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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)

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