Installation and Operation Manual for 4L80E and 4L85E Transmissions

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Installation and Operation Manual for 4L80E and 4L85E Transmissions US Shift Transmission Control System instruction and operation manual. Baumann Electronic Controls, LLC. Phone: (864)
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Installation and Operation Manual for 4L80E and 4L85E Transmissions US Shift Transmission Control System instruction and operation manual. Baumann Electronic Controls, LLC. Phone: (864) Address: 207 Mistr Lane, Pickens, SC This work and the ideas and processes contained herein are the exclusive property of Baumann Electronic Controls, LLC and may not be copied, reproduced, or distributed in any form without the express written consent of Baumann Electronic Controls, LLC or Karl Baumann. The technology and processes contained in this product are proprietary and may be used only on a single unit basis or as defined by the written permission of Baumann Electronic Controls, LLC. vf5.6.1 Copyright by Baumann Electronic Controls, LLC. All rights reserved. WARRANTY Baumann Electronic Controls, LLC. is dedicated to producing the highest quality products available in the industry and is committed to customer satisfaction. Because we have no control over the circumstances under which our products are used, we can assume no more responsibility for damages (consequential or otherwise) or defects in materials and workmanship than the original purchase price of our product. Baumann Electronic Controls, LLC. will repair or replace all defective components unconditionally for a period of five years from the date of sale. This warranty does not cover damages due to abuse, improper application, or connection of the device. After the warranty period, Baumann Electronic Controls, LLC. will service this device for a nominal fee. APPLICATION COVERAGE This system works with 4L60E, 4L65E, 4L70E, 4L80E, and 4L85E automatic transmissions. It is recommended that you use the Baumann wiring harness with this system. 2 CONTENTS Preparation Page 4 Connecting the Essentials Page 5 Setting up the Quick 4 Page 9 Notes on Installation Page 11 Transmission Diagrams Page 13 Optional Features Page 14 Manual Shift Connections Page 19 Built-In Display Page 23 Shiftware Page 31 Important Information Page 34 Troubleshooting Error Messages Page 35 Contact Page 39 READ BEFORE PROCEEDING Before installing the Quick 4 unit, we recommend you read the manual from beginning to end. Some of the information in this manual is very important and, if the unit is improperly installed or an error messages misunderstood, could result in serious damage to your vehicle and transmission. 3 PREPARATION Pre L80E transmissions use a different internal wiring harness and passthrough connector. This early harness has a problem with leaking fluid at the pass-through connector. GM recommends upgrading to the newer connector and wiring harness. Because of this, we do not provide a wiring harness for it. If you have one of these early transmissions, it will be necessary to upgrade to the internal wiring harness. The Bosch pressure control solenoid used in pre L80E transmissions is not compatible with the Quick 4 controller. You will need to upgrade it to the Holley solenoid. The older Bosch solenoid is silver, while the newer Holley solenoid is black. If your solenoid is already black, you have the right one and it doesn't need to be changed. The GM part number for the Holley pressure control solenoid is Step 1: Ground Splice the ground wires (Pins 15 & 16 Black) from the Quick 4 into the main ECU (Engine Control Unit) ground wire. Do NOT connect the ground wires to sheet metal or other ground sources. The Quick 4 MUST be connected to the Main ECU ground, as close to the ECU as possible. CONNECTING THE ESSENTIALS (ELECTRONIC FUEL INJECTION) Step 2: Power Splice the power wire (Pin 9 Red with 7.5 Amp fuse) from the Quick 4 into the main ECU (Engine Control Unit) ignition-switched power wire. Step 3: Throttle Position Sensor or Accelerator Pedal Position Sensor Splice the Throttle Position Sensor signal wire (Pin 3 Green) from the Quick 4 into the Throttle Position Sensor (TPS) signal input of the ECU (Engine Control Unit). If the vehicle has Electronic Throttle Control, use the Accelerator Pedal Position (APP) Sensor instead of the TPS. 5 CONNECTING THE ESSENTIALS (CARBURETED AND MECHANICALLY-INJECTED DIESEL) Step 1: Ground Connect the ground wire (Pin 15 Black) from the Quick 4 directly to the battery ground post or negative battery cable. Do NOT connect the ground wire to sheet metal or other ground sources. The Quick 4 MUST be connected directly to the battery ground post or negative battery cable. Step 2: Power Connect the power wire (Pin 9 Red with 7.5 Amp fuse) from the Quick 4 to ignitionswitched power wire. Do NOT use accessoryswitched power. Step 3: Throttle Position Sensor Attach the 3 Throttle Position wires from the Quick 4 to the Throttle Position Sensor. Pin 16 Black is dedicated ground. Pin 11 Orange is +5v reference feed. Pin 3 Dark Green is the position sensor signal. See the Throttle Position Sensor section for details. 6 7 Step 4: Transmission Connectors Connect the Solenoid and TSS cables to the transmission. THE CONNECTORS MUST BE KEYED CORRECTLY for proper transmission operation (see the diagram below for details). Connect both TSS cables according to their labels. Additionally, connect the Neutral Safety Switch and the Backup Lamp Switch. The neutral safety switch isn t related to the Quick 4 controller or harness, but should be included in every installation. In some 4x4 transmissions, the output speed sensor may be missing or nonfunctional due to lacking a tone ring. You can use a speed sensor in the transfer case instead or install a 40 pulse tone ring in the transmission. A similar type of 40 pulse sensor may be used in transfer cases that do not have a mechanical speedometer drive. Step 5: Optional Features Connect any extra features you wish to use. See the Optional Features section for details. 8 SETTING UP THE QUICK 4 Step 6: Calibration For a detailed video walkthrough of the setup process, scan the QR code to the right using your smart phone. You can also find the video on USshift.com. Verify that the correct calibration is loaded on the Quick 4. A standard calibration specific to your order is loaded before shipment. However, if the transmission configuration has changed since the order was placed, you'll need to connect the Quick 4 to a Windows PC and install the Shiftware Tuning Software. (See the Shiftware section for installation instructions.) Using the software, load the calibration that matches your transmission's configuration. Step 7: Throttle Position Sensor Calibration Whether you have electronic fuel injection or a carburetor, you will need to set the throttle position. To do this, use the throttle position calibration option on the built-in tuning interface. When navigating the built-in tuning interface, use the knob to move through menu items and click to choose them. If you wait on an item, the long-form name will scroll across the screen. To calibrate throttle position, the ignition should be on but the engine not running. For carbureted engines, make sure the choke is fully open and off the fast idle cam before beginning. Turn the knob to SET (Set Up System) and click to enter the setup menu. TPS (Calibrate TPS) will be shown and you can click the knob again to enter calibration mode. It will begin detecting the idle throttle position right away, so leave the pedal untouched. When the display scrolls PRESS ACCEL PEDAL, push the accelerator pedal all the way to the floor and hold it. After a few seconds, RELEASE ACCL. PEDAL will scroll on the screen and you can release the pedal. TPS SUCCESSFUL will scroll if the setting completed. Afterward, it will show the measured closed and full throttle voltages. If an error occurs during calibration, the display will show the error and abort calibration. If this happens, you can try running the calibration again. If errors continue, you may need to check your wiring for problems. 9 Once the TPS calibration procedure is completed, the values are permanently stored in the controller and will be active for every tune written. TPS values displayed within individual tunes are then irrelevant. If you require TPS customization for individual tunes or are using a negative slope TPS, then the TPS values stored in the controller can be reset by double-clicking the knob while in TPS calibrate mode, causing the TPS reset message to be displayed. Our provided tuning software can then be used to calibrate TPS values for specific tunes. Possible TPS Calibration Errors as shown on the built-in display: ACCEL PEDAL NOT PRESSD / ACCEL PEDAL NOT HELD The throttle wasn t pushed or held at maximum long enough for the test to complete. Accelerator pedal must be held for 3 seconds and voltage must not drop more than 0.168V below the maximum recorded value. ACCEL PEDAL NOT RELEASED The throttle wasn t released within 5 seconds. The voltage must drop at least 0.96V below the maximum measured WOT value. TPS NOT STABLE The idle throttle position has changed values too drastically over the course of the calibration. The idle voltage is more than 0.6V greater than the lowest recorded value. ERROR TPS LO = 0.00 The voltage is below the minimum allowed 0.2V during any of the tests. 10 NOTES ON INSTALLATION If any error messages or unexpected characters are displayed, refer to the troubleshooting section at the end of this manual for detailed explanations. General Installation The Quick 4 unit should be mounted within the passenger compartment of the vehicle in a protected location. Good mounting areas include under the dash, behind a kick panel, or under the seat, as long as the unit and wiring are not subject to damage. Under-hood mounting is NOT possible with the Quick 4 unit. It is not waterproof or rated for under-hood temperatures. Passenger compartment mounting is also necessary to provide easy access to the USB port, which is used to interface with a PC for programming and diagnostics, as well as the display and function control knob. For this reason, be sure to mount the unit in a way that gives easy access to the USB port, knob, and display. If you will be using a desktop PC for programming, install the unit so that it can be unplugged and moved easily. All electrical connections should be made using 60/40 rosin core solder. Cover the connection with heat-shrinkable tubing for improved insulation and mechanical strength. Individual connector terminals can be connected using a piggy-back method, where the terminal is removed from the plastic connector housing to allow the new wire to be soldered on to the terminal atop the original wire. Two wires may be connected together by twisting them together longitudinally, soldering, then covering with the appropriate size heat-shrink tubing. Before Driving the Vehicle Start the engine and move the shifter through all positions, ensuring that the gear position and all sensor readings shown on the controller are correct. Most importantly, make sure that no error messages are shown on the Quick 4 display. It is a good idea to periodically check the Quick 4 display for errors as you drive, so it is wise to consider an accessible mounting location. If possible, perform a line pressure check to ensure that line pressure is correct at idle (typically 60-80PSI), and that it smoothly increases toward maximum (typically PSI) as the throttle position increases. If you have any questions about the installation or line pressure readings, please contact our technical support department. 11 Adaptation for Factory-Equipped Transmissions It is possible to use the Quick 4 controller in a vehicle which was originally equipped with one of the intended transmissions. This could be done in conjunction with an engine management system upgrade that no longer supports the transmission. Use of the controller for this purpose allows flexibility in choosing the engine management system, in addition to the increased control, performance, and transmission durability afforded by Quick 4. If you retain the stock PCM/VCM, it can probably be modified or re-flashed to disable the transmission functionality. Identifying the Terminals of an Unknown Throttle Position Sensor This is a procedure for identifying the correct terminal connections of any potentiometer-style throttle position sensor (almost all three-terminal TP sensors). A DVOM or analog Ohmmeter is required. 1. Set the meter to resistance mode and set it to a scale that can read up to 10K or 20K Ohms (if it is not auto-ranging). Please keep in mind when setting up and reading the meter that K means thousands of Ohms. In other words, 15K Ohms is the same as 15,000 Ohms. 2. Connect the meter to two pins at a time while operating the lever or cam of the TPS. Watch the meter while rotating the sensor. Check all three pairs of pins until you find a pair that does not change resistance when you rotate the sensor. The two pins that do not change resistance are the fixed ends of the resistance element (+5V and ground). The remaining pin that did change is known as the wiper . It is the moving contact that slides along the resistance element to give the varying voltage. This is the output terminal of the sensor and should be connected to our green wire (Vehicle pin 3). 3. Next, with the sensor at the idle or closed throttle position, measure the resistance between the wiper (output) and each of the end terminals (the two whose resistance did not change in step 2) of the sensor. The end terminal with the lowest resistance to the wiper (at idle) is the ground terminal, and should connect to the black main ground wire of the controller (Vehicle pin 16). The terminal with the higher resistance to the wiper is the 5 volt reference input to the sensor and should connect to the orange wire (Vehicle pin 11) in our harness. General Guidelines for setting up Throttle Position Sensors The linkage to a throttle position sensor should use most of the rotating range of the throttle position sensor. This can be adjusted by changing the ratio of the linkage. Also, please make sure that a small amount of the sensor's travel is being used at idle. You will want a TPS voltage at idle of at least 0.35 volts. This is done to allow the controller to detect problems with the TP sensor. For instance, if the sensor becomes disconnected or the linkage falls off, the TPS voltage will fall below the set idle threshold. If the TPS voltage goes below the idle threshold, the controller assumes that the TPS is bad and will switch to failsafe line pressure and default shift points. This is done to prevent damage to the transmission from low line pressure and will provide a safe limp home mode. 12 TRANSMISSION DIAGRAMS 13 OPTIONAL FEATURES Multi-Tune This feature allows completely different calibrations to be used for the transmission at any time. The table selection switch can be a latching type switch (maintained toggle switch, latching push-button, etc.) or a momentary type switch (spring-loaded push-button switch, spring-loaded toggle switch, etc.) which applies ground to the table select input at Vehicle connector pin 5 when turned on. When a latching switch is used, it can only be used to switch between two tables. When the latching switch is activated, the controller will use the secondary calibration table (normally table 2), and it will run off of the primary table (normally table 1) when the switch is off. A momentary switch will cycle through all of the tables in use ( ). The Table Selection input may also be connected to a nitrous oxide system to provide an alternate calibration for use when the nitrous system is engaged. Other uses for this input include a Sport/Economy switch or a Normal/Aggressive switch. Whenever the table state is changed, it will be scrolled on the controller s display (tb1, tb2, tb3, tb4). There are alternative table select input methods that can be used. You can single-click the controller knob while at the status screen or attach a latching or momentary switch to the brown wire (pin 4). This would free up the purple wire (pin 5) to be a low-range selection switch. Different modes can be selected in the tuning software which will select different tables for different situations. For example, Select Tables Using Only 4WD Mode will use table 1 in 2WD and 4WD high range, with table 2 for 4WD low range (Tables 3-4 will be used for the second and third low ranges, if equipped) If a switch is connected to the table select wire, Select Tables Using Switch and 4WD Mode chooses tables 1 or 2 in 2WD mode and table 3 or 4 in 4WD (depending on switch position). Select Tables Using Manual Mode Status will choose the table according to whether manual mode is enabled or not. Auto mode will use table 1 and Manual mode will use table 2. (Table 3 and 4 will go unused.) 14 4x4 Low Range Detection Low range detection can be enabled if you want the controller to switch to an alternate calibration table when 4x4 low range is engaged. Configure the options in Shiftware under the 2WD/4WD Options and Table Select tabs in the settings window. For example, 4x4 low range detection can be enabled so that when ground is applied to pin 5 (purple) of the vehicle harness, the controller will switch to table 2. Another option includes single-clicking the controller knob to enable 4x4 low range calibration. Up to 3 low range ratios can be used. Whenever 4x4 low-range state is changed, it will be scrolled on the controller s display (4HI, 4Lo, 4L2, 4L3). Speedometer Output We have provided an adjustable speed signal output on the tan wire on pin 12 of the vehicle connector that can be used to drive an electronic speedometer, if desired. Use of this output signal is not necessary, but it can be helpful if your speedometer can not be driven correctly from another source. This signal can also be corrected for different gear ratios and tire heights, so it can be very useful in some applications. The speedometer output signal is normally provided as a 5 Volt square wave, but it can also be configured to provide a 12 Volt square wave when required. For more information, see the Jumper Settings document on USshift.com under Support / Manuals & Publications. There are two speedometer output modes that can be selected via the tuning software or the built-in tuning interface. It can also be disabled if not used. In the replicated speed sensor output mode, the speedometer output provides an amplified and squared version of the original speed sensor signal. Replicated mode is useful for applications that require a signal with the exact pulse rate of the speed sensor being used. There is also an adjustable corrected mode, which is very useful for correcting speedometer errors or providing unusual speedometer output signal frequencies. Adjustable mode is essentially the electronic equivalent of a ratio corrector gear box for a mechanical speedometer. In adjustable mode, the correction factor is entered as a decimal number. The correction factor is the frequency ratio of the speedometer output frequency to the speed sensor frequency. This number can be easily adjusted to synchronize the vehicle speedometer to a GPS or other instrument. 15 In some cases, such as driving the input of an engine control ECU, the 0-5 Volt (or 0-12 Volt) square wave signal will not be able to properly drive the device that it is connected to. This is because some devices are only designed to accept an input signal from a variable reluctance (magnetic coil) sensor. Because of this, they may expect the input signal to swing below ground (0 Volts). To drive this type of input, use the included capacitor to offset the DC value of the speedometer signal to 0 Volts. As a result, the driven device will see a -2.5V to +2.5V signal instead of 0V to 5V. To make this signal work, install the provided 10µF, 25v, non-polar, electrolytic capacitor inline between the speedometer output of the Quick 4 and the device that it is driving. To install the capacitor, cut the speedometer output wire and solder a capacitor lead to each
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