GTSports DALLARA F - 320 User manual
DALLARA
F - 3 20
Owner’s MANUAL
2022
320 Owner’s Manual
Rev. 2022 v_220419 1
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320 Owner’s Manual
Rev. 2022 v_220419 2
0 Contents & General Information
0Contents & General Information ....................................................................................... 2
0.1Preface .............................................................................................................................. 5
0.2Issues ................................................................................................................................ 6
0.3Contacts ............................................................................................................................ 7
0.4General Agreements and Warranty ...................................................................................... 8
1Chasis & Safety ................................................................................................................. 9
1.1General data ...................................................................................................................... 9
1.2Main views and Dimensions ................................................................................................ 9
1.3Reference plane ............................................................................................................... 10
1.4Track Equipment .............................................................................................................. 11
1.5Safety overview and equipment ......................................................................................... 12
1.6Monocoque ...................................................................................................................... 12
1.7Protection secondary panel ............................................................................................... 13
1.8Side Crash Structure ......................................................................................................... 13
1.9Sacrificial keel .................................................................................................................. 14
1.10Front crash ...................................................................................................................... 14
1.11Rear crash ....................................................................................................................... 14
1.12Halo ................................................................................................................................ 14
1.13Extractable seat ................................................................................................................ 15
1.14Seat Pillow ....................................................................................................................... 15
1.15Seat belt .......................................................................................................................... 16
1.16Wheel tether .................................................................................................................... 16
1.17Fire Extinguisher System ................................................................................................... 16
1.18Components Mileage ........................................................................................................ 17
2Bodywork ........................................................................................................................ 19
2.1Halo Fairing ...................................................................................................................... 19
2.2Halo Painting .................................................................................................................... 20
3Setup ............................................................................................................................... 21
3.1Setup adjustment ............................................................................................................. 21
3.1.1 Lowerwishbonedesignconfigurationset‐up...........................................................................................22
3.1.2 Rideheightandpushrodsadjustment......................................................................................................23
3.1.3 Toe............................................................................................................................................................24
3.1.4 Camber.....................................................................................................................................................25
3.1.5 Casterfront...............................................................................................................................................26
3.1.6 CasterRear...............................................................................................................................................27
3.2Suspension coordinates .................................................................................................... 28
3.2.1 Front(STDconfiguration).........................................................................................................................28
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3.2.2 Rear(STDconfiguration)...........................................................................................................................29
3.3Front Geometry Adjustment
UMP Options ........................................................................... 30
3.3.1 RollCentreHeight.....................................................................................................................................32
3.4Rear Geometry adjustment ............................................................................................... 33
3.5Front torsion bar settings .................................................................................................. 35
3.5.1 Fronttorsionbarpre‐load........................................................................................................................36
3.5.2 FrontAntirollbarsettings........................................................................................................................37
3.6Rear Anti roll bar settings .................................................................................................. 41
4Maintenance and assembly instructions ......................................................................... 44
4.1Front Uprights .................................................................................................................. 44
4.1.1 Uprightassembly......................................................................................................................................44
4.2Rear Uprights ................................................................................................................... 47
4.2.1 Uprightassembly......................................................................................................................................47
4.3Wheel nut ........................................................................................................................ 51
4.4Assembly and Maintenance ............................................................................................... 51
4.5Anti-Roll bar backlash ........................................................................................................ 52
4.6Rear Rocker ..................................................................................................................... 53
4.6.1 Replacementprocedure:..........................................................................................................................54
4.7Front wing adjustment ...................................................................................................... 55
4.7.1 MainplaneGurneyOptionalTrimming.....................................................................................................55
5Steering ........................................................................................................................... 56
5.1Longitudinal adjustment .................................................................................................... 56
5.2Vertical adjustment ........................................................................................................... 57
5.3Kinematic backlash adjustment .......................................................................................... 57
5.4Pinion backlash adjustment ............................................................................................... 58
5.5CV joint orientation ........................................................................................................... 58
5.6Steering housing treatment ............................................................................................... 59
5.7Steering rack travel stop ................................................................................................... 59
5.8Steering rack potentiometer installation.............................................................................. 60
5.9Steering Line for KIT car ................................................................................................... 61
5.10Electric Power Steering (EPS) ............................................................................................ 62
5.11Alternative Ackermann Arms ............................................................................................. 62
6Gearbox, Clutch & Differential. Kinematic Chain ............................................................ 63
6.1Gearbox ........................................................................................................................... 63
6.1.1 Authorizedratios......................................................................................................................................63
6.2Differential & C/W ............................................................................................................ 64
6.3Clutch .............................................................................................................................. 64
7Oil System ........................................................................................................................ 64
8Leg Padding ..................................................................................................................... 64
9Heat Shields..................................................................................................................... 62
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10
Battery
............................................................................................................................. 6 3
“320.002‐OWNER’SMANUALSUPERBLITHIUMIRONPHOSPHATESTARTERBATTERIES.pdf”
............................63
11Fuel System ..................................................................................................................... 63
“320.001‐USEANDMAINTENANCEMANUALFORM.E.RINFLEXIBLETANKS.pdf”
..............................................63
12
Pedals
.............................................................................................................................. 65
12.1Pedals for KIT car ............................................................................................................. 68
12.2Brake Balance Adjuster ..................................................................................................... 69
12.3Pedals’ adjustments .......................................................................................................... 69
13Dampers .......................................................................................................................... 69
“320.004‐CALIBRATIONCURVEFORKONI320DAMPERS.pdf”
...................................................................................69
14Halo device ...................................................................................................................... 70
15Wheel Tethers Routing and covers .................................................................................. 71
15.1Wheel Tethers Protection .................................................................................................. 72
16Side Cones replacement .................................................................................................. 73
17Other important aspects ................................................................................................. 76
17.1Suspension ...................................................................................................................... 76
17.2Mirror .............................................................................................................................. 76
17.3Brakes ............................................................................................................................. 76
17.4Data acquisition ................................................................................................................ 76
17.5Engine ............................................................................................................................. 76
17.6Kinematic Chain ............................................................................................................... 77
17.7Cooling ............................................................................................................................ 77
17.8Ballast ............................................................................................................................. 78
17.9Skid pad .......................................................................................................................... 79
17.10Headrest and head protection ........................................................................................... 79
18Annexes ........................................................................................................................... 80
320 Owner’s Manual
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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.
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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
320 Owner’s Manual
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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
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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
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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.
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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
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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, …)
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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.
Any part of the bodywork that is facing the ground, may deflect NO more than 5mm vertically
when a load of 20kg is applied vertically at both sides of the chassis, at the outermost points
directly in front of the rear wheels. The load will be simultaneously applied on both sides of the
car in downward direction. During the test the car must stay on the skid block and the deflection
is measured on both sides of the car.
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).
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