DALLARA F300 - Nordic F3 Masters
Contents
1. CAR INFO 4 5 SET UP 6 7 SUSPENSION FRONT 8 12 REAR 12 14 RIDE HEIGHT 15 DIFFERENTIAL 16 17 DAMPERS 18 19 AERODYNAMICS 20 24 UPRIGHT amp HUB ASSEMBLY 25 26 SYSTEMS OIL 27 BRAKES 28 FUEL 29 ELECTRICS 30 33 EXTINGHUISHER 34 GEARBOX 35 SAFETY AND UTILITY NOTES 36 37 TIGHTENING TORQUES 38 CONVERSION TABLE 39 GENERAL AGREEMENT AND 40 WARRANTY CERTIFICATES amp FIA DOCUMENTS Dallara Automobili TOP AND SIDE VIEW F300 Dallara Automobili 5 GENERAL DIMENSIONS AND SUPPLIERS Wheelbase 2678mm Front Track 1500mm Rear Track 1430mm Overall height 915 mm from ground to top of roll hop Overall width 1750 mm wide front suspension Overall length 4060 mm front endplate to rearmost edge of rear wing Weight 540 Kg including driver and ballast Front suspension push rod monodamper Rear suspension push rod twin damper Chassis Carbon and KEVLAR sandwich with AL NOMEX h comb Bodywork Glass fibre prepreg with NOMEX honeycomb Composites HEXCEL HERCULES Castings AGUSTA FLABO Gearbox DALLARA casing five ratios and reverse gear Gears and differential HEWLAND Springs EIBACH 36 mm ID Dampers KONI 2812 140 bump and rebound adjustable Fuel cell PREMIER FT3 Extinguisher system SPA design electrical operated Steering wheel OMP 270 mm OD Steering release system SPA design Coolers BEHR Filters F2. 4000km and 5000km after 5000km each 500km or after each race meeting or test day HUB ASSEMBLY The following procedure tells to change front and rear hub bearings Removal of bearing a Remove spigot by removing the 6 screws A b Push off drive flange by using two 6x1 screws set on thread B c Remove seeger C d Press off bearing from the upright e Push off retainer by means of two 6x1 screws set on thread B Replacement of bearing a Press wheel bearing into the upright b Fit seeger C C Press the retainer into the wheel bearing d Place spigot in position on the drive flange fit A screws washers and nuts and tighten to 41 Nm Caution this value is for 12K screws only Wheel stud removal a To reduce resistance to Loctite heat wheel stud and retainer to 180 C b Remove pin D remove wheel stud Wheel stud replacement a Remove pin D b Clean and degrease retainer thread and wheel stud C Spray degreaser to threaded area of retainer and wheel stud Caution Don t use petrol d Apply LOCTITE 638 to wheel stud thread e Screw wheel stud into retainer and tighten to 245 Nm by forcing on head T f Drill wheel stud and insert pin D Bearing assembly into hub replacement Warm the hub to 100 C Fit the bearing assembly FRONT HUB REAR HUB Dallara Automobili HUB ASSEMBLY 26 Dallara Automobili 27 SYSTEMS ENGINE OIL SYSTEM e We recommend keeping the oil level at 115 mm from the oil cap
3. SETUP ADJUSTMENT EFFECTS ON ADJUSTMENTS ON THE SET UP Positive change in means Height car rises Toe toe out Camber upper part of rim outward Castor lower part of rim points ahead ADJUSTMENTS FRONT REAR PUSHROD ADJUSTER Height change 4 30mm 6 52mm 1TURN Camber change deg 2 14 Thread step TOE ADJUSTER PER WHEEL M1 25R 24 L 2 31mm M1 25R 24 L 2 31mm 1TURN toe change deg 36 1 25 thread step 24 M1 25R 24 L 2 31mm CAMBER SPACER 1mm 17 15 toe variation 0 5mm 18 CASTOR ADJUSTER 20 brakecaliper 14 5 Castor change deg 26 38 thread step 24 20 1TURN height change mm 0 8 0 2 camber change deg 7 4 toe change deg 2 4 SPRING PLATFORM 1TURN thread step mm 2 2 height change mm 1 78 2 42 WHEEL SPRING RATIO vertical 0 91 1 21 WHEEL BELLEVILLE RATIO lateral 1 56 WHEEL DROP LINK RATIO roll 1 77 ROLL CENTRE HEIGHT Tyre dependent Tyre dependent Available front camber spacers 1 0 1 5 and 2 0 mm For the rear are available 0 8 1 0 1 2 1 5 and 2 0mm Combine these to make fine adjustments Front and rear wheel to spring front wheel to Belleville and rear wheel to drop link motion ratios may be considered as constant for all the wheel motion Dallara Automobili 8 FRONT SUSPENSION VERTICAL or SPRING PRELOAD In a non pre load condition as long as the damper is not fully extended turning the platform C raises the ride height and lowers
4. an 80 degrees angle will transmit little or no force while 45 degrees does Check to see which different side rear rings are available for each model of diff 60 80 is normally fitted as standard The pre load with which they are assembled to start In each diff there is a pre load spacer that looks like one of the B plates but thicker Depending on diff model it is either the first or last component assembled into the diff casing Its thickness dictates to what degree the plates are pre loaded forced against each other The pre load is set and checked on each diff by holding one side gear still via a dummy output shaft held in a vice and by turning the other with a torque wrench If the measured resistance is deemed too high the spacer is ground down until the desired figure is achieved usually between 5 to 20 Ibs ft The figure should be checked periodically as it tends to reduce as the diff runs meanwhile a new A slightly thicker spacer will allow re setting The final and easiest adjustment is the re arrangement of the contact order of the plates The arrangement 1 with a plates succession A B A B A has the maximum number of working friction faces and is the standard one It gives the maximum resisting torque The arrangement 3 has the minimum of working friction faces and gives the minimum resisting torque By swapping from arrangement 1 to 3 the resisting torque approximately halves AVAILABLE RAMP ANGLES Power side
5. of front hub to prevent coming loose Check the front upright lower stud on cracks after 3000km 4000km and 5000km after 5000km check them every 500km or after each race meeting or test day After any accident check alignment of front and rear pushrod and of their respective adjusters Wishbones are treated with PARCO LUBRITE Clean the surface with acetone before inspection Check periodically the K nuts which fixes the blades of rear antiroll bar to the drop links they shouldn t come loose Ball joint A used in front lower and rear lower wishbones must be fitted with sharp side in contact with seeger B as shown in following sketch Dallara Automobili 38 TIGHTENING TORQUES The table lists some suggested tightening torques For additional security use LOCTITE 242 or 243 Tightening torques Nm Kgm lbs ft Bevel gear nuts Lay shaft main shaft nuts Final drive bolts Wheel stud 245 25 0 185 Damper end stroke spacer 65 o 6 6 49 Wheel driver columns 50 5 1 38 Bolt 8 8 see hub assembly Bolt 12K see hub assembly 10 32 UNF K nut 3 03 2 UNE nt 15 15 lo la UNF K nut Dallara Automobili 39 SWG amp CONVERSION TABLE This table provides conversion from SWG Std Wire Gage to metric units for sheet metal thickness CONVERSION TABLE Length 1 inch 25 4 mm 1 millimeter 0 03937 in 1 foot 304 8 mm 12 in 1 centimeter 0 3937 in 1 mile 5280 ft 1 60934 km Volume 1 cubi
6. settings Dallara Automobili FRONT WING FRONT WING CONFIGURATIONS FRONT WING SIDEPLATE HOLES 20 Dallara Automobili REAR WING REAR WING PROFILES REAR WING CONFIGURATION LDF MDF LOW DOWNFORCE MID DOWNFORCE REAR WING SIDEPLATE HOLES 21 HDF HIGH DOWNFORCE Dallara Automobili 22 FRONT AND REAR WING SIDEPLATE TABLE e Front flap angle is measured on top of the flap front and inside the Gurney corner as shown on page 20 e Correspondence between holes and incidence angle is just indicative because wing angle is also function of front and rear ride heights e The machined side plates allow 1 deg step adjustment FRONT FLAP A IB C D E F G 8 19 110 111 129 13 114 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Q N REAR TOP A B C D E F 0 1 2 3 5 6 IRE 18 9 ge 111 12 113 1142 15 116 17 18 199 20 121 22 23 AJOIN Dallara Automobili 23 POLAR DIAGRAM Every point corresponds to a downforce level listed below F300 POLAR DIAGRAM 2 200 2 000 4 e E ar LU o 1 800 O LL z e 3 1 600 o 1 400 1 200 I I 0 600 0 650 0 700 0 750 0 800 DRAG CxT REAR FRONT LDF Low Down Force single small top MDF Medium DF twin
7. slightly the pressure inside the damper When the damper gets fully extended turning on the platform C puts vertical spring pre load on the car We advise though not to proceed this way because some dampers including Koni should not be used fully extended Therefore we advise to use the droop stop A Remind that there is some pre load in each damper With a Koni damper this pre load is about 30kg This pre load depends on damper type settings and internal gas pressure Pre load is the force that has to be applied on the spring to start to modify its length with respect to the static value To set the on car pre load put the car with the driver seated on the set up floor Unscrew the droop stop A to contact the opposite bolt B Now turn platform C to set the pre load As the platform thread step is 2 mm the pre load P Ks xt x 2 P pre load in kg Ks spring stiffness in kg mm spring stiffness in Lb in 56 spring stiffness in kg mm T number of platform C turns 2 mm turn for Koni SETTING THE ON CAR PRE LOAD Mount the damper spring combination with the platform C just in contact with the spring Mount damper spring combination on the car and put the car with the driver seated on the set up floor Make the car bounce a few times to settle down Screw the droop stop A into the rocker away from touching bolt B Adjust ride height with the pushrod adjusters to the desired setting Bring droop stop A in contact with bo
8. small top HDF High DF small and mid combined top MF Medium Flap small flap SF Standard Flap EF Extended Flap standard plus extension REAR TOP CFG TYPE SETT NG LOWER 1 NONE 1 2 LDF 2 5 3 MDF 6 5 4 MDF 10 5 5 MDF 14 5 6 MDF 18 5 7 HDF 11 5 8 HDF 14 5 9 HDF 17 5 10 HDF 17 7 11 HDF 20 7 12 HDF 23 7 FRONT FLAP MAIN TYPE SETT NG PLANE CFG NONE 0 5 1 MF 9 0 5 2 MF 14 0 5 3 MF 18 0 5 4 MF 22 0 5 5 MF 26 0 5 6 SF 16 0 5 7 SF 18 0 5 8 SF 20 0 5 9 EF 20 0 5 10 EF 22 0 5 11 EF 24 0 5 12 ALL NUMBERS ARE DEGREES Dallara Automobili AERODYNAMIC information 24 e Front wing main plane and rear lower wing are set relative to the chassis reference plane e The optimum setting for most of the setting range is for front wing main plane 0 5 and for the rear lower wing 5 Any chassis rake angle will alter this setting e Front flap inclination is intended to be the angle relative to the chassis reference plane measured between front of the flap on top and rearmost trailing edge without any Gurney e Rear top wing assembly inclination is intended to be the angle relative to the chassis reference plane measured between front of the flap on top and rearmost trailing edge Any chassis rake angle will alter this setting e Front and r
9. structural failure not later than two years after delivery from DALLARA factory and after each major accident After first check or after any major accident itis mandatory to check the chassis every year in a centre recognised by FIA authority DALLARA is not responsible for damage caused by non genuine spare parts Under maintenance following parts should be replaced after 25000 Km or two years use wiring loom starter motor steering column steering rack and tie rods brake pedal brake disc bell wheel bearings suspension arms and spherical joints engine installation parts drive shafts wings and rear wing supporting plates We firmly remind you that Main roll over hoop Monocoque and Front nose box crushable structure are FIA approved and cannot be modified by unauthorised personnel for whatever reason Any change to these parts is sufficient reason for disqualification Dallara Automobili FUEL SYSTEM LAYOUT 41 Dallara Automobili 42
10. ANSMISSION To prevent the drive shaft bolts from loosing fit them with LOCTITE 242 FIRE SYSTEM Take good care to the fire extinguisher F399 models have electrically operated activation with small explosive charge Notice to all the team crew for improper handling AERODYNAMICS It is forbidden to extract from mid downforce rear wing assembly the small profile and to use it for the rear low downforce configuration because they are differently reinforced Buy the specific part When running the car with a rear ride height of 45mm or more please check the height of the wing endplate Total height cannot exceed 900mm STEERING Steering rack side tie rod ends must be absolutely replaced in case of crash FUEL SYSTEM Dallara on request can deliver quick release adapter for the fuel line connector CLUTCH When using a thicker than F3 typical AP twin plate metal clutch i e carbon clutch please check that the clutch piston can move backwards enough to release the clutch completely You can shorten the clutch piston spacer by turning off the required amount WISHBONES Never lift up the car taking the middle of the wishbones Never sit or stand on the wishbones Dallara Automobili 37 SUSPENSION Check pin to inner hub tightening both for front and rear upright assembly You can notice if the locknut came loose by observing relative displacement of two red notches on locknut and on spigot Check every 1000 Km lower pin locknut
11. Brake side Dallara Automobili DIFFERENTIAL LAY OUT Make sure the plate arrangement is always equal on left and right hand side Side gear ring diff end plate diff wall and pre load spacer all act as B plates Bigger ramp angle transmits less thrust onto plates than smaller one 17 Dallara Automobili 18 DAMPERS DIMENSIONS amp GENERAL INFORMATION e Standard dampers are KONI 2812 140 Front and rear dampers have identical valving the same full extended length and identical installation parts Damper assembly dimensions are mm full open length 335 full closed length front 297 rear 291 stroke front 38 rear 44 e The difference in stroke and full closed length is due to the 6mm Teflon spacer on front damper to prevent the rocker to lock If you use different dampers check that max stroke is not more than 38 mm e The standard Koni damper has about 30kg of pre load due to the internal gas pressure e Dallara on request delivers installation kits for PENSKE and QUANTUM dampers Eibach dampers can be installed using standard mountings Dallara Automobili 19 DAMPERS DIAGRAM The Koni dampers are adjustable both in bump and rebound by acting on the adjuster wheels marked B for bump adjustment and R for rebound adjustment on the damper top Each adjuster wheel has eight different positions KONI 2812 140 Figure shows force velocity graphs for full soft and full stiff
12. DALLARA F300 FORMULA 3 2000 USER MANUAL Dallara Automobili FOREWORD Dallara Automobili is happy with the choice you made buying out Formula 3 cat and wishes you the very best in racing it For any question advice or idea you might have please don t hesitate to contact us Dallara Automobili Via Provinciale 33 43040 VARANO MELEGARI PR ITALY Telephone 39 0525 550711 Fax 39 0525 53478 design Mr Ferdinando Concari Email F3 dallara it technical assistance Mr Jos Claes Email F3 dallara it business Mrs Caterina Dallara Email comm dallara it commercial Mr Alberto Lecordetti Email sales dallara it Dallara has its own web site www dallara it where you can find useful information about our company our people and our factory DALLARA PARTS DISTRIBUTORS JAPAN Le Mans Company Le Mans Building 3215 Hiroo Shibuya ku Tokyo JAPAN Contact Mrs Katsuhisa Homma Shiro Matsunaga Telephone 81 3 3400 5086 781 550 840 100 Fax 81 3 3486 0820 81 550 885 552 UNITED KINGDOM AMT Motorsport Aldershot Hampshire Contact Mr Martin Stone Telephone 44 0 1252 333 294 Fax 44 0 1252 321 661 Email amtmsport aol com GERMANY Contact Miss Katrin Eichstaedt Telephone 49 2331 954 275 Fax 49 2331 961 842 FRANCE Contact ASM Phillipe Telephone 33 386 660 036 Fax 33 386 660 929 Dallara Automobili CONTENTS
13. IAAM Rims SPEEDLINE 9 front 10 5 rear Brake system BREMBO Battery FIAMM Seat belt TRW SABELT Installed engines Fiat Alfa BMW Novamotor Honda Mugen Opel Spiess Renault Sodemo Toyota Tom s Mitsubishi HKS VW Bertil s USA Dallara Automobili 6 SET UP TIRE INFORMATION Tire dimensions depend on tyre pressure rim width and camber angle The stiffness values are based on the recommended inflating pressure hot tyres FRONT TIRE Avon Bridgestone Michelin Pirelli Yokohama Specification 180 50 13 Free radius mm 278 0 Loaded radius mm 273 2 Vertical stiffness Kg mm 17 0 Hot tire pressure bar 6 REAR TIRE 250 570 13 240 45 13 288 0 281 0 Vertical stiffness Kg mm 17 8 Hot tire pressure bar 1 65 1 5 1 6 1 55 1 55 SUGGESTED SETUP The set ups consider the complete car with the driver seated ready to race The front anti roll setting pre load is double stiffness pre load for details look at the FARB pages Camber deg 2 45 315 345 47 315 6 A 5 J AAA EPA CIA i pere reos mm RE EL ea le 1 S Kirma 9 ie Ba Ride height mm 34 j wo EE WP 4 Vio z V V V wo gt Camber deg 5 1 Toe deg total two wheels 10 IN on o 800 so 90 jo Oo p Jo LAE o eoo O Springs bin 800 Pre load mm O p boi ra Oh Dallara Automobili 7
14. also of military grade and use two contacts per lead to guarantee the best connections Actuators are designed either to operate individually or connected in series if two heads are used TESTING The power pack electronics can test the continuity of the electrical wiring and provides a high current pulse test on the battery to ensure system integrity before use The battery test electronics do not excessively drain the battery during this test The tests are carried out using a three way switch on the power pack Since the system is only as good as the battery that powers it and the integrity of the wiring and its connections the tests should be performed before each race To check the battery press and hold up the power pack switch Every 2 seconds you ll see a YELLOW light flash If the light flashes very dimly the battery should be replaced In doubt change the battery To check the wiring continuity ensure that the power pack switch is on SYSTEM INACTIVE to ensure that the extinguisher is not fired Press the internal firing button and check that the RED light comes on Press the external firing button and check that this also makes the RED light comes on CARES Ensure that the electric command cables are not laying next to or in the same loom as the car battery power cables or ignition cables Ideally all cables should lie next to the chassis earth Ensure that all plugs exposed to water spray are protected with rubber
15. boots If tubing is to be removed push orange collet in While holding in the collet pull out the tube Avoid any cable to run over sharp edges without protection Do not fix the cables next to or onto any surface likely to exceed 200 C Do not turn the firing heads when the system is activated Dallara Automobili 35 GEARBOX GEARBOX BEARINGS AND TORQUES For ease of maintenance and replacement you find in this drawing the standard fitted bearings in the gearbox and the tightening torques we suggest for the primary and secondary shaft nuts Dallara Automobili 36 SAFETY AND UTILITY NOTICES In case of anomalies contact immediately Dallara SAFETY NOTICES STUD INSTALLATION AND REMOVAL It is very important to take an extreme care when removing and substituting the studs Typically use Loctite 270 soft Loctite for suspension brackets brake calipers Loctite 242 hard Loctite for chassis gearbox bell housing roll hop Most of these studs are loctited and do require a proper installation procedure to follow Clean the hole from dust debris Drive a screw tap to remove machining residuals Clean the hole with compressed air Pre assemble the stud without Loctite and remove Clean the hole again with a degreaser and dry with compressed air Coat the hole with Loctite Install the stud Tight the stud with the recommended tightening torque you can do so by using a pair of nuts locked against each other TR
16. c inch c i 16 387 cubic centimetres ss Wiiiter 1000cc 61 0255cubicinch Pressure 1 psi 0 0716 bar 1 kg cm2 1 019 bar SS fbar 10 Pa 0 1MPa x y y fbar1395psi Weight 1pound lb 16 ounces 453 592 grams Speed 1 MPH 1 467 feet per second Gw 1 mph 0 62137 kilometres per hour 1 kilometre per hour 1 60934 mph 1 IPS in s 25 4 mm s 1 mm s 0 039 IPS Specific weight Useful formulas British horsepower BHP RPM x torque Ibs ft 5250 MPH RPM x tire diameter in gear ratio x 336 Km h RPM x tire diameter mm gear ratio x 5308 Lap speed MPH track length miles x3600 lap time seconds Lap speed km h track length Km x 3600 lap time s Average speed MPH track length miles x3600 x no of laps total time seconds Average speed km h track length Km x3600 x no of laps total time seconds Dallara Automobili 40 GENERAL AGREEMENT AND WARRANTY Motor racing is not covered by warranty due to the intentional choice of drivers to race in a dangerous environment DALLARA indicates that under normal operating conditions a new car would not show failure in structural components before it has completed around 25000 Km This holds true if necessary maintenance and checks are provided and if the car had no previous incidents DALLARA is not responsible for incorrect chassis repairs if made outside its factory or in centres not recognised by FIA Chassis should be checked for
17. curately the transition point of pre load no pre load since the consequently stiffness variation is sudden and reflects immediately on the cars balance and behaviour You can combine different stacks in series to obtain a progressive load displacement characteristic Total length of the combined stack should never be more than 28mm Pay attention to The clearance between the platform and the rocker B should not be more than 6 5mm when platform just touches the Belleville stack with no pre load For any Belleville stack in running condition rocker lateral displacement and the chosen pre load must never reach the Maximum Deflection see Table below to avoid a sudden lateral locking of the rocker BELLEVILLE STACK CONFIGURATIONS Belleville thickness 2 0mm Stack Nominal Stack Maximum Maximum configuration stiffness kg mm length deflection notches mm mm lt lt lt lt gt gt gt gt CE E lt lt lt gt gt gt lt lt lt le on lt lt gt gt lt lt gt gt basi 362 44 V 57 362 E ds a lt lt lt gt gt gt lt lt gt gt lt lt lt gt lt gt lt gt lt gt lt lt gt lt gt lt gt Dallara Automobili 10 SETTING THE PRE LOAD DOUBLE STIFFNESS PRE LOAD Mount the stack you want to use and turn the platform until contact with the Belleville stack Adjust by turning the platforms until distance A is the same on both sides Check distance B to be unde
18. disassembly of the rocker and the pivot A Contact DALLARA customers service to get the tools E and F e Unscrew nut C The tightening torque to fit it back is 3 5 Kgm e Take off the top cap and the rocker e Unscrew nut D with a long 14mm tubular dowel The tightening torque to fit it back is 5 5 Kgm e Fit extractor F around the pivot s outer flange screwing in bolt E and remove the pivot e Remove stud B with the proper tool The stud is fitted with Loctite in its insert When removing the stud heat up the stud s thread to break the Loctite with a heat gun up to 140 C RIDE HEIGHT CHECK AND REFERENCES Dallara Automobili 15 Ride height is fundamental for setting and changing the aerodynamic performance of the car It might be difficult to measure it directly so we provide alternative references The example shows front ride height 15mm and rear 34mm at wheel axis With 2678mm wheelbase pitch angle is 0 40 Calculation 34 15 2678 inv tanx x 0 40 The two round platforms on top of the tub to measure front ride height at front axis are 50mm behind the axis when using the long wheelbase front suspension Measuring front ride height A flat surface skid about 310 mm behind the wheel axis and 50 mm behind the skid leading edge You can measure its distance from ground as 17 tan0 40 x310 15mm Measuring rear ride height Two machined areas at 327 5 mm from car bottom on the gearbox at wheel axle line Yo
19. ear ride height settings are fundamental to the aerodynamic balance and ultimate performance of the car Pay attention to the changes between the static setting and the dynamic values on track Downforce CFG Part Min Suggested Max Suggested Hole Incidence Hole Incidence Flap Rear top LDF Rear top MDF HDF A4 FA 18 23 How to balance 1 FR flap variation by changing the rear wing RR ride height or FR ride height RR TOP gt LDF MDF HDF 2 holes RR top 1 hole RR top MF 1 5mm lower RR height MF 1 5mm lower RR height 1mm higher FR height 1mm higher FR height FR 2 holes RR top 1 hole RR top FR FLAP SF 3 5mm lower RR height SF 2 5mm lower RR height 2mm higher FR height 1 5mm higher FR height 2 holes RR top EF 2 5mm lower RR height 1 5mm higher FR height MF Medium Flap SF Standard Flap as 99 EF Extended Flap COOLING ADJUSTMENT Depending on air temperature and engine optimum water temperature you can set the cooling capacity of the radiators Efficiency increases by sealing any eventual leakage in the inlet ducts to the radiators Dallara Automobili 25 FRONT UPRIGHT SAFETY NOTE We advice to regularly check the lower stud on the front uprights which could show little cracks difficult to detect by men s eye Use penetrating liquid to check these studs after each accident and according the following schedule Check after 3000km
20. lt B Turn platform C until desired pre load force is achieved P Ks xtTx 2 Dallara Automobili 9 FRONT ANTI ROLL AND PRE LOAD There are 3 different ways of setting the front anti roll Belleville washers Mount a stack configuration and turn the platforms just in contact with the stack This way there is no pre load on the stack and the roll stiffness is the nominal stack stiffness For example the configuration lt lt gt gt lt lt gives 761kg mm stiffness When both platforms get turned on a few notches the system is preloaded The roll stiffness under this pre load is double the nominal stiffness When the rocker passes the pre load the stiffness gets back to the nominal For example gt gt lt lt gt gt 5 notches is for 0 5mm of lateral movement 761x2 1522kg mm stiff When both platforms get turned on a few notches and locked up with the two extra locknuts the system is infinite stiff this means there is no lateral movement as long as the force doesn t overcome the pre load Once the pre load passed the stiffness gets back to nominal Both pre load settings 2 and 3 generally help for sharper turn in Soft no pre load settings 1 can make the tyres last longer and make the car easier to drive Over the pre load the stiffness gets back to the nominal stiffness The driver may prefer some pre load in certain conditions turn in and wish to overcome the pre load in some other conditions mid corner curbs Set ac
21. measured with running engine e Less oil may cause cavitation and so air to get into the oil circuit e More oil may cause power loss e Typically you would need 4 5 litres to fit in the oil tank or 5 0 when using an oil cooler GEARBOX OIL Typically you would need 1 2 litres to properly run the gearbox and the differential Dallara Automobili BRAKE SYSTEM BREMBO BRAKE CALIPER ASSEMBLY 28 Dallara Automobili FUEL SYSTEM F300 features twin electrical submerged fuel pumps as a redundant caution in case one pump fails The driver can switch between the two pumps from the cockpit OPEL Spiess installation has a specific high pressure pump 29 Analogical dashboard wiring Dallara Automobili ELECTRICAL SYSTEM 30 Dallara Automobili Pl and BOSCH dashboard wiring 31 Dallara Automobili MARELLI dashboard wiring 32 Dallara Automobili STANDARD ENGINE WIRING 33 Dallara Automobili 34 EXTINGUISHER SYSTEM LAYOUT DETAILS The SPA Fire Fighter system is an electrically triggered Halon or foam spray fire extinguisher system The system uses actuators to operate the valves located on the pressurised container containing the extinguishing liquid These are triggered remotely using a battery powered power pack In order to guarantee reliability the actuators are of military specifications The system battery test electronics are integrated into the remote power pack Connectors on the firing heads are
22. r than 6 5mm if it s more replace adjustment spacer Mark this platform position as the zero pre load notch Turn both left and right platforms the amount of notches to set the desired pre load One turn of platform is 15 notches corresponding to 1 5mm displacement 1 notch 0 1mm INFINITE STIFFNESS PRE LOAD Set the pre load as described for the double stiffness procedure here above Mount nut D in contact with the platform Tighten counter nut E against nut D Dallara Automobili 11 FRONT ROLL CENTER Moving the spacer underneath or above the lower wishbone spherical joint changes the height of the front roll centre When choosing low roll centre configuration push rod length has to be shortened by 1 4 register turns 8 faces of the adjuster to keep the car at the same ride height When adjusting the roll centre height there will also be a slight change in camber gain in function of vertical wheel travel OPTION Roll centre height Camber change static ride height for 10mm wheel travel STEERING ASSEMBLY Pinion primitive diameter 15 71 mm 12 6 steering wheel wheel Ackermann 96 Dallara Automobili 12 MEASURING CASTOR FRONT When the car is flat front ride height equals rear and the front upright inclination is 1 80 castor angle is 10 5 With different front to rear ride heights castor angle changes because of the pitch angle of the car For instance with 15 mm front and 40mm rear ride height measu
23. red at wheel axis wheelbase is 2678 mm the pitch angle is 0 53 as Pitch angle 40 15 2678 1 tan 0 53 castor angle 10 5 0 53 9 97 REAR The rear wheel castor not relevant because the wheel is not steered can be checked using the brake calliper mounting platforms When the car is flat front ride height equals rear and the measured angle is 20 the castor is 14 5 The pitch angle must be added because the castor is rearward Dallara Automobili 13 REAR SUSPENSION REAR SUSPENSION ROLL CENTER AND ANTISQUAT SETTING OPTION Roll centre height Camber change Antisquat static ride height for 10mm wheel travel Fr UE Option D 1 and E 2 alter caster angle To obtain std value shorten by 2 turns the castor uniball Option B 2 needs special bracket for front top mounting available at Dallara REAR ANTIROLL BAR STIFFNESS Dallara Automobili 14 F300 has a rear anti roll bar with two 75mm long adjustable blades 40mm diameter ARB is the stiffest available this can be milt down to any softer ARB The two digits in this table represent the blade positions 1 full soft 5 full hard Stiffness in kg mm EET RET 1 5 108 9 118 6 24 mm STD 104 3 109 2 126 7 156 8 177 9 28 mm 85 1 128 6 136 1 164 3 218 9 262 2 REAR SUSPENSION ROCKER REPLACEMENT The rear rocker spins around a steel pivot A fitted onto the gearbox casing by stud B fixed with LOCTITE 242 The following procedure shows the
24. u can measure their distance from the ground as 361 5 327 5 34mm height Under the flat bottom 50mm ahead of the start of the diffuser and 313mm ahead of the rear wheel axis you can measure and calculate the floor distance from the ground as following measured 32mm tan0 40 x313 34mm REAR RIDE HEIGHT FRONT RIDE HEIGHT 34mm 15mm POWER FLOW DIFFERENTIAL Dallara Automobili 16 WORKING PRINCIPLE AND SETUP This differential diff is designed with versatility as its major asset Many parameters will lead you to the required setting A car with good grip and low power may require a completely different arrangement than that for a high power low grip car The working principles of powerflow differentials Ten friction plates within the diff six connected to the side gears four to the diff casing control the amount of differential action available The amount of limited slip depends only on the frictional resistance between these ten plates Four factors contribute in defining this frictional resistance see figure next page 1 2 The bevel gears thrust apart as soon as the car moves This is a feature of bevel gears and is not adjustable The ramp angle on the side gear ring influences the amount of the driving force on the diff round that is directed sideways and onto the plates E g on the power drive side ramp 45 degrees transmits less force sideways than 30 degrees Likewise on the brake coast side ramp
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