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Tatuus T318, Technical Manual

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Tatuus T318 Technical Manual Download Page 103

 

 

 

 

Release 3.00 (22/06/2020)

 

Page 102 

 

4.

 

Press the hub out. Is suggested to do this operation with a hydraulic press. Pictures below shows the 
procedure using a TATUUS

’

 special tool available upon request.  

To avoid buckling and misalignment problems the procedure should be done with the pins as short 
as possible in the very first phase of stroke. Once the first part of extraction stroke switch to longer 
pins and complete the extraction. Different lengths of the pins should be used during the extraction. 
Do not heat the upright assembly before removing the hub. Cooling the hub (only the hub) before 
pressing out, i.e. filling it with dry ice, could make the extraction easier. 
 

           

 

 

 

 

 

 

 

Pay attention to the 
length of the pins 

Summary of Contents for T318

Page 1: ...T318 TECHNICAL MANUAL Release 3 00 22 06 2020 ...

Page 2: ... 18 2 1 Survival Cell 18 2 2 Extractable Seat 19 2 3 Driver Padding 20 2 4 Seat Belts 20 2 5 Front Impact Structure 21 2 5 1 Retention system adjustment 21 2 5 2 Front nose repair specification and procedure 22 2 5 2 1 Applicable requirements 22 2 5 2 2 Replacement procedure 22 2 6 Rear Impact Structure 24 2 7 Side Impact Structure 24 2 8 Halo 25 2 8 1 Installation procedure 25 2 8 2 Disassembly p...

Page 3: ...ering Wheel Controls 53 3 5 3 Steering Wheel Display 54 3 5 3 1 Page 1 Driver page 55 3 5 3 2 Page 2 Setting page 56 3 5 3 3 Page 3 Logger page 58 3 5 3 4 Page 4 Electric Power Distribution 59 3 5 3 5 Page 5 Engine warmup 60 3 5 3 6 Page 6 Gearbox page 61 3 6 Driver installation 62 3 6 1 Steering Wheel Position 62 3 6 2 Pedals 63 3 6 2 1 Brake pedal 64 3 6 2 2 Throttle pedal 65 3 6 2 3 Clutch peda...

Page 4: ... Toe adjustment 88 5 2 4 Caster adjustment 89 5 2 5 UMP adjustment 90 5 3 Vertical stiffness 91 5 3 1 Front vertical stiffness 91 5 3 2 Rear vertical stiffness 91 5 4 Dampers 92 5 5 Rolling stiffness 94 5 5 1 Front roll stiffness 94 5 5 2 Rear roll stiffness 94 5 6 Suspension Geometry 95 5 6 1 Front suspension geometry 95 5 6 2 Rear suspension geometry 96 5 6 2 1 Anti effects 98 5 6 2 1 1 Front 98...

Page 5: ...cteristics Static measurement 126 7 2 3 1 1 Dimension 126 7 2 3 1 2 Static Radial Deflection Kv 127 7 2 3 2 Tyre Characteristics Dynamic Measurement 131 7 2 3 2 1 Dynamic measurements 230 560R13 F200 10J Slick 1 5Bar CA 0 0 131 7 2 3 2 2 Dynamic measurements 280 580R13 F200 12J Slick 1 5Bar CA 0 0 132 7 2 3 2 3 Dynamic measurements 230 560R13 Z217 10J Rain 1 5Bar CA 0 0 133 7 2 3 2 4 Dynamic measu...

Page 6: ...6 Sensors 153 12 7 Vref list 154 12 7 1 Alfa Romeo configuration VREF list 154 12 7 2 Renault configuration VREF list 154 13 Engine 155 14 Transmission 156 14 1 Ratio Chart 156 14 1 1 Gear option 01 157 14 1 2 Gear Option 158 14 2 Differential 159 14 3 Lubrication 160 14 4 Particular precautions 160 14 5 Storage and use 160 14 5 1 Washing under pressure 160 14 6 Glue components 161 14 7 Special to...

Page 7: ... 14 11 4 Differential 181 14 11 5 Main case 182 14 11 6 Selection and reverse 183 14 11 7 Oil pump 184 14 12 Rebuilding of the gearbox 185 14 12 1 Sadev workshop rebuilding 185 14 12 2 Private revision 185 15 Shift system 186 15 1 System Overview 186 15 1 1 Gearshift control 186 15 1 2 ESA resting position 187 15 1 3 ESA maintenance 188 16 Electronic Software 189 16 1 Electronic 189 17 Annexes 190...

Page 8: ...Tatuus Halo installation Aeromaps Kinematic data Gearbox torques 2 00 21 01 2019 Tatuus Engine options added 2 01 24 01 2019 Tatuus Pickup updates 2 10 10 02 2019 Tatuus Front Rear suspensions update UMP anti effects 2 20 01 03 2019 Tatuus Differential info Radio plug Pirelli Data Booklet 2 30 05 04 2019 Tatuus Brake system info Fuel machine option Sensors 3 00 22 06 2020 Tatuus Mileage Chart upda...

Page 9: ...0863 Concorezzo MB Italy Tel 39 039 6040828 Fax 39 039 6041764 Web www tatuus it 1 2 2 Engine AUTOTECNICA Via A Bernardi 3 26041 Casalmaggiore CR Italy Contact Giovanni Delfino Tel 39 0375 40174 Fax 39 0375 40174 ORECA Technopole du Circuit 58470 Magny Cours France 33 0 3 86 21 08 00 33 0 3 86 21 08 02 ...

Page 10: ...Release 3 00 22 06 2020 Page 9 1 2 3 Gearbox SADEV 6 rue Grand Montains 85110 Saint Prouant Tel 33 2 51 66 42 68 Fax 332 51 66 49 60 sadev sadev tm com Web www sadev tm com 1 2 4 Electronic 1 2 5 Tires ...

Page 11: ...Release 3 00 22 06 2020 Page 10 1 2 6 Brakes 1 2 7 Dampers 1 2 8 Seat belts Fire Extinguisher ...

Page 12: ...related application or for product development evaluation or exper imentation are supplied subject to the Customer recognizing that such goods may operate under extreme loads and conditions and that it is the Customer s responsibility to ensure that the goods are correctly in spected adjusted and maintained at all times to suit the specific conditions in which they may be used Lightweight and weig...

Page 13: ... homologated BODYWORK Carbon fiber FRONT SUSPENSION Push rod twin damper spring REAR SUSPENSION Push rod twin damper spring SPRINGS Eibach 36mm DAMPERS Koni BRAKES Brembo TIRES Giti Hankook Pirelli WHEELS OZ Racing ENGINE Autotecnica Motori Renault Sport Oreca Toyota EXHAUST Aros ELECTRONICS Magneti Marelli Next Solution Motec GEARBOX SADEV SLR82 GEARSHIFT Magneti Marelli ESA STEERING WHEEL Tatuus...

Page 14: ...Release 3 00 22 06 2020 Page 13 1 5 GENERAL INFORMATION ...

Page 15: ...Release 3 00 22 06 2020 Page 14 ...

Page 16: ... any accident or abnormal usage In doubt replace the components For safety reasons please contact immediately Tatuus if you discover premature wear or problems Many of the components stated above with a maximum typical life of 20 000km may be found to perform successfully for extended mileage however extended running above 20 000km is done at customer s risk Inspection km Limit km Chassis Survival...

Page 17: ...00 10 000 Rear upright bracket 5 000 10 000 Rear anti roll bar 2 500 5 000 Rocker assembly 5 000 10 000 Front Wing Front wing 5 000 15 000 Front pillars 5 000 15 000 Rear wing Front wing 5 000 15 000 Front pillars 5 000 10 000 Front endplates 5 000 15 000 Transmission Wheel shaft 5 000 10 000 Slave cylinder sealings 5 000 10 000 Release bearing 5 000 10 000 Gearbox Gearbox internals see SADEV ESA ...

Page 18: ...s 5 000 10 000 Chassis loom 10 000 20 000 Gearbox loom 10 000 20 000 Powerbox 10 000 20 000 Steering wheel 5 000 10 000 GCU 10 000 20 000 Extinguisher system Extinguisher bottle see expire date Extinguisher mountings 5 000 10 000 Extinguisher pipelines 10 000 20 000 Extinguisher CU 5 000 10 000 Engine lubrication system Oil lines 10 000 20 000 Tank filter cartridge 5 000 10 000 Fuel system Fuel ta...

Page 19: ...f Tatuus 2 1 SURVIVAL CELL The survival cell is the main safety and structural component of the car and it has been approved by the FIA great attention must be paid in checking for structural failure not later than two years after delivery from Tatuus factory and after each major accident Chassis must be checked and repaired by a center authorized by Tatuus ...

Page 20: ... located in front of the driver s crotch Any seat liner must have the same holes as the seat shell identical and perfectly aligned with them in order to prevent the harness straps being trapped However if the lap straps have to pass through holes in the seat it is necessary to fit the car with a harness having the buckle attached to a shoulder belt given that the buckle will not pass between the d...

Page 21: ...ecessary and only for driver comfort an additional piece of padding no greater than 20mm thick may be attached to this headrest provided it is made from the same material which incorporates a low friction surface Leg padding 14 6 5 The leg padding must cover the area 100mm behind the face of the rearmost pedal when in the inoperative position Teams are therefore allowed to cut the padding accordin...

Page 22: ...FIA great attention must be paid in checking for structural failure not later than two years after delivery from Tatuus factory and after each major accident The structure must be checked and repaired by a center authorized by Tatuus 2 5 1 Retention system adjustment The retaining pins of the front impact structure must be properly set to ensure the correct installation ...

Page 23: ...rements The following procedure is applicable only when the damage is contained in the first 100mm from the nose tip 715mm from the chassis bulkhead all the other damages must be inspected by the manufacturer 2 5 2 2 Replacement procedure Spare nose tip is available as spare part the reference code is 2401032 ...

Page 24: ...you should find the resin between first and second ply 5 Use sandpaper on the new nose tip inner surface to produce a rough surface that will match the outer surface of the crashbox 6 Spread specific resin 3M 9323 over the junction surface carefully respect the percentage between resin and catalyst 7 3M 9323 Mixing specification Resin Catalyst Weight ratio 100 g 27 g Volume ratio 100 g 31 g 8 Posi...

Page 25: ...us factory and after each major accident The structure must be checked and repaired by a center authorized by Tatuus 2 7 SIDE IMPACT STRUCTURE The side impact is one of the major safety and structural component of the car and it has been approved by the FIA great attention must be paid in checking for structural failure not later than two years after delivery from Tatuus factory and after each maj...

Page 26: ...but not tighten green arrow screw and tighten When installing the HALO apply on the bolts some water and oxidation resistant grease As example the PETRONAS TUTELA Z2 grease is suitable for this purpose 1 Insert the front fairing 24 01 043 on the HALO center bar 2 Install the front bracket on the HALO 24 01 010 ...

Page 27: ...Release 3 00 22 06 2020 Page 26 ...

Page 28: ...he left side and the HALO front fixing pin 24 01 016 shall be on the right side 5 Do not apply any tightening torque Screw the HALO front fixing screw 24 01 017 until the screw s under head gets in contact with the plane of the counterbore on the front bracket At this point do not apply any tightening torque but loose the HALO front fixing screw 24 01 017 one turn coun terclockwise 24 01 017 24 01...

Page 29: ...sis 7 Fasten the two shoulder bolts 24 01 033 Do not apply any tightening torque Screw the bolts until the screw s underhead gets in contact with the plane of the counterbore on the HALO foot At this point do not apply any tightening torque but loose the bolt one turn counterclockwise ...

Page 30: ...rbore on the HALO foot At this point do not apply any tightening torque but loose the bolt one turn counterclockwise 9 Fasten the two M12X30 bolts Do not apply any tightening torque Screw the bolts until the screw s underhead gets in contact with the plane of the counterbore on the HALO foot At this point do not apply any tightening torque but loose the bolt one turn counterclockwise ...

Page 31: ...ontact with the plane of the counterbore on the front bracket At this point do not apply any tightening torque but loose the bolt one turn counterclockwise 11 Tighten the two shoulder bolts 24 01 033 Do not tighten to target value one bolt first and then the other Apply the tightening torque gradually keeping the balance on the two bolts Target value is 51Nm ...

Page 32: ...t and then the other Apply the tightening torque gradually keeping the balance on the two bolts Target value is 51Nm 13 Tighten the two M12X30 bolts Do not tighten to target value one bolt first and then the other Apply the tightening torque gradually keeping the balance on the two bolts Target value is 51Nm ...

Page 33: ...first and then the other Apply the tightening torque gradually keeping the balance on the four bolts Target value is 51Nm 15 Double check the tightening torque on each bolt starting from the two shoulder bolts then on the M12 bolts and finally on the MS21250 08 08 16 Tighten the HALO front fixing screw 24 01 017 ...

Page 34: ...Release 3 00 22 06 2020 Page 33 17 Position the front fairing 24 01 043 and fix it with two button head bolts UNI7380 TX M5X10 ...

Page 35: ... Page 34 2 8 2 Disassembly procedure 1 Lift the front fairing 2 Unscrew and remove the four MS21250 08 08 bolts Do not unscrew one bolt first and then the other Loose the bolts gradually keeping the balance on the four bolts ...

Page 36: ...olts Do not unscrew one bolt first and then the other Loose the bolts gradually keeping the balance on the two bolts 4 Unscrew and remove the M12X55 bolts Do not unscrew one bolt first and then the other Loose the bolts gradually keeping the balance on the two bolts ...

Page 37: ...Release 3 00 22 06 2020 Page 36 5 Unscrew and remove the two shoulder bolts 24 01 033 Do not unscrew one bolt first and then the other Loose the bolts gradually keeping the balance on the two bolts ...

Page 38: ...IA 8864 2013 standard It is recommended to replace wheel tethers if The cable has been on the car for more than 12 months Accident The cable has been damaged i e the braid or tape have been damaged exposing the fiber The cable has been over tensioned 2 11 REAR CRASHBOX TETHERS Cortex 3kJ FIA 8864 2013 standard It is recommended to replace wheel tethers if The cable has been on the car for more tha...

Page 39: ... multimeter to check that whit the lever switch on the control unit in the OFF position when either of the activation buttons is pressed the potential difference between the ends of the wires is about 7 8V with the lever switch on the control unit in the ON position when either of the activation buttons is pressed the potential difference between the ends of the wires is about 9V when neither of t...

Page 40: ... seat Cockpit panel push pull button 3 WARNING once activated the button must be pulled to be rearmed Marshall switch located behind the main rollhoop WARNING once activated the unit must be rearmed releasing the lock The LED verifies the functionality of the system and turns on ONLY when the extinguisher valve is connected to the system If the LED does not turn on after having connected the syste...

Page 41: ... by the manufacturer for a period of up to another 2 years 2 14 RAIN LIGHT Tatuus 12x High intensity LED A minimum of 85 of the LED s must be operational at any time 2 14 1 Rain Light modes The rain light operates different modes according to car condition Main switch ON LED turning IGN ON Engine OFF Stall 10Hz flashing Rain Light ON 4Hz flashing Pit Limiter ON 1 25Hz flashing ...

Page 42: ...shed 4 The car can be moved 2 16 FIA THROTTLE FAIL SAFE The car is equipped with a throttle fail safe algorithm which in case throttle and brake pedal are pressed at the same time overrides the throttle and cuts the engine Alfa Romeo Renault Car Speed 10 km h 10 km h Engine rpm 2 000 rpm 2 000 rpm Brake Pressure Front and or Rear 50 bar 40 bar Throttle Pedal 70 70 Time 150 ms 150 ms If Throttle Fa...

Page 43: ...e 3 00 22 06 2020 Page 42 3 CHASSIS 3 1 WORKSHOP TOOLS 3 1 1 Front Jacking The highlighted area is suitable to carry the weight of the car the jack plate should fit as better as possible the underwing surface ...

Page 44: ...Release 3 00 22 06 2020 Page 43 3 1 2 Rear Jacking The highlighted jacking points are suitable to carry the weight of the car ...

Page 45: ...Release 3 00 22 06 2020 Page 44 3 2 SETUP TOOLS Here below some views of the main reference points 3 2 1 Front references ...

Page 46: ...Release 3 00 22 06 2020 Page 45 3 2 2 Rear references ...

Page 47: ...Release 3 00 22 06 2020 Page 46 3 2 3 Wheel hub ...

Page 48: ...Total deg 20 0 Rear Suspension position BE24 SUSPENSIONS Springs lb in 900 1300 Spring preload Turn 0 5 0 5 Anti roll mm 22 5 12 Anti roll blade M M S S Damper bump 0 click full closed 4 4 Damper reb 0 click full closed 4 4 AERO Wing position 28 B4 10 A5 Gurney mm BRAKES Master cylinder mm 19 05 20 64 GEAR DIFF Diff Ramp on power 65 Diff Ramp off power 70 Diff plates config 6 TIRES Tire pressure h...

Page 49: ...Release 3 00 22 06 2020 Page 48 3 4 WEIGHT AND BALLAST The T318 chassis has three locations for the ballast installation the following drawings are a simple guideline ...

Page 50: ...Release 3 00 22 06 2020 Page 49 ...

Page 51: ...Release 3 00 22 06 2020 Page 50 ...

Page 52: ...Release 3 00 22 06 2020 Page 51 ...

Page 53: ...tarter button YELLOW starter motor is cranking note that this button will crank the starter in any condition but the engine will fire up only if Ignition is ON 3 Fire Extinguisher 4 Fire extinguisher status green when armed 5 ADR status 6 Communication Port depending on ECU configuration 7 ADR communication All the switches are ON when HIGH 1 3 2 4 6 5 7 ...

Page 54: ... Button 4 START KILL only when IGN is ON this button act as a starter When the engine is ON a long pressure will kill the engine Button 5 PIT LIMITER when pushed the ECU will set engine rev limiter to control pit limited speed if wheel speeds are available Button 6 MARK when pushed the ECU will register the input in the log file Double click will acti vate fuel pump for fuel drain purpose Button 7...

Page 55: ...Blue LED are ON when pit limiter is engaged Alarm 2 LOW Oil Pressure Alarm 3 Hight Oil Temperature Alarm 4 3x RED LED will blink when a general alarm is on the display will highlight the relevant value and will show a text message Alarm 5 Electric Fault Alarm 6 HIGH Coolant Temperature 6 5 1 2 3 4 7 ...

Page 56: ...es Water Temperature Engine Oil Pressure Battery Voltage Oil Temperature Warning boxes see chapter for details All the value boxes turn red when the value is over the maximum alarm values are set by engine control and blue when the value is below the minimum all the alarm messages can be skipped pushing AKN button ...

Page 57: ...tion of steering potentiometer mV it should be set 2500mV when the steering wheel is straight TPS1 TPS2 Throttle valve absolute position mV Pedal 1 Pedal 2 Throttle pedal absolute position mV used to adjust pedal position before throt tle calibration process Pedal percentage of Throttle pedal Gear Pot gear barrel absolute position mV the value must be o Neutral 930mV 10mV o 1st gear 1250mV 10mV ES...

Page 58: ...sh Throttle Pedal to full throttle o Release Throttle Pedal to rest position o Wait for the Throttle Valve learning o Throttle calibration process completed successfully o Throttle calibration process NOT completed o Power cycle the car switch OFF and then ON the electric system ...

Page 59: ...Shock Front Left damper position mm FR Shock Front Right damper position mm RL Shock Rear Left damper position mm RR Shock Rear Right damper position mm FL Speed Front Left wheel speed km h FR Speed Front Right wheel speed km h Steer Angle Steering wheel position deg Acc X longitudinal acceleration mg Acc Y lateral acceleration mg All the listed channels except wheel speeds are set to zero when AC...

Page 60: ...ower Distribution This page shows the power system of the car each box contains the current drained by the relevant line the boxes turn RED if the powerbox shut down the relevant line i e short circuit detected Refer to powerbox chapter 12 4 for line details ...

Page 61: ...gine Coolant Temperature C Toil Engine Engine Oil Temperature C TFuel NU TAir Air Temperature C LPFuel Low pressure Fuel bar if available from ECU HPFuel Low pressure Fuel bar Poil Engine Oil Pressure bar PCranck Engine Case Pressure mbar if available from ECU IGN Limiter Ignition Limiter threshold RPM if available from ECU VBatt Battery Voltage V RPM Engine revs RPM ...

Page 62: ...warming the gearbox Pad Dwn Box turns green when paddle input is active Pad UP Box turns green when paddle input is active Gear Gear number 1 to 6 PClutch Clutch Pressure bar ToilG Gearbox Oil Temperature C if available Gear Pot Gear barrel absolute position mV ESAP absolute actuator position mV VBatt Battery Voltage V RPM Engine revs RPM ...

Page 63: ...LLATION 3 6 1 Steering Wheel Position The spacers allow the adjustment of the steering wheel depth each spacer add 13mm and can be stack up to two Different stack of requires different studs length Check the Spare parts Catalogue for the options 2 1 ...

Page 64: ...Release 3 00 22 06 2020 Page 63 3 6 2 Pedals The three pedals may be placed independently all of these are standalone ...

Page 65: ... operating on the rod end the pedal plate can be moved It is recommended to inspect and set the brake balance in order that the adjustment stops are cor rectly in position and far from their contact It is recommended to replace the balance bar and the pedal base every 10 000 km ...

Page 66: ...late can be moved Stroke full stroke the stroke and the final position can be adjusted adding or removing shims on the damper shaft The throttle potentiometer has to be checked after every pedal adjustment in order to respect the calibration thresholds After every operation on the pedal the throttle learning must be repeated ...

Page 67: ...nd the final position can be adjusted operating on the bush counter nut must then be locked The standard master cylinder for clutch actuation is a 5 8 here below a guideline of theoretical strokes to operate the clutch mechanism Master cylinder displacement mm Slave cylinder displacement mm Pedal top displacement mm TM Clutch 12 2 5 45 Sachs Clutch max 20 4 0 72 ...

Page 68: ...Release 3 00 22 06 2020 Page 67 3 6 2 4 Heel rest A heel rest can be bolted on the unused holes here below a generic guideline ...

Page 69: ...ing clockwise will shift the brake balance towards front with the standard master cylinders Front 19 05 mm Rear 20 68 mm 1 complete turn give a 1 5 front balance Brake pressure Front and Rear and Brake Bias defined as 𝑃𝐵𝑟𝑎𝑘𝑒𝐹𝑅𝑂𝑁𝑇 𝑃𝐵𝑟𝑎𝑘𝑒𝐹𝑅𝑂𝑁𝑇 𝑃𝐵𝑟𝑎𝑘𝑒𝐹𝑅𝑂𝑁𝑇 𝑃𝐵𝑟𝑎𝑘𝑒𝑅𝐸𝐴𝑅 can be checked on page 2 of the steering wheel 1 turn CW 1 5 FB ...

Page 70: ...t the front contact patches All forces are reported as percentage from the datum point measurements see chapter 4 4 Aerodynamic loading is a function of atmospheric conditions 5 C increase in ambient temperature from ISA conditions result in a 2 7 reduction in aerodynamic forces 10 mbar increase in air pressure from ISA conditions results in a 1 increase in aerodynamic forces 50 increase in humidi...

Page 71: ...e side and the reference plane As reference line for the tangent on the flap the straight line on the upper side of the flap fishplate can be used A B C D E 1 20 25 30 35 40 2 21 26 31 36 41 3 22 27 32 37 42 4 23 28 33 38 5 24 29 34 39 TATUUS recall that by FIA Technical Regulation the use of a gurney flap on the front wing 500mm central part FIA standard profile is currently not allowed FLAP INCI...

Page 72: ...ngle between the tangent on the upper side of the rear flap without gurney flap and the reference plane A B C D 1 6 11 16 21 2 7 12 17 22 3 8 13 18 23 4 9 14 19 24 5 10 15 20 25 TATUUS recall that by FIA Technical Regulation the use of gurney flaps on any of the rear aerofoils is cur rently not allowed ...

Page 73: ... a plane orthogonal to both the Reference Plane and the car symmetry plane passing on the Front Wheel Centre Line Rear Ride Height RRH is the distance between the ground and a point intersection of the Reference Plane 5mm above the lower surface of the skid block when new plane between the skid block and the wooden plank with a plane orthogonal to both the Reference Plane and the car symmetry plan...

Page 74: ... Height Sensitivity is referred to a configuration with both the front flaps on without gurney flap installed The following tables report the percentage changes from the datum point resulting from the change of the ride heights FRH Front Ride Height RRH Rear Ride Height ...

Page 75: ... 2 1 1 9 1 7 1 5 1 3 1 1 0 9 0 7 0 5 0 4 0 2 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 7 1 9 2 1 2 3 2 5 15 3 5 3 3 3 1 2 9 2 8 2 6 2 4 2 2 2 0 1 8 1 6 1 4 1 2 1 1 0 9 0 7 0 5 0 3 0 1 0 1 0 3 0 5 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 16 3 8 3 6 3 5 3 3 3 1 2 9 2 7 2 5 2 3 2 1 2 0 1 8 1 6 1 4 1 2 1 0 0 8 0 6 0 4 0 3 0 1 0 1 0 3 0 5 0 7 0 9 1 1 1 2 1 4 1 6 1 8 17 4 1 4 0 3 8 3 6 3 4 3 2 3 0 2 8 2 6 2 5 2 ...

Page 76: ...93 3 93 3 93 2 SCz RRH 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 FRH 5 98 6 98 8 99 1 99 4 99 7 100 0 100 3 100 6 100 9 101 2 101 5 101 8 102 1 102 4 102 7 102 9 103 2 103 5 103 8 104 1 104 4 104 7 105 0 105 3 105 6 105 9 106 2 106 5 106 8 107 0 107 3 6 98 3 98 6 98 8 99 1 99 4 99 7 100 0 100 3 100 6 100 9 101 2 101 5 101 8 102 1 102 4 102 6 102 9...

Page 77: ...lowing table report the percentage changes from the datum point resulting from the change of flap angles FW Front Wing Flap Angle RW Rear Wing Top Assembly Angle The following tables are referred to the both the front flaps on without gurney flap installed maps ...

Page 78: ... 7 8 8 8 9 8 10 8 B4 14 11 3 10 4 9 4 8 4 7 4 6 4 5 4 4 4 3 4 2 4 1 5 0 5 0 5 1 5 2 5 3 5 4 5 5 5 6 4 7 4 8 4 9 4 10 4 B5 15 11 7 10 7 9 7 8 7 7 7 6 8 5 8 4 8 3 8 2 8 1 8 0 8 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 0 8 0 9 0 10 0 C1 16 12 0 11 0 10 0 9 1 8 1 7 1 6 1 5 1 4 2 3 2 2 2 1 2 0 2 0 8 1 7 2 7 3 7 4 7 5 7 6 6 7 6 8 6 9 6 C2 17 12 3 11 4 10 4 9 4 8 4 7 5 6 5 5 5 4 5 3 5 2 6 1 6 0 6 0 4 1 4 2 3 3 3 4 ...

Page 79: ...09 4 109 6 109 9 110 1 110 4 110 6 110 9 111 1 111 4 111 6 111 9 112 1 112 4 112 6 112 9 113 1 FW A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5 D1 D2 D3 D4 D5 E1 E2 E3 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 RW A1 6 91 1 91 7 92 3 92 8 93 4 94 0 94 6 95 1 95 7 96 3 96 9 97 4 98 0 98 6 99 2 99 7 100 3 100 9 101 4 102 0 102 6 103 2 103 7 A2 7 92 0 92 6 93 1 93 7 94 3 94 8...

Page 80: ... 1 10 2 11 4 12 6 13 8 B4 14 12 3 11 2 10 0 8 8 7 7 6 5 5 3 4 2 3 0 1 8 0 7 0 5 1 7 2 8 4 0 5 2 6 3 7 5 8 7 9 9 11 0 12 2 13 4 B5 15 12 7 11 5 10 3 9 2 8 0 6 9 5 7 4 5 3 4 2 2 1 0 0 1 1 3 2 5 3 6 4 8 6 0 7 1 8 3 9 5 10 6 11 8 13 0 C1 16 13 0 11 8 10 7 9 5 8 4 7 2 6 0 4 9 3 7 2 6 1 4 0 2 0 9 2 1 3 3 4 4 5 6 6 7 7 9 9 1 10 2 11 4 12 6 C2 17 13 3 12 2 11 0 9 9 8 7 7 6 6 4 5 2 4 1 2 9 1 8 0 6 0 6 1 7 ...

Page 81: ... 2 110 5 110 8 111 1 111 4 111 6 111 9 112 2 112 5 112 8 113 1 113 3 113 6 113 9 114 2 114 5 114 7 115 0 FW A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5 D1 D2 D3 D4 D5 E1 E2 E3 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 RW A1 6 91 7 92 3 92 9 93 5 94 0 94 6 95 2 95 8 96 4 97 0 97 6 98 1 98 7 99 3 99 9 100 5 101 1 101 6 102 2 102 8 103 4 104 0 104 6 A2 7 92 6 93 2 93 8 94 ...

Page 82: ...18 0 17 3 16 5 15 7 15 0 14 2 13 4 12 7 11 9 11 1 10 3 9 6 8 8 8 0 7 3 6 5 5 7 5 0 4 2 B5 15 21 4 20 7 19 9 19 1 18 4 17 6 16 8 16 1 15 3 14 6 13 8 13 0 12 3 11 5 10 7 10 0 9 2 8 4 7 7 6 9 6 1 5 4 4 6 C1 16 21 8 21 0 20 2 19 5 18 7 18 0 17 2 16 4 15 7 14 9 14 2 13 4 12 6 11 9 11 1 10 3 9 6 8 8 8 1 7 3 6 5 5 8 5 0 C2 17 22 1 21 3 20 6 19 8 19 1 18 3 17 6 16 8 16 0 15 3 14 5 13 8 13 0 12 2 11 5 10 7...

Page 83: ... 5 101 6 101 7 101 9 102 0 102 1 FW A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5 D1 D2 D3 D4 D5 E1 E2 E3 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 RW A1 6 89 0 89 3 89 5 89 7 90 0 90 2 90 4 90 7 90 9 91 1 91 4 91 6 91 8 92 1 92 3 92 5 92 8 93 0 93 2 93 5 93 7 93 9 94 2 A2 7 89 9 90 2 90 4 90 6 90 8 91 0 91 3 91 5 91 7 91 9 92 1 92 4 92 6 92 8 93 0 93 2 93 5 93 7 93 9 94 ...

Page 84: ...6 4 15 7 15 0 14 4 13 7 13 0 12 3 11 6 10 9 10 2 9 5 8 8 8 1 7 4 6 7 6 0 5 3 4 6 3 9 3 2 2 5 B5 15 18 2 17 5 16 8 16 1 15 4 14 7 14 0 13 3 12 6 11 9 11 2 10 5 9 8 9 1 8 4 7 8 7 1 6 4 5 7 5 0 4 3 3 6 2 9 C1 16 18 5 17 8 17 1 16 4 15 7 15 1 14 4 13 7 13 0 12 3 11 6 10 9 10 2 9 5 8 8 8 1 7 4 6 7 6 1 5 4 4 7 4 0 3 3 C2 17 18 8 18 2 17 5 16 8 16 1 15 4 14 7 14 0 13 3 12 6 12 0 11 3 10 6 9 9 9 2 8 5 7 8...

Page 85: ... 103 7 103 8 103 9 104 0 104 1 104 2 104 3 104 4 104 5 104 6 104 7 FW A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5 D1 D2 D3 D4 D5 E1 E2 E3 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 RW A1 6 89 8 90 0 90 3 90 5 90 8 91 1 91 3 91 6 91 8 92 1 92 4 92 6 92 9 93 1 93 4 93 7 93 9 94 2 94 4 94 7 95 0 95 2 95 5 A2 7 90 7 90 9 91 2 91 4 91 7 91 9 92 2 92 4 92 6 92 9 93 1 93 4 93 6...

Page 86: ...Championship rules a jig will be available at the Tatuus and Championship Organizer s truck In case of damages to the spat fins pn 2402017003 004 spares are available The spare must be bonded to the diffuser following the position shown below referring to the Rear Wheel axis and the underfloor ex ternal side TATUUS discourages to refer to the tire cut out side as its shape is depending on the Cham...

Page 87: ...tersection between the vertical plane passing through the axle and the vehicle center line Zero when reference plane is coincident with ground positive change when the car is raised TOE Zero when wheels are parallel positive change when toe out CAMBER Zero when wheels are vertical positive change when the top of the wheel is outward CASTOR Zero when steering axis is vertical positive change when t...

Page 88: ... 1 Ride height adjustment Front ride height is increased adding the shims into the front push rod the following tables represents the available size and its respective effect Ride height adjustment Front Ride Height change Rear Ride Height change 1mm 2 7mm 3 2mm ...

Page 89: ...between Ackermann and upright Camber adjust ment Front Rear Camber change Camber change Toe Change 1 mm 0 43 deg 25 0 31 deg 18 0 55 deg 33 5 2 3 Toe adjustment Toe can be adjusted by the steering arm length Toe adjustment Front Rear Total Toe Change Total Toe Change 1 turn 1 18 deg 1 10 2 59 deg 1 35 ...

Page 90: ... adjustment The apparent caster is measured on the top of the front upright when steer angle is zero measuring an angle of 0 parallel to the reference plane equals to 10 of caster angle Caster adjustment Front Rear Caster Change 1turn 0 90 deg 54 ...

Page 91: ...can be adjusted longitudinally resulting in a different weight transfer as function of the steering angle The farthest the point is from steer axis the higher will be the weight transfer and by consequence the steer ing effort The following diagrams summarize the possible configuration and the distance pickup to steering axis ...

Page 92: ... mm 12 0 15 4 18 9 22 3 Motion ratio wheel damper 1 02 Springs can be preloaded acting on the damper spring platform the pitch of the thread is 2mm 5 3 2 Rear vertical stiffness The table below resumes stiffness options available Spring stiffness lb in 700 900 1100 1300 Ground stiffness daN mm 8 5 11 0 13 4 15 9 Motion ratio wheel damper 1 21 Springs can be preloaded acting on the damper spring pl...

Page 93: ...discs is colored red Rotate the discs according to the markings on the top eye The adjusters have 8 distinct stops clicks each of which marks an adjustment position There is a total of 8 adjustment positions from minimum to maximum adjustment The minimum position is referred to as position 1 and the maximum adjustment position as position 8 The adjusters have a positive stop at the minimum and max...

Page 94: ...0 0 50 0 0 0 50 0 100 0 150 0 200 0 250 0 0 50 100 150 200 250 300 daN mm s Front RMIN daN RMAX daN BMIN daN BMAX daN 250 0 200 0 150 0 100 0 50 0 0 0 50 0 100 0 150 0 200 0 250 0 0 50 100 150 200 250 300 daN mm s Rear RMIN daN RMAX daN BMIN daN BMAX daN ...

Page 95: ...length mm 100 90 80 100 90 80 ARbar Torsion stiffness daN mm 7300 11700 Roll stiffness ground daN m deg 1200 1470 1852 1920 2370 2990 5 5 2 Rear roll stiffness The motion ratio of the front anti roll bar is Blade length mm 80 70 60 Anti rollbar Chassis 14 6 16 7 19 4 The ratio represents the torsion angle of the antiroll bar resulting from a roll of 1 on the chassis The following table summarizes ...

Page 96: ...y a value of Rd Zn where Rd is the Rolling Radius of the tire and Zn is the z coordinate of point N X Y Z A 50 0 179 4 269 B 6 9 663 9 225 C 300 0 196 2 271 D 50 0 179 4 440 E 19 5 626 6 375 F 300 0 196 2 429 S 85 1 683 3 354 T 130 0 195 0 422 H 0 0 775 6 262 L 0 0 787 5 Rd ZN N 0 0 787 5 262 U 383 6 80 0 567 V 83 8 81 0 566 P 80 0 163 0 525 Q 80 0 140 3 480 M 45 1 160 6 526 W 2 1 651 2 276 X 185 ...

Page 97: ...5mm standard configuration BE 24 The following table summarize the pickup point coordinates of the standard configuration BE 24 the origin is located at the intersection of rear wheel axle and reference plane the coordinate of the contact point is then below the reference plane by a value of Rd Zn where Rd is the Rolling Radius of the tire and Zn is the z coordinate of point N ...

Page 98: ...8 246 8 75 0 659 8 241 8 T 78 0 101 0 232 5 78 0 101 0 227 5 H 0 0 750 3 234 6 0 0 750 3 229 6 L 0 0 765 0 Rd ZN 0 0 765 0 Rd ZN N 0 0 765 0 235 0 0 0 765 0 230 0 U 435 0 106 0 389 7 435 0 106 0 384 7 V 144 0 52 9 386 6 144 0 52 9 381 6 P 130 0 145 1 353 5 130 0 145 1 348 5 Q 137 0 112 4 259 3 137 0 112 4 254 3 M 92 2 141 4 352 0 92 2 141 4 347 0 W 53 1 607 6 187 1 53 1 607 6 182 1 X 94 0 100 0 28...

Page 99: ...g tables shows the anti effects of the vehicle they show the relevant numbers for the following setting Front wheel hub 262mm over reference plane Rear wheel hub 235mm over reference plane Brake bias 55 Front 5 6 2 1 1 Front Pick Up position RC Height mm Camber derivative 10mm Anti dive STD 27 0 20 37 ...

Page 100: ...0 22 2 25 AE24 41 54 0 15 17 8 BD13 61 47 0 15 18 52 BD14 22 52 0 08 1 84 BD23 66 41 0 16 38 18 BD24 27 22 0 09 19 50 BE13 78 27 0 22 0 32 BE14 39 67 0 15 19 64 BE23 83 39 0 23 21 3 BE24 44 55 0 16 2 30 BF13 94 66 0 29 17 13 BF14 56 38 0 22 36 45 BF23 99 94 0 30 5 22 BF24 61 44 0 23 15 10 CE13 81 08 0 23 19 54 CE14 42 62 0 16 0 85 CE23 86 22 0 24 40 19 CE24 30 33 0 10 37 72 CF13 97 33 0 30 2 34 CF...

Page 101: ...l not undoing the studs item In order to reduce the wear at the link with the lower wishbone a modification of the rear upright has been developed The upgrade consists in the installation of a bush This upgrade has been implemented in the produc tion parts To upgrade an old spec rear upright please contact TATUUS as the teams are not allowed to make this modification on their own 1 2 ...

Page 102: ...101 5 7 2 Upright Disassembly The upright can be disassembled for inspection 1 Remove the secure ring f 2 Apply unlock spray 3 Using the special tool e pn 2491011 available on Spare Part Catalogue unscrew and remove the ring nut d ...

Page 103: ...ure should be done with the pins as short as possible in the very first phase of stroke Once the first part of extraction stroke switch to longer pins and complete the extraction Different lengths of the pins should be used during the extraction Do not heat the upright assembly before removing the hub Cooling the hub only the hub before pressing out i e filling it with dry ice could make the extra...

Page 104: ...Release 3 00 22 06 2020 Page 103 5 For the final phase of the extraction remove the hub with a drift punch through the 4mm holes A 6 Remove the bearing retention ring a ...

Page 105: ...Release 3 00 22 06 2020 Page 104 7 Heat the upright and bearing subassembly up to about 120 C 8 Once heated use the machined slot B to press out the bearing acting on the outer bearing ring ...

Page 106: ...uicker maximizing the temperature difference effect 3 Fit the external rim a then tight the 6x M5 screws 8 Nm Loctite 243 4 Heat the upright and bearing subassembly to about 120 C and cool the hub to about 20 C 5 Put the hub in the upright Use a press to make the procedure quicker maximizing the temperature difference effect Act on the bearing internal ring reacting on the hub pegs flange paying h...

Page 107: ...e 3 00 22 06 2020 Page 106 6 Fit the ring nut d 7 Using the special tool e pn 2491011 available on Spare Parts List tight the ring nut to 500Nm 8 Fit the secure ring nut f and the M4 screws g 4Nm Loctite 222 ...

Page 108: ...Release 3 00 22 06 2020 Page 107 6 STEERING 6 1 STEERING GEOMETRY 6 1 1 Standard ratio 8 teeth pinion Steering ratio 11 9 6 1 2 Option ratio 7 teeth pinion Steering ratio 14 0 ...

Page 109: ...Release 3 00 22 06 2020 Page 108 6 2 STEERING MAINTENANCE Installation drawings please not the orientation of the front joint assembly ...

Page 110: ...Release 3 00 22 06 2020 Page 109 7 WHEELS AND TIRES 7 1 WHEELS Front wheels 10 0 inches Rear wheels 12 0 inches Wheel nut tightening torque 250 Nm ...

Page 111: ...Release 3 00 22 06 2020 Page 110 7 2 TIRES 7 2 1 Giti Tires ...

Page 112: ...nts are taken with the tyre fitted on a rim inflated to 1 4bar 20 3 Psi D mm Circumference length along the middle tread line of the tyre C mm Max width maximum width of the tyre Cb mm Tread width width of the tread A full characterization of deflection vs vertical load at different pressures is given measurements are taken at three different camber levels 0 2 0 and 3 0 for slick tyres ...

Page 113: ... be over the declared minimum running pressure defined within this book After each run Temperatures the offset in measured garage bulk temperature between the inside and outside of the tyre should not exceed 20 C for optimum tyre performance the offset in measured garage bulk temperatures between front and rear axle should not exceed 25 C for optimum tyre performance Pressures the measured garage ...

Page 114: ...nical prescriptions will expose the product to excessive levels of mechanical stress which could affect the integrity of the product To avoid any damage to the tyres caused by air leaks we recommend the following use metal valves bodies instead of rubber ones check the fixing of the valves and their seal frequently check the valve core use metal valve caps with integral rubber o ring seal 7 2 2 5 ...

Page 115: ...Release 3 00 22 06 2020 Page 114 7 2 2 6 Dynamic measurements 230 570 13x10 0J SLICK 1 4bar 20 5psi CA 0 0 ...

Page 116: ...Release 3 00 22 06 2020 Page 115 7 2 2 7 Static Radial Deflection 230 570 13x10 0J CA 0 0 SLICK ...

Page 117: ...Release 3 00 22 06 2020 Page 116 ...

Page 118: ...Release 3 00 22 06 2020 Page 117 7 2 2 8 Static Radial Deflection 230 570 13x10 0J CA 3 0 SLICK ...

Page 119: ...Release 3 00 22 06 2020 Page 118 ...

Page 120: ...Release 3 00 22 06 2020 Page 119 7 2 2 9 Dynamic measurements 300 590 13x12 0J SLICK 1 4bar 20 5psi CA 0 0 ...

Page 121: ...Release 3 00 22 06 2020 Page 120 7 2 2 10 Static Radial Deflection 300 590 13x12 0J CA 0 0 SLICK ...

Page 122: ...Release 3 00 22 06 2020 Page 121 ...

Page 123: ...Release 3 00 22 06 2020 Page 122 7 2 2 11 Static Radial Deflection 300 590 13x12 0J CA 3 0 SLICK ...

Page 124: ...Release 3 00 22 06 2020 Page 123 ...

Page 125: ...Release 3 00 22 06 2020 Page 124 7 2 3 Hankook ...

Page 126: ...Release 3 00 22 06 2020 Page 125 ...

Page 127: ...tic measurement 7 2 3 1 1 Dimension The rim width shall be selected used within the range recommended for each tire size The outer diameter of the tyre shall be measured with no load applied under the appropriate pres sure conditions based on the recommended rim size ...

Page 128: ...Release 3 00 22 06 2020 Page 127 7 2 3 1 2 Static Radial Deflection Kv ...

Page 129: ...Release 3 00 22 06 2020 Page 128 ...

Page 130: ...Release 3 00 22 06 2020 Page 129 ...

Page 131: ...Release 3 00 22 06 2020 Page 130 ...

Page 132: ...cteristics Dynamic Measurement Tire dynamic characteristics are dimensional changes due to speed and vertical load Loaded Radius DLR Distance between wheel center and ground Unit mm 7 2 3 2 1 Dynamic measurements 230 560R13 F200 10J Slick 1 5Bar CA 0 0 ...

Page 133: ...Release 3 00 22 06 2020 Page 132 7 2 3 2 2 Dynamic measurements 280 580R13 F200 12J Slick 1 5Bar CA 0 0 ...

Page 134: ...Release 3 00 22 06 2020 Page 133 7 2 3 2 3 Dynamic measurements 230 560R13 Z217 10J Rain 1 5Bar CA 0 0 ...

Page 135: ...Release 3 00 22 06 2020 Page 134 7 2 3 2 4 Dynamic measurements 230 560R13 Z217 10J Rain 1 5Bar CA 0 0 ...

Page 136: ...Release 3 00 22 06 2020 Page 135 7 2 3 2 5 Dynamic measurements 280 580R13 Z217 12J Rain 1 5Bar CA 0 0 ...

Page 137: ...3 3 Operating Temperature After driving the temperature difference between the Inside and the outside of the tire must be between 20 degrees and the temperature difference between the front and rear wheels must also be between 20 de grees ...

Page 138: ...ceed Front 4 0 Rear 3 0 Purpose To secure Safety margin The initial pressure shall be maintained at least1 0bar Purpose To secure Safety margin Dry air is recommended to avoid sudden pressure changes caused by humidity when inflating the inside of the tire Set the Recommended 1 4 1 5bar air pressure to the conditions of using ...

Page 139: ...Release 3 00 22 06 2020 Page 138 ...

Page 140: ...Release 3 00 22 06 2020 Page 139 ...

Page 141: ... BRAKE SYSTEM SETUP Master cylinder suggested configuration FRONT DIA REAR DIA Standard 19 05 mm 20 64mm The following table shows the front brake balance when the balance bar is set at the mid adjustment master cylin ders have the same distance from trunnion REAR 5 8 15 88mm 3 4 19 05mm 13 16 20 64mm FRONT 5 8 15 88mm 50 59 63 3 4 19 05mm DO NOT USE 50 54 13 16 20 64mm DO NOT USE DO NOT USE 50 ...

Page 142: ...y These braking must be done far from the tyre adhesion limit 50 60 of the max race pedal pressure in order to achieve a corresponding gradual increase of torque and temperature to the brake system and promote a regular third layer deposit Between the stops let the system to cool down to avoid overheating During this phase the friction coefficient starts high and then decreases to the stabiliza ti...

Page 143: ...ith the bladder with PVC tape i e Permacel or Neoprene foam Sheet 10 2 FUEL DRAIN PROCEDURE Refer to chapter 3 5 2 Button 6 MARK when pushed the ECU will register the input in the log file Double click will acti vate fuel pump for fuel drain purpose 10 3 FUEL COUPLING The feeding line to the engine is equipped with a safety dry break Staubli SPT08 3655 L JV SPT08 7655 L JV The fuel tank port is eq...

Page 144: ... optional system can be installed to have a breather valve dry coupled refer to page 24D of the spare part catalogue The breathing line to the tank is equipped with a safety dry break Staubli SPT08 7655 L JV the mating port machine side have to be SPT08 3655 L JV ...

Page 145: ...o the catch tank regularly drain and clean it to optimize oil level We recommend to respect the following procedure in order to have a consistent level measurement Turn on the engine Warm up temperatures oil at 80 C Run the engine for 30 second at 3000rpm Turn off the engine Measure the oil level from the filler plug plate the oil level should be 180mm ...

Page 146: ...ch tank regularly drain and clean it to optimize oil level We recommend to respect the following procedure in order to have a consistent level measurement Turn on the engine Warm up temperatures oil at 80 C Run the engine for 10 second at 3000rpm Turn off the engine Measure the oil level from the filler plug plate the oil level should be 180mm ...

Page 147: ...Release 3 00 22 06 2020 Page 146 11 3 TOYOTA OIL TANK The oil tank is located within the gearbox bellhousing some oil may overflow into the catch tank regularly drain and clean it to optimize oil level ...

Page 148: ... EGA harness The power system 12V includes Battery installed in the cockpit behind driver seat Main switch electrically operated located on the battery carrier Generator installed on the engine Powerbox current distribution is provided to the vehicle by a 9 lines power distribution module Starter direct power connection ESA gear actuator fused power connection ...

Page 149: ...0 Page 148 12 2 MAIN SWITCH The master switch is actuated by the cockpit panel and emergency switches connection schematics A 12V Generator 12V Chassis loom ring B 12V Battery Main switch coil supply C chassis loom connector ...

Page 150: ...the battery in place the padding is not excessively compressed as this would minimize its effect We also recommend that the battery cables are fully supported so they do not add any extra stress onto the battery terminals If they are too short the engines movement when revved will be transferred through the cable to the battery If the cables are too long they may have weigh enough and move when ac...

Page 151: ...N Diagnostic and functional information are available in the logger system see chapter for details 12 4 1 Alfa Romeo configuration Line Log name name on Steering Wheel User list 1 PSD_Fuel Fuel Fuel pump 2 PSD_FED Federation Rain Light ADR Transponder 3 PSD_CU_LP LP Elec ECU GCC Dashboard 4 PSD_Engine Engine Lambda Turbo Valves Engine Valves 5 PSD_AUX Aux Beacon AUX ports 6 PSD_Coils Coils Engine ...

Page 152: ...alve GDI Injection ECU GCC Dashboard 4 PSD_CU_HP 2 2 LP Elec 5 PSD_AUX Aux Beacon AUX ports 6 PSD_Coils Coils Engine coils 7 PSD_Engine Engine Lambda Turbo Valves Engine Valves 8 PSD_Starter Starter 1 Engine starter 9 PSD_Starter Starter 2 Engine Starter redundant 12 4 3 Toyota configuration The electric system of the Toyota engine version does not use the standard powerbox please refer to engine ...

Page 153: ...2 5 WIRING LOOM Refer to pdf files for electrical schematics 12 5 1 Radio plug A radio connector is provided in the chassis wiring it provides a 12V power and repeat the switch of the steering wheel on pins 2 3 Mating connector DTM04 4P ...

Page 154: ...ition sensor hall effect position sensors Further available options are ADR wiring loom compatible with EMM units Micro ADR plug available behind the driver s back External accelerometer CoG installed two axis accelerometers Plug available behind the driver s back GPS unit GPS 10Hz unit compatible with Magneti Marelli data logger standard and high gain anten nas available Plug available at the fro...

Page 155: ... Position SMOT Rail Pressure Rear Left Damper Pos Gear Position Cam IN Cranckase Pressure Rear Right Damper Pos Clutch Pressure Cam EX p T fuel Accelerometer Manifold Pressure Turbo Pressure 12 7 2 Renault configuration VREF list VREF 1 VREF 2 VREF 3 VREF 4 Rail P E WasteGate Accelerometer F Brake P Throttle P 2 2 FL Damper R Brake P Oil P P 2 1 T 2 1 FR Damper Steering Pos Pedal A Gear Pos RL Dam...

Page 156: ...Release 3 00 22 06 2020 Page 155 13 ENGINE For any technical information contact the engine tuners ...

Page 157: ...Release 3 00 22 06 2020 Page 156 14 TRANSMISSION 14 1 RATIO CHART Here below the ratio options Final drive Ref Secondary shaft 9 Crown wheel 30 Reverse gear Primary shaft 14 Idler 22 Secondary shaft 47 ...

Page 158: ...6 2020 Page 157 14 1 1 Gear option 01 Gear Ratio 16 36 2 25 16 25 1 56 22 27 1 23 31 32 1 03 21 19 0 90 29 24 0 83 3000 3500 4000 4500 5000 5500 6000 6500 7000 0 0 50 0 100 0 150 0 200 0 250 0 300 0 RPM Speed km h SLR82 ...

Page 159: ...2020 Page 158 14 1 2 Gear Option Gear Ratio 16 36 2 25 16 25 1 56 23 29 1 26 26 28 1 08 26 25 0 96 23 20 0 87 3000 3500 4000 4500 5000 5500 6000 6500 7000 0 0 50 0 100 0 150 0 200 0 250 0 300 0 RPM Speed km h SLR82_SHORT ...

Page 160: ...e with the first equipment ramp set Pn F19103191 Coast Power 70 std 65 std 65 70 70 80 80 70 The preload is applied by a belleville washer pn F1910313 and its carrier spacer F1910307 4 4 available in three different thicknesses F1910307 4 2 F1910307 4 3 F1910307 4 4 Note An approximate reduction of the preload about 15 will be noticed after the first 60 kilometres Note The cold measured preload wo...

Page 161: ...tial oil do not mix any other oil with that already in the box 14 5 STORAGE AND USE Be particularly careful with any bottles which are open when used Close the bottle again properly after use to prevent the introduction of water or dirt Store bottles horizontally protected from severe weather Do not store bottles close to a washing station Do not decant the oil into larger containers 14 5 1 Washin...

Page 162: ...ring tests sessions Only Loctite brand components must be used Sadev can t ensure consequences of false glue component choice 14 7 SPECIAL TOOLS IMAGE PN DESCRIPTION FOUT9047007 Anti splay plate FOUT9047005 Fork adjustment tool FOUT1910300 FOUT1910001 Compression tool mechanism FOUT9004606 Preload adjustment tool FOUT9004604 Preload adjustment tool CHc M6x70 Bolt FOUT9045201 Tool for shaft nut ...

Page 163: ...4 8 GEAR MAINTENANCE 14 8 1 Removal Drain gearbox through lower drain plug Loose the 10x Simmonds nuts M8 retaining the cover plate Remove the cover plate Remove the axis of fork circlips and nuts stopping then engage 2nd gears manually ...

Page 164: ... Page 163 Assemble the anti splay plate FOUT9047007 Loose the 2x nuts primary and secondary with the screwing socket FOUT9045201 Remove the anti splay plate Remove the parts one by one noting the direction of initial assembly ...

Page 165: ... of the primary shaft towards the operator Engage 2nd gear to prevent gearbox turning Assemble the anti splay plate FOUT9047007 Clean and degrease threads on shafts and screws then use copper grease Screw primary shaft bolt and secondary shaft nut to torques 18 daN m Reinstall the splined washers the circlips Replace forks in initial locations Assemble the cover plate while making turn shaft to en...

Page 166: ...all the fork adjustment tool FOUT9047005 Engage all the gears in order to check that shifting is working well and forks do not push the dog ring on its gear wheel Make this check turning by hand the dog ring and its relevant gear For example engage the 3rd gear then check that there is not excessive friction between the 3rd to 4th dog ring and the 3rd gear ratio ...

Page 167: ...ear is concerned and follow this procedure Disassemble the gears and change the gear cluster shim o Replace the shim with a thinner one if Reverse 1st 3rd 5th gears are concerned o Otherwise replace the shim with a thicker one Reassemble the gears and check again until the friction disappears ...

Page 168: ...lid then remove the adapter and the com pression washer FOUT1910300 FOUT1910001 Remove one by one all the components inside the differential noting their direction and the order in which they are assembled 14 9 3 Refitting the differential elements Clean and degrease the parts check their wear and replace them if necessary Lubricate with gearbox oil and put one by one the components inside the dif...

Page 169: ...REPLACEMENT 14 10 1 Secondary shaft Drain the box through the lower drain plug Remove primary shaft and secondary shaft see paragraph 14 8 1 Remove differential housing see paragraph 14 9 1 Using a mallet remove the secondary shaft and the NU207 flange ...

Page 170: ...n the threads used for the NU207 flange Use a bearing extractor to remove the NU207 roller bearing Remove the QJ207 bearing pushing with one of the internal races of the bearing Remove the O ring seal 1 Check their wear replace if necessary Clean the housing of the bearings ...

Page 171: ...s shown on the picture note the smallest usually around 137 25 this is dimension A On a flat plane pile both the new bearings and note their combined height this is dimension B AD assembly dimension this assembly dimension is printed on the secondary shaft theoretical measure 99 64 ...

Page 172: ...ickness C of the secondary shaft shim 2 is calculated as follows C A AD B Assemble the shim being the closest F1910205 to the calculated thickness C on the secondary shaft Press fit the inner race of the NU207 bearing on the secondary shaft ...

Page 173: ...ress fit the 4 point contact bearing QJ207 Fit the NU207 bearing 2 in the casing Place the NU207 flange on the housing add some Loctite 270 on the M8 bolts and tighten them to 2 5 daN m Fit the shaft through the bearings using a mallet to set it in place Refit the gears Do not close the gearbox do not fit the nut locking washer and the circlips immedi ately ...

Page 174: ...Release 3 00 22 06 2020 Page 173 ...

Page 175: ...the crown from the differential Degrease the differential case and check it carefully bearing contact patch splines etc Change it if excessive wear or damage are observed Degrease the new crown Fit the new crown on the differential case Put some Loctite 648 on new 8x M10 bolts and tighten them to 9 daN m Press fit the bearings change them if damaged during disassembly on the differential case care...

Page 176: ...housing two dimensions are marked as indicated on picture note the highest around 170 75 This is dimension X Measure the highest distance between the external races of the bearings assembled on the differential case and note it this is dimension Y ...

Page 177: ...main housing the differential case and the two crown positioning shims The shims must be put between the main housing and each of the 2 bearings refer to following view At the first attempt use two shims of similar thicknesses NOTE The total thickness of both crown positioning shims must always be as close as possible of the calcu lated dimension Z ...

Page 178: ...m available and replace the opposite shim by the next thicker shim available 2b If it is higher than 0 06mm replace the crown side shim 2a by the next thicker shim available and replace the opposite shim by the next thinner shim available 2b Repeat the procedure until getting into the allowed clearance interval Unscrew and remove the 10x M10 bolts of the differential cap glue them with Loctite 243...

Page 179: ...e 3 00 22 06 2020 Page 178 14 11 EXPLODED VIEWS Refer to spare catalogue for part numbers 14 11 1 Layshaft Item Part number Description Glue Torque DaN m 3a F9047105 Shaft plug 518 12 F9046206 M35x1 25 nut 18 ...

Page 180: ...Release 3 00 22 06 2020 Page 179 14 11 2 Mainshaft Item Part number Description Glue Torque DaN m 2c F1910210 Secondary shaft nut 18 2f 0301077 M8x20 Cl 12 9 Chc bolt 270 2 5 ...

Page 181: ... CHC M6x18 cl12 9 bolt 243 1 5 7 0301373 CHc M7x16 cl10 9 ZN bolt 243 2 2 11 F0059021 Selector shouldered bolt 243 2 5 14 0301138 CHc M5x12 cl10 9 ZN bolt 222 0 8 15 0301394 CHc M5x 10 ZN Cl 8 8 bolt 222 0 8 21 0101004 Bearing 6004 518 25 0101050 Bearing 6005 518 31a F0077120 Fork pin 648 32a F0077120 Fork pin 648 ...

Page 182: ...Release 3 00 22 06 2020 Page 181 14 11 4 Differential Item Part number Description Glue Torque DaN m 16c F1910323 M10x100 Ig 16 Cl 12 9 H bolt 648 9 ...

Page 183: ...0022 Machined M10x30 bolt 243 5 5 3a 0301525 M10x30 CHc bolt 243 5 5 4i F9001922 Centering pin 648 4j F9047008 Gearbox closing plate stud 648 4p F9047031 Differential housing stud long 648 4q F9047030 Differential housing stud short 648 7a F1404429 Centering pin 648 7b 1202029 PAP 1005 P11 bushing 648 8 0499003 M8x1 25 Simmonds nut 243 2 5 ...

Page 184: ... Page 183 14 11 6 Selection and reverse Item Part number Description Glue Torque DaN m 10 0106001 HK1816 bearing 648 12 0301007 M6x20 cl 10 9 CHc bolt 270 1 6 13 F1910419 Reverse gear axle 12847 14a 0106021 HK2016 bearing 648 ...

Page 185: ...Release 3 00 22 06 2020 Page 184 14 11 7 Oil pump Item Part number Description Glue Torque DaN m 5b 0301422 M6x16 CHc bolt 243 1 5 5c 0301385 M6x20 CHc bolt 243 1 5 ...

Page 186: ... Gear box drained and cleaned Drain plug and drain plug seal in place Differential in place A card specifying the kilometers since the last service The absence of elements can be specified on the card but in case of doubt the material will be sent back re equipped Administrative procedure Send a request for service to SADEV sales department Forward the material and its card description above in ou...

Page 187: ...tting and maintenance 15 1 1 Gearshift control The semi automatic gearshift is controlled by several parameters of the vehicle critical sensors are Paddle sensors RPM Throttle position Barrel position Clutch pressure sensor REV button Upshift 1st to 6th gear right paddle N to 1st gear Clutch pressure right paddle R to N Clutch pressure right paddle Downshift 6th to 1st gear left paddle if over rev...

Page 188: ...2 ESA resting position On Page 6 of the steering wheel display the parameter ESAP shows the rest position of the gear actuator the rest position should be within a range of 30mV A suggested length for the ESA resting position is shown below ...

Page 189: ...e 3 00 22 06 2020 Page 188 15 1 3 ESA maintenance It is reminded to check regularly the AV mounting of the ESA The rubber ring pn ORN4036 should be inspected each 1 000 km and must be replaced before 3 000 km ...

Page 190: ...Release 3 00 22 06 2020 Page 189 16 ELECTRONIC SOFTWARE 16 1 ELECTRONIC Refer to engine builder docs ...

Page 191: ... 25 23 7 17 45 33 3 24 5 8 1 26 4 19 50 37 2 27 4 10 1 5 47 0 34 70 66 2 48 8 10 1 25 51 4 37 91 72 3 53 3 12 1 75 81 0 59 72 113 9 84 0 12 1 25 93 4 68 90 131 4 96 9 14 2 129 9 95 85 182 7 134 8 14 1 5 146 9 108 34 206 6 152 3 16 2 206 5 152 30 290 4 214 2 16 1 5 229 0 168 90 322 0 237 5 Grade 5 Grade 8 Thread Inch Pitch TPI Torque Lbs ft Torque Lbs ft 1 4 28 7 10 5 16 24 14 20 3 8 24 25 35 7 16 ...

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