DALLARA F - 320...DALLARA is not responsible for any modification or alteration or incorrect repairs...

DALLARA

F - 320

Owner’s MANUAL

Rev. 2021.v1.2

320 Owner’s Manual

Rev. 2021 v1.2 of April 21, 2020 1

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Rev. 2021 v1.2 of April 21, 2020 2

0 Contents & General Information

0 Contents & General Information ..................................................................................... 2

0.1 Preface ............................................................................................................................ 5

0.2 Issues ............................................................................................................................. 6

0.3 Contacts .......................................................................................................................... 7

0.4 General Agreements and Warranty .................................................................................... 8

1 Chasis & Safety ............................................................................................................... 9

1.1 General data .................................................................................................................... 9

1.2 Main views and Dimensions ............................................................................................... 9

1.3 Reference plane ............................................................................................................. 10

1.4 Track Equipment ............................................................................................................ 11

1.5 Safety overview and equipment ....................................................................................... 12

1.6 Monocoque .................................................................................................................... 12

1.7 Protection secondary panel.............................................................................................. 13

1.8 Side Crash Structure ....................................................................................................... 13

1.9 Sacrificial keel ................................................................................................................ 14

1.10 Front crash .................................................................................................................... 14

1.11 Rear crash ..................................................................................................................... 14

1.12 Halo .............................................................................................................................. 14

1.13 Extractable seat .............................................................................................................. 15

1.14 Seat Pillow ..................................................................................................................... 15

1.15 Seat belt ........................................................................................................................ 16

1.16 Wheel tether .................................................................................................................. 16

1.17 Fire Extinguisher System ................................................................................................. 16

1.18 Components Mileage....................................................................................................... 17

2 Bodywork ...................................................................................................................... 19

2.1 Halo Fairing ................................................................................................................... 19

2.2 Halo Painting ................................................................................................................. 20

3 Setup ............................................................................................................................. 21

3.1 Setup adjustment ........................................................................................................... 21 3.1.1 Lower wishbone design configuration set-up ........................................................................................... 22

3.1.2 Ride height and pushrods adjustment ...................................................................................................... 23

3.1.3 Toe ............................................................................................................................................................ 24

3.1.4 Camber ..................................................................................................................................................... 25

3.1.5 Caster front ............................................................................................................................................... 26

3.1.6 Caster Rear ............................................................................................................................................... 27

3.2 Suspension coordinates ................................................................................................... 28 3.2.1 Front (STD configuration) ......................................................................................................................... 28


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3.2.2 Rear (STD configuration) ........................................................................................................................... 29

3.3 Front Geometry Adjustment UMP Options.......................................................................... 30 3.3.1 Roll Centre Height ..................................................................................................................................... 32

3.4 Rear Geometry adjustment .............................................................................................. 33

3.5 Front torsion bar settings ................................................................................................ 35 3.5.1 Front torsion bar pre-load ........................................................................................................................ 36

3.5.2 Front Anti roll bar settings ........................................................................................................................ 37

3.6 Rear Anti roll bar settings ................................................................................................ 41

4 Maintenance and assembly instructions ....................................................................... 44

4.1 Front Uprights ................................................................................................................ 44 4.1.1 Upright assembly ...................................................................................................................................... 44

4.2 Rear Uprights ................................................................................................................. 47 4.2.1 Upright assembly ...................................................................................................................................... 47

4.3 Wheel nut ...................................................................................................................... 51

4.4 Assembly and Maintenance .............................................................................................. 51

4.5 Anti-Roll bar backlash ...................................................................................................... 52

4.6 Rear Rocker ................................................................................................................... 53 4.6.1 Replacement procedure: .......................................................................................................................... 54

4.7 Front wing adjustment .................................................................................................... 55 4.7.1 Mainplane Gurney Optional Trimming ..................................................................................................... 55

5 Steering ......................................................................................................................... 56

5.1 Longitudinal adjustment .................................................................................................. 56

5.2 Vertical adjustment ......................................................................................................... 57

5.3 Kinematic backlash adjustment ........................................................................................ 57

5.4 Pinion backlash adjustment ............................................................................................. 58

5.5 CV joint orientation ......................................................................................................... 58

5.6 Steering housing treatment ............................................................................................. 59

5.7 Steering rack travel stop ................................................................................................. 59

5.8 Steering rack potentiometer installation ............................................................................ 60

5.9 Steering Line for KIT car ................................................................................................. 61

5.10 Electric Power Steering (EPS) .......................................................................................... 62

5.11 Alternative Ackermann Arms ............................................................................................ 62

6 Gearbox, Clutch & Differential. Kinematic Chain........................................................... 63

6.1 Gearbox ......................................................................................................................... 63 6.1.1 Authorized ratios ...................................................................................................................................... 63

6.2 Differential & C/W .......................................................................................................... 64

6.3 Clutch ............................................................................................................................ 64

7 Oil System ..................................................................................................................... 64

8 Leg Padding .................................................................................................................. 64

9 Heat Shields .................................................................................................................. 62


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10 Battery ........................................................................................................................... 63 “320.002 - OWNER’S MANUAL SUPER B LITHIUM IRON PHOSPHATE STARTER BATTERIES.pdf” ............................ 63

11 Fuel System ................................................................................................................... 63 “320.001 - USE AND MAINTENANCE MANUAL FOR M.E.RIN FLEXIBLE TANKS.pdf” .............................................. 63

12 Pedals ............................................................................................................................ 65

2.2 Pedals for KIT car ........................................................................................................... 68

2.3 Brake Balance Adjuster .................................................................................................... 69

13 Dampers ........................................................................................................................ 69 “320.004 - CALIBRATION CURVE FOR KONI 320 DAMPERS.pdf” ................................................................................... 69

14 Halo device .................................................................................................................... 70

2.4 Ballast ........................................................................................................................... 71

15 Wheel Tethers Routing and covers ................................................................................ 72

15.1 Wheel Tethers Protection ................................................................................................ 73

16 Side Cones replacement ................................................................................................ 74

17 Other important aspects ............................................................................................... 77

17.1 Suspension .................................................................................................................... 77

17.2 Mirror ............................................................................................................................ 77

17.3 Brakes ........................................................................................................................... 77

17.4 Data acquisition.............................................................................................................. 77

17.5 Engine ........................................................................................................................... 77

17.6 Kinematic Chain ............................................................................................................. 78

17.7 Cooling .......................................................................................................................... 78

18 Annexes ........................................................................................................................ 80


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0.1 Preface

• This document describes the DALLARA 320 main technical characteristics and settings as well as the

maintenance, repairing and operating procedures.

• The foundation of the 320-car development is the intention to give continuity to the concept of the former 317 car and technically the DALLARA 320 is an upgrade from the existing DALLARA 317 car. The suspension, mechanical components, gearbox and general layout remain unchanged.

• A solution has been chosen that allows effective cost reduction for customers who have the current cars.

• The F-320 is the only one that is authorized to participate at the Euroformula Open, within the

configuration that is described in this manual.

• It is not authorized, unless any other stated, any modification of any of the parts that have been

delivered with the vehicle. Whatever non-authorized modification will immediately mean that the car

is not according to the technical regulations.

• For any doubt, enquiry or suggestion, please do not hesitate to contact with the Organizer and

Promoter of the Championship.

• All the spare parts orders that are necessary to properly entertain and maintain the vehicle, would be

done through the Organizer and Promoter of the Championship.

• The 320 project guidelines have pursued several objectives, among which Safety, weight

reduction and aerodynamic performance, have been specially considered, setting the 320

as a clear benchmark vehicle, in terms of dynamic capabilities and performances.

• The chassis passive safety has been raised to the latest FIA standards. The monocoque and crash

structures are FIA F1 2018 homologated.

• The design and all the manufacturing technologies choices have been oriented to the weight

optimization. The adopted solutions largely compensate the extra weight of the titanium halo, the

composite side-impact structures and other safety features necessary for the FIA F1 standards

• We wish you much sporting success with your 320 car.


Rev. 2021 v1.2 of April 21, 2020 6

0.2 Issues

- 20.07.2020: Owner’s Manual Release 1.0 - 15.04.2021 (Rev. 2021 v1.2): Revised items: 4.7.1 / 5.10 / 5.11 / 15.1 / 17.3 and 17.7


Rev. 2021 v1.2 of April 21, 2020 7

0.3 Contacts

GT Sport Organización S. L.

C/ Juan Bravo nº 17, Bajo derecha

Madrid 28006

Tel:91 432 27 50

Fax: 91 578 05 82

Fax:91 426 35 96

www.gtsport.es

Sporting manager: D. José Miguel García Galán

Spare parts manager: D. Luis Mayoral

http://www.gtsport.es/


Rev. 2021 v1.2 of April 21, 2020 8

0.4 General Agreements and Warranty

Motor racing is not covered by warranty due to the intentional choice of drivers to race in a

dangerous environment.

In the "320 OWNER’S MANUAL" you will find the details of the terms and conditions for the

maintenance/replacement/refurbishment/dimensional and crack check of the car and its

components.

DALLARA guarantees that, under normal operating conditions, the car and its components delivered

are free from defects and imperfections in materials, construction and assembly, and they would not

show failure in structural components. This holds true if necessary maintenance and checks are

provided and if the car had no previous accidents.

Any modification or alteration of the car, or its components, could seriously compromise safety and

road holding and cause accidents, with potentially fatal risks for driver and third parties.

DALLARA is not responsible for any modification or alteration or incorrect repairs or any incorrect

use of any car's components being Dallara parts or parts made outside DALLARA factory.

The purchaser undertakes to carry out the scheduled maintenance of the car (as paragraph 4.2

"Components Milage"), in accordance with the indications and within km limits set out in this "320

OWNER’S MANUAL", differently the car could have serious safety problems and DALLARA shall not

be liable for relative damage.

This owner’s manual is part of the technical regulations so, although most of the settings, data and

information that is reported in it are intended as a guideline for the correct use of the car, all those

aspects that are clearly stated, will be mandatory for the Euroformula Open Championship.

Anyhow, in case of doubt, please do not hesitate to contact the Technical Commission of the

Championship by writing, before making any modification to any part, and / or adding or removing

any component.


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1 Chasis & Safety

1.1 General data

Components Type/supplier

Front suspension Push-rod with twin dampers, anti-roll bar and third element

Rear suspension Push-rod with twin dampers, anti-roll bar and third element

Front Springs Torsion bars

Rear Springs Coil springs

Chassis Carbon sandwich with AL honeycomb, additional protection panels

Bodywork Carbon micro-sandwich

Gearbox Gears and differential Hewland longitudinal six ratios plus reverse gear

Fuel cell M.E.RIN S.r.l. – FT5/99

Extinguisher system OMP Cefal 3 (remote activation led) or 2019 version without remote activation led.

Coolers/Exchanger Dallara

Brake system BREMBO Calipers and master cylinders – BREMBO disc & pads

Battery Super B SB12V15P-EC

Seat belt Sparco

1.2 Main views and Dimensions

Dimensions Measurements Remarks

Front Track 1618mm

Rear Track 1540mm

Wheelbase 2866mm

Overall Length 4934mm From nose tip to rear impact structure

Overall Width 1875mm Measured external to the wheels

Overall Height 951mm From Z-0 ref. Plane to the top of the roll bar


Rev. 2021 v1.2 of April 21, 2020 10

1.3 Reference plane

The reference plane is located on the monocoque’s reference pads and on the stripe along the

centerline of the car.

Bottom side of the monocoque is at +3.0mm from Ref. Plane and side stripes are at +1.5mm.


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1.4 Track Equipment

Here below dimension which could be useful for 320 trackside equipment.


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1.5 Safety overview and equipment

The new 320 complies with the most stringent safety regulation in the motorsport. The monocoque

has been homologated fulfilling the FIA F1-2018 regulations.

An overview of the safety equipment of the new 320 car is reported below.

1.6 Monocoque

Several tests have been performed on the monocoque according to the FIA procedures. An overview

of the main tests with the applied loads are reported in the following images.


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1.7 Protection secondary panel

Following the FIA F1-2018 regulation, a new wider protection panel has been adopted for the 320

cars, with the purpose to extend the area which is reinforced and then to increase the safety of the

monocoque.

Particular care should be taken in case of damaging of the panel. In case of doubt Dallara is

available to provide support to evaluate the damaging and the possible repairing approach.

1.8 Side Crash Structure

Side crash structure have been applied to the 320 monocoque. The structures are FIA spec (in

common with F1 cars), so they have been designed by FIA and manufactured by Dallara. The

structure allow the chassis to withstand much higher load than before, with good crash performance

also in case of an angular crash.

The side crash structures are bonded to the monocoque, in case of extensive damaging the

structure should be replaced. Procedure of side structure replacing can be find on the chapter

6 of this document.


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1.9 Sacrificial keel

A new “sacrificial” keel has been developed by Dallara. The purposes of this component are:

a) Protect the monocoque keel edge (complex repairing procedure) in case of a kerb or ground

contact during the normal use of the car

b) Provide an additional reinforcement to the monocoque for the driver safety

c) Making the repairing easier: in case the sacrificial keel get damaged it can be replaced easily

without the need of a complex and expensive repairing on the monocoque

Once the sacrificial keel will be damaged, it should be replaced to provide again protection

to the edge of the monocoque and the surrounding area. It has been developed to absorb

energy and once its function is performed, it cannot be repaired providing for a second time

the original safety performance.

1.10 Front crash

The nose has been developed to comply with the FIA F1-2018 safety regulation. One crash test and

one push-off test have been performed on the nose.

1.11 Rear crash

The rear impact structure (RIS) has been developed to comply with the FIA F1-2018 safety

regulation. One crash test and one push-off test have been performed on the RIS.

1.12 Halo

The 320 car has been designed to accommodate the halo device. The involved fixing devices follow

to the FIA specifications and required design (including pins and bolts). No modification to such

structures or devices are allowed.

In case of accident which involve the Halo, all the fixing bolts and pins must be replaced.

The front bracket should be checked carefully and if any deformation or damaging is detected

it must be replaced. Guidelines about the Halo safety evaluation after an accident are

provided by FIA and can be found in the appendix to this document.


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1.13 Extractable seat

An additional bracket has been added to the back of the extractable seat to provide an additional

support to the extractable seat on case of a severe rear impact. A gap of 10mm should guaranteed

between the two shown surfaces. This gap can be filled with foam, polystyrene or soft rubber to

reduce the flexibility of the seat. The use of harder materials is not recommended.

The use of the extractable seat bracket is mandatory.

1.14 Seat Pillow

The 320 extractable seat has been provided with three additional safety pillows, which helps in

reducing the load coming into the driver back in case of accident or excursion on rough road (grass,

kerbs, unpaved surfaces…).

The use of the seat pillow is mandatory.


Rev. 2021 v1.2 of April 21, 2020 16

1.15 Seat belt

The seat belts for 320 have been updated to the latest safety standard (8853/2016).

Only the use of safety belt that are approved following the 8853/2016 regulation is allowed.

1.16 Wheel tether

The 320 car has been equipped with two wheel tether for each suspension corner.

1.17 Fire Extinguisher System

The 320 car has been equipped with fire extinguisher from OMP.

The fire extinguisher is located behind the extractable seat. A pressure gauge indicates the

extinguisher bottle status (it is visible removing the extractable seat). The system is equipped with:

A. Extinguisher bottle

B. Internal extinguisher switch and led light

C. One cockpit nozzle

D. External extinguisher switch

E. Five engine nozzles

F. Extinguisher Control-Unit

Always check that the fire extinguisher is armed when the car is on by checking the led light

on the dashboard.

The cable connected to the external extinguisher switch (D) is designed also to disengage

the master switch. When assembling it pay attention that pulling the cable is possible to

disengage completely the master switch before reaching the end of the stroke of the

extinguisher switch.


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1.18 Components Mileage

The following parts must follow a life-mileage program for periodic maintenance / replacement /

refurbishment / dimensional and crack checks. Listed below are typical expected life (in kilometres).

For safety reasons, please contact immediately Dallara if you discover premature wear or problems

Chassis Inspection Inspection procedure Limit Remark

Engine studs 4000km Dye penetrant inspection 32000km

Sacrificial keel 8000km Visual and tapping test - Change if damaged

Front Suspension Inspection Inspection procedure Limit Remark

Wishbones 4000km Dye penetrant inspection 20000km 8000km COP lower wishbone

Pushroads 4000km Dye penetrant inspection 20000km

Anti Roll Bars 4000km Dye penetrant inspection 16000km

Torsion bar 2000km Visual 32000km

Rockers 4000km Dye penetrant inspection 20000km

Suspension ball joints Every event Visual -

Suspension studs Every event Visual -

Hubs 4000km Dye penetrant inspection 32000km

Uprights 4000km Dye penetrant inspection 15000km

Ackerman Brackets 4000km Dye penetrant inspection 20000km Change after every crash

Wheel bearing 4000km Visual 10000km

Rear Suspension Inspection Inspection procedure Limit Remark

Wishbones 4000km Dye penetrant inspection 15000km

Pushroads 4000km Dye penetrant inspection 20000km

Anti Roll Bars 4000km Dye penetrant inspection 16000km

Rockers 4000km Dye penetrant inspection 20000km

Suspension ball joints Every event Visual -

Suspension studs Every event Visual -

Hubs 4000km Dye penetrant inspection 32000km

Upright 4000km Dye penetrant inspection 20000km

Wheel bearing 4000km Visual 10000km

Driveshaft and Tripods 4000km Dye penetrant inspection 10000km

Steering system Inspection Inspection procedure Limit Remark

Steering column 4000km Dye penetrant inspection 20000km

Steering rack and pinion 4000km Dye penetrant inspection 32000km

Wings assembly Inspection Inspection procedure Limit Remark

Wing profiles 8000km Visual and tapping test 32000km

Front endplate 8000km Visual and tapping test 32000km

Rear Endplate 4000km Visual and tapping test 32000km

Front wing pillars Each event Visual 4000km

Rear wing pillars Each event Visual 4000km

Miscellaneus Inspection Inspection procedure Limit Remark

Fuel bladder Each event Visual See expire date

Self locking nuts Change after three mountings process


Rev. 2021 v1.2 of April 21, 2020 18

The limit mileage reported above are meant as the maximum kilometers allowable in case of a normal operation of the car, with no contacts, no unexpected maneuvers (example

hard jump on kerbs, run on grass) and no damaging due to any unexpected condition (exposure to high temperature or humidity, damaging while handling the parts, …). The inspection mileage are meant as the maximum travelled kilometers which require a mandatory and accurate inspection of the parts. Visual inspection of all the main parts should be done in any case after every event.

After every accident, even of minor entity, every structural part of the car must be inspected with extreme care. Particular care should be place on:

d) Wishbones, Toe links, Track rods and Pushrods e) Uprights

f) Suspension brackets, steering arms and rockers g) Anti roll bars and anti roll bar adjustable blades, and torsion springs h) Brake disc bells

i) Monocoque (suspensions pick up points, engine pick up points, …)


Rev. 2021 v1.2 of April 21, 2020 19

2 Bodywork

• Unless other thing specifically stated, no modification of the initially supplied parts is authorized

• For the time being, no modification of the body panels’ mountings is accepted.

• No tape is allowed to cover the junctions between bodywork panels

• It is allowed to fit an aerodynamic shroud between the engine cover & the airbox, but it has to

be previously accepted by the Technical Commission, and cannot be changed / modified through

the season.

• Airbox Shroud: Although it is still strongly recommended to use one engine builder’s previously

approved layout, in case the team wants to define their own design, it should be previously

approved by the Technical Comission and, once fixed, it would be frozen.

• Antenna mounting hole: It is allowed to perform an antenna mounting hole in the front access

panel.

• Data downloading connector: It is allowed to make a data downloading connector access hole

in the engine cover.

• For Spiess engine equipped vehicles, 2020.06.16-Bulletin.320.005 – Spiess Engine Cover

additional installation must be followed.

• Dallara bulletin 320 - Technical Bulletin 006 - Rear Diffuser must be considered when trimming

the underfloor.

2.1 Halo Fairing

The 320 is equipped with a front halo fairing. The adoption of the fairing help in reducing the

aerodynamic impact of the halo structure.

The front halo fairing can be opened and deformed to fit to the halo. Once in position the fairing is

fixed with 4 bolts and it could be kept in position by using additional tape film along the borders

(helicopter tape is suggested, but different tape can be used).

To further help keeping the fairing in position, some pieces (example 20x10mm) of double tape (0.5

to 1mm thick) can be used as first step. In any case tape film along the border should be anyway


Rev. 2021 v1.2 of April 21, 2020 20

used.

2.2 Halo Painting

It is ALLOWED to paint the Halo and to stick logos, publicity, name of the team, etc, provided that

Dallara’s instructions are strictly followed (2020.02.10-Bulletin.320.002-Halo.Painting).


Rev. 2021 v1.2 of April 21, 2020 21

33

3 Setup

3.1 Setup adjustment

Positive change in: Means:

Ride Height car moves up

Toe toe-out

Camber upper part of rim outward

Castor lower part of rim points ahead

Unit Front Rear

Pushrod Adjuster

+1 barrel turn [mm] 2,12 2,33

Thread size 2x 5/8"-24 UNEF 3/8"-24 UNF (LH) 1/2’’-20 UNF

Ride height change [mm] 5,974 6.082

Camber change [deg] 0,090 0,188

Toe Adjuster (per Wheel)


Thread size 5/16"-24UNEF 3/8"-24 UNF (LH) 1/2’’-20 UNF

Toe change [deg] 0,613 -0,316

Camber shim +1mm

Camber change [deg] 0,434 0,388

Toe change [deg] -0,063 -0,201

Caster Adjuster


Thread size 5/16"-24UNF 1/2"-20UNF

Castor change [deg] 0,516 -0,780

Ride height change [mm] -0,885 -1,550

Camber change [deg] -0,169 +0,025

Toe change [deg] 0,040 -0,029

Wheel/Damper Ratio

Ratio [mm/mm] 1,447 1,289

Wheel/Spring Ratio

Ratio [mm/deg] 1,699 -

Ratio [mm/mm] - 1,289

Wheel/Heave Ratio

Assuming a parallel wheel travel [mm/mm] 1,045 To see ARB table

Wheel/Drop Link Ratio

Assuming an opposite wheel travel [mm/mm] To see ARB table To see ARB table

Roll Centre height

From ground @ design ride height [mm] 9.4 To see rear geom. adj.

∆ C ambe r

@10mm BUMP [deg] 0.15 To see rear geom. adj.

Design ride height

From ground to Z-0 ref plane [mm] 25 39.5

From ground to skid bottom [mm] 20 34.5


Rev. 2021 v1.2 of April 21, 2020 22

3.1.1 Lower wishbone design configuration set-up

Front Lower Wishbone:

Rear Lower Wishbone:

In order to secure the integrity of the assembly, distance A of lower wishbone rod end must be less

than a certain value:

AFR < 27 mm

ARR < 27 mm


Rev. 2021 v1.2 of April 21, 2020 23

3.1.2 Ride height and pushrods adjustment

Front and rear ride height can be changed by lengthened/shorten the pushrods. Maximum ride

height depends on the maximum regulation allowed by the system.

Front Pushrod:

Although the front pushrod is carried over from F312, the nuts and adjuster have been modified to

meet the adjustment range. Front pushrod holes must not be used to check the turn-buckle position.

Please always refer to the dimension reported below: BFR < 29 mm

Rear pushrods:

Rear pushrods turn-buckle limits are written below: B1-

RR < 34 mm B2-RR < 27 mm


Rev. 2021 v1.2 of April 21, 2020 24

3.1.3 Toe

Front and Rear toe can be changed by lengthened/shorten toe link arm. When the toe link arm is

lengthened.

Front Toe Link

In order to secure the integrity of the assembly, the adjustment shaft must always protrude less

than “CFR” reported below: CFR < 14 mm

Although the front toe link is carried over from F312, the spherical end has been modified

to meet the new front suspension layout. Only the use of the updated part is allowed.

Rear Toe Link

Rear Toe link turn-buckle limits are written below: C1-

RR < 34 mm C2-RR < 27 mm


Rev. 2021 v1.2 of April 21, 2020 25

3.1.4 Camber

Spacer to adjust camber are available in the following thickness:

Front: 0.5, 0.6, 0.8, 1.0, 1.2, 1.5 and 2.0 mm

Rear: 0.8, 1.0, 1.2, 1.5, 2.0 and 5.0 mm

In order to secure the integrity of the assembly, the recommended maximum camber shims’

thickness are:

Front: 9 mm

Rear: 16 mm


Rev. 2021 v1.2 of April 21, 2020 26

3.1.5 Caster front

When the car is flat (front and rear ride height are identical) and the front upright inclination is

6.77° [APPARENT CASTER] the effective caster angle is 16.03° [BUILT-IN CASTER].

With different front to rear ride heights, caster angle changes because of the pitch angle of the car.

For instance, with 20 mm front and 40mm rear ride heights, measured at wheel axis, (wheelbase is

2866 mm) the pitch angle is 0.4° and caster angles (both apparent and total) are reduced.

Pitch angle: arctan [(40-20)/2866] = 0,4°

Total Caster angle: 16.03° - 0,4° = 15.63°

Apparent Caster angle : 6.77° - 0,4° = -6.37°


Rev. 2021 v1.2 of April 21, 2020 27

3.1.6 Caster Rear

When the car is flat ( front and rear ride height are identical ) and the front upright inclination is

23° [APPARENT CASTER] the effective caster angle is 17.14° [BUILT-IN CASTOR].

With different front to rear ride heights, castor angle changes because of the pitch angle of the car.

For instance, with 20 mm front and 40mm rear ride heights, measured at wheel axis, (wheelbase is

2866 mm) the pitch angle is 0.4° and caster angles (both apparent and total) are reduced.

Pitch angle: arctan [(40-20)/2866] = 0,4°

Total Castor angle: 17.14° - 0,4° = -16.74°

Apparent Castor angle : 1.6° - 0,4° = 22.6°


Rev. 2021 v1.2 of April 21, 2020 28

3.2 Suspension coordinates

3.2.1 Front (STD configuration)

Point X [mm] Y [mm] Z [mm] Description

1 190,948 59,026 254,828 Bottom Wishbone Front Joint

2 -379,667 162,047 239,825 Bottom Wishbone Rear Joint

3 2,306 165,292 412,979 Top Wishbone Front Joint

4 -394,353 185,829 381,175 Top Wishbone Rear Joint

5 147,041 170,000 389,500 Toe Link Joint - Tub Side

6 -65,974 675,450 348,831 Top Wishbone Joint - Wheel Side

7 -23,840 708,908 203,332 Bottom Wishbone Joint - Wheel Side

8 31,447 734,770 323,867 Toe Link Joint - Wheel Side

9 0,000 809,221 -25,000 Ground Contact Point

10 0,000 792,810 243,505 Centre Wheel Point

11 -27,202 690,374 240,886 Push/Pull Rod Joint - Wheel Side

12 91,507 141,606 508,210 Push/Pull Rod Joint - Tub Side

13 80,355 125,000 479,789 Rocker Rotational Axis First Point

14 76,462 58,500 469,886 Damper Joint - Rocker Side

15 5,471 96,520 288,983 Damper Joint - Tub Side

16 173,441 125,000 443,256 Rocker Rotational Axis Second Point

17 213,500 0,000 317,390 ARB Rotational Axis First Point

18 97,373 111,500 523,157 Center Spring Pickup on Rocker

19 213,500 35,000 317,390 ARB Rotational Axis Second Point

20 43,793 35,000 367,362 ARB Link rod Joint - ARB Side

21 77,002 32,000 471,229 ARB Link rod Joint - Rocker Side


Rev. 2021 v1.2 of April 21, 2020 29

3.2.2 Rear (STD configuration)

Point X [mm] Y [mm] Z [mm] Description

1 415,000 150,000 167,000 Bottom Wishbone Front Joint

2 121,880 134,000 155,500 Bottom Wishbone Rear Joint

3 309,000 135,000 308,100 Top Wishbone Front Joint

4 -156,000 90,000 279,000 Top Wishbone Rear Joint

5 -92,500 101,000 237,000 Toe Link Joint - Wishbone side

6 25,000 623,500 364,500 Top Wishbone Joint - Wheel Side

7 85,000 680,000 170,000 Bottom Wishbone Joint - Wheel Side

8 -122,000 637,000 289,000 Toe Link Joint - Wheel Side

9 0,000 770,000 -39,500 Ground Contact Point

10 0,000 757,100 238,700 Centre Wheel Point

11 12,000 678,000 113,000 Push/Pull Rod Joint - Wheel Side

12 164,487 138,173 368,717 Push/Pull Rod Joint - Rocker Side

13 129,124 128,075 364,657 Rocker Rotational Axis First Point

14 142,365 59,727 395,139 Damper Joint - Rocker Side

15 -143,381 37,657 339,227 Damper Joint - Gearbox Side

16 137,454 113,498 328,351 Rocker Rotational Axis Second Point

17 380,000 0,000 290,000 ARB Rotational Axis First Point

18 361,669 0,000 477,104 Third Damper Joint - ARB Side

19 380,000 50,000 290,000 ARB Rotational Axis Second Point

20 365,000 39,000 443,108 ARB Link rod Joint - ARB Side

21 168,265 65,248 398,896 ARB Link rod Joint - Rocker Side

22 74,983 0,000 362,740 Third Damper Joint - Gearbox Side


Rev. 2021 v1.2 of April 21, 2020 30

3.3 Front Geometry Adjustment UMP Options

“UMP” means Upright Mounted Pushrod.

The front suspension jacking effect with steering can be tuned by bolting the pushrod on the upright

on the 4x different positions listed here below:

Position

Δx [mm]

Arrow laser etched on bracket pointing at

P11 Coordinates

X [mm] Y [mm] Z [mm]

P+1 +5 Opposite to travel direction -22,202 -690,374 240,886

P0 0 (std) Travel direction -27,202 -690,374 240,886

P-1 -5 Opposite to travel direction -32,202 -690,374 240,886

P-2 -10 Travel direction -37,202 -690,374 240,886

P-0 (std) and P-2 → achieved by fitting the pushrod bracket with the etched arrow aligned with the

car’s travel direction.

P+1 and P-1 → achieved by fitting the pushrod bracket with the etched arrow opposite to the car’s

travel direction.


Rev. 2021 v1.2 of April 21, 2020 31

Table below compares the different options described above respect to the rack travel. All these

values are referred to the design configuration with the front ride height at 25mm from reference

plane.

P+1 P-0 (std) P-1 P-2

Side Rack

Travel St. Ratio Jacking Acker Jacking Acker Jacking Acker Jacking Acker

[-] [mm] [-] [mm] [%] [mm] [%] [mm] [%] [mm] [%]

in

ne

r wh

ee

l

-40,0 13,3 3,70 33,6 7,52 34,9 11,40 36,2 15,34 37,5

-36,0 13,8 3,17 32,0 6,66 33,4 10,20 34,7 13,79 36,1

-32,0 13,0 2,67 30,6 5,82 32,0 9,01 33,4 12,25 34,8

-28,0 11,9 2,22 29,4 5,01 30,8 7,85 32,2 10,71 33,6

-24,0 11,6 1,80 28,3 4,23 29,7 6,69 31,1 9,18 32,5

-20,0 12,3 1,41 27,3 3,46 28,7 5,55 30,1 7,65 31,6

-16,0 13,5 1,06 26,5 2,72 27,9 4,41 29,3 6,12 30,7

-12,0 14,1 0,74 25,7 2,01 27,1 3,29 28,5 4,59 30,0

-8,0 13,3 0,45 25,1 1,31 26,5 2,18 27,9 3,06 29,3

-4,0 12,1 0,21 24,5 0,65 25,9 1,08 27,3 1,53 28,7

0,0 11,5 0,00 24,2 0,00 25,5 0,00 26,9 0,00 28,3 o

ute

r wh

ee

l

4,0 12,0 -0,17 24,5 -0,62 25,9 -1,07 27,3 -1,52 28,7

8,0 13,0 -0,29 25,1 -1,20 26,5 -2,12 27,9 -3,04 29,3

12,0 13,6 -0,36 25,7 -1,75 27,1 -3,15 28,5 -4,55 30,0

16,0 12,9 -0,38 26,5 -2,26 27,9 -4,15 29,3 -6,05 30,7

20,0 11,5 -0,33 27,3 -2,72 28,7 -5,12 30,1 -7,52 31,6

24,0 10,8 -0,20 28,3 -3,12 29,7 -6,04 31,1 -8,97 32,5

28,0 10,9 0,02 29,4 -3,45 30,8 -6,91 32,2 -10,38 33,6

32,0 11,7 0,34 30,6 -3,69 32,0 -7,71 33,4 -11,74 34,8

36,0 12,1 0,80 32,0 -3,82 33,4 -8,42 34,7 -13,02 36,1

40,0 11,4 1,43 33,6 -3,80 34,9 -9,01 36,2 -14,21 37,5

Please note that on the 320 the rack travel is limited to 30 mm.


Rev. 2021 v1.2 of April 21, 2020 32

3.3.1 Roll Centre Height

The Front roll center height can be changed by moving the spacer on the fixing point of the wishbone

spherical joint on the wheel side.

When changed one step towards higher roll center configuration the push-rod length has to be

shortened by 1/12 register turns to put the car back at the same front ride height.

When adjusting the roll center height also camber gain ratio varies a little.

Position

Δz [mm]

P7 Coordinates Roll Center Height @Design

Configuration

Camber Gain @10mm From Design Configuration X [mm] Y [mm] Z [mm]

A_1 0 (std) -23,840 708,908 203,332 9.4 +0.15

A_2 -2 -23,840 708,908 201,332 17.4 +0.14

A_3 -4 -23,840 708,908 199,332 25.2 +0.12

A_4 -6 -23,840 708,908 197,332 32.7 +0.10


Rev. 2021 v1.2 of April 21, 2020 33

3.4 Rear Geometry adjustment

The rear wishbones fixing points on gearbox can be mounted in different position. The standard

position is considered the middle one (A2, B2, C2, D2)

Changing the fixing points position move the suspension points as follow:

j) Position A2 to position A1: Z +14 mm

k) Position A2 to position A3: Z -14 mm

l) Position B(X) to position B(X+1): 14 mm

m) Position B(X) to position B(X-1): -14 mm

n) Position C is fixed

o) Position D1 to position D2: Z -14 mm

p) Position E1 to position E2: Z -8 mm (obtained by mounting upside-down the clevis)

q) Position F1 to position F2: Z -8 mm (obtained by mounting upside-down the clevis)

It is not allowed to mount the wishbones in the following configuration:

A3/B1


Rev. 2021 v1.2 of April 21, 2020 34

Rear roll centre height in A2-B2-C1-D2-E1-F1 (STD configuration) is 63,40mm from ground at an

effective static rear ride height of 39.5 mm (measured from ground to reference plane).

Antilift and Antisquat are calculated considering a center of gravity height at 295mm from the car

reference plane.

CONFIGURATION

Roll centre height from ground @39.5mm ride height

Camber Gain @10mm From Design Config.

Antisquat

Antilift

G-BOX SIDE WHEEL SIDE

[mm] [°] [%] [%]

A1-B1-C1-D2-E1

F2

44.4

-0,23

46.2

6.1

A2-B2-C1-D2-E1 F1 63.4

-0.31

46.2

6.1

STANDARD CONFIGURATION

A3-B3-C1-D2-E2

F1

81.8

-0.38

46.2

6.1

A2-B3-C1-D1-E1

F1

62,3 Shorten 0.5 turns caster adjust joint

-0.34

66.0

63.9

A1-B2-C1-D1-E1

F2

44.2 Shorten 0.5 turns caster adjust joint

-0.27

66.0

63.9

A2-B3-C1-D2-E1

F1


-0.35

35.8

20.3

A1-B2-C1-D2-E1

F2


-0.27

35.8

20.3

A1-B3-C1-D2-E1

F2


-0.31

25.5

34.5

A3-B2-C1-D2-E1

F1

75.0 Lengthen 1.0 turns caster adjust joint

-0.36

56.6

-8.1

A2-B1-C1-D2-E1

F1

56.4 Lengthen 0.5 turns caster adjust joint

-0,27

56.6

-8.1

A3-B2-C1-D1-E2

F1

77.1

Lengthen 1.0 turns caster adjust joint

-0,34

86.7

35.4

A2-B4-C1-D2-E1

F1


-0,38

25.5

34.5

A1-B3-C1-D2-E1

F1


-0,30

25.5

34.5

A3-B5-C1-D2-E1

F1

94.8

Shorten 1.5 turns caster adjust joint

-0,47

25.5

34.5

A1-B4-C1-D2-E1

F1


-0,33

15.1

48.7

A2-B5-C1-D2-E1

F1


-0,42

15.1

48.7


Rev. 2021 v1.2 of April 21, 2020 35

3.5 Front torsion bar settings

Ten different front torsion bars are available.

Dallara Code Commercial code OD diameter [mm] Stiffness @ GND [kgf/mm]

31255353 F31206B014 14,96 15,1

31255354 F31206B015 14,70 14,2

31255355 F31206B016 14,44 13,3

31255356 F31206B017 14,16 12,3

31255357 F31206B018 13,87 11,4

31255358 F31206B019 13,57 10,5

31255359 F31206B020 13,25 9,6

31255360 F31206B021 12,90 8,6

31255361 F31206B022 12,54 7,7

31255362 F31206B023 12,15 6,8


Rev. 2021 v1.2 of April 21, 2020 36

3.5.1 Front torsion bar pre-load

The front suspension torsion bar is equipped with a pre-load adjuster. After set the desired racecar

ride-height with driver on-board (adjusting the pushrods turnbuckle) the rebound-stop could be

moved in contact with the rocker. Once done this is possible to un-screw the locking nuts of the

torsion bar cap and adjust the preload. Reached the desired pre-load level tighten the locking nuts.

The pre-load limit is 6deg for all torsion bars.


Rev. 2021 v1.2 of April 21, 2020 37

3.5.2 Front Anti roll bar settings

Several U-shaped and a T-shaped anti roll bars are available:

r) U-shaped, Long blades configuration

Ø30mm 3mm thick body Ø18mm solid body Ø15mm solid body

s) U-shaped, Medium blades configuration


t) U-shaped, Short blades configuration



Rev. 2021 v1.2 of April 21, 2020 38

u) T-shaped

Here below the coordinates of the significant points used in the calculation for each configuration:

Anti-Roll bar configuration

P17 Coordinates P19 Coordinates P20 Coordinates

X [mm] Y [mm] Z [mm] X [mm] Y [mm] Z [mm] X [mm] Y [mm] Z [mm]

U-shaped, Long blades 213,500 0,000 317,390 213,500 35,000 317,390 43,793 35,000 367,362

U-shaped, Medium blades 173,500 0,000 317,390 173,500 35,000 317,390 43,793 35,000 367,362

U-shaped, Short blades 115,500 0,000 335,390 115,500 35,000 335,390 43,793 35,000 367,362

T-shaped, Wide fixing 173,500 0,000 317,390 173,500 35,000 317,390 41,190 37,000 360,000

T-shaped, Narrow fixing 173,500 0,000 317,390 173,500 35,000 317,390 41,190 27,000 360,000

Below the corresponding motion ratio at an effective static rear ride height of 25 mm (measured

from ground to reference plane):

Anti-Roll bar configuration

Motion Ratio

U-shaped, Long blades 1.046

U-shaped, Medium blades 1.045

U-shaped, Short blades 1.040

T-shaped, Wide fixing 1.045

T-shaped, Narrow fixing 1.053

Table below shows front anti-roll bar stiffness value at ground calculated using the anti-symmetric

model. Respect to the standard model used in the past for calculating the component stiffness, this

method gives more precise values but the value obtained using anti-symmetric model is the double

of the standard component stiffness.


Rev. 2021 v1.2 of April 21, 2020 39

Please consider that all the values are calculated not considering the stiffness of the chassis

and the compliance of the joints between mechanical elements.

The digits reported represent the blade positions: 1=full soft → 5=full hard

Anti-roll bar configuration

Stiffness @ground [kgf/mm]

1-1 1-2 1-3 1-4 1-5 2-2 2-3 2-4 2-5 3-3 3-4 3-5 4-4 4-5 5-5

Long blades, Ø15 solid 7,3 7,7 8,8 10,4 11,4 8,2 9,5 11,4 12,5 11,4 14,2 16 18,8 22 25,7

Long blades, Ø18 solid 7,9 8,3 9,7 11,6 12,8 8,9 10,5 12,8 14,3 12,8 16,5 19 23,1 28,2 34,6

Long blades, Ø30x3 8,4 8,8 10,4 12,7 14,1 9,5 11,3 14,1 15,9 14,1 18,8 22 27,7 35,2 46

Medium blades, Ø15 solid 27,7 28,7 31,7 35,6 37,7 30 33,3 37,7 40 37,7 43,2 46,4 50,5 54,8 58,8

Medium blades, Ø18 solid 33,4 34,8 39,3 45,5 49 36,8 41,9 49 53 49 58,7 64,6 73 82,4 91,9

Medium blades, Ø30x3 39,1 41,1 47,6 56,9 62,5 43,9 51,4 62,5 69,1 62,5 79,3 90,3 108 129 155

Short blades, Ø15 solid 131 134 142 152 157 138 147 157 163 157 170 176 184 192 198

Short blades, Ø18 solid 175 180 196 216 226 187 205 226 238 226 253 268 286 304 321

Short blades, Ø30x3 232 241 270 309 331 254 287 331 356 331 391 427 476 529 582

The angle value is measured from the full soft position (0 deg) with the positive direction as shown

in the picture below. It is possible to rotate the blade in both directions by switching it upside-down.

Anti-roll bar configuration


-90° -67.5° -45° -22.5° 0° +22.5° +45° +67.5° +90°

T-bar, Wide Fixing 415 329 250 211 208 240 311 403 415

T-bar, Narrow Fixing 765 780 608 458 389 385 445 588 765


Rev. 2021 v1.2 of April 21, 2020 40

Here attached a diagram showing all the possible configurations for the front anti-roll bar:

FRONT ARB

T-bar, Narrow Fixing

T-bar, Wide Fixing

Short blades, Ø30x3

Short blades, Ø18 solid

Short blades, Ø15 solid

Medium blades, Ø30x3

Medium blades, Ø18 solid

Medium blades, Ø15 solid

Long blades, Ø30x3

Long blades, Ø18 solid

Long blades, Ø15 solid

0 100 200 300 400 500 600 700 800

Ground Stiffness [kgf/mm]


Rev. 2021 v1.2 of April 21, 2020 41

3.6 Rear Anti roll bar settings

Two different T shaped and one Double-T shaped anti roll bars are available:

Ø14mm solid, Not-Adjustable blade Ø17mm solid Ø25x2 mm

The digits reported represent the droplink positions: 1=full soft → 7=full hard

Two positions are available on the rocker side fixing in order to allow additional tuning options.

Here below the coordinates of the significant points used in the calculation for each configuration:

Anti-Roll bar configurations

P20 Coordinates P21 Coordinates

X [mm] Y [mm] Z [mm] X [mm] Y [mm] Z [mm]

ARB side position 1 365 93 443.108 - - -







Rocker side narrow position - - - 168.265 65.248 398.896

Rocker side wide position - - - 167.638 77.350 393.862


Rev. 2021 v1.2 of April 21, 2020 42

Below the corresponding motion ratio at an effective static rear ride height of 39.5 mm (measured

from ground to reference plane) and in the standard layout of the wishbones fixing to the gearbox

(A2-B2-C1-D2-E1-F1).

Anti-Roll bar Configurations

ARB Motion Ratio

Heave Motion Ratio

Rocker Side

ARB side

Wide position 1 1.302 1.065







Narrow position 1 1.662 1.361







Table below shows front anti-roll bar stiffness value at ground calculated using the anti-symmetric

model. Respect to the standard model used in the past for calculating the component stiffness, this

method gives more precise values but the value obtained using anti-symmetric model is the double

of the standard component stiffness.

Please consider that all the values are calculated not considering the stiffness of the

chassis and the compliance of the joints between mechanical elements.

Anti-roll bar

configuration


P1

P2

P3

P4

P5

P6

P7

Ø15mm solid, Wide 13,1 10,1 8 6,5 5,5 4,7 4,1

Ø15mm solid, Narrow 24,9 18,3 14,1 11,2 9,1 7,7 6,6

Ø17mm solid, Wide 38,8 27,8 21,2 16,9 13,9 11,8 10,2

Ø17mm solid, Narrow 69 48,4 36,3 28,5 23,2 19,4 16,5

Ø25x2mm, Wide 79,9 57,5 43,7 34,7 28,5 24 20,6

Ø25x2mm, Narrow 144 101 75,2 58,7 47,4 39,4 33,4


Rev. 2021 v1.2 of April 21, 2020 43

Here attached a diagram showing all the possible configurations for the rear anti-roll bar:

REAR ARB

Ø25x2mm, Narrow

Ø25x2mm, Wide

Ø17mm solid, Narrow

Ø17mm solid, Wide

Ø15mm solid, Narrow

Ø15mm solid, Wide

0 20 40 60 80 100 120 140 160

Ground Stiffness [kgf/mm]


Rev. 2021 v1.2 of April 21, 2020 44

4 Maintenance and assembly instructions

4.1 Front Uprights

4.1.1 Upright assembly

v) Place the upright under a press using the specific jig (F31220B003). Press in position the bearing using the specific pad (F31220B002).

w) Place the hub into jig F31220B008, place the upright on top of the hub driving its position by using the jigs F31222B005-006 as shown in the picture below. Move the hub in position by pressing on the jig F31220B005: this will introduce the hub into the upright through a guided movement.


Rev. 2021 v1.2 of April 21, 2020 45

x) Keeping the assembly in position using F31220B008+B007(x3) tighten the bearing nut at 800Nm using a socket wrench 65mm.

y) Secure the bearing nut in position mounting the locking plate with 3x M4 screw. The bolts must be mounted (after a proper degreasing with Acetone) with Loctite 638 (high temperature). The torque applied to each bolt should be 1Nm. Spring washer should be used.


Rev. 2021 v1.2 of April 21, 2020 46

4.1.1.1 Bearing removal

a) Remove the hub from the upright doing the opposite of the previous procedure. Doing this warm the upright up to 60-70°C and keep it warm while pressing or knocking off the hub from the upright. In case of knocking an aluminium jig is recommended. The outboard inner track of the bearing should remain on the hub.

b) Press off the inner track of the bearing from the hub the proper jig assembly (F31220B009+3xFCOM1465).


Rev. 2021 v1.2 of April 21, 2020 47

4.2 Rear Uprights

4.2.1 Upright assembly

z) Put the upright on a press and place one of the bearings into the upright using the specific jig (F31220C004) and spacer (F31220C002).

aa) Place the upright onto jig F31220C004 with the spacer F31220C002, against the bearing previously mounted. Insert the bearing preload spacer and using the jig F31220C003 with the spacer F31220C002 press the second bearing into the upright.


Rev. 2021 v1.2 of April 21, 2020 48

bb) Place the hub into jig F31220B008, place the upright on top of the hub driving its position by using the jigs F31222C005-006 as shown in the picture below. Move the hub in position by pressing on the jig F31220C005: this will introduce the hub into the upright through a guided movement.

cc) Keeping the assembly in position using F31220B008+B007(x3) tighten the bearing nut at 650Nm using the proper jig (F31220C008).


Rev. 2021 v1.2 of April 21, 2020 49

dd) Secure the bearing nut in position mounting the locking plate with 3x M4 screw. The bolts must be mounted (after a proper degreasing with Acetone) with Loctite 638 (high temperature). The torque applied to each bolt should be 1Nm. Spring washer should be used.

4.2.1.1 Bearing removal

a) Remove the hub from the upright doing the opposite of the previous procedure. Doing this warm the upright up to 60-70°C and keep it warm while pressing or knocking off the hub from the upright. In case of knocking an aluminium jig is recommended. The outboard inner track of the bearing should remain on the hub.

b) Press off the inner track of the bearing from the hub the proper jig assembly (F31220C009+3xFCOM1466).


Rev. 2021 v1.2 of April 21, 2020 50

4.2.1.2 Rear uprights bearing spacer

The uprights can be serviced by checking and adjusting the bearing spacers. In case an upright need to replace the bearing spacer, this must be dimensioned accordingly with the dimension in between the two bearing resting wall of the upright, measure “A” on the pics here below:

e) SPACER = “A” + 0,090 ± 0,010 [mm]

The replacement bearing spacers are delivered slightly oversized, in order to be grinded off up to the proper width


Rev. 2021 v1.2 of April 21, 2020 51

4.3 Wheel nut

4.4 Assembly and Maintenance

The nominal tightening torque prescribed for aluminum nuts is 50-55 Kgm.

In order not to compromise the functionality of the wheel assembly, please never exceed the

maximum allowed nut (both steel and aluminum ones) tightening torque (80kgm).

Please take care of the tightening torque applied through the pit stop air gun. Always double check

that the torque applied is corresponding to the desiderated value.

The axial load on the wheel assembly is the results of the torque applied on the nut.

The torque and the consequent axial load is strongly influenced by the status of the coupling surfaces

and in particular by the friction and the lubrication between the nut and rim surfaces. For this reason

only nuts and rims in good state should be used. Please always check after every session the status

of the nut and the rims. The coupling surfaces must be worn homogeneously especially in the area

of the bigger diameter of the cone. No deep imprinting or lines, dents or other lack of material are

permitted as they can jeopardize the torque force resulting in a dangerous wheel fixing. A good and

smooth contact between wheel and nuts shall be always present.

In case the optional wheel nut retainer is mounted the functionality of the locking pins which prevent

the wheel to be detached should be checked after every session. The locking pins should come out

freely when pushed and released.

The locking pins shouldn’t be worn, the original shape should be kept and the height with respect

to the hub surface should be checked after every session.

Nominal overhang is 3.3mm, a minimum of 2.5mm is permitted.


Rev. 2021 v1.2 of April 21, 2020 52

4.5 Anti-Roll bar backlash

Changing from an anti-roll bar to another or changing blade’s length at the front, it is possible to

experience a small amount of backlash of the ARB body due to mechanical tolerances.

In this case it is permitted to add washers between the spherical joint and the ARB body in order to

stop the sideway movements. It must be clear that shims have no other function than preventing

ARB backlash. Specific calibrated washers are available in the Dallara Spare Part List.


Rev. 2021 v1.2 of April 21, 2020 53

4.6 Rear Rocker

Radial tolerance: wear might occur on the rocker (hole) and on the rocker pivot (shaft). Periodically

replace bearings to remove play.

Axial tolerance: during regular maintenance you might find the rocker is axially too tight or too loose.

In order to tune the rocker assembly, follow the procedure below:

ee) Install the lower radial needle bearing

ff) Install the lower “case hardened” spacer

gg) Add grease

hh) Install the rocker

ii) Install the upper “case hardened” spacer

jj) Install the upper radial needle bearing

kk) Install the calibrated washer 0.90mm thick (39745029_M)

ll) Install the cap

mm) Tighten with the top nut

Measure how much force is needed to rotate the rocker from the damper pick-up point. If the force

is more than 0.05 kg, replace the calibrated shim with a thinner one.

Typically, to prevent the rocker from being too tight, the spacer should be close to 0.90 mm thick.

If the spacer is too thin, the rocker assembly has too much play, if the spacer is too thick the rocker

assembly is locked.

Calibrated shims from 0.77 to 1.00mm thick are available on the Dallara Spare Parts List

(39745029_A, 39745029_B, …, 39745029_Z, 39745029_AA, …, 39745029_AC).

In case the proper thickness value is outside the indicated tolerance, notify immediately to Dallara.

When found the proper thickness, perform a definitive installation with the prescribed tightening

torque and Loctite.

The rocker pivot is forced with interference into its housing.

During maintenance, do not swap the rockers left to right.


Rev. 2021 v1.2 of April 21, 2020 54

4.6.1 Replacement procedure:

This procedure helps when stripping down the rocker assy.

a) Unscrew the M10 nut on top and take the cap, washers, radial needle bearings and the rocker

off. Unscrew nut D by a tubular spanner.

b) Assemble the extractor tooling as shown below around the rocker pivot.

c) Take off the rocker pivot tightening the top screw of the tooling.

d) Remove stud B with the proper tool. As the stud has been tightened with Loctite warm it

with a heat gun up to 140°C. Be careful when trying to take the stud off from the gearbox

in order to not damage the casing.


Rev. 2021 v1.2 of April 21, 2020 55

4.7 Front wing adjustment

In order to overcome the consequence of tolerances in design and/or production, that could result

in a not perfectly straight or correct angle of the front wing main plane, it is allowed the use of

calibrated spacers between the front wing main plane and the front wing hangers, of a maximum

thickness of 0,6 mm.

In order to avoid the use of such spacers with the intent to lower the front wing, instead of merely

correcting its position, the spacers could be used in a maximum of 3 (three) of the 4 (four) fitting

points (studs).

Therefore, the allowance of none, one, two or three calibrated spacers, on maximum 3 of the fitting

studs, will always be sufficient to have a correct front wing main plane position and angle. The

thickness of any of these ‘adjusting’ spacers should be maximum 0.6 mm.

The four studs, fitting points:

4.7.1 Mainplane Gurney Optional Trimming

As shown in the attached drawing, it is authorized to trim the originally supplied front wing gurney

tabs (F32026077 RH & LH) within the specified area.


Rev. 2021 v1.2 of April 21, 2020 56

5 Steering

5.1 Longitudinal adjustment

The longitudinal position of the steering wheel is limited by FIA regulation with relation to the halo

position. According to the FIA F1-2018 Regulation the steering wheel must be positioned so as it

intersects the helmet free volume at all angular positions. For 320 this means that the steering wheel

must intersect a plane 690mm far from the back face of the chassis cockpit opening.

The steering line length could be adjusted only by shortening the highlighted part. Max shortening

allowed is 50mm from the brand-new component.

In case of shortening the steering column please attentively respect the dimension written below.

In particular distance between the steering line adjustable tube and the sphere of the steering line

support is important for guarantee the correct collapsible performance of the steering line.


Rev. 2021 v1.2 of April 21, 2020 57

5.2 Vertical adjustment

To adjust the steering wheel height is possible to add or remove shims (washers or bespoke spacers)

between steering column support and the chassis.

The STD position is 2.0mm distance, the height variation of the steering wheel for every 1mm shim

is 1.4mm

5.3 Kinematic backlash adjustment

The steering box has two devices in order to adjust the backlash between the pinion, idle gear and

the rack bar: the lower plunger cap and the pinion mounting eccentric bush.

In case of play between idle gear and rack, the backlash can be adjusted by setting the optimal

position of the lower plunger cap.

In case of play between pinion and idle gear, the preferable way for doing the adjustment is through

the pinion mounting eccentric bush. To do this operation the steering housing cap doesn’t need to

be removed, untighten the bush-locking top screw is enough to rotate the eccentric bush.

Once the backlash adjustment is done by rotating the eccentric bush tighten the bush-locking screw.


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5.4 Pinion backlash adjustment

In some case it is possible to experience a small amount of backlash of the pinion along its axis due

to mechanical tolerances.

In this case it is permitted to add calibrated shims between the bearing and the retaining ring in

order to stop any movement. It must be clear that shims have no other function than preventing

pinion backlash.

5.5 CV joint orientation

The following CV joint orientation is recommended in order to have a symmetrical behavior of the

steering system:


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5.6 Steering housing treatment

The 320 steering housing is in magnesium alloy. In order to increase its durability an anti-corrosion

superficial treatment has be done. This treatment gives a light grey color to the component.

It’s important to not scratch the external surface of the steering housing but in case this happens a

local paint is recommended to restore the surface protection.

5.7 Steering rack travel stop

The steering rack is provided with 2 rack travel stops, one each side.

Their standard thickness is 10mm.

In case a thinner stop is needed a minimum thickness of 3mm is strongly recommended.


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5.8 Steering rack potentiometer installation

Optional parts for installation of a linear potentiometer along the steering housing is available on the

Dallara Spare Parts List.


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5.9 Steering Line for KIT car

Teams are allowed to carry-over the column of the F312/317 steering line. In order to engage the

carried-over parts (c.o.p.) with the new cardan joint to install a reduction bush is needed to avoid

play between new and old parts.

In case of shortening the carried-over steering column please attentively respect the dimension

written below.

The longitudinal limit of the steering wheel position written in the longitudinal

adjustment chapter is mandatory also for the KIT steering line with carry-over parts. If c.o.p. doesn’t reach the minimum length they must be replaced.


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5.10 Electric Power Steering (EPS) Provided that NO modification is performed to any of the parts of the kit, and that the working parameters (torque management, etc) are those originally established by Dallara and Kayaba, the F32012DXXX Dallara kit is authorized.

5.11 Alternative Ackermann Arms On an individual basis, all those teams that, due to increase of steering wheel effort derived from the aero downforce improvement, could make a proposal to the Technical Commission of one set of alternative Ackermann arms. Once the alternative parts are authorized, no additional variation or modification will be accepted.


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6 Gearbox, Clutch & Differential. Kinematic Chain

6.1 Gearbox

Documentation concerning the gearbox Hewland F3B-200 can be found in the APPENDIX attached

to this document:

“320.003 - INSTRUCTIONS AND PARTS LIST FOR EUROFORMULA OPEN HEWLAND F3B GEARBOX.pdf”

6.1.1 Authorized ratios

Just the following gear ratios are authorized: It is authorized to polish the gear ratios (provided that the total mass of the parts keeps unaltered).

1st Gear 2nd Gears 3rd-6th Gears

1st 12/31 2nd 13/30 Standard 16/30

2nd 15/33 Standard 17/31




Standard 16/26

Standard 17/27

Standard 17/26

Standard 17/25

Standard 19/27

Standard 17/23

Standard 19/25

Standard 18/23

Standard 20/25

Standard 19/23

Standard 23/27

Standard 21/24

Standard 19/21

Standard 24/26

Standard 18/19

Standard 25/26

Standard 24/24

Standard 25/24

Standard 26/24


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6.2 Differential & C/W

• Differential casing: Both the FTR and FTRL are authorized.

• Differential cover: Just the FTRL is authorized.

• C/W & Pinion: Just the 12/34 one will be authorized (FTRL 221 12-34)

• Parts machining: Forbidden

• Diff. ramps: 30/60, 45/60, 45/80, 80/80, 45/45 and 60/80 (both senses)

• C/W & Pinion: It is not allowed to polish the C/W & Pinion

6.3 Clutch

Just the following clutches would be authorized:

• ZF Sachs, reference ZF/SA 88 3082 002 108 (EFO identified)

• AP Racing, reference CP 8665-BH13-SP (EFO identified)

• JUST for this 2020 season, that will be considered as a TRANSITORY PERIOD, teams will be allowed to

use their former clutches, once they have declared type, model, brand and reference.

• Each vehicle must select one of the clutches from the beginning of the season, and the selected

component could not be changed during the season.

Clutch hydraulic lines are free.

7 Oil System

Engine oil tank is positioned in the gearbox casing, in front of the differential housing.

Typical level of engine oil while the engine is running could be measured as shown in the drawing:

measuring 130mm from the top cap hole means that the tank contains 5.0 liters.

Engine oil level should always be according to the instructions of the engine supplier.

8 Leg Padding

In order to minimize the risk of legs injury during an accident, padding has to be fitted in the driver’s

legs area inside the chassis.


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According to the FIA F1 2018 regulations the leg padding must cover up to 100mm behind the face

of the rearmost pedal when in the inoperative position.

Leg padding is provided at maximum length to all cars but teams could shorten it when adjusting

the pedals position.

Dallara suggest to keep the most forward fixing point on both clutch and throttle sides up to pedal

position -75mm (in the picture below the -50mm position as example). When using pedal position

from -100mm to -175mm the leg padding foremost fixing should not be needed anymore and could

be cut.

If, after having already cut the padding, pedals have to be moved in forward direction

the padding doesn’t reach the minimum length and it must be replaced.


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9 Heat Shields

In order to protect bodywork and chassis from heat related issue, parts are delivered with heat

protection layers as shown in the picture below.

Chassis is protected on the rear surface facing the engine and on its sides where facing the exhaust.

Sidepods, engine cover and underwing are also protected where they could be close to the exhaust.

All the heat shields are symmetrical respect to the car centerline as different engines could have the

exhaust on opposite sides.

In case of need teams could improve the heat protection.

In some case, especially when exhaust exit is flushed with the sidepods surface, additional heat

protection could be necessary on the external surface of the bodywork in order to shield the area

directly blown by the exhaust gasses.

I3n case of damaging of the heat protection layers teams must fix it or replace it.


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10 Battery

Documentation concerning the battery can be found in the APPENDIX attached to this document:

“320.002 - OWNER’S MANUAL SUPER B LITHIUM IRON PHOSPHATE STARTER BATTERIES.pdf”

In order to not over-load the alternator battery must be charged before use.

11 Fuel System

Documentation concerning the bladder can be found in the APPENDIX attached to this document:

“320.001 - USE AND MAINTENANCE MANUAL FOR M.E.RIN FLEXIBLE TANKS.pdf”

Fuel Cell contains a maximum of approximately 46 liters (including the collector filled). The fuel

system for the 320 uses a flexible FT5/99 specification bladder.

The bladder is installed through an access hole in the rear face of the chassis. Before installing the

bladder, make sure that the cavity in the monocoque is clean and free of sharp edges. It is

recommended to add thin adhesive foam on the faces of the fuel cell cavity.

In order to avoid un-desired severe working condition a new vent valve has been provided by Dallara

and must replace the old one-way valve on the F312 carry over fuel systems.

Notice that the vent flange must be mounted in the correct way. The right orientation is laser-etched

on the body of the valve itself and is shown in the picture below.

Please consider that despite this updated vent valve, temperature and pressure conditions

inside the fuel bladder could be severe. In particular working conditions, due to the polymeric

nature of the safety fuel cell bladders, fuel permeation, or diffusion may occur.


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Moreover, some small blister could appear temporary on the external surface of the bladder:

don’t prick it or it will damage the external coating of the fuel cell.

Do not leave fuel in the bladder for long time, dry the fuel out at the end of every event/session.


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12 Pedals

Pedals are mounted on a support which can be placed in 8 different positions. The foremost position

is the standard one, and can be adjusted all the way from 0 to 175mm rearward by steps of 25mm.

Each position needs a proper pushrods for brake and clutch pump. Moreover throttle and clutch

pedal-stop for rearmost positions (from -125mm to -175mm) could need to be replaced with the

optional version. Pushrods and pedal-stops are available in the Dallara Spare Parts List.

Here below some example of different configuration suggested.

Optimal configuration is subjected to many factors as type of throttle cable end, stroke

required by the engine and pedal angle desired by the driver. The positions below are the

suggested ones but every case must be evaluated in detail. Whenever pedals position is

changed, teams must check for any clash and that nothing interferes with the cable sliding.

Foremost Position [STD-0]:

-25mm Position:

-50mm Position:


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-75mm Position:

-100mm Position:

-125mm Position: depending on the type of throttle cable used and on desired ratio of the

throttle pedal both options below could be adopted


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-150mm Position:

-175mm Position:

In case throttle ratio needs to be tuned specific optional brackets are available:

32035068: suggested for pedals position up to -125mm;

32035067: suggested for pedals position from -125mm to -175mm;

In the picture below dimension for calculating the throttle ratio available.

If 32035067 is used so the optional throttle pedal stop (32035038RH) must be mounted in

order to avoid clashes between throttle pedal and the body of the pedal stop.


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In some case the edge welded on the pedal could clash into the brackets above. In order

to avoid any clashes to use washers as spacer between the pedal and the bracket is allowed as shown in the picture below.

2.2 Pedals for KIT car

Almost the entirely pedals assembly of the Dallara 320 is in common with F312/317. Teams who

buy the 320-KIT instead of the new car are allowed to carry-over also the brake balance assembly.

In this case due to the higher distance from the front monocoque’s bulkhead to the pedal assembly,

brake pump pushrods are needed. When the pedals assembly is in the foremost position two

pushrods 32035054 are needed.


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2.3 Brake Balance Adjuster

Pedal assembly are equipped with a brake balance adjuster which allow to tune the ratio between

front and rear axle braking performance.

In order to guarantee the best performance of this system, particular attention must be paid on the

routing of the oil lines: try to keep the pipes as aligned as possible to the axis of the respectively

pump in order to not introduce un-desired forces which could affect the brake balance.

This system is designed to allow a regulation of about ±10% of balance from the centered position;

in case this is not enough it is allowed to use pump with different diameters on front and rear brake

lines. Four different interchangeable pumps are available on the Dallara Spare Part List and their

combination allow to tune the centered position value of balance from 50% to 61.7%. The table

below shows the centered position value of the front brake balance in the different configurations:

Front brake pump diameter Rear brake pump diameter Front brake balance in the

centered position

17.49 mm 16.0 mm 45.6%

17.49 mm 17.49 mm 50.0%

17.49 mm 19.00 mm 54.1%

17.49 mm 20.64 mm 58.2%

17.49 mm 22.22 mm 61.7%

13 Dampers

Documentation concerning the KONI dampers can be found in the APPENDIX attached to this

document:

“320.004 - CALIBRATION CURVE FOR KONI 320 DAMPERS.pdf”


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14 Halo device

The secondary roll structure (i.e. the Halo) must be secured on the chassis with Dallara homologated

fasteners only (including nuts); the use of any other type of fasteners is forbidden.

The halo fasteners should be mounted with the reported tightening torque:

Fastener number Tightening torque

1 -

2 52 Nm

3 52 Nm

4 65 Nm

5 28 Nm

6 28 Nm

Always use copper grease when mounting the halo fasteners. The front Halo bolts must be installed

with the washers and nuts provided by Dallara as shown below.

Additional notes:

It is not permitted to grind or modify the Halo structure to improve its aspect

Painting the Halo is permitted, although the label with the homologation number must not

covered


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2.4 Ballast

In case it it necessary to install ballast to reach the minimum weight, the ONLY authorized locations will

be: Keel (preferred), Cockpit Tray and Bellhousing (with the stated maximum quantities).

When installing the ballast on the keel, the attached layout must be followed.

The ballast can be made either from a block, or from horizontal “slices” of material corresponding

to the following criteria:

The “slices” or block can be made from lead or steel, being strictly forbidden other exotic materials like tungsten, etc.

Each “slice” must be made from a continuous single piece of material

Each “slice” must be fitted to the monocoque by the prescribed fixing points

Teams are allowed to make their own ballast provided that the ballast is maintained in place

with all the fixings designed for this purpose

Bellhousing

Max. Quant.5 Kg

Cockpit TrayMax.

Quant.3 Kg

Keel Max.

Quant.8 Kg


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33

15 Wheel Tethers Routing and covers

Dallara suggests the following routing for the wheel tethers. Make sure that the tethers cables do

not touch the wheel rim. Before run teams must check for any clash during the wheel movement

and that the cable doesn’t interfere with anything which could damage it and reduce its resistance.

Front wheel

Rear wheel

The use of all eight cables is mandatory. When required from design, the wheel restraint cables

MUST always be assembled with the bobbins on the end loops.

The wheel tether cable should be replaced in case the cable has been damaged, i.e. the braid,

tape or mold have been damaged exposing the fibre, the cable or cover has been cut, the cable

has been over-tensioned (cables are not designed to be exposed to any load prior to an accident)


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The front wheel wishbone covers should be mounted with the following orientation:

15.1 Wheel Tethers Protection

Following FIA policy, it is reminded that once any fiber of the wheel tether has been damaged, its

replacement with a new part is mandatory. In order to avoid these situations, while keeping the

safety standards, it is allowed to protect, with transparent sleeve, the wheel retention cables.

Anyhow, the homologation label should be readable at any time.


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16 Side Cones replacement

Damaging of a side cone is a rare event, which normally can happen in case of a really severe crash.

In this case the cone should be replaced. The following steps should be followed:

1. Cut the remaining part of the cone at the base, as much close as possible to the monocoque

surface

2. Remove the remaining cone carbon material inside the monocoque pocket by using a rotary

tool. The monocoque is protected by an aluminum cup, the carbon material can be removed

until reaching the aluminum. This operation is quite long and it require good tools with proper

rotating speed.

It is possible also to heat the material to soften the glue (maximum allowed temperature is

110°C) and remove the cone by a cutting tool, but this operation has been more difficult

than proceeding like described above according to Dallara experience and tryouts.


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3. Be sure to remove all the carbon material especially in the edge between the side and the

bottom of the cone cup.

4. Check the fitting of the cone without glue. Be sure that the cone is touching on the bottom

of the cone cup. Check the alignment by measuring the distance from the cone to the floor

of the monocoque.

5. Prepare both the surfaces (cone and aluminum cup) for bonding (grind the surfaces to make

them rough, clean with acetone)


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6. Bond the cone with epoxy glue 3M 9323.

7. Make the glue became harder at room temperature for 24h. If time is not enough the surfaces

can be heated by using a gun heater at roughly 80°C, in this case the harden process will

last 1h.

The repairing process has been simulated by Dallara, and during these tryouts the timing needed to

replace the side cone is about one hour of man work, plus the time to cure the glue.


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17 Other important aspects

17.1 Suspension

• Suspension third elements (both front and rear), are strictly forbidden.

• It is allowed to use conventional bump-stops on shock absorbers’ axle.

17.2 Mirror

• Provided that the modification is only made with the purpose of improving the view from

the drivers position when looking rearwards, it is authorized to extend the mirror support,

vertically upwards, of one side of the vehicle, up to a maximum of 100 mm.

17.3 Brakes

• Neither front nor rear brake ducts are authorized.

• Just Brembo (Refs. 09A26111 / 09A26121 or FCOM1151 / FCOM1152) and TM (Refs.

FRNDSC4339 / FRNDSC4340) brake discs are authorized.

• Just the Brembo originally supplied calipers are authorized (HRB option included).

• Just the two following PAGID brake pads are authorized: Pagid EFO [Ref. S7163EFO060], and

Pagid EFC [Ref. S7163EFC060]. GT Sport could decide to supply both types pre-bedded or

not-bedded, so both of them are authorized.

• (same references and compounds as last season, this is Ref. S7163EFO060) are authorized.

• Master cylinders: The brand is free, but all the diameters must be among the followings: 17,46

mm, 19 mm, 20,64 mm or 22,22 mm.

• Brake lines: Free. Quick couplings are also authorized.

17.4 Data acquisition

NOTE: The Technical Commission, together with the Organizing Committee, would analyze

any other proposal for this subject (modification of the authorized sensors, etc.).

17.5 Engine

For all that concerns to the engine and its ancillaries, the teams are free to choose the supplier that

they want for each vehicle. In any case, all the engine related components (including exhaust line,

engine electronics, alternator, etc.), must agree with the following specifications:

• Engine homologation. In order to ease as much as possible, the entertainment works, and to

keep costs as low as possible, the Technical Commission is working with the engine suppliers

(Spies and HWA) in some slight modifications, that would be included into the final form before

• It is allowed to complete the originally equipped data acquisition system with other sensors. The

manufacturer of those sensors that are not included into the engine homologation form (for example

suspension potentiometers, brake line pressure, etc.) is free.

• It is additionally allowed to install a pitot tube

• If any other sensors are used by the teams for private practice sessions (strain gauges,

thermocouples, ride height sensors, radars, etc), all of them should be disassembled from the cars

for the official events (from Friday’s FP1 until Sunday’s second race). It would just be allowed to

leave the extra wiring loom (the one that is needed to operate those sensors) into the vehicle, but

not the sensors.


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the start of the season. Some interesting aspects are the internal ballast decrease in both

engines, exhaust line optimization, life increase in some parts, etc.

• “Scrutineering box”: In addition to the homologation form, an “scrutineering box” will be sealed

for each type of available engines, including some drawings and some physical parts that would

be treated as “reference” or “homologated” parts, in case of any engine scrutineering work is

performed.

• “Exhaust line”: The engine builders have not finished the final definition, but once defined, it

would be frozen and included into the engine homologation form. It has also been agreed with

Spiess and HWA to converge, if possible, to a common spec silencer for both engines.

• Thermal protection: Thermal coating in contact with the exhaust pipes is allowed, provided that

they must be detachable. Thermal protective shields / barriers can be installed, in such a way

that they are of the same layout for each type of engine.

• ECU calibration: Free, but must be delivered to the Technical Delegate.

• Engine mileage: All the vehicles have the right to perform JUST one rebuilt of the engine (same

engine number) during the season. In case of catastrophic failure, instead of rebuilding the

engine, a complete substitution of the engine could be authorized. In case of any other

situation of “force majeure”, the Technical Delegate, with the Organizing Committee, will

decide with the Stewards how to proceed. For all the private tests, and / or collective ones,

apart from the runs of the 9 events of the season, the maximum allowed running time of the

engine for each car will be 14 hours (over 3000 rpm)

• Engine oil: Free, but must be accepted by the engine builder.

• Engine oil pipes: Just the Dallara standard ones are accepted.

17.6 Kinematic Chain

• In order to ease all the maintenance works and improve the reliability of the tripod joints

of the driveshafts, a separator like the attached one is authorized, provided that it has no

other function than separating, it is made of light plastic / Teflon material, and it is

previously approved by the Technical Commission.

17.7 Cooling

Provided that the only objective is to cool down some electro-mechanical important

components (alternator, shifting pneumatic box, etc), it is authorized to install a cooling duct

similar to the one that is described in the attached pictures. In any case, the final layout must

be previously approved by the Technical Delegate and, once fixed, it cannot be modified during

the season.


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18 Annexes

• Calibration Curve for Koni dampers

• Sachs Clutch Engineering Drawings

• AP Clutch Engineering Drawing

• Merin Fuel Tanks Use and Maintenance Information

• Super B Battery Use and Maintenance Information

• F3B Manual & Parts Information for EUROFORMULA

DALLARA F - 320...DALLARA is not responsible for any modification or alteration or incorrect repairs...

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Transcript of DALLARA F - 320...DALLARA is not responsible for any modification or alteration or incorrect repairs...