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trackstar
EXTREME COMPETITION CONTROLS INC. - ECCI TRACKSTAR 6000 Series - USB HD Ultra - OWNERS MANUAL (Edition 3.0 - July 2005) INDEX 1.0 WHEEL UNIT SETUP AND ADJUSTMENT 1.1 Unpacking the wheel unit 1.2 Wheel mounting bracket assembly 1.3 Steering wheel assembly 1.4 Wheel angle adjustment 1.5 Cockpit mounting 2.0 PEDAL UNIT SETUP AND ADJUSTMENT 2.1 Assembly sequence 2.2 Basic pedal pressure adjustment 2.3 PMB brake pedal pressure adjustment 2.4 Adjusting pedal unit geometry 3.0 STEERING RESISTANCE TUNING 3.1 The MONOPOINT system 3.2 Tuning suggestions 3.3 Steering lock adjustment 3.4 Steering spring resistance adjustment 3.5 Steering centering pressure at neutral 3.6 FLDS - fluid damped steering 3.7 Shift paddle adjustment II 4.0 CONNECTING TO YOUR COMPUTER 4.1 Connecting a basic USB unit 4.2 Connecting a USB HD equipped system 4.3 Modes of operation - USB HD 4.4 Separated mode calibration - USB HD 4.5 Linked mode calibration - USB HD 4.6 Properly calibrating the PMB-II brake pedal 4.7 Connecting and calibrating a DB-15 game port system 5.0 ACCESSORY EXPANSION PORT 6.0 POT REPLACEMENT AND POT SETUP 6.1 Steering pot replacement 6.2 Steering pot setup - USB HD 6.3 Pedal pot replacement 6.4 Pedal pot setup - USB HD 6.5 Cleaning 7.0 SERVICE AND TECHNICAL SUPPORT C The contents of this manual, including all descriptions, procedures, and graphics are the exclusive intellectual property of Extreme Competition Controls Inc and may not be copied or distributed without the written permission of ECCI. TRACKSTAR Figure 1 - WHEEL UNIT COMPONENTS STEERING UNIT CHASSIS 1.0 WHEEL UNIT SETUP AND ADJUSTMENT 1.1 UNPACKING THE WHEEL UNIT Before unpacking and setting up your driving system, prepare a clean area with adequate room for laying out the components. Review the list of wheel unit parts [Figure 1] and verify that everything is present to complete assembly. ECCI recommends keeping the original box and packing materials in case the unit needs to be shipped in the future. If shipping is needed, the unit MUST be shipped partially disassembled as originally received, or damage will result. 1.2 STEERING WHEEL SHIFT PADDLE SET TABLE BRACKET SCREWS & NUTS WHEEL SPACER (OPTIONAL) TABLE MOUNTING BRACKET BUTTON RETAINING RING CENTER BUTTON Figure 2 - WHEEL UNIT ASSEMBLY STEERING WHEEL WHEEL UNIT HOUSING HOUSING SCREWS POTENTIOMETER Before starting, examine Figure 2 for how the wheel unit should appear when assembled. In a sufficient workspace lay out the mounting bracket assembly, steering wheel, shift paddle set, center logo button, and button retaining ring. 1. Set the main steering chassis on a table upside down on a terry cloth towel or other soft non-abrasive cushioning material to avoid scratching the cover. 2. Using a 3/16 inch hex wrench, loosen the two center-most chassis tube bolts [Figure 3]. Do not remove them; back them out until the nuts between the bolt tubes and the gray central structural plate can be removed and discarded. Then re-install the two bolts about one turn and leave them loose. 3. Invert the table bracket assembly towards the central chassis structural plate and align the two central slots with the previously loosened chassis-tube bolts [Figure 3]. The table bracket should be seated between the spacer tubes and the gray central chassis structural plate. 4. Using a 1/8 inch hex wrench, attach the mounting bracket with the 3 supplied bracket mount screws and nuts [Figure 3]. After tightening these screws, turn the two center-most chassis bolts until tight, fully securing the mounting bracket to the central chassis structural plate. 5. Turn the unit upright and secure to a tabletop edge using the clamp of the mounting bracket [Figure 4]. Rotate the bracket tensioning bolt [Figure 2] until it is perpendicular to the underside of your mounting surface. Turn until it contacts the underside of the surface. Do not over tighten. Turn till fingertight and then using a wrench, turn one-half turn more. Then lock the bracket by tightening the pivot set screw. 1.3 1. REAR LEG CENTRAL CHASSIS STRUCTURAL PLATE TABLE MOUNTING BRACKET BRACKET TENSIONING BOLT TENSIONING PIVOT TABLE MOUNTING ARM PIVOT SET SCREW TRACKSTAR WHEEL MOUNTING BRACKET STEERING WHEEL ASSEMBLY With the wheel unit upright and secured to the tabletop the steering wheel and shift paddles can be mounted. Prior to assembly inspect the shift paddle set [Figure 5]. Note the importance of the two wire management slots at the back side of the paddles. These slots accommodate the button wiring when the paddle/wheel assembly is tightened down to the steering unit hub. It is critical that the wires pass through these slots and avoid getting pinched during assembly. Remove the five wheel attachment screws from the paddle set. Discard the small nuts that held them at the back of the assembly. From front to back, the screws will pass through the steering wheel, optional wheel spacer (if supplied), the shift paddle assembly, and into the threaded holes in the hub Figure 3 - TABLE BRACKET INSTALLATION BRACKET MOUNT SCREW HOLES 1. REMOVE 2 NUTS CHASSIS TUBE BOLTS CENTRAL STRUCTURAL PLATE Figure 4 - TABLE EDGE MOUNTING AND ADJUSTMENT HEX KEY 2. 3. MONITOR 6 IN. MONITOR SHELF WITH 8+ INCHES OF CLEARANCE 1.4 [Figure 5]. Begin assembly by putting two screws through the steering wheel at the ten and two o’clock position. Hold the heads in place on the wheel with a piece of masking tape. Note that the flanged button retaining ring must be placed between the steering wheel and the shift paddle set. The raised flange of this ring must point towards and fit into the large central hole in the paddle set. Place the paddle set over the screws making sure the button wires are in their slots. Once the paddles are close to the wheel. pull the paddle set wires towards you through the center hole of the wheel. Next position this assembly over the steering unit hub making sure the wheel is upright. Guide the two screws into their respective holes. Pull the hub wires and connectors towards you through the center of the wheel/paddle assembly. Next remove the masking tape and turn the screws in gently making sure before tightening that the paddle button wires are not in danger of being pinched. The wheel should be centered and not cocked to one side. If it is tilted, remove the screws and use the next set of hub holes to counter the tilt. Turn the screws in until snug. Then install the remaining three screws and finally tighten all five screws progressively using the supplied hex wrench until tight. Connect the button wires to the hub connectors as shown in Figure 5. Wire colors do not matter, the paddles will function any way they are plugged in. Carefully arrange the wires within the hub cavity such that none are pinched when the center logo button is installed. The center logo button is installed by engaging the four prongs of the button through the button retaining ring that sits behind the wheel. Push the button firmly until flush to the wheel. WHEEL ANGLE ADJUSTMENT 8” MIN. The final step of wheel unit setup is to adjust the angle of the steering wheel to your preference. This is done by loosening the rear leg screws [Figure 4] until the rear leg can be moved up or down. Making this adjustment will also require loosening the bracket tensioning bolt under the mounting surface [Figure 2]. The tensioning bolt and the rear leg essentially ‘pinch’ the mounting surface from bottom and top to hold the unit securely. To tilt the wheel more towards vertical, the rear leg must be extended downward and the bracket bolt must be backed down. To tilt the wheel more forward the rear leg must be raised and the bracket bolt extended. If a substantial change of wheel mounting angle is desired, it will be necessary to loosen the pivot set screw and the tensioning pivot nut [Figure 2]. For proper performance of the mounting system, the bracket tensioning bolt must be vertical and perpendicular to the underside of the mounting surface. REAR LEG ADJUSTMENT SCREWS 1.5 COCKPIT MOUNTING In addition to removable desktop mounting, the TRACKSTAR 6000 wheel unit is easily adapted to a custom driving cockpit. When attaching the unit permanently to a fixed framework, the table mounting bracket need not be used. The unit can be mounted directly to the cockpit sub-frame in its upright orientation or inverted under a monitor shelf. In either configuration, the most critical requirement is that the unit is attached at both the front and rear. Remove the rubber feet from the rear leg and fasten to a rigid support bracket through the screw holes. It is important to use BOTH front ELEVATION OF REAR LEG SETS ANGLE OF UNIT TRACKSTAR Figure 5 - WHEEL AND PADDLE SET INSTALLATION BEFORE AND DURING INSTALLATION OF THE WHEEL MAKE SURE THAT THE SWITCH WIRES ARE ROUTED THROUGH THESE SLOTS. THE WHEEL SCREWS SHOULD BE TIGHTENED ONLY AFTER VERIFYING THE CORRECT POSITION OF THESE WIRES WHEEL AND PADDLE SET EXPLODED VIEW and back support points - DO NOT CANTILEVER only from the central plate – structural damage will occur without two points of support. If inverted mounting is used, note that the hub is drilled with ten wheel mounting holes for the five wheel screws. The extra holes allow the wheel to be mounted upright without an adapter when the chassis is inverted 180 degrees. 2.0 PEDAL UNIT SETUP AND ADJUSTMENT 2.1 ASSEMBLY SEQUENCE 1 WHEEL MOUNT SCREWS (5) DISCARD TEMPORARY NUTS (5) STEERING WHEEL STEERING UNIT HUB 2 WHEEL MOUNT SCREWS (5) STEERING UNIT CHASSIS CENTER LOGO BUTTON 3 SHIFT PADDLE SET WHEEL SPACER (OPTIONAL) 4 BUTTON RETAINING RING 5 TWO BUTTON PADDLE HOOKUP WIRES FROM STEERING HUB 3-PIN FEMALE CONNECTORS SIX BUTTON PADDLE HOOKUP WIRES FROM STEERING HUB 6 3-PIN FEMALE CONNECTORS 3-PIN MALE CONNECTORS 6-PIN MALE CONNECTOR LEFT HAND PADDLE BUTTONS RIGHT HAND PADDLE BUTTONS LEFT HAND PADDLE BUTTONS RIGHT HAND PADDLE BUTTONS 7 Prepare a clean well lit area with adequate room for laying out the pedal components [Figure 8]. In addition to the supplied hex keys you will need a pair of ½ inch open end wrenches to complete assembly. The pedal unit is shipped in two components; the base and the pedal frame assembly. Study the side view illustration of the assembled pedal unit [Figure 9] before proceeding. If you have ordered a clutch pedal, refer to the clutch installation instructions first, for they supersede the following steps. In the pedal base assembly, locate the two silver diagonal struts. Remove the two bolts holding these struts nearest the heel rest. Leave the rear bolt in place. Rotate these struts vertically until they are tilted towards the rear of the base [Figure 10]. Retrieve the 6 inch long 5/16 diameter threaded rod and related nuts from the hardware kit supplied with the pedal unit. This rod will be used to attach the pedal frame assembly to the base at Pivot A as shown in Figure 10. Note that there are four vertical slots for this attachment. These are used to offer a variety of positions fore-to-aft of the pedal relative to the heel rest. If initial use will be at a typical desktop workstation, select the second slot from the front of the unit. If initial use will be in a low-slung cockpit situation, then select a slot further to the rear. In any case, after initial setup is completed, this position can be changed without disassembly of the entire pedal unit. Position the pedal frame vertically with its mounting holes aligned with the chosen slot in the base unit [Figure 10, step 1]. Guide one end of the threaded rod through one side of the base and frame holes. Before passing through the holes in the opposite side, twist two nuts onto the threaded rod. Guide the rod through the opposite side holes and twist the nuts apart so they contact the two sides of the pedal frame [Figure 11 step 2]. Makes sure the rod is centered in the frame. Turn the nuts no more than finger-tight. Place the two washers and remaining two nuts onto the threaded rod [Figure 11 step 3]. Turn the nuts down finger-tight to the frame. Note that each Pivot A base mounting slot has three notched positions. These are to adjust the vertical position of the pedals relative to the heel rest. Select the middle notch to start with and set the threaded rod into the same position on both sides. This adjustment can be easily changed after the entire pedal unit is assembled. Do not tighten the nuts at this time. Allow the pedal frame to rotate freely for now. Next pivot the diagonal struts forward [Figure 10 step 2] and align their holes with those in the pedal frame. The pedal frame and the struts will form a triangle. Insert the bolts at Pivot D [Figure 12] on each side. Make sure to TRACKSTAR Figure 6 - STEERING UNIT LAYOUT STEERING POTENTIOMETER HI-DEF USB CIRCUIT BOARD ELECTRONICS PAN FLDS FLUID DAMPER 1 2 ACCESSORY EXPANSION PORT CABLE (OPTIONAL) 2.2 PEDAL UNIT CABLE MONOPOINT II CAM SYSTEM POTENTIOMETER HEADER MOUNTING SCREWS USB TERMINAL HEADER SYSTEM LOGIC CHIPS BASIC PEDAL PRESSURE ADJUSTMENT Pedal pressure for all non-PMB equipped pedals is done in two steps. Perform adjustment in the following sequence: 1. Overall pedal pressure, has three settings: light, medium and heavy. These are adjusted by changing the location of the pedal resistance spring and its upper and lower mounts to one of three possible positions [Figure 17]. Moving the spring towards the pedal arm pivot point will reduce the pressure needed to depress the pedal. Moving the spring away from the pivot will increase the required pressure. Generally it is recommended that the brake pedal be set in the medium or heavy; and the gas pedal in the light or medium position. 2. Pedal spring preload is set by how far the screw supporting the lower spring seat is turned in towards the spring. Preload is defined as the amount of initial pressure needed to begin to move the pedal. To change preload, loosen the locknut on the lower spring bracket and turn the set screw. It may be advantageous to set preload at a moderate to high level if you like to rest your foot on the pedal. If preload is too light one might be applying brake with the slightest touch of the pedal. This is particularly a concern if one uses a two foot pedal method. Try different settings but make sure to tighten the lock nut to preserve your settings when finished with adjustment. 2.3 Figure 7 - USB HD-ULTRA R6000.1 BOARD LAYOUT insert the spacer washers between the strut and the pedal frame as shown. Turn finger tight, then back off one half turn. Make sure the nuts holding the bottom end of the diagonal struts are backed off a bit from contact so the rod assembly can mover freely in the slot. Grasp the rod in the center of the base with one hand, grasp the top of the pedal Frame with the other, and rotate the pedal frame upright sliding the rod in the adjustment slot forward until the unit is at your preferred angle. Test the pedals to see if their geometry is correct for your seating position. Adjust until comfortable, and finally tighten all pivot bolt nuts. For more tips on adjusting geometry, see Section 2.4. PMB BRAKE PEDAL PRESSURE ADJUSTMENT The second generation ECCI PMB II (Pressure Modulated Brake) mechanism has two basic adjustments: JUMPER J-1 4 - BUTTON MODE 8 - BUTTON MODE DIGITAL BUTTON HEADER TRACKSTAR Main PMB pressure adjustment screw [Figure 15]. This screw sets the ultimate amount of pressure required to bring the brake pedal down to full travel. This effect is highly progressive and this screw should only be used for setting maximum braking pressure. Do not use this screw to adjust initial pedal pressure. The Pedal spring preload adjustment screw sets the amount of initial pedal pressure required to begin to depress the pedal. It is set as described in Section 2.2. Make sure to tighten the lock nut after adjustment. 2.4 ADJUSTING PEDAL UNIT GEOMETRY The 6000 Trackstar pedals offer a wide range of adjustments [Figure 16]: Figure 8 - PEDAL UNIT COMPONENTS 1 DIAGONAL STRUTS 2 3 PEDAL FRAME ASSEMBLY BASE ASSEMBLY 4 5 PIVOT BOLTS, NUTS & WASHERS GROUNDING CABLE 6 Figure 9 - ASSEMBLED PEDAL UNIT - SIDE VIEW PIVOT PEDAL ARMS C PEDAL TENSION ADJUSTERS PEDAL PADS PEDAL FRAME HEEL REST PMB CAM PLATE MOUNTING BOLT 3.0 STEERING RESISTANCE TUNING POT CARTRIDGE 3.1 THE MONOPOINT II SYSTEM DIAGONAL STRUTS HEEL REST ADJUSTMENT BRACKET BASE ASSEMBLY PIVOT PIVOT A PIVOT D Fore and aft adjustment. Pivots A & B must be loosened and the bolt at ‘A’ installed in the desired stepped slot. The heel rest also rides in a horizontal slot allowing fine tuning of its spacing to the pedals. Vertical adjustment. The pedal frame can be raised and lowered in each stepped Pivot A mounting slot to adjust the distance of the pedals from the heel rest. This accommodates a wide range of user shoe sizes. The angle of the pedal frame from vertical is the most important ergonomic adjustment. A desktop setting will require a more canted geometry than a lay-down cockpit. Pedal frame angle is changed by loosening Pivots A , B, & D, and sliding the rod assembly of Pivot B along the adjustment slot until the desired angle is reached. All Pivots must be tightened after such an adjustment. Next the heel rest should be adjusted in angle to create a natural well for the driver’s heel. Lateral pedal spacing is adjusted by loosening the two screws that hold the pedal pad to the pedal arm. The pedal pads can slide laterally to the user’s preference. Make sure to tighten the nuts firmly before using the pedals. For those installing their controller in a tightly dimensioned cockpit… the Trackstar 6000 pedals can be reduced to only the pedal arm frame. When attached securely top and bottom, the pedal arm frame can be used without the base to provide a minimally intrusive installation. ECCI also offers an accessory part which locks the pedals in a fixed relationship to a driver’s seat. Called the “Instant Cockpit”, this is a telescoping bracket that locks the pedal chassis to the base of any chair. It is particularly useful if you use a caster-type office chair. It keeps the chair from rolling backward and the pedal unit from tipping forward when high PMB settings are used. Contact ECCI for more information or visit our website for the latest on this accessory. B ANGLE ADJUSTMENT SLOT GROUND CABLE CONNECT GROUND CABLE TO COMPUTER CHASSIS SCREW -ORTHE COVER SCREW OF A GROUNDED ELECTRICAL OUTLET -ORMETALLIC WATER SUPPLY PIPE -OR- OTHER SUITABLE GROUND TRACKSTAR The Trackstar 6000 was designed to provide the serious competitor the ability to tune all important steering feel characteristics to suit individual preference. The ECCI exclusive MONOPOINT II cam resistance system [Figure 21] offers fine adjustment of four important steering parameters: 1. Maximum steering resistance pressure - adjustable by changing the number of springs used [Figure 22 and 24]. 2. Steering centering pressure at the neutral position - adjustable by changing spring preload [Figure 24]. 3. Steering wheel lock - adjustable by changing positions of wheel travel limiters [Figure 23]. Rotational damping is also adjustable for FLDS equipped units. See Section 3.5 for more information. Figure 10 - PEDAL FRAME / BASE ASSEMBLY 3.2 PIVOT STEP 1 PIVOT A D STEP 2 PIVOT B Figure 11 - PIVOT A - TWO PEDAL UNIT BOLT INSTALLATION STEP 1 PEDAL FRAME STEP 3 STEP 2 FINGER TIGHT ONLY STEP 4 Figure 12 - PIVOT D - BOLTS Figure 13 - HEEL REST DIAGONAL STRUTS STEP 1 PEDAL FRAME ADJUSTMENT SCREWS STEP 2 TRACKSTAR TUNING SUGGESTIONS This setup might suit a driver with a light touch that races primarily tight road courses. This offers a short throw lightly sprung steering action which will get you through chicanes quickly all while maintaining optimal hand position for the accessory buttons at full lock. A light spring setting reduces driver fatigue for those competing in full-length races. With reduced pressure you can maintain precision cornering technique on the 190th lap without the sloppiness that can come from muscle fatigue. With light spring settings, the FLDS will provide primary resistance for wheel movement. A driver running ovals might prefer more resistance and travel. A wide range of travel can offer more fine steering adjustment in long sweeping corners, or could be set up for more pit lane maneuverability. Up to 240 degrees or travel is available with the Trackstar 6000. With heavier spring settings the role of FLDS is reduced. Most drivers will prefer moderate to light spring settings when using an FLDS equipped system. 3.3 STEERING LOCK ADJUSTMENT Four positions of steering lock are available: 180, 200, 220, and 240 degrees. The default factory setting is 240. This adjustment should be performed first before other changes to steering resistance are contemplated. 1 Loosen the ten screws that attach the steering unit cover to the chassis. Then remove the cover exposing the mechanism. 2 Loosen the locknut on the preload adjusting screw underneath the steering unit, directly below the springs [Figure 21]. Turn the adjusting screw counterclockwise until the spring pack is loosened. 3 Grasp the top of the spring pack and pull it out from underneath the pressure arm. Remove the springs and spring retainers from the unit. 4 Locate the wheel travel limiter [Figure 26], a disk-shaped element close to the main chassis structural plate. Rotate the steering wheel 90 degrees to the left. The two retaining screws for the left-hand travel adjuster stop will now be accessible. Using the supplied 3/32" hex key, loosen and remove the 2 screws and position the stop as desired, rotating the wheel as required to provide access. The positions are explained in Figure 23. 5 Next tighten the screws. Repeat the adjustment as described above for the right-hand travel adjuster stop, making certain that the adjuster is moved exactly the same amount as the left-hand stop. 6 Reinstall the spring set following steps 4-6 in the following section. Figure 14 - REMOVING THE POT CARTRIDGE POT CARTRIDGE PMB PIVOT BUSHING 7 8 5 6 3 4 3.4 9 PMB CAM PLATE 1 PMB PIVOT BOLT 2 REAR VIEW POT CARTRIDGE & PMB EXPLODED VIEW 9 PMB CAM PLATE PMB SPRING BRACKET 8 6 3.5 STEP 1 STEP 2 POT CARTRIDGE 7 POT CARTRIDGE 5 3 1 2 4 STEP 3 STEP 4 TRACKSTAR STEERING SPRING RESISTANCE ADJUSTMENT The MONOPOINT II system relies on a single spring pack of up to three springs. The springs are designed to rest one inside another. Figure 24 shows the various possible combinations of springs along with recommended preload settings. To adjust overall steering resistance pressure, perform the following steps: 1 Loosen the locknut on the preload adjusting screw underneath the steering unit, directly below the springs [Figure 21]. Turn the adjusting screw counterclockwise until the spring pack is loosened. 2 Grasp the top of the spring pack and pull out from underneath the roller on pressure arm. Remove the springs and spring retainers from the unit. 3 The tool and parts kit provided with the unit includes additional steering springs. Select the desired combination of springs [Figure 21], and install them on the lower spring retainer, making certain that they are seated in their respective pockets. The default factory setting is 116lb. 4 Place the spring pack with the lower retainer over the preload adjustment screw. Tilt the top of the spring set outward slightly to accept the upper spring retainer, insert the retainer, and tilt the assembly back underneath the roller on the pressure arm. Work the wheel from lock to lock to seat the springs. IMPORTANT! Before setting preload, perform the following step: 5 If using the large outer spring, make sure to rotate the spring on the lower spring seat counterclockwise until the lower end of the spring coil is seated firmly against the set screw provided in the spring seat [Figure 22]. If the spring is not seated against the set screw, the springs may make noise during operation. If spring noise is encountered, this is the likely culprit. 6 Next set centering pressure in accordance with the following section. STEERING CENTERING PRESSURE AT NEUTRAL To adjust centering pressure at neutral position, refer to the preload settings in Figure 24. This adjustment will not affect maximum resistance at full lock; it should be used only to adjust feel characteristics through the very center of travel. See Figure 25 for a graphic explanation of the effect of this adjustment. 1 Locate the preload adjusting screw [Figure 21]. Insert the supplied 3/16" hex key wrench. With the steering wheel at center position, turn the preload adjusting screw clockwise by hand (as viewed from the bottom) only until there is no up/down looseness (gap) in the spring pack between the upper and lower spring seats. Move the wheel back and forth to help determine the point between loose and engaged. Refer to the table [Figure 24] for the amount of preload desired. The preload setting has a major effect on centering force around neutral. The lowest setting will result in a very loose feeling through center with almost no centering force. The maximum setting will result in a pronounced centering effect, especially with heavier spring combinations. Figure 25 illustrates the effect this adjustment has on overall resistance characteristics. Carefully to count the number of rotations of the screw, turn only until the desired preload setting is reached. Figure 24 - STEERING RESISTANCE SPRING COMBINATIONS OUTER MIDDLE 116 lb. 57 lb. INNER COMBINATION MONOPOINT II CONCENTRIC SPRING SYSTEM 24 lb. 197 lb. SPRING COMBINATIONS PRELOAD RANGE AVAILABLE 197 lb. 2.0 TURNS FOR STRONGEST CENTERING FORCE 0.75 TO 1.25 TURNS FOR BALANCED FEEL 0.5 TURNS FOR LIGHTEST CENTERING 2.0 TURNS MAX PRELOAD 173 lb. 2.0 TURNS MAX PRELOAD 2.0 TURNS FOR STRONGEST CENTERING FORCE 0.75 TO 1.25 TURNS FOR BALANCED FEEL 0.5 TURNS FOR LIGHTEST CENTERING 140 lb. 2.5 TURNS MAX PRELOAD 2.5 TURNS FOR STRONGEST CENTERING FORCE 1 TO 1.5 TURNS FOR BALANCED FEEL 0.5 TURNS FOR LIGHTEST CENTERING 116 lb. 2.5 TURNS MAX PRELOAD 2.5 TURNS FOR STRONGEST CENTERING FORCE 1 TO 1.5 TURNS FOR BALANCED FEEL 0.5 TURNS FOR LIGHTEST CENTERING 81 lb. 3.0 TURNS MAX PRELOAD 3.0 TURNS FOR STRONGEST CENTERING FORCE 1.5 TO 2 TURNS FOR BALANCED FEEL 0.75 TURNS FOR LIGHT CENTERING 57 lb. 3.5 TURNS MAX PRELOAD 3.5 TURNS FOR STRONGEST CENTERING FORCE 2.0 TO 2.5 TURNS FOR BALANCED FEEL 0.75 TURNS FOR LIGHT CENTERING 3.7 MAXIMUM PRELOAD MAX 240 0 RESISTANCE FORCE MAX RESISTANCE FORCE 0 0 ROTATION FROM CENTER -240 0 ROTATION FROM CENTER TRACKSTAR FLDS - FLUID DAMPED STEERING The FLDS system uses a belt driven rotary fluid damper [Figures 6 & 26]. For each wheel rotation the damper will rotate multiple times. The damping ratio provided standard with the Trackstar 6000 provides a balance of damping and spring resistance. Some users may wish to reduce or increase the amount of damping. ECCI offers pulleys in several different ratios for purchase [Figure 27]. Generally, someone who uses many rapid wheel movement corrections while driving may prefer a lighter pulley, while someone using very steady measured wheel movements may prefer even heavier damping. Steering wheel diameter also has an effect on damping force. Diameters smaller than the standard 13-1/2 inch wheel will create less leverage on the steering shaft. This will increase the level of damping perceived by the driver. Figure 25 - STEERING CENTERING TUNING -240 WARNING! Do not exceed the maximum number of turns listed in the table for the combination of springs being used – excessive pressure will damage the steering camshaft. Exceeding the recommended number of turns is considered MISUSE and damage from misuse is NOT covered under warranty! Be careful! 2 Tighten the preload adjuster locknut, while holding the preload adjuster screw in position with the hex key wrench. Note: If the springs the springs make noise after installation, examine the assembly to make certain that all springs are seated properly in their respective pockets, both in the upper and lower spring retainer. Most noise issues are caused by the large outer spring not being rotated against the spring stop screw [Figure 22]. 3.6 BALANCED RANGE IS RECOMMENDED FOR THE BEST COMBINATION OF SMOOTHNESS AND CENTER FEEL MINIMUM PRELOAD 1 240 SHIFT PADDLE ADJUSTMENT The Trackstar 6000 unit is provided with F-1 style behind-the-wheel paddles to perform gear shift function. The paddles have a very short throw to make rapid shifting possible. However, there is a small range of adjustment. The factory setting provides a moderate amount of tolerance for the switch actuation point. If throw adjustment needs to be reset, the stop screws can be adjusted with a hex key and 3/8 in. wrench. If any button or paddle control remains on constantly or does not trigger except at the very end of travel, adjustment will be needed. Sometimes the switches will ‘wear in’ to a different engagement point than when new and require readjustment after a period of time. Depending on which steering wheel you have, stops may be located at the back and in some cases the front of each paddle. Before making adjustments, make sure the wheel and paddles are bolted tight to the steering hub. Unless compressed in place by the steering wheel, paddle components may warp slightly affecting the accuracy of the adjustment. Before adjusting, loosen the locknuts of the stop screws with a 3/8” wrench. Find the control trigger point with a continuity tester or by leaving the unit plugged in to your computer and set to a calibration utility. When the trigger point is found, turn the stop screws in gradually to ‘bracket’ this point to the desired tolerance. Be careful to not adjust travel too close to the actuation point, for inconsistent shifting operation may result. When finished make sure to tighten the locknuts to ensure that the stop screws are securely locked in place. Figure 15 - PMB CONNECTING TO YOUR COMPUTER 4.1 CONNECTING A BASIC USB UNIT The Trackstar 6000 USB system is connected via integral USB cable from the steering unit to a USB 1.1 compatible port on your computer. If you have many devices connected that rely on the USB connection for power, ECCI recommends you use a powered multi-port USB hub and free up one of the ports that connect directly into your computer for the driving system. If you are experiencing control anomalies, try unplugging all other USB powered items like scanners and DVR external drives and running the driving system alone into a port on your machine. This will determine whether the problem lies with other peripherals or the driving system. The pedal unit connects to the wheel unit via the integral DB-9 cable. This cable connects to a DB-9 port on the right side of the steering unit just underneath the main unit housing [Figure 6]. If you are having trouble connecting the screw terminals due to the tight space, remove the unit cover for access. The Trackstar 6000 uses the universal HID driver that is native to Windows operating systems. No driver disk or outside software is necessary. When the unit is plugged in it will be recognized as a four axis four button controller. 1 Install the unit by connecting the pedal component to the wheel and the wheel to the USB port on your computer. 2 Select linked axis or separated axis pedal operation via the switch located at the back face of the pot cartridge of your pedal unit. Separated mode allows independent and simultaneous operation of pedals. Linked mode links both gas and brake pedals as acting in opposite directions on the same control axis, Y-axis of Joystick 1. Separated mode is preferred for the most sophisticated racing simulations. However, some titles poorly implement or do not even support separated mode. In this case use linked mode. Separated mode is activated with the switch in the up position, and linked mode is in the down position. 3 Now turn on or reboot your computer. When the operating system comes up, click the Start button. Go to Control Panel and then select Game Controllers from the menu. 4 PRESSURE BRAKE SYSTEM PIVOT PRELOAD ADJUSTMENT SCREW AND LOCKNUT BRAKE PEDAL ARM SLOTTED BLACK DISC PEDAL PADS PMB CAM PLATE AND MOUNTING BOLT MAIN PRESSURE ADJUSTMENT SCREW AND LOCKNUT REAR SPRING SEAT PMB CAM PLATE SHOWN REMOVED FROM THE UNIT MAIN PRESSURE SPRING VIEW FROM LEFT SIDE OF BRAKE PEDAL Figure 16 - PEDAL GEOMETRY ADJUSTMENT PIVOT A PIVOT FORE AND AFT ADJUSTMENTS The Game Controllers dialog box should appear. Windows should automatically recognize a 4-axis 4-button controller is connected. If this does not appear check your connections and reboot. If it appears as a different configuration contact ECCI. Click on the controller then select Properties. Select the Settings tab and click on Calibrate. Follow the prompts carefully to calibrate your driving system. Not all calibration axes will show movement. This is normal; simply continue to the end. After finishing select Test. Carefully observe the movement of your controls in the square box and the vertical slider bars. Make sure that the wheel and each pedal are recognized and operating smoothly to their limits of travel. If not, recalibrate. Ignore any inactive slider bars as long as every pedal responds. A 2-pedal unit in linked mode will C H EEL R ES PEDAL T TO HEIGHT 4.0 II B VERTICAL ADJUSTMENT WITHIN SLOT PEDAL HEIGHT ADJUSTMENT PEDAL PAD SCREWS PIVOT A ANGLE ADJUSTMENTS PIVOT B PEDAL SPACING ADJUSTMENT TRACKSTAR Figure 19 - STEERING POT Figure 17 - PEDAL RESISTANCE SPRING ADJUSTMENT UPPER SPRING SEAT JUMPER LEAD LOWER SPRING SEAT NOTE: COMMON #3 OUTER TERMINALS OF ALL POTS ARE BRIDGED WITH A JUMPER LEAD. THE LEADS ATTACHED TO THE JUMPER ARE ALWAYS TO BE CONNECTED TO THE OUTSIDE POT TERMINALS COMMON #1 COMMON #5 LIGHT MED. RED MEDIUM WHITE LIGHT BLUE HEAVY PRELOAD ADJUSTMENT SCREW AND LOCKNUT PEDAL RESISTANCE SPRING Figure 20 - ACCESSORY PORT PEDAL ARM PIVOT LOWER SPRING SEAT BRACKET PEDAL ARM [HI-DEF USB] HEAVY BUTTON #2 BUTTON #4 1 2 6 3 7 4 8 5 9 COMMON #2 BUTTON #3 COMMON #4 BUTTON #1 PEDAL FRAME Figure 18 - PEDAL POTENTIOMETER WIRE CONNECTIONS [HI-DEF] ALL POTENTIOMETERS VIEWED FROM BACK SIDE GAS PEDAL POT BRAKE PEDAL POT (PMB UNIT) BRAKE PEDAL POT (NON-PMB UNIT) DIRECTION OF POT ROTATION B VIOLET WIRE COLORS BLUE ORANGE E RED D POT TERMINALS POT TERMINALS C GREEN F TRACKSTAR BLUE D ORANGE E RED F WIRE COLORS WHITE G BLACK H RED I I A BLACK WIRE COLORS I I DIRECTION OF POT ROTATION POT TERMINALS WIRE COLORS DIRECTION OF POT ROTATION I POT TERMINALS DIRECTION OF POT ROTATION CABLE GROUND ATTACHMENT CLUTCH PEDAL POT TRACKSTAR TIE DOWN POINT FOR CABLE TIE Figure 21 - ECCI MONOPOINT II SYSTEM RESISTANCE CAM 4.2 CAM FOLLOWER ROLLER 1. UPPER SPRING SEAT 2. MONOPOINT SPRING ASSEMBLY LOWER SPRING RETAINER PRELOAD ADJUSTER HEX KEY Figure 22 - CONNECTING A USB HD ULTRA EQUIPPED SYSTEM Before doing anything else, connect the pedal unit chassis to your computer case or other ground with the ground cable. MONOPOINT II SPRING RETENTION DETAILS SIDE VIEW TOP VIEW UPPER SPRING SEAT LOWER SPRING SEAT LOWER SPRING SEAT SPRING SUPPORT BRACKET SPRING SUPPORT BRACKET SPRING STOP SCREW LOCK NUT OUTER SPRING MUST BE TURNED UNTIL END RESTS AGAINST STOP SCREW PRELOAD ADJUSTMENT SCREW Figure 23 - STEERING TRAVEL STOP ADJUSTMENT The pedal unit connects to the wheel unit via the integral DB-9 cable. This cable connects to a DB-9 port on the right side of the steering unit just underneath the cover. If you are having trouble connecting the screw terminals due to tight space, remove the cover first. 3. The Trackstar 6000 USB system is connected to your computer via USB cable to a USB 1.1 compatible port on your computer. If you have several devices connected that rely on USB ports for power, make sure to connect the TRACKSTAR 6000 directly to a USB port on the host computer. NEVER connect the controller to a powered expansion hub. Voltage drops and interference from other devices will seriously affect performance. If one must simultaneously use other USB-powered devices, connect those to the remote hub instead. Control performance will be assured if you connect the TRACKSTAR as the sole peripheral on a USB root hub. Be especially wary of cheap motherboard integrated USB systems. Many of these use a single root hub controller that is shared by multiple ports on the computer case. If you have such a system, you may wish to install a quality USB PCI bus card that includes one USB root controller at each of several USB ports. A good choice would be an add-in card that utilizes the OPTI FireLink 82C861 USB controller. For a list of lab-certified add-on PCI cards using this controller, visit the following webpage: www.usbman.com/Guides/Upgrade%20Card%20Manufacturers.htm If you are experiencing control anomalies, try unplugging all other USB powered items like scanners and DVR external drives and running the driving system alone into a port on your machine. This will determine whether the problem lies with interference from other USB peripherals or the basic interface. Some USB 2.0 systems will exhibit problems with 1.1 peripherals like the ECCI HD. Try disabling USB 2.0 to see if the problem is solved. The Trackstar 6000 uses the universal HID driver that is native to Windows operating systems. No driver disk or outside software is necessary. When the unit is plugged in it will be automatically recognized as “ECCI HI-DEF USB” in your operating system and software titles. If you have multiple game controllers, make sure that the ECCI HI-DEF is at the top of the controllers list. The Trackstar 6000 HI-DEF USB offers nearly 1000 discrete points of resolution on the steering axis. Each pedal axis is capable of providing either 300 or 1000 points depending on the potentiometers used. 4.3 180 DEGREES TRAVEL 200 DEGREES TRAVEL 220 DEGREES TRAVEL TRACKSTAR 240 DEGREES TRAVEL MODES OF OPERATION - USB HD ULTRA The unit will automatically start up in Separated mode which allows independent and simultaneous operation of pedals. Separated mode is preferable for most sophisticated racing simulations. However, some titles poorly implement or fail to support separated pedal mode. In this case you must use linked mode. Linked mode emulates a simple two-axis joystick. Some titles will only run in this mode. Steering acts on the joystick X-axis and gas and brake pedals work in opposite directions on the ‘Y-axis’. Linked mode is simple to activate. 1. Disconnect the USB plug from the computer and wait ten seconds. 2. Next hold down one of the buttons or paddles on the wheel while you plug the unit back into the USB port. Be sure to hold the button down while plugging in and for at least five seconds after the plug insertion. This will initialize Linked mode. 3. It is important to remember when switching from separated to linked mode or back you must recalibrate the controller in the Windows Control Panel Game Controller routine. Failure to do this will cause improper operation. Do not reboot the computer when switching modes. The computer needs to be running to initialize linked mode. If your computer is rebooted for any reason and you wish to use linked mode, you will need to re-initialize it after restart using the above steps. If no buttons are held down during initialization, it will always start up in separated mode. 4.4 Close all other programs first. Then click the Start button. Go to Control Panel and select Game Controllers from the menu. 2. The Game Controllers dialog box should appear. Windows should automatically recognize that the ECCI HI-DEF USB controller is connected. If this does not appear check your connections, and if still no control shows up, reboot and start again. Highlight the controller, and then click on the Properties button. Select the Settings tab and click on Calibrate. You must follow the prompts carefully to calibrate your system. Leave the controls untouched to set center point then click a button on the wheel. 4. A square joystick calibration box will appear. It will prompt you to move the controller to the limits of travel. The steering wheel will be recognized here as the X-axis, moving the crosshair horizontally in the box. The Y-axis will not be active. After moving the wheel left and right, release it to center and press a button to move on. 5. Next you will be prompted to verify the center point once again Make sure the wheel is centered, then press a button. 6. A horizontal box with a blue calibration bar will appear. This box will calibrate the gas pedal. Move the pedal down all the way, release it, repeat several times and press a button. If the bar does not move fully to the ends of the box, ignore it. This is normal at this stage of calibration. Another horizontal box will appear. This will recognize the clutch pedal. Move the pedal down all the way, release it, repeat several times and press a button. If you do not have a clutch, simply press a button to bypass this step. A third horizontal box will appear. This will calibrate the brake pedal. Move the pedal down all the way, release it, repeat several times then press a button. If you have a PMB-equipped unit and wish to reduce the amount of brake pedal pressure to reach maximum braking, you can ‘short calibrate’ the brake pedal. Press down only as hard as you wish for maximum braking, release and press a button. 7. 8. 4.5 1. 2. 3. SEPARATED MODE CALIBRATION - USB HD ULTRA 1. 3. 9. 4. 5. 4.6 After finishing select Test. Carefully observe the movement of your controls in the square box and the vertical slider bars. Make sure that the wheel and each pedal are recognized and operating smoothly to their limits of travel. If not, recalibrate. Ignore the inactive slider bar if you do not have a clutch installed. You are now finished. Click OK to accept calibration. LINKED MODE CALIBRATION - USB HD ULTRA Initialize Linked mode as described in Section 4.3. Then follow steps 1 through 3 as listed in Section 4.4. The next steps are as follows: A square joystick calibration box will appear. It will prompt you to move the control to the limits of travel. Turn the steering wheel left and right to its limits. This will move the crosshair horizontally in the box. Gas and brake pedals will be recognized on the Y-axis, moving the crosshair vertically in the box. Move both pedals to the limit several times, release them, and press a button. You will be prompted to verify the center point now. Make sure the wheel is centered and none of the pedals are depressed. Then press a button to go to the next step. A horizontal box will appear. This will be inactive in Linked mode. Linked mode does not support clutch operation. If you need a clutch, use Separated mode. Press a button on the wheel to continue. Two more horizontal boxes will appear. These will be inactive as long as you are in Linked mode. Just press a wheel button when prompted until you finish. After finishing select Test. Carefully observe the movement of your controls in the square box. Make sure that the wheel and each pedal are recognized and operating smoothly to their limits of travel. If not, recalibrate. In linked mode none of the slider bars will be active. This is normal. You are now finished. Next click OK. PROPERLY CALIBRATING THE PMB-II BRAKE PEDAL The optional PMBII brake mechanism allows you to tailor both the feel and the response of the brake to your personal preferences. The action of the PMBII allows the brake to be set up based on pressure applied rather than distance traveled. 1. When calibrating the PMBII you most likely will not use the full mechanical travel of the pedal. Calibrate using the amount of pressure you want to establish as 100% braking pressure. Optimal anti-lockup performance is obtained when slightly more pressure is applied than you would normally desire. This helps prevent brake lock at the limit of braking. You should have to work the brake a bit to get full lock. Do not exceed your maximum pressure target during the calibration. If you exceed your target, go back and start calibration again. Note the calibration numbers returned at your desired maximum pressure setting and write them down. 1. 2. 3. 4. 4.7 Now finish calibrating the remaining controls and go to into your simulation program. If the program uses the Windows Direct-X calibration information directly, no further calibration is required, just go out on the track and drive. If the program requires its own calibration (i.e. NASCAR 2003), calibrate the PMB brake pedal in the controller options screen the same way as you did in Windows, being careful to only apply the amount of pressure you want to represent full braking. Write down the calibration number at your maximum desired pedal pressure level to use for future reference. Now go out and take a few laps. If it seems like you need to apply too much pressure to get the desired braking effect, go back and recalibrate. This time move the brake to a slightly lower maximum pressure which will return calibration numbers a few numbers lower than before. Go back out to the track and see how this works. If the brake feels too light, go back and recalibrate to calibration values that are slightly higher than the previous calibration values. You will need to do some experimentation to get just the right braking effect. If for some reason your desired pressures seem to be past the limit of brake travel, or are less than 50% of the brake travel you may need to adjust the PMBII pressure adjustment. If this does not get the desired result, you may need to change to a lighter or heavier PMBII spring. All but a very few users find their optimal setting by just adjusting calibration with the stock spring. CONNECTING AND CALIBRATING A DB-15 PORT UNIT The Trackstar 6000 joystick port system is connected to your computer using the pedal unit cable. The pedal unit cable also has a female connector on a short lead from the plug that attaches to the computer. This short lead is for attaching the cable from the wheel unit. 1. Connect all cables securely making sure the thumb-screws are tight. 2. Select linked axis or separated axis pedal operation via the switch located on the back face of the pot cartridge of your pedal unit. Separated mode allows independent and simultaneous operation of pedals. Linked mode combines gas and brake pedals acting in opposite directions on the same control axis, Y-axis of Joystick 1. Separated mode is preferred for the most sophisticated racing simulations. However, some titles poorly implement or do not support separated mode. In this case use linked mode. Separated mode is activated with the switch in the up position, and linked mode in the down position. 3. Now turn on or reboot your computer. When the operating system comes up, click the Start button. Go to Control Panel and select Game Controllers from the menu. 4. The Game Controllers dialog box should appear. Select the Add button and the Add game controller dialog box should appear. If you have a two pedal unit, scroll until you find 2-axis 4-button controller. If you have a three pedal unit scroll until you find 3-axis 4-button controller. In both cases select the controller type with your left mouse button, then enable the rudder pedal check box, and click the OK button. The controller should show OK under Status. If not, check all connections, reboot, and try again. 5. Next click on the controller line and select Properties. Select the Settings tab and click on Calibrate. Follow the prompts carefully to calibrate your driving system. In separated mode the brake pedal will act on the Y-axis and 6. 7. 5.0 the gas pedal on a slider bar. When using a clutch, it will always act on a slider bar. In linked mode, the pedals will act in opposite directions on the Yaxis of the large square box and only one slider (clutch pedal) will be active. After calibration select Test. Observe the movement of your controls in the square box and the vertical slider bars. Make sure that wheel and pedal input is being recognized and is operating smoothly to the limits of travel. If not, recalibrate. If you change pedal mode settings while the computer is running, you may need to reboot the computer to recognize the new configuration. This is particularly the case if you switch from linked pedal mode to separated pedal mode. If one pedal does not register a signal input, reboot and recalibrate. Joystick input electronics often require a resistance value to be present at boot-up before a particular joystick axis is recognized as active. ACCESSORY EXPANSION PORT The ECCI USB HD ULTRA system supports four analog control axes and up to 20 digital on/off buttons. ECCI wheels typically offer only four buttons, in the form of two shift paddles and two accessory buttons mounted near the wheel. In late summer of 2005, ECCI will introduce a new paddle set that will retroactively fit all 4000 and 6000 series steering units. Six accessory buttons will be available at the wheel in addition to the two shift paddles. However these new buttons will only work with the ECCI USB HD ULTRA. If your existing system does not have this interface, you will need to purchase an upgrade kit. Another feature of the USB HD system is the ability to electrically access all 20 buttons via a DB-9 port on the side of the enclosure. This allows the user to create their own custom peripherals like shifters, button pads, and the like to enhance their ECCI system. Refer to Figure 30 for pin assignments. Expansion port switches are organized in sets of four served by a single common. Rows 1 to 4 correspond with the four primary switches. Changing the common lead from one column to another accesses the next set of four, and so on. This allows a limited number of wires to control the full complement of buttons. If using more than four buttons, it is necessary to provide switching diodes in the circuit of each switch to avoid individual switches from ghosting across the matrix, creating false control inputs on other buttons. Wiring diagrams to assist making add-on peripherals are provided in this manual. [Figures 31 - 32]. If you are using the expansion port to access the extra buttons, you will need to make sure that diodes are also present at the wheel mounted buttons. These were not provided originally in systems with only two accessory buttons. If you have the six-button paddle set, this already has built-in diodes for the wheel buttons. If not then you will either need to order the six-button upgrade or hand wire in diodes into the wheel switch harness. Figure 26 - FLDS FLUID DAMPED STEERING SYSTEM DRIVE PULLEY NOTE: RESISTANCE CAM, FOLLOWER ARM, AND SPRING ASSEMBLY REMOVED FROM THIS VIEW FOR CLARITY DRIVE BELT DAMPER PULLEY MAIN STEERING STOP WHEEL TRAVEL LIMITER FLDS ROTARY FLUID DAMPER TRAVEL ADJUSTMENT STOPS DAMPER BELT TENSIONING SLOTS Figure 27 - DAMPING ADJUSTMENT OPTIONS DAMPER PULLEY LIGHTEST LIGHT STANDARD NOTES: 6.0 POT REPLACEMENT AND POT SETUP The following steps are required only if replacing pots. Pots are the electromechanical components that sense the position of the wheel or pedal and translate this to electrical information read by the ECCI USB HD system. These are long-lived but will eventually wear out. The sign of pot wear is notchy, inconsistent response at the same spot in the axis travel. If the problem is variable, occurring in different areas of travel at different times, the problem may instead be a loose pot shaft nut or a loose wire connector. Pots that do not maintain calibration can also be caused by a loose not. Rule these things out first before ordering new pots. If you need new pots, use only ECCI pots. ECCI pots are specifically made for ECCI controllers and have the required resistance range and performance characteristics. ECCI cannot warrant the performance of any system not using ECCI pots. When ordering replacements, order the ECCI HP Racing pots. The USB HD needs a 100K HP pot for the steering and 50K HP pots for the pedals. Unless you have a rare premature failure (under 1 year), ECCI recommends replacing the entire set rather than the single pot with the problem. 6.1 STEERING POT REPLACEMENT Replacing the wheel pot is a simple procedure. Refer to Figures 6 and 28 for illustrations. The steps to perform replacement are as follows: 1. Mount the wheel unit securely to a tabletop with the clamp. Unplug the USB cable from your computer. Remove the ten screws which secure the cover of the wheel unit to the chassis. Lift the cover and set aside. 2. Leave the pedal unit and its associated ground cable attached to the wheel unit. This will provide ground protection for the circuit board. If your pedal unit is not attached, use the ground cable originally supplied with your driving system to connect the steering unit chassis to a screw on the computer case, a screw attached to the faceplate of an electrical outlet, or other suitable ground. 3. Carefully pull the wire connectors from the pot terminals. Make sure to pull on the connector body, not the wire. 4. Using a 3/32” hex key, loosen the steering shaft clamping screw located on the pot connector [Figure 28]. Next use a philips screwdriver to remove the pot bracket screws. The pot bracket assembly can now be removed. 5. Loosen the pot shaft clamping screw on the pot connector. Slide the connector free and remove the pot retaining nut and the pot will fall free. 6. Mount the new replacement pot, into the pot bracket using the nut and lock washer. Make sure the pins in the pot body engage the slots in the bracket. Turn the retaining nut down until tight. Avoid over-tightening as this can damage the pot. Turn the pot shaft so the slot is vertically in-line with the center terminal of the pot. The slot must be vertical for the next step. Next examine the pot connector. Note that at each end, the clamping screw tightens a split in the ends of the connector. The split in the connector must be horizontal with the clamping screws facing upward, Making sure the pot TRACKSTAR Figure 28 - STEERING POTENTIOMETER REPLACEMENT STEERING POT BRACKET ASSEMBLY READY FOR CHASSIS INSTALLATION 1. 2. CENTER SLOT OF POT SHAFT MUST BE IN VERTICAL POSITION EXPLODED VIEW STEERING POT POT BRACKET SCREWS POT MOUNTING BRACKET HEX KEY 3. POT MOUNTING BRACKET POT SHAFT CLAMPING SCREW POT RETAINING NUT AND LOCK WASHER STEERING SHAFT CLAMPING SCREW 4. STEERING POT CONNECTOR REAR CHASSIS PLATE 6.2 1. STEERING SHAFT TERMINUS 2. STEERING UNIT CHASSIS STEERING UNIT CHASSIS 3. Figure 29 - PEDAL POTENTIOMETER REPLACEMENT POT FOLLOWER ARM PEDAL POT BRACKET FOLLOWER ARM SET SCREWS 4. SLOTTED POT SHAFT TURN SLOTTED SHAFT WITH SCREWDRIVER BLADE TO ADJUST STEERING POT SETUP - USB HD ULTRA The pot is setup using the Windows Game Controllers calibration routine. Reconnect all cables, making sure the ground cable is properly attached and start the computer. Go to Control Panel and select Game Controllers from the menu. The Game Controllers dialog box should appear showing the ECCI HI-DEF USB controller is connected. If this does not appear check your connections. Highlight the controller, and then click on the Properties button. Select the Settings tab and click on Calibrate. Leave the controls untouched to set center point then click a button on the wheel. A square calibration box will appear. The steering wheel will be recognized here as the X-axis, moving the crosshair horizontally in the box. Click the box next to Display raw data. Numbers will be displayed for the X-axis. Leaving the steering wheel centered, rotate the pot connector until the number displayed reads 510 +/- 10 points. Using a 3/32” hex key, tighten the steering shaft clamping screw of the pot connector. Move the wheel left and right, observing the numbers. Let the wheel return to center and make sure the numerical value at center has remained consistent. Press a button to move on. Your steering pot is now setup and the unit cover can be replaced. POT SHAFT 6.3 POT RETAINING NUT AND LOCK WASHER Place the pedal unit on a clean well-lit workbench with the pedal pads facing away from you. Remove the bolts at Pivot D [Figure 10] and rotate the pedal frame away from you towards the heel rest. To avoid scratching the finish put some cushioning material between the pedal frame and the heel rest. The next steps involve removing the pot cartridge and are illustrated step by step in Figure 14. POT FOLLOWER ARM TRACKSTAR shaft slot is vertical, carefully slide the connector onto the shaft without twisting. Slide down to about 1/8” from the bushing of the pot. Snug down the pot shaft clamping screw and look into the open end of the pot connector. Make sure the slot is perpendicular to the split in the connector as shown in Figure 28. If it is not, loosen the clamp screw a bit, adjust with a small screwdriver, and retighten. Next slide the pot bracket assembly through the hole in the rear chassis plate and onto the steering shaft terminus. Install the pot bracket screws but leave them a bit loose. With one hand grasping the pot connector use a Philips screwdriver to slowly tighten the pot bracket screws. While doing this, rotate pot connector back and forth to make sure it slides freely on the steering shaft. When the pot bracket screws are tight, the connector should still rotate on the pot shaft without binding. If it does not, loosen the bracket screws and try again. This procedure is important to avoid side-loading the pot. Side loading can wear out the pot bushing prematurely. Finally, slide on the wire terminal connectors as shown in Figure 19. Do not tighten the steering shaft clamp yet. The pot needs setup which is explained in the following section. PEDAL POT REPLACEMENT 1. 2. 3. 4. 5. 6. 6.4 1. 2. 3. 4. Begin by removing the PMB pivot bolt that holds the cam plate onto the shaft [Step 1]. You will need two 9/16-inch wrenches to do this. Remove the cam plate, spring, and hardware. Pot cartridge removal is next. Next remove the screws attaching the PMB spring bracket [Step 2]. Once this is removed, loosen the screws holding the pot cartridge as shown in steps 3 and 4. With the pot cartridge free of the unit, slide the connectors off the pot terminals. Next loosen the set screws that attach the pot follower arms to the pot shafts [Figure 29]. There are two screws per pot. Next slide them off the pot shafts. Using a 1/2-inch wrench remove the retaining nuts and washers. Put the new pots through the pot mounting holes in the pot cartridge. Turn the pots until the pots are in the positions illustrated in Figure 18 and the locating pins are in their respective slots. Attach the pots using the nuts and washers. Tighten with the 1/2-inch wrench. Slide the pot follower arms onto the pot shafts but do not tighten the set screws. Note that the pot arms are not all the same, the arm for the PMB pot is shorter than the others. Also push the pot arm further down the shaft on the PMB pot only. This is needed to clear the PMB cam plate. The wire connectors can now be relocated onto the pot terminals. Match them according to the jacket color / pot terminal information shown in Figure 18. Reinsert the pot cartridge by reversing the removal steps. Then making sure the PMB pot arm is engaged in the proper slot, mount the PMB cam plate and tighten down. Setup is next PEDAL POT SETUP - USB HD ULTRA Pedal pots are setup using the Windows Game Controllers calibration routine. Reconnect all cables, making sure the ground cable is properly attached and start the computer. Go to Control Panel and select Game Controllers from the menu. The Game Controllers dialog box should appear showing the ECCI HI-DEF USB controller is connected. If this does not appear recheck your connections. Highlight the controller, and then click on the Properties button. Select the Settings tab and click on Calibrate. Leave the controls untouched to set center point then click a button on the wheel. Move the wheel left and right, return to it to center, and Press a button. Leave the wheel stationary and again click a button. The following steps will apply to each of the three pedals in turn. A horizontal box with a blue bar will appear. The first box will recognize the gas pedal. Click the box next to Display raw data. Numbers will be displayed for the pedal pot. Using a slender flat blade screwdriver or bit, rotate the pot shaft in the gas pot follower arm. You will notice the numbers will change. This is the method used to setup the static (at rest) position of the pots before tightening them with the set screws. 6.4 PEDAL POT SETUP - USB HD ULTRA 5. Leaving the pedals at rest, turn the pot shaft to the following values for each pedal. The max and min extremes of movement are 10 and 1013. It is useful to turn the shaft just a bit past the point the number is reached to introduce some movement tolerance. For example turning just past 1013 on the gas pedal allows slight pedal movement before the numbers start downward. GAS raw data – 1013 at rest – 10 fully depressed CLUTCH raw data – 1013 at rest – 10 fully depressed BRAKE raw data – 1013 at rest – +/- 250 (variable with PMB) 6. When your pot is set to the right position, use a hex key to tighten the follower arm set screws. This locks the arm onto the pot shaft. Sometimes it is necessary to hold the slotted pot shaft end with a screwdriver so it does not rotate while the set screw is tightened. Test the range of raw numbers as you depress and release the pedal. Make sure the readings match those above. Then move on to the next pedal and repeat until finished. When you finish all pedals you will end up at the Test screen. Check to be sure that all pedals move fully from the top to the bottom of the colored bars. If a pedal does not quite hit the end, you might need to add a bit more tolerance to the static position of the pot. When all controls act reliably from end to end of travel, you are finished. 6.5 CLEANING The exterior surfaces of ECCI systems are powder coated steel with vinyl overlay graphics. Use a moderately wet cloth with plain hot water for cleaning. If you need to use a detergent, only use a diluted mild dishwashing liquid such as Dawn for cleaning. DO NOT use dripping wet cloths or strong cleaning solvents, for damage to electronic components and finishes may occur. NEVER use 409 or similar household cleaners. 409 will quickly etch and ruin aluminum finishes. Such damage is not covered under warranty. 7.0 SERVICE AND TECHNICAL SUPPORT If you are experiencing trouble, first make sure all of your connections are secure. This is the most common source of faults. Also check the white pin connectors on the circuit board for looseness. Sometimes installation and handling can cause a loose terminal. Before contacting ECCI about any problem, first check the ECCI website for troubleshooting updates. It is quite possible that the problem you are having has a solution available just a mouse click away. If an answer to your problem is unavailable online, ECCI support can be reached by E-mailing: [email protected] or calling (612) 824-6733. BUTTON #1 BUTTON #2 BUTTON #3 BUTTON #4 Figure 3 - SWITCH CONNECTION ILLUSTRATION WITH DETAIL COMMON #1 1 2 3 4 BUTTON #1 COMMON #2 5 6 7 8 COMMON #3 9 10 11 12 Figure 30 - DB-9 PORT PIN-OUTS COMMON #5 COMMON #3 BUTTON #2 COMMON #1 BUTTON #4 PIN - 1 PIN - 6 2 3 7 4 8 5 COMMON #4 13 14 15 16 9 COMMON #2 BUTTON #3 COMMON #5 17 18 19 20 COMMON #4 BUTTON #1 BUTTON ASSIGNMENT MATRIX SWITCH DIODES BUTTON #1 BUTTON #2 COLOR CODED WIRE GROUP BUTTON #2 BUTTON #3 BUTTON #3 BUTTON #4 COMMON Figure 31 - BUTTON ACCESSORY PANEL ELECTRICAL SCHEMATIC BUTTON #4 BUT #2 (2) BUT #3 (3) BUT #4 (4) DB-9 CONNECTOR BUT #5 (1) BUT #6 (2) RED BUT #7 (3) COMMON #2 BUT #1 (1) COMMON #1 GROUND PIN 1 PIN 6 PIN 2 PIN 7 PIN 3 PIN 8 PIN 4 PIN 9 PIN 5 BUT #6 (2) DB-9 CONNECTOR BUT #7 (3) BUT #8 (4) BUT #9 (1) BUT #10 (2) BLUE BUT #11 (3) COMMON #3 BUT #5 (1) COMMON #2 BUT #8 (4) BUT #12 (4) LEGEND BUT #13 (1) BUT #14 (2) BUT #13 (1) SWITCH DIODE BUT #14 (2) MOMENTARY CONTACT SWITCH BUT #15 (3) BUT #16 (4) COMMON #4 GREEN BUT #15 (3) BUT #16 (4) BUT #17 (1) BUT #17 (1) BUT #18 (2) BUT #19 (3) BUT #20 (4) TRACKSTAR COMMON #5 BUT #18 (2) ELECTRICAL CONNECTION COMMON #4 BUT #11 (3) YELLOW BUT #19 (3) BUT #20 (4) GROUND FOR BUTTON POD HOUSING TRACKSTAR COMMON #5 BUT #10 (2) COMMON #3 BUT #12 (4) BUT #9 (1)