of your TCM-2800, connect this wire to the tachometer output wire of your ignition system. The TACHOMETER GROUND
wire must also be connected in the Hardware Setup, there are 4 windows that are used to congure this input. The Speed
Input Selection is precongured for Speed 1, since this is what the standard harness utilizes. Reference Figure 4.
The “Speed input Trigger Value” for speed 1, needs to be set to the signal input value from your engine management
system. Reference Figure 5.
The settings for “Speed Input 1 Pulses Per Revolution”, need to be congured. The value for this will depend on what type
of input you are using to monitor Engine RPM. Reference Figure 6.
Figure 6: Speed Input Pulses
Figure 5: Speed Input Trigger Levels
Figure 4: Speed Input Selection

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CAL A/B Wire
This single wire is one of the unterminated digital inputs that can be used to enable a secondary calibration, Such
as Sport mode. This gives you the ability to create a completely separate shift map and pressure tables for use as a
sport or tow mode. This lead can be attached to a switch that will enable it when pulled low (Grounded) to change to a
completely different calibration. When it is not activated the default position (off) will be the Cal A setting. When switched
on (grounded), the TCM will change to operate from the Cal B calibration.
Cancel Overdrive
When enabled this cancels gear ratios over a 1:1 ratio (overdrive). In automatic transmissions this is almost always the
highest gear.
4WD Low
When enabled, this acts as an output speed divisor. This is for 4WD applications where the transfer case and the speed
output are connected to the output of the transmission. Without any correction, this would cause the speedometer to
read abnormally high. The correction factor enabled by this digital input must be programmed in the gear ratio tables. This
input should be wired to the 4WD low button or (if lever activated) to the 4WD low sensor in the transfer case or shift lever.
Dyno Mode
When enabled, this mode will allow you lockup the torque converter and choose a gear for dynamometer use. Locking
up the torque converter will lower transmission loss and may increase power numbers on the dyno. Typically you will
want to choose a gear that is 1:1 to use for the dyno as this gear ratio usually has the smallest amount of loss in the
transmission. Both parameters are congurable. All upshifts/downshifts will occur at the value specied by 0% TPS in the
upshift/downshift tables. Upshifts will occur until reaching the desired gear specied in the dyno mode form. TCC lockup
will occur based on the speed set in the dyno mode form.
Manual Mode
When enabled, this setting allows the user to upshift or downshift with the press of a button. An analog multiplexed
steering wheel input or two digital inputs may be used for the upshift and downshift commands.
Upshift
This digital input will issue an upshift command to the TCM. This command is only effective when in manual mode.
Downshift
This digital input will issue a downshift command to the TCM. This command is only effective when in manual mode.
The “Speed Input Filter Values” settings lters will assist in receiving a stable signal. Reference Figure 7.
Figure 7: Speed Input Filter Values

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Brake Light Wire
Although not necessary, the wire labeled “brake light” should be run to a factory brake pedal switch (NC) so the TCC will
unlock when you apply the brakes
1.4.2 Outputs
Overdrive Cancel Indicator
This output is driven when Overdrive Cancel is selected. It can be used to activate an LED to indicate that Overdrive
Cancel is in use.
Spare Output (unterminated)
This output can be congured for other indicators such as TCC Status, Dyno Mode etc…
Speedometer Drive
Some speedometers may not be driven correctly by the normal speedometer output of the TCU. In such cases, a digital
output may be programmed to output the same speed signal. The default is 2000 PPM. This value can be modied in the
Tuning Software if needed. Under the Hardware Setup/Speedo Output Settings Window. Reference Figure 8.
Figure 8: Speedo Output Settings

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2 Install Software
2.1 System Overview
Use the supplied USB drive or download link to install the PC tuning software. The PC software installation also includes
drivers for any supplied communication cables. Leave the cable unplugged from the PC until this process has completed.
Once software installation is complete, you can plug in the communication cable.
2.2 System Requirements
PC: 80386 or higher CPU
Operating System: Microsoft® Windows XP /Vista/Windows 7, Windows 8, Windows 10
Graphics: VGA
RAM: 2MB minimum
Hard Disk: 1 MB minimum
RS-232: A free COM port (#1, 2, 3 or 4 without conicting interrupts) is required. Use of a USB to RS-232 adapter is
required in the event your PC is only equipped with a USB port.
2.3 Congurable Tuning Software Installation
Option 1: Installation from Download Link
Visit the link below and download “TCM2800_Tuning-Install.exe” to your computer.
https://www.powertraincontrolsolutions.com/download/Released/Public/TCM2800_Tuning-Install.exe
1. Double click the downloaded le to begin the installation.
2. Follow the instructions that appear on the screen to complete the installation.
Option 2: Installation from USB Drive
1. Insert the supplied software on the USB into your computer’s USB port.
2. Open the contents of your USB drive.
3. Double click “TCM2800_Tuning-Install.exe”
4. Follow the instructions that appear on the screen to complete the installation
2.4 Connecting the Communication Cable
Executing the Software
To execute the program once it’s installed, click on the desktop shortcut open the software. The software is also installed
in the Start Menu Programs folder.
Special Notes
If the TCM is not connected and powered (key off) when the software is executed for the rst time, the software will be in
an ‘Ofine’ mode. Reference Figure 9. If the software is executed after the TCM is powered up (key on) and connected (by
the communication cable), communication will be attempted. You can also press the CTRL G keys to cause the software
to attempt communication with the TCM. Once controller installation has been completed, power on the controller from its
switched 12V source. With the communication cable connected, start the PC software. If everything has been installed
correctly, the software will automatically nd the controller and connect. This is indicated by the software background
turning blue and by a green icon on the Tool Bar. Reference Figure 10.

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Figure 9: Software Ofine
Figure 10: Software Online

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3 Save Calibration File
When the software is connected with the controller, click the “Read Cal” tool bar button. Reference Figure 11. You will
be prompted, with a window, to select where to save the calibration le and what to name it. It is recommended that you
save a copy of the calibration le, that your controller came with, before you start making changes. After clicking “save,”
the calibration will be retrieved from the controller and saved in the selected location. After this process completes, the
software will automatically open the retrieved calibration. When a calibration le is open in the software, you will have the
calibration tree view on the left hand side of the software. Reference Figure 12.
Figure 12: Tree View
Figure 11: Read Calibration Button