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dallara F303 Manual
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dallara F303 Manual

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Manual F302/3/4
CAR VIEWS
CAR INFO
SET-UP
SUSPENSION
DIFFERENTIAL
DAMPERS
RIDE HEIGHT
AERODYNAMICS
COOLING
UPRIGHT ASSEMBLY
SYSTEMS
GEARBOX
SAFETY AND UTILITY NOTES
TIGHTENING TORQUES
CONVERSION TABLE
GENERAL AGREEMENT
TWIN-DAMPER INFO
CONTENTS
Update 03/04
3
4
5-6
7-11
13-14
15-16
17
19
20-24
25
26-27
28
29
30
31
32
33
34
35
36
37

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Summary of Contents for dallara F303

  • Page 1: Table Of Contents

    DALLARA F302/3/4 CONTENTS Manual F302/3/4 Update 03/04 CAR VIEWS CAR INFO SET-UP SUSPENSION Front 7-11 Rear 13-14 DIFFERENTIAL 15-16 DAMPERS RIDE HEIGHT AERODYNAMICS 20-24 COOLING UPRIGHT ASSEMBLY 26-27 SYSTEMS Brakes Fuel Extinguishers GEARBOX SAFETY AND UTILITY NOTES TIGHTENING TORQUES CONVERSION TABLE...

  • Page 2: Dallara F302/3/4

    DALLARA F304 DALLARA AUTOMOBILI IS HAPPY WITH THE CHOICE YOU MADE BUYING THE DALLARA F303, AND WISHES YOU THE VERY BEST IN RACING IT. For any question, advice or idea you might have, please don’t hesitate to contact us. Dallara Automobili Via Provinciale 33 43040 VARANO MELEGARI –...
  • Page 3 SIDE & TOP VIEW OF THE F303/4...
  • Page 4 Fuel cell PREMIER – FT3 Extinguisher system Lifeline (electrical operated) Steering wheel Sparco – 270 mm OD Steering release system SPA design Coolers BEHR/DALLARA Filters FIAAM Rims SPEEDLINE 9” front – 10.5” rear Brake system BREMBO Battery GATES/DEKA Seat belt...

  • Page 5: Front

    TIRE INFORMATION Tire dimensions depend on inflating pressure, rim width and camber angle. These stiffness values are based on the recommended inflating pressure (hot tyres). FRONT TIRE Avon Bridgestone Kumho Hankook Yokohama Specification 180/55-13 180/55-13 180/55-13 180/550-13 190/50-13 Free radius (mm) 277.5 277.2 275.0...
  • Page 6 SETUP ADJUSTMENT Effects of the adjustments on the cars’ set-up. Positive change in: means: Height car rises toe-out Camber upper part of rim outward Castor lower part of rim points ahead FRONT REAR PUSHROD ADJUSTER Height change 4.275mm 6.97mm 1TURN Camber change (deg) 2’...
  • Page 7 [(Ks in Lb/in) / 56 = Ks in kg/mm] T = number of platform (C) turns 2 = mm / turn (for standard Dallara damper top) SETTING THE PRE-LOAD • Mount the damper-spring combination with the platform C just in contact with the spring •...
  • Page 8 FRONT CASTOR ANGLE SETTING When the car is flat (same ride height front and rear), the upright inclination angle (apparent castor) is 1.75° and the castor angle (build in castor) is 10.5°. With different front and rear ride heights: For instance, with 15 mm front and 28mm rear ride height, measured at wheel axis, (wheelbase is 2675 mm) you would measure a ‘apparent’...
  • Page 9 FRONT ANTI-ROLL AND ROLL PRE-LOAD You can use each of the Belleville stacks with or without pre-load. There are two types of pre-load, described in detail here below. The limit of the system is the rocker touching the magnesium support when moving laterally. Double stiffness pre-load •...
  • Page 10 PRE-LOAD SETTING PROCEDURES DOUBLE STIFFNESS PRE-LOAD • Mount the stack you want to use and turn the platform until in contact with the Belleville stack • Turn the platforms until distance A is the same on both sides • Check distance B to be less than 6.5mm, if more, replace adjustment spacer •...
  • Page 11 FRONT SUSPENSION ROLL CENTRE SETTING Front roll centre height can be changed by moving the spacer to its upper or lower position on the wishbone spherical joint. When choosing "low roll centre" configuration, push-rod length has to be shortened by 1.2 register turns ( 7 faces of the adjuster) to keep the car at the same ride height.. When adjusting the roll centre height camber gain versus wheel travel varies a little.
  • Page 13 10mm wheel travel 20’ 16’ 24’ *D-1 23’ *E-2 18’ 22’ 18’ Option D-1 and E-2 alter caster angle. To obtain std value shorten by 2 turns the ‘caster’ uniball.Option B-2 needs special bracket for front top mounting (available at Dallara).
  • Page 14 . The following procedure shows the disassembly of the rocker and the pivot A. Contact DALLARA customer’s service regarding the special tools E and F. • Unscrew the nut C. The tightening torque to fit it back is 3.5 Kgm;...
  • Page 15 This table shows the % of lock from minimum to maximum lock. Lock%= (slower wheel torque – faster wheel torque)/ total torque LOCK% 2.5 12.0 15.5 18.0 24.0 25.0 33.5 42.0 44.0 55.0 68.5 RAMP DISCS 60/70 and 70/80 ramps are available at Dallara Automobili S.r.l.
  • Page 16 DIFFERENTIAL LAY-OUT • Check the plate arrangement is equal on both sides. • Side gear ring, diff end plate, diff wall and pre-load spacer all act as “B” plates • A bigger ramp angle transmits less thrust onto the plates than a smaller ramp angle.
  • Page 17 If you plan to use alternative products check that maximum stroke to be less than 36 Dallara, on request, delivers installation kits for PENSKE and QUANTUM dampers. If you want to install other dampers, remind that full open and closed length must be equal to those listed above.
  • Page 18 DAMPER GRAPH KONI 2812/140 -100 V (mm/s) BUMP min BUMP max REBOUND min REBOUND max...
  • Page 19 RIDE HEIGHT CHECK AND REFERENCES • Ride height is fundamental for setting and changing the aerodynamic balance of the car. • A lower car generally generates more down-force than a higher car. • A lower car improves performance as it features a lower centre of gravity. •...
  • Page 20 FRONT WING FRONT WING CONFIGURATIONS FRONT WING SIDEPLATE HOLES...
  • Page 21 REAR WING REARWING PROFILES REAR WING CONFIGURATION UHDF REAR WING SIDEPLATE HOLES _____________________...
  • Page 22 18° 19° 20° 21° 22° 23° 24° 25° The following gives the F304 HDF rear wing incidence to achieve the same level of down-force as the F303 HDF/UHDF rear wing configuration. F304 F303 LOWER 7° 7° LOWER 12° 17° 16°...
  • Page 23 TOP WING DIFUSER FLOOR TURNING VANES 2003-short LDF/MDF LOW & MEDIUM 2004 HIGH (std) 2004 HDF/UHDF HIGH (std) <HIGH> central difuser is the standard F302/3/4 difuser part under the gearbox, <LOW & Medium> is available at Dallara or your parts dealer.
  • Page 24 AERODYNAMIC INFORMATION • Front wing main-plane and rear lower wing are set relative to the chassis reference plane. • The optimum setting for the front main-plane is -0.5° (minus 0.5°). Any chassis rake angle will alter this setting. • Front flap inclination is intended to be the angle, relative to the chassis reference plane, measured on top of the flap front and inside the Gurney ‘corner’.
  • Page 25 COOLING ADJUSTMENT • Depending on the ambient temperature and the ‘engine tuner’ requested water temperature you might need to adjust the cooling capacity of the radiators. • Cooling efficiency increases by sealing any eventual leakage in the inlet ducts to the radiators.
  • Page 26 HUB ASSEMBLY The following procedure explains how to change front and rear hub bearings • Removal of bearing a) Remove spigot by removing the 6 screws A; b) push off drive flange by using two 6x1 screws set on thread B; c) remove circlip C;...
  • Page 27 HUB ASSEMBLY FRONT HUB REAR HUB...

  • Page 28: Oil

    SYSTEMS ENGINE OIL SYSTEM The distance between the oil cap and the oil surface should be about 115 mm. Less oil may cause cavitation and lead air into the oil circuit. More oil may cause excessive power consumption due to the oil squash. Typically you would need a total of 4.5 litres to fit in the oil tank (including the oil in the engine and hoses).

  • Page 29: Brakes

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

  • Page 30: Fuel

    The driver can switch one or the other low pressure pump from the cockpit. Available at Dallara is a ‘SAFETY’ filling system with dry-brake valves and a system to empty the tank using an external fuel pump. Contact us for detail information.

  • Page 31: Extinguishers

    EXTINGUISHER SYSTEM LAYOUT DETAILS The LIFELINE system is an electrically triggered Halon or foam spray fire extinguisher system. The system uses an actuator to operate the valve located on the pressurised container, containing the extinguishing liquid. These are triggered remotely using a battery powered power pack. In order to guarantee reliable operation the actuator follow military specifications.
  • Page 32 To open the differential you have to remove the bearing in order to reach the bolts of the casing cover. Use proper tools in order to avoid damaging the bearing and the diff cover. IMPORTANT BASIC INFO • The mandatory standard Dallara crown-wheel & pinion ratio: 12/34 • Total oil quantity for diff and gearbox: 2.5L •...
  • Page 33 • do not remove from high- and mid-downforce rear top wing assembly the small profile for use as rear low downforce wing because these are not reinforced. Use the specific wing profile, available at Dallara; • when running the car with a rear ride height of 40mm or more, check the height of the rear wing endplate.
  • Page 34 SUSPENSION • ball joint A, used in the front lower and rear lower wishbones, must be fitted with sharp-edge side in contact with circlip B, as shown in following drawing TIGHTENING TORQUES This table lists suggested tightening torques. For additional security use LOCTITE 242 or 243. Tightening torques lbs ft Pinion bearing nut...
  • Page 35 SWG & CONVERSION TABLES Table shows conversion from SWG (Std Wire Gage) to metric units for sheet-metal thickness Metric (mm) 4.064 3.251 2.642 2.032 1.626 1.219 0.914 CONVERSION TABLE Length 1 inch=25.4 mm 1 millimeter=0.03937 in 1 foot=304.8 mm=12 in 1 centimeter=0.3937 in 1 yard=914.4 mm=3 ft 1 meter=39.37 in...
  • Page 36 25000 Km. It holds true if necessary maintenance and checks are provided and if the car had no incidents from the origin. DALLARA is not responsible for incorrect chassis repairs, if made outside its factory or in centres not- recognised by FIA.
  • Page 37 TWIN DAMPER TO MONO DAMPER STIFFNESS REAR SPRINGS 1000 1100 1200 Bar @ Bar @ Bar @ Bar @ Bar @ Bar @ Bar @ Bar @ T-bar and Mono blade only Ground Ground Ground Ground Ground Ground Ground round (kg/mm) (kg/mm) (kg/mm)
  • Page 38 The list below gives comparable stiffness at ground for various mono damper anti roll settings. Take into account that while the car rolls the mono damper does not contribute in the resistance to roll. With the twin damper system, especially when using soft spring and anti-roll bars, the contribution of the dampers to the roll resistance is not negligible.

This manual is also suitable for:

F302F304