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DALLARA F302

Manual F302/1

CONTENTS

3

4

5-6

SUSPENSION

7-11

13-14

DIFFERENTIAL

15-16

17

RIDE HEIGHT

19

AERODYNAMICS

20-24

25

UPRIGHT ASSEMBLY

26-27

SYSTEMS

28

29

30

31

32

SAFETY AND UTILITY NOTES

33

TIGHTENING TORQUES

34

CONVERSION TABLE

35

GENERAL AGREEMENT

36

CERTIFICATES

37-

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Summary of Contents for F302

Page 1: ...ont 7 11 Rear 13 14 DIFFERENTIAL 15 16 DAMPERS 17 RIDE HEIGHT 19 AERODYNAMICS 20 24 COOLING 25 UPRIGHT ASSEMBLY 26 27 SYSTEMS Oil 28 Brakes 29 Fuel 30 Extinguishers 31 GEARBOX 32 SAFETY AND UTILITY NOTES 33 TIGHTENING TORQUES 34 CONVERSION TABLE 35 GENERAL AGREEMENT 36 CERTIFICATES 37 ...

Page 2: ...ssistance Mr Jos Claes Email F3support dallara it business Mrs Caterina Dallara Email comm dallara it Dallara has its own web site www dallara it where you can find useful information about the company our people and the factory DALLARA SPARE PARTS DISTRIBUTORS JAPAN FRANCE ENGLAND GERMANY contact Shiro Matsunaga Steeve Marcel Martin Stone Katrin Eichstadt Tel 81 550 885 550 33 386 660 036 44 1252...

Page 3: ...3 SIDE TOP VIEW OF THE F302 ...

Page 4: ...comb Bodywork Glass fibre composite with NOMEX honeycomb Composites HEXCEL HERCULES Castings AGUSTA FLABO ALLMAG Gearbox HEWLAND six forward gears plus reverse Gears and differential HEWLAND Springs EIBACH 36 mm ID Dampers KONI 2812 140 bump and rebound adjustable Fuel cell PREMIER FT3 Extinguisher system Lifeline electrical operated Steering wheel Sparco 270 mm OD Steering release system SPA desi...

Page 5: ... mm 8 6 6 8 Damper static length mm 335 335 335 335 Solid spacer mm 6 6 6 6 Push rod length mm Roll centre setting STD LOWER STD STD Roll bar setting Roll pre load notches none none none none REAR Ride height mm 27 28 28 28 Camber deg 1 45 2 30 3 00 3 15 Toe deg total two wheels 10 IN 20 IN 20 IN 20 IN Springs lb in 900 800 800 800 Pre load mm none none none none Damper static length mm 335 335 33...

Page 6: ...ADJUSTER 20 brake calliper 14 5 Castor change deg 25 35 thread step 24 1 06mm 20 1 06mm 1TURN height change mm 0 14mm 0 8mm camber change deg 6 1 toe change deg 2 3 SPRING PLATFORM 1TURN thread step mm 2 2 height change mm 1 79 2 47 WHEEL SPRING RATIO vertical 0 896 1 237 WHEEL BELLEVILLE RATIO lateral 1 548 WHEEL DROP LINK RATIO roll 1 808 ROLL CENTRE HEIGHT Tyre dependent Tyre dependent Spacers ...

Page 7: ...cluding Koni should not be used fully extended Therefore we advise to use the droop stop A Pre load is the necessary force that has to be applied to the spring to modify its length with respect to the static length value P Ks x t x 2 P pre load in kg Ks spring stiffness in kg m Ks in Lb in 56 Ks in kg mm T number of platform C turns 2 mm turn for standard Dallara damper top SETTING THE PRE LOAD Mo...

Page 8: ...03 Pitch angle 28 15 2675 x 57 29 0 28 Build in castor angle becomes 10 5 0 28 10 22 corresponding to a 2 03 measured apparent castor angle each change in front and or rear ride height alters the castor angle REAR The rear wheel castor angle can be measured to check bump steer to be zero You can measure the angle on the brake caliper mounting platforms When the car is flat front ride height equal ...

Page 9: ...any Belleville stack in running condition rocker lateral motion and the chosen pre load must never reach the Maximum Deflection see Table 6 to avoid a sudden lateral locking of the rocker Once the rocker overcomes the pre load the total stiffness reduces to the nominal stiffness of one Belleville stack You may like to work within the roll pre load range under certain conditions turn in and wish to...

Page 10: ...lace 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...

Page 11: ...d length has to be shortened by 1 2 register turns 7 faces of the adjuster to keep the car at the same ride height When adjusting the roll centre height camber gain versus wheel travel varies a little OPTION Roll centre height static ride height Camber change with 10mm wheel travel Std X 5 Low 10 mm 3 STEERING ASSEMBLY Pinion primitive diameter 15 60 mm Static steering ratio 13 1 steering wheel wh...

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Page 13: ...tain std value shorten by 2 turns the caster uniball Option B 2 needs special bracket for front top mounting available at Dallara OPTION Roll centre height Camber change Antisquat static ride height with 10mm wheel travel A 1 Std 20 48 B 2 18 16 48 C 1 18 24 48 D 1 std 23 66 E 2 15 18 66 F 1 8 22 35 G 2 10 18 35 ...

Page 14: ... 6 35 7 61 0 79 6 88 7 106 9 123 0 137 2 149 8 172 3 185 9 3 5 17 5 22 9 36 6 63 5 83 9 94 2 114 9 133 8 150 7 166 0 194 2 211 5 4 4 17 8 23 4 37 9 67 5 91 0 103 1 128 4 152 5 174 9 195 8 236 3 262 5 4 5 18 0 23 8 38 8 70 6 96 7 110 5 140 2 169 3 197 5 224 5 279 4 316 8 5 5 18 2 24 2 39 8 74 0 103 2 119 1 154 3 190 4 226 7 263 1 341 7 399 4 REAR SUSPENSION ROCKER REPLACEMENT Rear rocker spins arou...

Page 15: ... the re arrangement of the contact order of the friction discs The arrangement 1 with a disc succession A B A B A has the maximum number of working friction faces It gives the maximum resisting torque The arrangement 3 has the minimum of working friction faces and gives the minimum resisting torque Standard Hewland available ramp angles are 30 60 45 45 45 80 60 80 80 80 Differential settings have ...

Page 16: ...UT 16 Check the plate arrangement is equal on both sides Side gear ring diff end plate diff wall and pre load spacer all act as B plates A bigger ramp angle transmits less thrust onto the plates than a smaller ramp angle ...

Page 17: ...99 REAR 291 Stroke FRONT 36 REAR 44 On Koni dampers you should always use the 8mm Teflon spacer on front assembly to prevent the rocker to lock If you plan to use alternative products check that maximum stroke to be less than 36 mm Dallara on request delivers installation kits for PENSKE and QUANTUM dampers If you want to install other dampers remind that full open and closed length must be equal ...

Page 18: ...DAMPER GRAPH 18 KONI 2812 140 100 80 60 40 20 0 20 40 60 80 100 0 20 40 60 80 100 120 V mm s F kg BUMP min BUMP max REBOUND min REBOUND max ...

Page 19: ...at wheel axis With 2675mm wheelbase this gives 0 32 pitch angle 30 15 2675 x 57 29 0 32 At the front end of the car you have two alternative references Two round platforms 513 5mm from car bottom on top of the tub at the wheel axle line You can measure their distance from the ground as 528 5 513 5 15mm ride height A flat surface skid about 310 mm behind the wheel axis and 40 mm behind the skid lea...

Page 20: ...FRONT WING 20 FRONT WING CONFIGURATIONS FRONT WING SIDEPLATE HOLES ...

Page 21: ...21 REAR WING REARWING PROFILES REAR WING CONFIGURATION LDF MDF HDF UHDF REAR WING SIDEPLATE HOLES _____________________ ...

Page 22: ...es allow 1 degree step adjustment FRONT FRONT FLAP MF SF A B C D E F G 1 10 11 12 13 14 15 16 2 17 18 19 20 21 22 23 3 24 25 26 27 28 29 30 4 31 32 33 34 35 36 37 REAR REAR TOP LDF A B C D E F 1 0 1 2 3 4 5 2 6 7 8 9 10 11 MDF HDF A B C D E F 1 2 3 4 5 6 7 2 8 9 10 11 12 13 3 14 15 16 17 18 19 4 20 21 22 23 24 25 The following gives the F302 HDF rear wing incidence to achieve the same level of dow...

Page 23: ...own Force twin small top MF Medium Flap HDF High Down Force std small and mid combined top SF Standard Flap UHDF Ultra High Down Force twin mid top SF Standard Flap REAR FRONT CFG TOP TYPE TOP SETTING LOWER FLAP TYPE FLAP SETTING MAIN PLANE CFG 1 LDF 2 5 NONE 0 5 1 2 MDF 8 5 MF 10 0 5 2 3 MDF 13 5 MF 16 0 5 3 4 MDF 18 5 MF 21 0 5 4 5 HDF 11 5 SF 12 0 5 5 6 HDF 15 5 SF 15 0 5 6 7 HDF 17 5 SF 18 0 5...

Page 24: ...hassis rake will alter this setting Front and rear ride height settings are fundamental to the aerodynamic balance and ultimate performance of the car Pay attention to the changes between static setting and the dynamic values on the track MINIMUM SUGGESTED MAXIMUM SUGGESTED DOWNFORCE CFG HOLE INCIDENCE HOLE INCIDENCE FRONT MF FLAP A1 10 G4 37 FRONT SF FLAP A1 10 D4 34 REAR TOP MDF WING A1 0 A4 18 ...

Page 25: ...he same balance you might need to reduce the rear top wing incidence or increase the front flap incidence The most efficient way of adjusting the cooling is the following CONFIGURATION EQUIVALENT INCREASE IN REAR HDF WING INCIDENCE Without Blanking Reference 1 30 FRONT 0 5 2 30 FRONT REAR 1 3 60 FRONT REAR 1 5 Figure shows the 30 and 60 blanking of the radiator inlet regarding configuration 1 2 an...

Page 26: ...igot 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...

Page 27: ...27 HUB ASSEMBLY FRONT HUB REAR HUB ...

Page 28: ...rcuit More oil may cause excessive power consumption due to the oil squash Typically you would need a total of 4 5 litres to fit in the oil tank including the oil in the engine and hoses Check with the engine tuner for the specific amount for your engine GEARBOX OIL In order to properly run the gearbox and the differential you need 2 5 litres of oil SAE 80 or 90 ...

Page 29: ...29 BRAKE SYSTEM BREMBO BRAKE CALIPER ASSEMBLY Note the dark piston is the bigger in diameter from both The car features four different callipers TRAVEL DIRECTION BRAKE DISC ASSEMBLY ...

Page 30: ...FUEL SYSTEM 30 F302 features twin electrical submerged low pressure fuel pumps as a redundant caution in case one pump fails The driver can switch one or the other low pressure pump from the cockpit ...

Page 31: ...od 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 If in doubt change the battery To check the wiring continuity ensure that the power pack switch ...

Page 32: ...Hewland by e mail sales hewland com To take the differential out you first need to take remove the LH side outer tripod housing which is locked with a wire ring circlip type fitting inside the RH tripod housing We build a specific tool available at Dallara s stores To open the differential you have to remove the bearing in order to reach the bolts of the casing cover Use proper tools in order to a...

Page 33: ...rofile for use as rear low downforce wing because these are not reinforced Use the specific wing profile available at Dallara when running the car with a rear ride height of 40mm or more check the height of the rear wing endplate Total height cannot exceed 900mm STEERING steering rack end rod ends must absolutely get replaced after crashing CLUTCH When using a thicker than F3 typical AP twin plate...

Page 34: ...t Pinion bearing nut 176 17 9 130 pinion shaft nut 135 13 8 100 Final drive bolts 73 7 5 55 Brake disc bolt 7 0 7 5 Brake caliper studs 50 5 1 37 Wheel nut 165 17 0 125 Wheel stud 245 25 0 180 Damper end stroke spacer 65 6 6 49 Wheel driver columns 50 5 1 37 Nut 7 1 see hub assembly 17 1 7 13 Bolt 8 8 see hub assembly 25 2 5 19 Bolt 12K see hub assembly 39 4 0 29 Rocker cap nut 34 3 5 25 Rocker st...

Page 35: ...0 cc 61 0255 cubic inch Pressure 1 psi 0 0716 bar 1 kg cm2 1 019 bar 1 bar 105 Pa 0 1MPa 1 bar 13 95 psi Weight 1 ounce oz 28 35 grams 1 Kg 1000 grams 2 205 lb 1 pound lb 16 ounces 453 592 grams Speed 1 MPH 1 467 feet per second 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 Water 1 kg l Mineral Oil 0 903 Kg l Gasoline 0 74 ...

Page 36: ...and anyway after any major accident After first check or after any major accident it is 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 brak...

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