GTSports DALLARA F - 320 Owner's Manual
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GTSports DALLARA F - 320 Owner's Manual

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DALLARA
F - 320
Owner's MANUAL
2022
 
 

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  • Page 1                                                             DALLARA F - 320 Owner’s MANUAL 2022        ...
  • Page 2   320 Owner’s Manual                                                                          ...

  • Page 3: Table Of Contents

      320 Owner’s Manual   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 ...
  • Page 4   320 Owner’s Manual 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 ...
  • Page 5   320 Owner’s Manual 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  12.1  Pedals for KIT car ......................68  12.2  Brake Balance Adjuster ..................... 69  12.3  Pedals’ adjustments ......................69  13 ...

  • Page 6: Preface

      320 Owner’s Manual 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.

  • Page 7: Issues

      320 Owner’s Manual   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 19.04.2022 (Rev. v_220419: Revised items: 2 / 6.3 / 12.3 / 17.3 / 17.4 / 17.8 / 17.9 / 17.10  ...

  • Page 8: Contacts

      320 Owner’s Manual   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.

  • Page 9: General Agreements And Warranty

      320 Owner’s Manual   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.

  • Page 10: Chasis & Safety

      320 Owner’s Manual   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...

  • Page 11: Reference Plane

      320 Owner’s Manual   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. Rev.

  • Page 12: Track Equipment

      320 Owner’s Manual   1.4 Track Equipment   Here below dimension which could be useful for 320 trackside equipment. Rev. 2022 v_220419  ...

  • Page 13: Safety Overview And Equipment

      320 Owner’s Manual     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.  ...

  • Page 14: Protection Secondary Panel

      320 Owner’s Manual   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.

  • Page 15: Sacrificial Keel

      320 Owner’s Manual   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...

  • Page 16: Extractable Seat

      320 Owner’s Manual   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.

  • Page 17: Seat Belt

      320 Owner’s Manual   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.  ...

  • Page 18: Components Mileage

      320 Owner’s Manual   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  ...
  • Page 19   320 Owner’s Manual     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, …).

  • Page 20: Bodywork

      320 Owner’s Manual 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 ...

  • Page 21: Halo Painting

      320 Owner’s Manual         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 used.

  • Page 22: Setup

      320 Owner’s Manual   33  3 Setup     3.1 Setup adjustment   Positive change in: Means: Ride Height car moves up toe-out Camber upper part of rim outward Castor lower part of rim points ahead     Unit Front Rear Pushrod Adjuster...

  • Page 23: Lower Wishbone Design Configuration Set-Up

      320 Owner’s Manual   3.1.1 Lower wishbone design configuration set-up   Front Lower Wishbone:                                                    ...

  • Page 24: Ride Height And Pushrods Adjustment

      320 Owner’s Manual   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:    ...

  • Page 25: Toe

      320 Owner’s Manual   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                    ...

  • Page 26: Camber

      320 Owner’s Manual   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  ...

  • Page 27: Caster Front

      320 Owner’s Manual   3.1.5 Caster front                                                                  ...

  • Page 28: Caster Rear

      320 Owner’s Manual   3.1.6 Caster Rear                                                                  ...

  • Page 29: Suspension Coordinates

      320 Owner’s Manual   3.2 Suspension coordinates   3.2.1 Front (STD configuration)                                                        ...

  • Page 30: Rear (Std Configuration)

      320 Owner’s Manual   3.2.2 Rear (STD configuration)                                                                ...

  • Page 31: Front Geometry Adjustment Ump Options

      320 Owner’s Manual   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:  ...
  • Page 32   320 Owner’s Manual   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-0 (std) Rack Side St.

  • Page 33: Roll Centre Height

      320 Owner’s Manual   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.

  • Page 34: Rear Geometry Adjustment

      320 Owner’s Manual   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)            ...
  • Page 35   320 Owner’s Manual   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.

  • Page 36: Front Torsion Bar Settings

      320 Owner’s Manual   3.5 Front torsion bar settings   Ten different front torsion bars are available.                                              ...

  • Page 37: Front Torsion Bar Pre-Load

      320 Owner’s Manual   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.

  • Page 38: Front Anti Roll Bar Settings

      320 Owner’s Manual   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                        ...
  • Page 39   320 Owner’s Manual   u) T-shaped                                   Here below the coordinates of the significant points used in the calculation for each configuration:    ...
  • Page 40   320 Owner’s Manual   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  ...
  • Page 41   320 Owner’s Manual   Here attached a diagram showing all the possible configurations for the front anti-roll bar:     FRONT ARB                                             ...

  • Page 42: Rear Anti Roll Bar Settings

      320 Owner’s Manual   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 ...
  • Page 43   320 Owner’s Manual   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...
  • Page 44   320 Owner’s Manual   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   ...

  • Page 45: Maintenance And Assembly Instructions

      320 Owner’s Manual   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).  ...
  • Page 46   320 Owner’s Manual     x) Keeping the assembly in position using F31220B008+B007(x3) tighten the bearing nut at 800Nm using a socket wrench 65mm.                                ...
  • Page 47   320 Owner’s Manual   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.

  • Page 48: Rear Uprights

      320 Owner’s Manual   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).        ...
  • Page 49   320 Owner’s Manual   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.
  • Page 50   320 Owner’s Manual   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.  ...
  • Page 51   320 Owner’s Manual   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”...

  • Page 52: Wheel Nut

      320 Owner’s Manual   4.3 Wheel nut   4.4 Assembly and Maintenance                               The nominal tightening torque prescribed for aluminum nuts is 50-55 Kgm.    ...

  • Page 53: Anti-Roll Bar Backlash

      320 Owner’s Manual                                             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.

  • Page 54: Rear Rocker

      320 Owner’s Manual   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”...

  • Page 55: Replacement Procedure

      320 Owner’s Manual   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.  ...

  • Page 56: Front Wing Adjustment

      320 Owner’s Manual 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.

  • Page 57: Steering

      320 Owner’s Manual   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.

  • Page 58: Vertical Adjustment

      320 Owner’s Manual   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  ...

  • Page 59: Pinion Backlash Adjustment

      320 Owner’s Manual   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.

  • Page 60: Steering Housing Treatment

      320 Owner’s Manual   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.

  • Page 61: Steering Rack Potentiometer Installation

      320 Owner’s Manual   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. Rev. 2022 v_220419  ...

  • Page 62: Steering Line For Kit Car

      320 Owner’s Manual   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.

  • Page 63: Electric Power Steering (Eps)

      320 Owner’s Manual   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.           Rev. 2022 v_220419  ...

  • Page 64: Gearbox, Clutch & Differential. Kinematic Chain

      320 Owner’s Manual   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: 1st Gear 2nd Gears 3rd‐6th Gears...

  • Page 65: Differential & C/W

      320 Owner’s Manual   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) ...
  • Page 66   320 Owner’s Manual                                                     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.

  • Page 67: Heat Shields

      320 Owner’s Manual   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.

  • Page 68: 320.002 - Owner's Manual Super B Lithium Iron Phosphate Starter Batteries.pdf

      320 Owner’s Manual   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.  ...
  • Page 69   320 Owner’s Manual 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.
  • Page 70   320 Owner’s Manual   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 pushrod for brake and clutch pump.
  • Page 71   320 Owner’s Manual   -75mm Position:                                    -100mm Position:                           ...
  • Page 72   320 Owner’s Manual   -150mm Position:                                    -175mm Position:                           ...

  • Page 73: Pedals For Kit Car

      320 Owner’s Manual     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.  ...

  • Page 74: Brake Balance Adjuster

      320 Owner’s Manual   12.2 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.

  • Page 75: 14  Halo Device

      320 Owner’s Manual   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.    ...

  • Page 76: 15  Wheel Tethers Routing And Covers

      320 Owner’s Manual   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.

  • Page 77: Wheel Tethers Protection

      320 Owner’s Manual   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.

  • Page 78: 16  Side Cones Replacement

      320 Owner’s Manual   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:  ...
  • Page 79   320 Owner’s Manual   3. Be sure to remove all the carbon material especially in the edge between the side and the bottom of the cone cup.                          ...
  • Page 80   320 Owner’s Manual     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.

  • Page 81: 17  Other Important Aspects

      320 Owner’s Manual 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.

  • Page 82: Kinematic Chain

      320 Owner’s Manual 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 the start of the season.

  • Page 83: Ballast

      320 Owner’s Manual 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. 17.8 Ballast  ...

  • Page 84: Skid Pad

      320 Owner’s Manual The ballast that is included into the engine homologation form can also be used to adjust the total weight of the car, so it could be installed or not. In this case:  It should always be under the conditions and procedures established by the engine builder and included in the homologation form.
  • Page 85   320 Owner’s Manual 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  Rev_ 220419  ...

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