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Tatuus T318 Technical Manual

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T318 TECHNICAL MANUAL
Release 3.00 (22/06/2020)

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Summary of Contents for Tatuus T318

  • Page 1 T318 TECHNICAL MANUAL Release 3.00 (22/06/2020)

  • Page 2: Table Of Contents

    General Information ..........................7 Releases ............................. 7 1.1.1 Release list ..........................7 Technical Contacts ..........................8 1.2.1 Chassis ............................8 1.2.2 Engine ............................8 1.2.3 Gearbox ............................. 9 1.2.4 Electronic ........................... 9 1.2.5 Tires ............................9 1.2.6 Brakes ............................10 1.2.7 Dampers...........................
  • Page 3 2.14.1 Rain Light modes ........................40 2.15 Clutch Disengagement ........................41 2.16 FIA Throttle Fail Safe ........................41 Chassis ..............................42 Workshop Tools ..........................42 3.1.1 Front Jacking ..........................42 3.1.2 Rear Jacking ..........................43 Setup Tools ............................44 3.2.1 Front references ........................
  • Page 4 Wing Sensitivity ..........................76 4.6.1 Wing Sensitivity, both the front flaps on, without gurney flap installed ........ 77 4.6.2 Wing Sensitivity, both the front flaps on, with gurney flap (190mmx15mm) installed ..79 4.6.3 Wing Sensitivity, only lower front flaps on, without gurney flap installed ......
  • Page 5 Tires ............................... 110 7.2.1 Giti Tires ..........................110 7.2.2 Pirelli ............................111 7.2.2.1 Static measurements ......................111 7.2.2.2 Dynamic measurements ....................112 7.2.2.3 Operating instructions ....................... 112 7.2.2.4 Technical Limitations – F3 Regional................... 113 7.2.2.5 Static measurements ......................113 7.2.2.6 Dynamic measurements 230/570-13x10.0J SLICK @ 1.4bar (20.5psi), CA 0.0°...
  • Page 6 11.1 Alfa Romeo Oil tank ........................144 11.2 Renault Oil tank ..........................145 11.3 Toyota Oil tank ..........................146 Electric system ........................... 147 12.1 Overview ............................147 12.2 Main switch ........................... 148 12.3 Battery and Alternator ........................149 12.3.1 Battery installation ........................ 149 12.3.2 Jump battery ..........................
  • Page 7 14.9.3 Refitting the differential elements ..................167 14.10 Crown-wheel replacement ......................168 14.10.1 Secondary shaft ......................... 168 14.10.2 Crown..........................174 14.11 Exploded views .......................... 178 14.11.1 Layshaft ..........................178 14.11.2 Mainshaft ........................... 179 14.11.3 Barrel and forks ......................... 180 14.11.4 Differential .........................

  • Page 8: General Information

    ENERAL NFORMATION 1.1 R ELEASES Modifications from previous release are in purple. 1.1.1 Release list Version Release Date Author Notes 0.02 20/06/2018 Tatuus Startup version 1.00 03/07/2018 Tatuus First release 1.01 04/07/2018 Tatuus Minor updates 1.10 10/10/2018 Tatuus Gearbox maintenance 1.20...

  • Page 9: Technical Contacts

    1.2 T ECHNICAL ONTACTS 1.2.1 Chassis Tatuus Racing SpA Via G. Verga, 12 20863 Concorezzo (MB) - Italy Tel: +39 039 6040828 Fax: +39 039 6041764 Web: www.tatuus.it 1.2.2 Engine ORECA AUTOTECNICA Technopole du Circuit Via A. Bernardi, 3 58470 Magny-Cours...

  • Page 10: Gearbox

    1.2.3 Gearbox SADEV 6 rue Grand’Montains 85110 Saint Prouant Tel: +33 2 51 66 42 68 Fax: +332 51 66 49 60 @ : sadev@sadev-tm.com Web: www.sadev-tm.com 1.2.4 Electronic 1.2.5 Tires Release 3.00 (22/06/2020) Page 9...

  • Page 11: Brakes

    1.2.6 Brakes 1.2.7 Dampers 1.2.8 Seat belts – Fire Extinguisher Release 3.00 (22/06/2020) Page 10...

  • Page 12: General Agreement And Warranty

    Tatuus in connection with the performance or purported performance of or failure to perform the contract other than as set out in this Condition. In no circumstances shall Tatuus be liable for any claims for indirect or consequential injury or damage (including loss of profits) arising from any such matters.’...

  • Page 13: Overview

    NGINE Toyota Aros XHAUST Magneti Marelli / Next Solution / Motec LECTRONICS SADEV SLR82 EARBOX Magneti Marelli ESA EARSHIFT Tatuus / Next Solution TEERING WHEEL DEKA ATTERY PREMIER FT5 UEL CELL Sabelt EAT BELTS XTINGUISHER Release 3.00 (22/06/2020) Page 12...

  • Page 14: General Information

    1.5 G ENERAL INFORMATION Release 3.00 (22/06/2020) Page 13...
  • Page 15 Release 3.00 (22/06/2020) Page 14...

  • Page 16: Mileage Chart

    NOTES: The table below is provided for guidance on the expected life of key components based on Tatuus’ experience of this product in similar applications, however no warranty is implied by figures stated above and mileage targets are no substitute for testing and regular inspection of the chassis.
  • Page 17 Inspection [km] Limit [km] Steering column 5’000 10’000 Steering rack 5’000 10’000 Rack/pinion 5’000 10’000 Ball joint 1’250 5’000 Rear suspension Upright 5’000 10’000 Wheel bearing 5’000 10’000 Outer hub 10’000 20’000 Inner hub 5’000 10’000 Hub bolts 2’500 5’000 Wheel spindle 5’000 10’000...
  • Page 18 Inspection [km] Limit [km] Radiators 5’000 10’000 Water tank cap 2’500 5’000 Pipelines 10’000 20’000 Exhaust Tail pipe 3’000 6’000 Catalytic 2’500 5’000 Electrical system Battery 5’000 10’000 Switch panel 5’000 10’000 Master switch 5’000 10’000 Marshall switches 5’000 10’000 Chassis loom 10’000 20’000...

  • Page 19: Safety

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

  • Page 20: Extractable Seat

    2.2 E XTRACTABLE The seat must be removable without the need to cut any of the seat belts or remove the harness buckle. The shoulder and lap belts must fall away over the seat edges as it is withdrawn and the crotch straps must pass freely through the seat bottom hole or holes, which must be located in front of the driver's crotch.

  • Page 21: Driver Padding

    2.3 D RIVER ADDING As per FIA regulation: Rear area of headrest padding [14.6.2] If necessary, and only for driver comfort, an additional piece of padding no greater than 10mm thick may be attached to this headrest provided it is made from the same material. Side areas of headrest padding [14.6.3] If necessary, and only for driver comfort, an additional piece of padding no greater than 20mm thick may be attached to this headrest provided it is made from the same material...

  • Page 22: Front Impact Structure

    FIA, great attention must be paid in checking for structural failure not later than two years after delivery from Tatuus factory, and after each major accident. The structure must be checked and repaired by a center authorized by Tatuus.

  • Page 23: Front Nose Repair Specification And Procedure

    2.5.2 Front nose repair specification and procedure 2.5.2.1 Applicable requirements The following procedure is applicable only when the damage is contained in the first 100mm from the nose tip (715mm from the chassis bulkhead), all the other damages must be inspected by the manufacturer. 2.5.2.2 Replacement procedure Spare nose tip is available as spare part, the reference code is 2401032...
  • Page 24 1. Trace a line parallel to the chassis bulkhead 700 mm from the bulkhead, you should find the line 15 mm from the old nose tip junction. 2. Cut off the nose tip forward the traced line. 3. Using sandpaper on the outer surface, reduce the thickness of the crashbox by about 1mm for a length of 15-25 mm (red area).

  • Page 25: Rear Impact Structure

    FIA, great attention must be paid in checking for structural failure not later than two years after delivery from Tatuus factory, and after each major accident. The structure must be checked and repaired by a center authorized by Tatuus.

  • Page 26: Halo

    2.8 H 2.8.1 Installation procedure General notes: grey arrow: unscrew/screw but not tighten green arrow: screw and tighten When installing the HALO apply on the bolts some water and oxidation resistant grease. As example the PETRONAS TUTELA Z2 grease is suitable for this purpose. 1.
  • Page 27 Release 3.00 (22/06/2020) Page 26...
  • Page 28 3. Fasten the HALO front fixing screw (24-01-017) and pin (24-01-016). Do not apply any tightening torque. 24-01-016 24-01-017 4. Please note that the HALO front fixing screw (24-01-017) shall be on the left side and the HALO front fixing pin (24-01-016) shall be on the right side. 5.
  • Page 29 6. Place the assembly obtained at point 3 on the chassis. 7. Fasten the two shoulder bolts (24-01-033). Do not apply any tightening torque. Screw the bolts until the screw’s underhead gets in contact with the plane of the counterbore on the HALO foot. At this point do not apply any tightening torque but loose the bolt one turn (counterclockwise) Release 3.00 (22/06/2020) Page 28...
  • Page 30 8. Fasten the two M12X55 bolts. Do not apply any tightening torque. Screw the bolts until the screw’s underhead gets in contact with the plane of the counterbore on the HALO foot. At this point do not apply any tightening torque but loose the bolt one turn (counterclockwise) 9.
  • Page 31 10. Fasten the four MS21250-08-08 bolts. Do not apply any tightening torque. Screw the bolts until the screw’s underhead gets in contact with the plane of the counterbore on the front bracket. At this point do not apply any tightening torque but loose the bolt one turn (counterclockwise) 11.
  • Page 32 12. Tighten the two M12X55 bolts. Do not tighten to target value one bolt first and then the other. Apply the tightening torque gradually, keeping the balance on the two bolts. Target value is 51Nm 13. Tighten the two M12X30 bolts. Do not tighten to target value one bolt first and then the other. Apply the tightening torque gradually, keeping the balance on the two bolts.
  • Page 33 14. Tighten the four MS21250-08-08 bolts. Do not tighten to target value one bolt first and then the other. Apply the tightening torque gradually, keeping the balance on the four bolts. Target value is 51Nm 15. Double check the tightening torque on each bolt starting from the two shoulder bolts, then on the M12 bolts and finally on the MS21250-08-08 16.
  • Page 34 17. Position the front fairing (24-01-043), and fix it with two button head bolts (UNI7380-TX-M5X10) Release 3.00 (22/06/2020) Page 33...

  • Page 35: Disassembly Procedure

    2.8.2 Disassembly procedure 1. Lift the front fairing 2. Unscrew and remove the four MS21250-08-08 bolts. Do not unscrew one bolt first and then the other. Loose the bolts gradually, keeping the balance on the four bolts Release 3.00 (22/06/2020) Page 34...
  • Page 36 3. Unscrew and remove the M12X30 bolts. Do not unscrew one bolt first and then the other. Loose the bolts gradually, keeping the balance on the two bolts 4. Unscrew and remove the M12X55 bolts. Do not unscrew one bolt first and then the other. Loose the bolts gradually, keeping the balance on the two bolts Release 3.00 (22/06/2020) Page 35...
  • Page 37 5. Unscrew and remove the two shoulder bolts (24-01-033). Do not unscrew one bolt first and then the other. Loose the bolts gradually, keeping the balance on the two bolts Release 3.00 (22/06/2020) Page 36...

  • Page 38: Steering Column

    2.9 S TEERING OLUMN The steering column has an integrated collapsible section ① to absorb impact energy. Extreme attention must be paid on this part to avoid any damage or overload. IMPORTANT: in case of impact the aluminum crashbox must be replaced and column carefully inspected. 2.10 W HEEL ETHERS...

  • Page 39: Fire Extinguisher

    2.12 F XTINGUISHER Before every race, replace the battery in the electrical control. If the battery is dead, the system will not activate. Before every race, make sure that the needle on the bottle gauge is in the green zone. When the bottle gauge needle is outside the green zone, the extinguishing system is drained and must be charged.
  • Page 40 With the switch still in the OFF position, press one of the buttons and check that the LED turns on, thus indicating that the system is connected correctly. Activating devices: • OMP Extinguisher box, installed behind the driver’s seat • Cockpit panel: push-pull button #3.

  • Page 41: Fuel Cell

    2 years. 2.14 R IGHT Tatuus 12x High intensity LED A minimum of 85% of the LED’s must be operational at any time. 2.14.1 Rain Light modes The rain light operates different modes according to car condition: •...

  • Page 42: Clutch Disengagement

    2.15 C LUTCH ISENGAGEMENT In case of a sudden stall, the car can still be moved following this procedure: 1. Press the clutch. Turn the valve ①. To avoid an improper/unwanted use, the valve ① is protected by a cover. 3.

  • Page 43: Chassis

    HASSIS 3.1 W ORKSHOP OOLS 3.1.1 Front Jacking The highlighted area is suitable to carry the weight of the car, the jack plate should fit as better as possible the underwing surface. Release 3.00 (22/06/2020) Page 42...

  • Page 44: Rear Jacking

    3.1.2 Rear Jacking The highlighted jacking points are suitable to carry the weight of the car. Release 3.00 (22/06/2020) Page 43...

  • Page 45: Setup Tools

    3.2 S ETUP OOLS Here below some views of the main reference points 3.2.1 Front references Release 3.00 (22/06/2020) Page 44...

  • Page 46: Rear References

    3.2.2 Rear references Release 3.00 (22/06/2020) Page 45...

  • Page 47: Wheel Hub

    3.2.3 Wheel hub Release 3.00 (22/06/2020) Page 46...

  • Page 48: Standard Set-Up

    3.3 S TANDARD Standard set-up sheet, refer to specific chapter for adjustment details: 3.3.1 Road Course Set-Up FRONT REAR Ride Height [mm] Camber [deg] -3.5° -2.2° GEOMETRY Toe (Total) [deg] +20’ 0° Rear Suspension position BE24 Springs [lb/in] 1300 Spring preload [Turn] Anti-roll [mm] 22.5 SUSPENSIONS...

  • Page 49: Weight And Ballast

    3.4 W EIGHT AND BALLAST The T318 chassis has three locations for the ballast installation, the following drawings are a simple guideline: Release 3.00 (22/06/2020) Page 48...
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  • Page 51 Release 3.00 (22/06/2020) Page 50...
  • Page 52 Release 3.00 (22/06/2020) Page 51...

  • Page 53: Controls And Display

    3.5 C ONTROLS AND ISPLAY 3.5.1 Cockpit Controls • [1] Main power switch: ▪ Position 1: master switch ON; ▪ Position 2: Ignition ON • [2] Starter button (YELLOW): starter motor is cranking (note that this button will crank the starter in any condition but the engine will fire up only if Ignition is ON);...

  • Page 54: Steering Wheel Controls

    3.5.2 Steering Wheel Controls • Button [1]: RADIO PTT, the button signal is forwarded to the radio plug (see wiring diagram for pinout). • Button [2]: ACKNOWLEDGE, when pressed all the alarms are skipped, critical alarms will persist. Long pressure will reset chassis sensors (damper position, steering angle, accelerometers). •...

  • Page 55: Steering Wheel Display

    3.5.3 Steering Wheel Display • LED strip #1: Shift lights • LED strip #1b: Blue LED are ON when pit limiter is engaged • Alarm [2]: LOW Oil Pressure • Alarm [3]: Hight Oil Temperature • Alarm [4]: 3x RED LED will blink when a general alarm is on, the display will highlight the relevant value and will show a text message •...

  • Page 56: Page #1: Driver Page

    3.5.3.1 Page #1: Driver page The first page of the display shows the following values: • Water Temperature • Engine Oil Pressure • Battery Voltage • Oil Temperature • Warning boxes (see chapter for details) All the value boxes turn red when the value is over the maximum (alarm values are set by engine control), and blue when the value is below the minimum, all the alarm messages can be skipped pushing AKN button.

  • Page 57: Page #2: Setting Page

    3.5.3.2 Page #2: Setting page This page summarizes the parameters useful for the sensor setting. • P Brake F: Front brake pressure [bar] • P Brake R: Rear brake pressure [bar] • Brake Bias: percentage of front brake pressure over total brake pressure (Front+Rear) [%] •...
  • Page 58 • E-Throttle: throttle calibration messages Push Throttle Pedal to full throttle Release Throttle Pedal to rest position Wait for the Throttle Valve learning Throttle calibration process completed successfully Throttle calibration process NOT completed o Power cycle the car: switch OFF and then ON the electric system Release 3.00 (22/06/2020) Page 57...

  • Page 59: Page #3: Logger Page

    3.5.3.3 Page #3: Logger page This page contains the channels logged by the data systems and low to check the zero procedure. all the channels are set to zero when ACK button is pressed longer than 1 second. • FL Shock: Front Left damper position [mm] •...

  • Page 60: Page #4: Electric Power Distribution

    3.5.3.4 Page #4: Electric Power Distribution This page shows the power system of the car, each box contains the current drained by the relevant line, the boxes turn if the powerbox shut down the relevant line (i.e. short-circuit detected) Refer to powerbox chapter (12.4) for line details. Release 3.00 (22/06/2020) Page 59...

  • Page 61: Page #5: Engine Warmup

    3.5.3.5 Page #5: Engine warmup This page contains the engine parameters, it could be useful while starting and warming the engine. • TCool: Engine Coolant Temperature [°C] • Toil Engine: Engine Oil Temperature [°C] • TFuel: • TAir: Air Temperature[°C] •...

  • Page 62: Page #6: Gearbox Page

    3.5.3.6 Page #6: Gearbox page This page contains the gearbox parameters, it could be useful while testing and warming the gearbox. • Pad Dwn: Box turns green when paddle input is active • Pad UP: Box turns green when paddle input is active •...

  • Page 63: Driver Installation

    3.6 D RIVER INSTALLATION 3.6.1 Steering Wheel Position The spacers ① allow the adjustment of the steering wheel depth, each spacer add 13mm and can be stack up to two. Different stack of ① requires different studs ② length. Check the Spare parts Catalogue for the options. Release 3.00 (22/06/2020) Page 62...

  • Page 64: Pedals

    3.6.2 Pedals The three pedals may be placed independently, all of these are “standalone”. Release 3.00 (22/06/2020) Page 63...

  • Page 65: Brake Pedal

    3.6.2.1 Brake pedal Rest position adjustment: operating on the rod end ① the pedal plate can be moved It is recommended to inspect and set the brake balance ③ in order that the adjustment stops ② are cor- rectly in position and far from their contact. It is recommended to replace the balance bar and the pedal base every 10’000 km.

  • Page 66: Throttle Pedal

    3.6.2.2 Throttle pedal Rest position adjustment: operating on the bottom rod ends the pedal plate can be moved. Stroke/full stroke: the stroke and the final position can be adjusted adding or removing shims ① on the damper shaft. The throttle potentiometer has to be checked after every pedal adjustment in order to respect the calibration thresholds.

  • Page 67: Clutch Pedal

    3.6.2.3 Clutch pedal Rest position adjustment: operating on the rod end the pedal plate can be moved. Stroke/full stroke: the stroke and the final position can be adjusted operating on the bush ②, counter nut ① must then be locked. The standard master cylinder for clutch actuation is a 5/8”, here below a guideline of theoretical strokes to operate the clutch mechanism: Master cylinder...

  • Page 68: Heel Rest

    3.6.2.4 Heel rest A heel rest can be bolted on the unused holes, here below a generic guideline. Release 3.00 (22/06/2020) Page 67...

  • Page 69: Brake Bias

    3.6.3 Brake Bias The brake bias knob is located on the right-hand side of the driver seat. Rotating clockwise will shift the brake balance towards front: with the standard master cylinders (Front = 19.05 mm, Rear = 20.68 mm) 1 complete turn give a +1.5% front balance. 1 turn CW = +1,5% FB ������������...

  • Page 70: Aerodynamic

    ERODYNAMIC 4.1 G ENERAL OTES Downforce [SCz]: total downforce generated by the car, excluding wheel lift. Drag [SCx]: total drag (including wheels) of the car resolved to the tire contact point. Balance %F: percentage of the total downforce acting at the front contact patches. All forces are reported as percentage from the datum point measurements (see chapter 4.4).

  • Page 71: Front Wing Setting

    34° 39° LAP INCIDENCE ARALLEL TO EFERENCE LANE TATUUS recall that, by FIA Technical Regulation, the use of a gurney flap on the front wing 500mm central part (FIA standard profile) is currently not allowed. Release 3.00 (22/06/2020) Page 70...

  • Page 72: Rear Wing Setting

    8° 13° 18° 23° 9° 14° 19° 24° 10° 15° 20° 25° TATUUS recall that, by FIA Technical Regulation, the use of gurney flaps on any of the rear aerofoils is cur- rently not allowed. Release 3.00 (22/06/2020) Page 71...

  • Page 73: Aerodynamic Reference Setup

    4.4 A ERODYNAMIC EFERENCE ETUP Aerodynamic baseline setup (datum): 10 mm RONT EIGHT 25 mm EIGHT RONT SSY ANGLE FIXED RONT LAPS ANGLE 30° (C1) BOTH LAPS ON NO GURNEY FLAP 10° (A5) SSEMBLY ANGLE Front Ride Height (FRH) is the distance between the ground and a point intersection of the Reference Plane (5mm above the lower surface of the skid block when new, plane between the skid block and the wooden plank) with a plane orthogonal to both the Reference Plane and the car symmetry plane passing on the Front Wheel Centre Line.

  • Page 74: Ride Height Sensitivity

    4.5 R EIGHT ENSITIVITY The Ride Height Sensitivity is referred to a configuration with both the front flaps on, without gurney flap installed. The following tables report the percentage changes from the datum point resulting from the change of the ride heights (FRH = Front Ride Height / RRH = Rear Ride Height): Release 3.00 (22/06/2020) Page 73...
  • Page 75 Release 3.00 (22/06/2020) Page 74...
  • Page 76 Release 3.00 (22/06/2020) Page 75...

  • Page 77: Wing Sensitivity

    4.6 W ENSITIVITY The following table report the percentage changes from the datum point resulting from the change of flap angles (FW = Front Wing Flap Angle / RW = Rear Wing Top Assembly Angle). The following tables are referred to the “both the front flaps on, without gurney flap installed”...

  • Page 78: Wing Sensitivity, Both The Front Flaps On, Without Gurney Flap Installed

    4.6.1 Wing Sensitivity, both the front flaps on, without gurney flap installed Release 3.00 (22/06/2020) Page 77...
  • Page 79 Release 3.00 (22/06/2020) Page 78...

  • Page 80: Wing Sensitivity, Both The Front Flaps On, With Gurney Flap (190Mmx15Mm) Installed

    4.6.2 Wing Sensitivity, both the front flaps on, with gurney flap (190mmx15mm) installed Release 3.00 (22/06/2020) Page 79...
  • Page 81 Release 3.00 (22/06/2020) Page 80...

  • Page 82: Wing Sensitivity, Only Lower Front Flaps On, Without Gurney Flap Installed

    4.6.3 Wing Sensitivity, only lower front flaps on, without gurney flap installed Release 3.00 (22/06/2020) Page 81...
  • Page 83 Release 3.00 (22/06/2020) Page 82...

  • Page 84: Wing Sensitivity, Only Lower Front Flaps On, With Gurney Flap (250Mmx15Mm) Installed

    4.6.4 Wing Sensitivity, only lower front flaps on, with gurney flap (250mmx15mm) installed Release 3.00 (22/06/2020) Page 83...
  • Page 85 Release 3.00 (22/06/2020) Page 84...

  • Page 86: Diffuser

    Rear Wheel axis and the underfloor ex- ternal side: TATUUS discourages to refer to the tire cut-out side as its shape is depending on the Championship. Release 3.00 (22/06/2020)

  • Page 87: Suspensions

    USPENSIONS 5.1 M EASUREMENT STANDARD REFERENCE PLANE: it is the plane where skid block and wooden plank are in contact, the skid block is then the only suspended part of the car sitting below this plane. RIDE HEIGHT: it is measured at the intersection between the vertical plane passing through the axle and the vehicle center line.

  • Page 88: Geometry Adjustments

    5.2 G EOMETRY DJUSTMENTS 5.2.1 Ride height adjustment Front ride height is increased adding the shims ① into the front push-rod, the following tables represents the available size and its respective effect: Ride height adjustment Front Ride Height change Rear Ride Height change +1mm +2.7mm +3.2mm...

  • Page 89: Camber Adjustment

    5.2.2 Camber adjustment Front camber is set changing the shims stack between Ackermann and upright: Camber adjust- Front Rear ment Camber change Camber change Toe Change +1 mm +0.43 deg (+25’) +0.31 deg (+18’) +0.55 deg (+33’) 5.2.3 Toe adjustment Toe can be adjusted by the steering arm length Toe adjustment Front...

  • Page 90: Caster Adjustment

    5.2.4 Caster adjustment The apparent caster is measured on the top of the front upright (when steer angle is zero), measuring an angle of 0° (parallel) to the reference plane equals to 10° of caster angle. Caster adjustment Front Rear Caster Change +1turn +0.90 deg (+54’)

  • Page 91: Ump Adjustment

    5.2.5 UMP adjustment The front pushrod is directly installed on the upright, its pick-up point can be adjusted longitudinally resulting in a different weight transfer as function of the steering angle. The farthest the point is from steer axis the higher will be the weight transfer and by consequence the steer- ing effort.

  • Page 92: Vertical Stiffness

    5.3 V ERTICAL STIFFNESS 5.3.1 Front vertical stiffness The table below resumes stiffness options available and relevant stiffness at the wheel: Spring stiffness [lb/in] 1100 1300 Ground stiffness [daN/mm] 12.0 15.4 18.9 22.3 Motion ratio (wheel/damper): 1.02 Springs can be preloaded acting on the damper/spring platform, the pitch of the thread is 2mm. 5.3.2 Rear vertical stiffness The table below resumes stiffness options available:...

  • Page 93: Dampers

    5.4 D AMPERS The standard damper is the KONI 2812, full open length is 320mm and maximum stroke is 44mm. Rotating the adjustment discs, located in the window of the top eye, adjust the damping. You only need a steel pin adjustment tool of 1.5mm diameter. The adjusters are marked with letters that are visible on the alloy top eye, with a ‘B’...
  • Page 94 Front 250,0 200,0 150,0 100,0 50,0 -50,0 -100,0 -150,0 -200,0 -250,0 [ mm/s ] RMIN [daN] RMAX [daN] BMIN [daN] BMAX [daN] Rear 250,0 200,0 150,0 100,0 50,0 -50,0 -100,0 -150,0 -200,0 -250,0 [ mm/s ] RMIN [daN] RMAX [daN] BMIN [daN] BMAX [daN] Release 3.00 (22/06/2020)

  • Page 95: Rolling Stiffness

    5.5 R OLLING STIFFNESS 5.5.1 Front roll stiffness The motion ratio of the front anti-roll bar is: Blade length [mm]  /  12.8 14.2 15.9 [°/°] Anti-rollbar Chassis The ratio represents the torsion angle of the antiroll bar resulting from a roll of 1° on the chassis. The following table summarizes anti-roll bar options available: Rollbar diameter [mm] 18.7...

  • Page 96: Suspension Geometry

    5.6 S USPENSION EOMETRY 5.6.1 Front suspension geometry The origin is located at the intersection of front wheel axle and reference plane, the coordinate of the contact point is then below the reference plane by a value of Rd-Zn where Rd is the Rolling Radius of the tire and Zn is the z coordinate of point N.

  • Page 97: Rear Suspension Geometry

    51.3 96.5 5.6.2 Rear suspension geometry Pickup nomenclature according to the following image The vertical step between pickup point is 12.5mm, standard configuration BE-24. The following table summarize the pickup point coordinates of the standard configuration (BE-24), the origin is located at the intersection of rear wheel axle and reference plane, the coordinate of the contact point is then below the reference plane by a value of Rd-Zn where Rd is the Rolling Radius of the tire and Zn is the z coordinate of point N.
  • Page 98 ALFA RENAULT -450.0 170.0 164.9 -450.0 170.0 159.9 -40.3 694.8 158.3 -40.3 694.8 153.3 -86.0 119.4 159.3 -86.0 119.4 154.3 -280.4 163.3 301.4 -280.4 163.3 296.4 -15.0 626.3 331.8 -15.0 626.3 326.8 34.0 108.0 306.4 34.0 108.0 301.4 75.0 659.8 246.8 75.0 659.8...

  • Page 99: Anti-Effects

    -105.8 76.6 375.5 -105.8 76.6 370.5 5.6.2.1 Anti-effects The following tables shows the anti-effects of the vehicle, they show the relevant numbers for the following setting: Front wheel hub: 262mm over reference plane Rear wheel hub: 235mm over reference plane Brake bias: 55% Front 5.6.2.1.1 Front...

  • Page 100: Rear

    5.6.2.1.2 Rear Camber derivative Pick Up position RC Height [mm] Anti-squat [%] Anti-lift [%] [°/10mm] AD13 58.48 0.13 AD14 19.39 0.07 AD23 63.40 0.14 -19% AD24 24.06 0.07 AE13 75.47 0.21 AE14 62.16 0.25 AE23 80.53 0.22 -25% AE24 41.54 0.15 BD13 61.47...

  • Page 101: Suspension Maintenance

    The upgrade consists in the installation of a bush ②. This upgrade has been implemented in the produc- tion parts. To upgrade an old spec rear upright please contact TATUUS, as the teams are not allowed to make this modification on their own. Release 3.00 (22/06/2020) Page 100...

  • Page 102: Upright Disassembly

    5.7.2 Upright Disassembly The upright can be disassembled for inspection: 1. Remove the secure ring [f]. 2. Apply unlock spray. 3. Using the special tool [e] (pn. 2491011, available on Spare Part Catalogue), unscrew and remove the ring nut [d]. Release 3.00 (22/06/2020) Page 101...
  • Page 103 4. Press the hub out. Is suggested to do this operation with a hydraulic press. Pictures below shows the procedure using a TATUUS’ special tool available upon request. To avoid buckling and misalignment problems the procedure should be done with the pins as short as possible in the very first phase of stroke.
  • Page 104 5. For the final phase of the extraction remove the hub with a drift punch through the 4mm holes [A]. 6. Remove the bearing retention ring (a). Release 3.00 (22/06/2020) Page 103...
  • Page 105 7. Heat the upright and bearing subassembly up to about 120°C. 8. Once heated, use the machined slot [B] to press out the bearing acting on the outer bearing ring. Release 3.00 (22/06/2020) Page 104...

  • Page 106: Upright Assembly

    5.7.3 Upright Assembly Here below the reassembling procedure: 1. Heat the upright to about 120°C and cool the bearing to about -20°C. 2. Put the bearing into the housing acting on the outer race (a press can make the procedure quicker, maximizing the temperature difference effect).
  • Page 107 6. Fit the ring nut [d] 7. Using the special tool [e] (pn. 2491011, available on Spare Parts List) tight the ring nut to 500Nm. 8. Fit the secure ring nut [f] and the M4 screws [g] (4Nm, Loctite 222) Release 3.00 (22/06/2020) Page 106...

  • Page 108: Steering

    TEERING 6.1 S TEERING EOMETRY 6.1.1 Standard ratio: 8 teeth pinion Steering ratio: 11.9°/° 6.1.2 Option ratio: 7 teeth pinion Steering ratio: 14.0°/° Release 3.00 (22/06/2020) Page 107...

  • Page 109: Steering Maintenance

    6.2 S TEERING MAINTENANCE Installation drawings: please not the orientation of the front joint assembly: Release 3.00 (22/06/2020) Page 108...

  • Page 110: Wheels And Tires

    HEELS AND IRES 7.1 W HEELS Front wheels: 10.0 inches Rear wheels: 12.0 inches Wheel nut tightening torque: 250 Nm Release 3.00 (22/06/2020) Page 109...

  • Page 111: Tires

    7.2 T IRES 7.2.1 Giti Tires Release 3.00 (22/06/2020) Page 110...

  • Page 112: Pirelli

    7.2.2 Pirelli 7.2.2.1 Static measurements The static measurements within this book are provided for each combination of tyre-rim size. Geometric measurements are taken with the tyre fitted on a rim, inflated to 1.4bar/20.3 Psi D [mm] Circumference length along the middle tread line of the tyre; C [mm] Max width maximum width of the tyre;...

  • Page 113: Dynamic Measurements

    7.2.2.2 Dynamic measurements Tyre dynamic characterization describes changes in dimensions due to speed and vertical load. All measure- ments are made without any applied camber (0°) with the tyre inflated to 1.4bar/ 20.3 Psi Loaded radius LR [mm] distance between the wheel center and the ground; Rolling radius RR [mm] the length travelled by the tyre for each wheel's revolution divided by 2p.

  • Page 114: Technical Limitations - F3 Regional

    7.2.2.4 Technical Limitations – F3 Regional Tyre Inflation Pressure Minimum Inflation Pressure Front 14.5 PSI Minimum Inflation Pressure Rear 13.5 PSI Hot Pressure Target (Both Axles) 20.5 PSI Car Setup Parameters Maximum Static Camber Front Qualifying: -4.75° / Race: -4.25 Maximum Static Camber Rear Qualifying: -3.0°...

  • Page 115: Dynamic Measurements 230/570-13X10.0J Slick @ 1.4Bar (20.5Psi), Ca 0.0

    7.2.2.6 Dynamic measurements 230/570-13x10.0J SLICK @ 1.4bar (20.5psi), CA 0.0° Release 3.00 (22/06/2020) Page 114...

  • Page 116: Static Radial Deflection 230/570-13X10.0J @ Ca 0.0° Slick

    7.2.2.7 Static Radial Deflection 230/570-13x10.0J @ CA 0.0° SLICK Release 3.00 (22/06/2020) Page 115...
  • Page 117 Release 3.00 (22/06/2020) Page 116...

  • Page 118: Static Radial Deflection 230/570-13X10.0J @ Ca 3.0° Slick

    7.2.2.8 Static Radial Deflection 230/570-13x10.0J @ CA 3.0° SLICK Release 3.00 (22/06/2020) Page 117...
  • Page 119 Release 3.00 (22/06/2020) Page 118...

  • Page 120: Dynamic Measurements 300/590-13X12.0J Slick @ 1.4Bar (20.5Psi), Ca 0.0

    7.2.2.9 Dynamic measurements 300/590-13x12.0J SLICK @ 1.4bar (20.5psi), CA 0.0° Release 3.00 (22/06/2020) Page 119...

  • Page 121: Static Radial Deflection 300/590-13X12.0J @ Ca 0.0° Slick

    7.2.2.10 Static Radial Deflection 300/590-13x12.0J @ CA 0.0° SLICK Release 3.00 (22/06/2020) Page 120...
  • Page 122 Release 3.00 (22/06/2020) Page 121...

  • Page 123: Static Radial Deflection 300/590-13X12.0J @ Ca 3.0° Slick

    7.2.2.11 Static Radial Deflection 300/590-13x12.0J @ CA 3.0° SLICK Release 3.00 (22/06/2020) Page 122...
  • Page 124 Release 3.00 (22/06/2020) Page 123...

  • Page 125: Hankook

    7.2.3 Hankook Release 3.00 (22/06/2020) Page 124...
  • Page 126 Release 3.00 (22/06/2020) Page 125...

  • Page 127: Tyre Characteristics (Static Measurement)

    7.2.3.1 Tyre Characteristics (Static measurement) 7.2.3.1.1 Dimension The rim width shall be selected/used within the range recommended for each tire size. The outer diameter of the tyre shall be measured with no load applied under the appropriate pres- sure conditions, based on the recommended rim size. Release 3.00 (22/06/2020) Page 126...

  • Page 128: Static Radial Deflection (Kv)

    7.2.3.1.2 Static Radial Deflection (Kv) Release 3.00 (22/06/2020) Page 127...
  • Page 129 Release 3.00 (22/06/2020) Page 128...
  • Page 130 Release 3.00 (22/06/2020) Page 129...
  • Page 131 Release 3.00 (22/06/2020) Page 130...

  • Page 132: Tyre Characteristics (Dynamic Measurement)

    7.2.3.2 Tyre Characteristics (Dynamic Measurement) Tire dynamic characteristics are dimensional changes due to speed and vertical load. Loaded Radius (DLR) : Distance between wheel center and ground (Unit: mm) 7.2.3.2.1 Dynamic measurements 230/560R13 F200(10J) Slick @ 1.5Bar, CA 0.0° Release 3.00 (22/06/2020) Page 131...

  • Page 133: Dynamic Measurements 280/580R13 F200(12J) Slick @ 1.5Bar, Ca 0.0

    7.2.3.2.2 Dynamic measurements 280/580R13 F200(12J) Slick @ 1.5Bar, CA 0.0° Release 3.00 (22/06/2020) Page 132...

  • Page 134: Dynamic Measurements 230/560R13 Z217(10J) Rain @ 1.5Bar, Ca 0.0

    7.2.3.2.3 Dynamic measurements 230/560R13 Z217(10J) Rain @ 1.5Bar, CA 0.0° Release 3.00 (22/06/2020) Page 133...

  • Page 135: Dynamic Measurements 230/560R13 Z217(10J) Rain @ 1.5Bar, Ca 0.0

    7.2.3.2.4 Dynamic measurements 230/560R13 Z217(10J) Rain @ 1.5Bar, CA 0.0° Release 3.00 (22/06/2020) Page 134...

  • Page 136: Dynamic Measurements 280/580R13 Z217(12J) Rain @ 1.5Bar, Ca 0.0

    7.2.3.2.5 Dynamic measurements 280/580R13 Z217(12J) Rain @ 1.5Bar, CA 0.0° Release 3.00 (22/06/2020) Page 135...

  • Page 137: Operating Temperature

    7.2.3.3 Operating Temperature After driving, the temperature difference between the Inside and the outside of the tire must be between 20 degrees, and the temperature difference between the front and rear wheels must also be between 20 de- grees. Release 3.00 (22/06/2020) Page 136...

  • Page 138: Tyre Care Information (Technical Limitations)

    7.2.3.4 Tyre Care Information (Technical Limitations) The value of the Camber used shall not exceed (Front -4.0°, Rear -3.0°) (Purpose: To secure Safety margin) The initial pressure shall be maintained at least1.0bar. (Purpose: To secure Safety margin) Dry air is recommended to avoid sudden pressure changes caused by humidity when inflating the inside of the tire.
  • Page 139 Release 3.00 (22/06/2020) Page 138...
  • Page 140 Release 3.00 (22/06/2020) Page 139...

  • Page 141: Brake System

    RAKE SYSTEM 8.1 T ECHNICAL NOTES 8.1.1 Balance bar Rotating the brake bias knob clockwise will shift the brake balance towards front by 1.5% per complete turn. 8.2 B RAKE SYSTEM ETUP Master cylinder suggested configuration: FRONT DIA REAR DIA Standard 19.05 mm 20.64mm...

  • Page 142: Brake System Bedding-In

    8.3 B RAKE SYSTEM EDDING The brake bedding-in procedure is a process of repeatedly and quickly heating and cooling the brakes, in a way that the pad deposits a uniform layer of its material on the disk surface and to evenly remove the thin anti-corrosion coating of the disk.

  • Page 143: Cooling System

    OOLING YSTEM Cooling system pressure: 1.8 bar. Colling system volume: 7.5lt (approx.) 10 F UEL SYSTEM 10.1 F Fuel tank capacity: 60lt It is recommended to protect the outer surfaces of the fuel bladder from scratching over carbon fibers, cutomers are invited to protect the carbon surfaces that are in contact with the bladder with PVC tape (i.e. Permacel) or Neoprene foam Sheet.

  • Page 144: Fuel Machine Options

    10.4 F UEL MACHINE OPTIONS An optional system can be installed to have a breather valve dry coupled, refer to page 24D of the spare part catalogue. The breathing line to the tank is equipped with a safety dry-break Staubli SPT08.7655/L/JV, the mating port (machine side) have to be SPT08.3655/L/JV.

  • Page 145: Oil System

    11 O YSTEM 11.1 A OMEO IL TANK The oil tank is located within the gearbox bellhousing, some oil may overflow into the catch tank, regularly drain and clean it to optimize oil level. We recommend to respect the following procedure in order to have a consistent level measurement: •...

  • Page 146: Renault Oil Tank

    11.2 R ENAULT IL TANK The oil tank is located within the gearbox bellhousing, some oil may overflow into the catch tank, regularly drain and clean it to optimize oil level. We recommend to respect the following procedure in order to have a consistent level measurement: •...

  • Page 147: Toyota Oil Tank

    11.3 T OYOTA IL TANK The oil tank is located within the gearbox bellhousing, some oil may overflow into the catch tank, regularly drain and clean it to optimize oil level. Release 3.00 (22/06/2020) Page 146...

  • Page 148: Electric System

    12 E LECTRIC SYSTEM 12.1 O VERVIEW The wiring loom is split in four main parts: • Chassis harness • Engine harness • Gearbox harness • GCC/EGA harness The power system (+12V) includes • Battery: installed in the cockpit behind driver seat •...

  • Page 149: Main Switch

    12.2 M AIN SWITCH The master switch is actuated by the cockpit panel and emergency switches, connection schematics: A: +12V Generator, +12V Chassis loom ring; B: +12V Battery, Main switch coil supply; C: chassis loom connector. Release 3.00 (22/06/2020) Page 148...

  • Page 150: Battery And Alternator

    12.3 B ATTERY AND LTERNATOR Battery is a crucial component interacting with engine and gearbox management systems always pay atten- tion to its charge level especially if you are running reset procedures. NOTE: running engine at low revs will not charge battery! NOTE: if the battery power is low high current consumptions (like a gearshift actuation/recharge) can result in an engine stall, keeping higher revs and generator in charge will fix this occurrence.

  • Page 151: Powerbox

    12.4 P OWERBOX The PSD9 powerbox manages the current distribution on the power lines listed on the following paragraphs. User devices connected to customer available connections (AUX ports) must not exceed 5A in total and 2A per power supply pin. WARNING: Do not disconnect the powerbox connection when power is ON! Diagnostic and functional information are available in the logger system, see chapter for details.

  • Page 152: Renault Configuration

    12.4.2 Renault configuration Log name Line # User list (name on Steering Wheel) PSD_Fuel Fuel pump (Fuel) Rain Light PSD_FED (Federation) Transponder Throttle valve PSD_CU_HP (1/2) GDI Injection (HP Elec) PSD_CU_HP (2/2) (LP Elec) Dashboard PSD_AUX Beacon (Aux) AUX ports PSD_Coils Engine coils (Coils)

  • Page 153: Wiring Loom

    12.5 W IRING LOOM Refer to pdf files for electrical schematics. 12.5.1 Radio plug A radio connector is provided in the chassis wiring, it provides a 12V power and repeat the switch of the steering wheel on pins #2/#3. Mating connector DTM04-4P. Release 3.00 (22/06/2020) Page 152...

  • Page 154: Sensors

    12.6 S ENSORS The T318 chassis is delivered with the following chassis sensors: • Pedal position sensor: twin way contactless rotary sensor. • Brake pressure sensors: 100bar pressure sensor. • Clutch pressure sensors: 100bar pressure sensor. • Steering position sensor: contactless rotary sensor.

  • Page 155: Vref List

    12.7 V REF LIST 12.7.1 Alfa Romeo configuration V list Front Brake Pressure Throttle Pedal (B) Throttle Pedal (A) Front Left Damper Pos. Rear Brake Pressure Oil Pressure Front Right Damper Pos. Steering Position SMOT Rail Pressure Rear Left Damper Pos. Gear Position Cam IN Cranckase Pressure...

  • Page 156: Engine

    13 E NGINE For any technical information contact the engine tuners. Release 3.00 (22/06/2020) Page 155...

  • Page 157: Transmission

    14 T RANSMISSION 14.1 R ATIO HART Here below the ratio options: Final drive Ref. Secondary shaft Crown wheel Reverse gear Primary shaft Idler Secondary shaft Release 3.00 (22/06/2020) Page 156...

  • Page 158: Gear Option 01

    14.1.1 Gear option 01 Gear Ratio 16/36 2.25 16/25 1.56 22/27 1.23 31/32 1.03 21/19 0.90 29/24 0.83 SLR82 7000 6500 6000 5500 5000 4500 4000 3500 3000 50,0 100,0 150,0 200,0 250,0 300,0 Speed [km/h] Release 3.00 (22/06/2020) Page 157...

  • Page 159: Gear Option

    14.1.2 Gear Option Gear Ratio 16/36 2.25 16/25 1.56 23/29 1.26 26/28 1.08 26/25 0.96 23/20 0.87 SLR82_SHORT 7000 6500 6000 5500 5000 4500 4000 3500 3000 50,0 100,0 150,0 200,0 250,0 300,0 Speed [km/h] Release 3.00 (22/06/2020) Page 158...

  • Page 160: Differential

    14.2 D IFFERENTIAL ZF type self-locking differential with triple friction discs and pressing plates with ramps acting symmetrically or not, for driving or braking condition. The following table summarize the options available with the first equipment ramp set: F19103191 Coast Power 70°...

  • Page 161: Lubrication

    14.3 L UBRICATION Oil capacity: 1.8 L + cooler circuit 1rst drain Drain frequency Viscosity After a 50Km running-in Each meeting 75W140 14.4 P ARTICULAR PRECAUTIONS No additives should be added to the oil. The resulting consequences are not in any circumstances covered by SADEV.

  • Page 162: Glue Components

    14.6 G LUE COMPONENTS Glue components and tightening torque are shown in the 3D exploded view, refer to paragraph 14.11. WARNING: Glue components have been chosen during tests sessions. Only ‘Loctite’ brand components must be used. Sadev can’t ensure consequences of false glue component choice. 14.7 S PECIAL TOOLS IMAGE...

  • Page 163: Gear Maintenance

    14.8 G EAR MAINTENANCE 14.8.1 Removal • Drain gearbox through lower drain plug. • Loose the 10x Simmonds nuts M8 retaining the cover plate. • Remove the cover plate. • Remove the axis of fork, circlips and nuts stopping then engage 2nd gears manually. Release 3.00 (22/06/2020) Page 162...
  • Page 164 • Assemble the anti-splay plate. (FOUT9047007) • Loose the 2x nuts (primary and secondary) with the screwing socket FOUT9045201 • Remove the anti-splay plate. • Remove the parts one by one noting the direction of initial assembly. Release 3.00 (22/06/2020) Page 163...

  • Page 165: Refitting

    14.8.2 Refitting • Clean and check condition of parts. • Lightly lubricate the forks and the needle roller bearing cages using gearbox oil. • Replace gears one after the other in the reverse order from removal. For new gears, put the refer- ence of the gears of the primary shaft towards the operator.

  • Page 166: Selector Fork Adjustment

    14.8.3 Selector fork adjustment Each time gears are dismantled check the fork tuning: after tightening the secondary shaft nut, install the fork adjustment tool (FOUT9047005). Engage all the gears in order to check that shifting is working well and forks do not push the dog ring on its gear wheel.
  • Page 167 If excessive friction is found during checking, note which gear is concerned and follow this procedure: • Disassemble the gears and change the gear cluster shim: o Replace the shim with a thinner one if Reverse, 1 gears are concerned Otherwise replace the shim with a thicker one.

  • Page 168: Differential

    14.9 D IFFERENTIAL 14.9.1 Removal • Disconnect potentiometer. • Drain the box through the lower drain plug. • Remove differential housing. • Extract the differential assembly. 14.9.2 Dismantling the differential elements • Compress the differential using the adapter (FOUT1910300), the compression washer (FOUT1910001) and the bolt CHC M6x70.

  • Page 169: Crown-Wheel Replacement

    14.10 C ROWN WHEEL REPLACEMENT 14.10.1 Secondary shaft • Drain the box through the lower drain plug. • Remove primary shaft and secondary shaft (see paragraph 14.8.1). • Remove differential housing (see paragraph 14.9.1). • Using a mallet, remove the secondary shaft and the NU207 flange. Release 3.00 (22/06/2020) Page 168...
  • Page 170 • Remove the 6x M8 bolts, heating them. Clean the threads used for the NU207 flange. • Use a bearing extractor to remove the NU207 roller bearing. • Remove the QJ207 bearing (pushing with one of the internal races of the bearing) •...
  • Page 171 In the main housing, two dimensions are marked (as shown on the picture), note the smallest (usually around 137.25): this is dimension “ “. On a flat plane, pile both the new bearings, and note their combined height: this is dimension ” ”.
  • Page 172 The thickness “C” of the secondary shaft shim (2) is calculated as follows: C = A – AD - B Assemble the shim being the closest (F1910205) to the calculated thickness “C” on the secondary shaft. Press fit the inner race of the NU207 bearing on the secondary shaft. Release 3.00 (22/06/2020) Page 171...
  • Page 173 In the casing: • Set in place a new O-ring on (1) the chamfer of the gear casing located on the housing of the QJ207 bearing. • Press fit the 4-point contact bearing QJ207 • Fit the NU207 bearing (2) in the casing. •...
  • Page 174 Release 3.00 (22/06/2020) Page 173...

  • Page 175: Crown

    14.10.2 Crown NOTE: In the described procedure, the differential case is supposed to be empty. Press remove both bearings on the differential case (1). • Unscrew and remove the 8x M10 bolts of the crown by heating them. • Remove the crown from the differential. •...
  • Page 176 In the main housing, two dimensions are marked (as indicated on picture), note the highest (around 170.75). This is dimension “ ”. Measure the highest distance between the external races of the bearings assembled on the differential case and note it: this is dimension “ “...
  • Page 177 The combined thickness of both crown positioning shims (2a and 2b) is calculated as follows: Z = X + 0.1 – Y Fit inside the main housing the differential case and the two crown positioning shims. The shims must be put between the main housing and each of the 2 bearings (refer to following view).
  • Page 178 Measure the clearance between the teeth of the final drive pinion and crown. Take 5 to 8 measurements on multiple turns of the secondary shaft. The average value must be included between 0.01mm and 0.06mm. • If it is lower than 0.01mm: replace the crown side shim (2a) by the next thinner shim available, and replace the opposite shim by the next thicker shim available (2b).

  • Page 179: Exploded Views

    14.11 E XPLODED VIEWS Refer to spare catalogue for part numbers 14.11.1 Layshaft Torque Item Part number Description Glue (DaN m) F9047105 Shaft plug F9046206 M35x1.25 nut Release 3.00 (22/06/2020) Page 178...

  • Page 180: Mainshaft

    14.11.2 Mainshaft Torque Item Part number Description Glue (DaN m) F1910210 Secondary shaft nut 0301077 M8x20 Cl.12.9 Chc bolt Release 3.00 (22/06/2020) Page 179...

  • Page 181: Barrel And Forks

    14.11.3 Barrel and forks Torque Item Part number Description Glue (DaN m) 0301516 CHC M6x18 cl12.9 bolt 0301373 CHc M7x16 cl10.9 ZN bolt F0059021 Selector shouldered bolt 0301138 CHc M5x12 cl10.9 ZN bolt 0301394 CHc M5x 10 ZN Cl 8.8 bolt 0101004 Bearing 6004 0101050...

  • Page 182: Differential

    14.11.4 Differential Torque Item Part number Description Glue (DaN m) F1910323 M10x100 Ig.16 Cl.12.9 H bolt Release 3.00 (22/06/2020) Page 181...

  • Page 183: Main Case

    14.11.5 Main case Torque Item Part number Description Glue (DaN m) 0499005 M10x1.25 Simmonds nut F1910022 Machined M10x30 bolt 0301525 M10x30 CHc bolt F9001922 Centering pin F9047008 Gearbox closing plate stud F9047031 Differential housing stud (long) F9047030 Differential housing stud (short) F1404429 Centering pin 1202029...

  • Page 184: Selection And Reverse

    14.11.6 Selection and reverse Torque Item Part number Description Glue (DaN m) 0106001 HK1816 bearing 0301007 M6x20 cl 10.9 CHc bolt F1910419 Reverse gear axle 12847 0106021 HK2016 bearing Release 3.00 (22/06/2020) Page 183...

  • Page 185: Oil Pump

    14.11.7 Oil pump Torque Item Part number Description Glue (DaN m) 0301422 M6x16 CHc bolt 0301385 M6x20 CHc bolt Release 3.00 (22/06/2020) Page 184...

  • Page 186: Rebuilding Of The Gearbox

    14.12 R EBUILDING OF THE GEARBOX 14.12.1 Sadev workshop rebuilding. The gearboxes are delivered sealed and numbered. The absence of Sadev's seal imposes a careful attitude in the event of minor or major problem to us, and applies to complete reserve of our share if necessary. Return gear boxes to revision: At the time of the return of the gearboxes in our buildings, a certain procedure of delivery has to be re- spected, so that our intervention can be total and practical (casing 'closed' for passage to the bench).

  • Page 187: Shift System

    HIFT SYSTEM 15.1 S YSTEM VERVIEW The T318 is equipped with a semi-automatic shift system, here below a quick overview: • GCU (Gear Control Unit): embedded in the ECU. • GCC (Gearshift Current Controller): Magneti Marelli SRG-140/GCC, this unit manage the actuator (ESA) control •...

  • Page 188: Esa Resting Position

    15.1.2 ESA resting position On Page 6 of the steering wheel display the parameter ESAP shows the rest position of the gear actuator, the rest position should be within a range of 30mV. A suggested length for the ESA resting position is shown below: Release 3.00 (22/06/2020) Page 187...

  • Page 189: Esa Maintenance

    15.1.3 ESA maintenance It is reminded to check regularly the AV mounting of the ESA: The rubber ring (pn. ORN4036) should be inspected each 1’000 km and must be replaced before 3’000 km. Release 3.00 (22/06/2020) Page 188...

  • Page 190: Electronic & Software

    16 E & S LECTRONIC OFTWARE 16.1 E LECTRONIC Refer to engine builder docs. Release 3.00 (22/06/2020) Page 189...

  • Page 191: Annexes

    17 A NNEXES 17.1 T IGHTENING TORQUE 8.8 grade 10.9 grade Thread Pitch Torque Torque Torque Torque [mm] [mm] [Nm] [Lbs ft] [Nm] [Lbs ft] 0,92 2,08 4,26 7,13 13,6 10,0 1,25 23,7 17,45 33,3 24,5 26,4 19,50 37,2 27,4 47,0 34,70 66,2...

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