PMB2 Race Brake Kit Installation, Stage 1 and 2

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1.  Loosen PMB2 adjusting screw locknut.  Back off adjuster      screw until it stops. 2.  Wrap rubber band around spring bracket and stop rod to hold in place for spring removal.  Pull spring back as shown to clear spring bracket and remove.

 

3.  Remove pivot bolt nut and pull pivot bolt out.  Remove cam assembly. 4.  Remove cam retaining screws and remove cam.

 

5.  Remove locking ring. 6.  Locate Race Brake components.

 

7.  Install new cam and cam plate with 10-24 x 1/2" (12mm) screws.  Tighten lightly and then loosen 1 turn.  8.  Install locking ring and locating ring on pivot bolt. 

 

9. Install pivot bolt/locking ring/locating ring assembly into cam assembly. 10.  Slide cam as required to obtain gaps that are approximately equal on both sides of the locking ring.  Tighten securely.
If you are installing the Stage 2 kit you can now go to this page for Stage 2 installation detail:  PMB2 Stage 2 Upgrade Install

 

11.  Rotate pot arm counter-clockwise until the guide pin is down at the bottom of travel. 12.  Remove pivot bolt and locking ring from cam assembly.  Leave locating ring in cam.  Slide cam assembly into position for installation into pedal unit.  Insert pivot bolt/locking ring and tighten.

 

13.  Move cam assembly and rotate pot arm as required to engage guide pin into slot in cam plate assembly. 14.  Re-install rubber band around spring bracket and stop rod to hold in place for spring installation.

 

15.  Install new spring adjuster end first.  You must use the spring included with the kit.  Do not use any other spring. Compress spring as shown and slide onto spring bracket. Do not turn adjusting screw in at all, lightly tighten the locknut.  For proper Race Brake operation the adjuster must be in the minimum pressure position. 16.  Install one of the clamp plates, the stop plate, and the two 10-24 x 3/4" (19mm) screws in the travel limiter slot of the brake arm.   Note the orientation of the notch in the top edge of the clamp plates and stop plate.  See the next image for a detail from the other side of the pedal arm.

 

17.  View from outside of pedal unit.  18.  Install the other clamp plate and retaining nuts.  Lightly tighten nuts and then loosen 1 turn. 

 

19.  Slide stop assembly all the way to the end of the travel limiter slot.  Tighten securely.  If you have installed the Stage 2 upgrade you will now need to go to 6000 HDUSB Pot Service to re-setup your throttle and brake pots. 

If you have installed only the Stage 1 version of the Race Brake you are now ready to check calibration values.  Firmly secure the driving seat and pedal unit.  They must be immovable.  Go to the Windows joystick calibration utility and calibrate controls using the Windows raw values.  When you get to the brake calibration section note the at-rest value.  It should be 1013.  If it is not adjustment will be required.  At the other end of travel  sure to apply a very high force to the brake to get it to full travel.  Note the raw value at the end of travel. It needs to be less than 200, the optimal values are between 170 and 150.   If your at-rest value is 1013 and your max travel value is between 200 and 150 you are finished with the installation.  If your values do not fall within this range go to the next step (step 20).		 20.  Adjustment (if required).   If your calibration values do not fall within the described range adjustment will be required.   Use the table below as a guide for where to begin adjustments.  If you need to adjust the cam, remove the cam assembly and loosen the 5 cam plate screws slightly.  Nudge the cam slightly in the recommended direction shown to adjust end travel raw values.  A tiny bit of movement here will change the end value significantly. Firmly tighten the 5 screws.  Re-install the cam assembly and check calibration values.  If required re-adjust until the proper values are achieved.  If pot adjustment is required see detail images below.
Adjustment Recommendations for PMB2 Race Brake
At-rest value 1013, holds 1013 for first 1/16" to 1/8" (1.5mm to 3mm) of pedal movement, full travel value 150 to 200. No adjustment necessary.
At-rest value 1013, holds 1013 for first 1/16" to 1/8" (1.5mm to 3mm) of pedal movement, full travel value 200 to 300. Remove cam assembly and slide cam slightly in direction shown in fig. 20 to decrease full travel value.
At-rest value 1013, holds 1013 for first 1/16" to 1/8" (1.5mm to 3mm) of pedal movement, full travel value less than 140. Remove cam plate assembly and slide cam slightly in direction shown in fig. 20 to increase full travel value.
At-rest value less than 1013, full travel value 120 to 170. Adjust pot to obtain at-rest value 1013, holding 1013 for first 1/16" to 1/8" (1.5mm to 3mm) of pedal movement.  Pot details shown below.

 

PMB pot arm detail 1, locking screw 1.  Loosen  1/2 to 1 turn with 5/64" (2mm) hex wrench. PMB pot arm detail 2, locking screw 2.  Loosen  1/2 to 1 turn with 5/64" (2mm) hex wrench.

PMB pot arm detail 3, pot shaft adjustment.  When adjustment is completed be sure to maintain pot arm clearance per pot arm detail 1.