1. Manuals
  2. Brands
  3. Tatuus Manuals
  4. Motorized Toy Car
  5. T-421
  6. User manual

Tatuus T-421 User Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
T-421 USER MANUAL
Release 2.1.0
(08/06/2023)

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the T-421 and is the answer not in the manual?

Questions and answers

Related Manuals for Tatuus T-421

Summary of Contents for Tatuus T-421

  • Page 1 T-421 USER MANUAL Release 2.1.0 (08/06/2023)

  • Page 2: Table Of Contents

    ONTENTS General Information ..........................8 Releases ............................. 8 1.1.1 Release list ..........................8 Technical Contacts ..........................9 1.2.1 Chassis ............................9 1.2.2 Engine ............................9 1.2.3 Gearbox ........................... 10 1.2.4 Electronic ..........................10 1.2.5 Tires ............................10 1.2.6 Brakes ............................11 1.2.7 Dampers...........................
  • Page 3 2.11 Steering Column ..........................40 2.12 Wheel Tethers ..........................40 2.13 Rear Crashbox Tethers........................40 2.14 Fire Extinguisher ..........................41 2.14.1 Fire extinguisher setup ......................42 2.14.2 Fire extinguisher system Test Mode ..................43 2.14.3 Fire extinguisher maintenance ....................43 2.14.4 Activating devices ........................
  • Page 4 3.6.3.3 Page #3: Logger page ......................68 3.6.3.4 Page #4: Electric Power Distribution ................... 69 3.6.3.5 Page #5: Engine warmup ..................... 70 3.6.3.6 Page #6: Gearbox page ......................71 Driver installation ..........................72 3.7.1 Steering Wheel Longitudinal Adjustment................72 3.7.2 Steering Wheel Vertical Adjustment ..................
  • Page 5 5.4.1 Front vertical stiffness ......................100 5.4.2 Rear vertical stiffness ......................100 Dampers ............................101 5.5.1 Adjust damping ........................101 5.5.2 Spring preload ........................101 5.5.3 Cleaning ..........................102 5.5.4 Inspection ..........................102 5.5.5 Recommended Service Intervals ................... 102 5.5.6 Compression damping curve ....................
  • Page 6 Fuel Coupling ..........................126 Fuel Machine Options ........................127 Oil System ............................128 Electric System ........................... 129 11.1 Overview ............................129 11.2 Power system ..........................129 11.2.1 Power loom routing ....................... 129 11.2.2 Main switch ........................... 131 11.2.3 Battery ........................... 132 11.2.4 Battery installation ........................
  • Page 7 13.8 Glued Components ........................151 13.9 Special tools ........................... 151 13.10 Information about disassembly ....................152 13.11 Assembly /disassembly ......................152 13.11.1 Gears disassembly ......................152 13.11.2 Gears refitting ........................155 13.11.3 Selector shaft disassembly ....................156 13.11.4 Selector shaft refitting ....................... 158 13.11.5 Barrel and reverse gear rocker removal ................
  • Page 8 Annexes ............................. 185 16.1 Tightening Torque ......................... 185 RELEASE 2.1.0...

  • Page 9: General Information

    Modifications from previous release are in purple. 1.1.1 Release list Version Release Date Author Notes 1.07 26/11/2021 Tatuus Startup version 1.08 12/01/2022 Tatuus First release 2.2 Added Homologation number 11.2.3 Added Lithium Battery information 11.2.5 Added Jump battery information 1.09...

  • Page 10: 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 AUTOTECNICA Via A. Bernardi, 3 26041 Casalmaggiore (CR) - Italy Tel.

  • Page 11: 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 Email : sadev@sadev-tm.com Web: www.sadev-tm.com 1.2.4 Electronic 1.2.5 Tires RELEASE 2.1.0...

  • Page 12: Brakes

    1.2.6 Brakes T.M. Tecnologie Meccaniche S.r.l. via dei Pioppi, 30 Padulle di Sala Bolognese – 40010 (BO) Tel +39 051 829092 Email: info@tmperformance.com 1.2.7 Dampers ANDREANI GROUP INTERNATIONAL Strada della Romagna, 361 (Loc. Colombarone) 61121 Pesaro (PU) Tel. (+39) 0721 209020 Email: info@andreanigroup.com 1.2.8...

  • Page 13: 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 14: Overview

    Aros XHAUST Magneti Marelli / Next Solution LECTRONICS SADEV SLR75 EARBOX Magneti Marelli ESA 2 EARSHIFT TATUUS / Next Solution TEERING WHEEL MegaLife ATTERY PREMIER FT3-1999 UEL CELL Carbon fiber extractable shell with gap fillers. Three sizes of seat available.
  • Page 15 RELEASE 2.1.0...

  • 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 Steering/toe arms** 2’000 10’000 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...

  • Page 18: 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 19: Extractable Seat & Gap Fillers

    2.3 E & G XTRACTABLE ILLERS The F4 cockpit has been design in a way that drivers with a spread of body size from 1.50m to 1.97m may be fitted in the car. In order to fit correctly the drivers and achieve a limitation of the seat foam inserts thickness of 50mm, different size of extractable seats (small, medium and large) are available.
  • Page 20 Small: Small foam insert Medium Large Medium carbon seat shell Additional gap filler must be used to fill the gap between the carbon seat shell and the survival cell. Two different size of gap filler are available for the different size of the seat shell. Large gap fillers Small/Medium gap fillers RELEASE 2.1.0...
  • Page 21 For the sole purpose of improving the habitability and the driver comfort it is allowed to cut the foam of the medium gap filler in the indicated area. The trimmed gap filler cannot be longer used in addiction with the small size seat. Cut-outs for the routing of break/clutch/extinguisher lines, wiring looms and similar are permitted in the large gap filler, the highlighted area below indicates the maximum recess allowed.
  • Page 22 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 23: Driver Padding

    2.4 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 24: Seat Belts

    2.5 S ELTS The straps must be securely fixed to the car and must comply with FIA standard 8853-2016. Shoulder belts fixing points (4 positions available) Medium seat fixing point (lap belt) Large seat fixing point (lap belt) Crotch belts fixing points RELEASE 2.1.0...

  • Page 25: Driver Installation

    2.6 D RIVER INSTALLATION Please find below the relevant articles from the FIA Formula F4 2 GEN Technical Regulation 14.7.5 Any seat made from foam must be covered with a non-flammable and non-combustible material. The thickness of any foam insert is limited to maximum 50mm The foam thickness is measured as the following: Behind and underneath the driver parallel to the car center plane Beside the driver normal to the car center plane...
  • Page 26 RELEASE 2.1.0...

  • Page 27: 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 28 CHASSIS Seeger [J24X1,2V] Shims (if any) [2401059/60] Shims (if any) [2401059/60] Barrel [2401020] Belleville washer stacking Barrel lock [2401025] < > < or > < > [S4271] It is possible to adjust the axial play of the quick release barrel nut stacking or removing items #2: Quick release shims.

  • Page 29: Front Nose Repair Specification And Procedure

    2.7.3 Front nose repair specification and procedure 2.7.3.1 Applicable requirements The following procedure is applicable only when the damage is contained in the first 150mm from the nose tip (700mm from the nose/FAIP interface), all the other damages must be inspected by the manufacturer. 2.7.3.2 Replacement procedure Spare nose tip is available as spare part, the reference code is 33-01-032...

  • Page 30: Front Anti Intrusion Panel

    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. In general evident damages must be inspected by the manufacturer, the structure must be checked and repaired by a center authorized by Tatuus.

  • Page 31: Halo

    2.10 H 2.10.1 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. For example, the PETRONAS TUTELA Z2 grease is suitable for this purpose. 1.
  • Page 32 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 33 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). 8.
  • Page 34 9. Fasten the two M12X30 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). 10.
  • Page 35 11. Tighten the two shoulder bolts 24-01-033. 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. 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.
  • Page 36 14. Tighten the six NAS6207-12 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 (24-01-033), then on the M12 bolts and finally on the NAS6207-12 bolts.
  • Page 37 17. Position the front fairing (33-01-043) and fix it with two button head bolts (UNI7380-TX-M5X10). RELEASE 2.1.0...

  • Page 38: Disassembly Procedure

    2.10.2 Disassembly procedure 1. Lift the front fairing 2. Unscrew and remove the six NAS6207-12 bolts. Do not unscrew one bolt first and then the others. Loose the bolts gradually, keeping the balance on all of them. RELEASE 2.1.0...
  • Page 39 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.

  • Page 40: Halo Painting And Certification

    (i.e., helicopter tape). If the hologram needs to be re-placed or re-fitted, the HALO should come back to Tatuus for inspection and re-certification. Please get in contact with Tatuus for timeline and quote for the activity.

  • Page 41: Steering Column

    2.11 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 ① must be replaced and the column carefully inspected. 2.12 W HEEL ETHERS...

  • Page 42: Fire Extinguisher

    2.14 F XTINGUISHER The car is equipped with an electrically actuated fire extinguishing system. Extinguisher system components: 1. OMP CEFAL3 0.9 lt. ecolife extinguisher bottle 2. Control box 3. Cockpit extinguisher button 4. Marshal extinguisher switch 5. Cockpit nozzle 6. Engine nozzle Homologation: FIA 2000 OM.

  • Page 43: Fire Extinguisher Setup

    2.14.1 Fire extinguisher setup The fire extinguisher system must be checked and armed each time before an event where the car is driven on the racetrack. Check that the switch on the control box ② is in the ON (armed) position before using the vehicle. On the cockpit panel, when the switch is set to ON, the GREEN LED ⑧...

  • Page 44: Fire Extinguisher System Test Mode

    2.14.2 Fire extinguisher system Test Mode Switch the control unit to OFF mode on the control box ②, press the button ③ or pull the marshal switch ④, the LED ⑩ will turn ON, thus indicating that the system is connected correctly. The LED on the extinguisher control box verifies the functionality of the system and turns on ONLY when the extinguisher bottle is connected to the system.

  • Page 45: Activating Devices

    2.14.4 Activating devices • Cockpit panel: push-pull button ③. WARNING, once activated the button must be pulled to be rearmed. • Marshal switch: located behind the main rollhoop. WARNING, once activated the unit must be rearmed releasing the lock pin. In the event of fire extinguisher activation, pay attention to clean all the extinguisher foam from the electrical connections.

  • Page 46: Rain Light

    2.15 R IGHT The F4 car must have three rear lights in working order throughout the events. The rain light features 16x High intensity LED A minimum of 85% of the LED’s must be operational at any time. 2.15.1 Rain Light modes The three lights operate different modes according to car condition: •...

  • Page 47: Clutch Disengagement

    2.16 C LUTCH ISENGAGEMENT In case of a sudden stall, the car can still be moved following this procedure: 1. Press the clutch. 2. Turn the valve (90° deg. Clockwise). To avoid an improper/unwanted use, the valve ① is protected by a cover. 3.

  • Page 48: Fia Throttle Fail Safe

    2.17 FIA T HROTTLE The car is equipped with a FIA throttle fail safe algorithm, which, in case throttle and brake pedal are pressed at the same time, overrides the throttle and cuts the engine. Abarth Car Speed > 10 km/h Engine rpm >...

  • Page 49: 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 2.1.0...

  • Page 50: Rear Jacking

    3.1.2 Rear Jacking The highlighted jacking points are suitable to carry the weight of the car. RELEASE 2.1.0...

  • Page 51: Stands Position/Width

    3.1.3 Stands Position/Width RELEASE 2.1.0...

  • Page 52: Setup Tools

    3.2 S ETUP OOLS Here below some views of the main reference points 3.2.1 Front references RELEASE 2.1.0...

  • Page 53: Rear References

    3.2.2 Rear references RELEASE 2.1.0...

  • Page 54: Wheel Hub

    3.2.3 Wheel hub Wheel nuts socket wrench dimension: 35 mm RELEASE 2.1.0...

  • Page 55: Straight Steering Wheel Position

    3.2.4 Straight steering wheel position 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] Reference Plane Camber [deg] -4.0° -3.0° GEOMETRY Caster [deg] 9.4° Toe (Total) [deg] +20’...

  • Page 56: Weight And Ballast

    3.4 W EIGHT AND BALLAST The T421 chassis has two locations for the ballast installation, the following drawings are a simple guideline to achieve the maximum allowed weight using steel. Shape and weight (limited to the maximum value shown below) is free. Length of the screws are free but must respect the Diameter listed below. Please refer to the relevant sporting regulations for possible restrictions.

  • Page 57: Ballast Position 2

    3.4.2 Ballast Position 2 Maximum weight in position 2: 5.0 kg. Fixing: 2 x M8 CSCH screws. RELEASE 2.1.0...

  • Page 58: Engine Ballast

    3.4.3 Engine Ballast Max 20.0 kg, fixation 5x M8 bolts (Preliminary plan above). Please refer to the engine manufacturer for further details and prescriptions. RELEASE 2.1.0...

  • Page 59: Dimension For Transportation

    3.5 D IMENSION FOR TRANSPORTATION 3.5.1 Nosecone reverse position RELEASE 2.1.0...

  • Page 60: Power Unit -To-Chassis Mounting Points

    3.5.2 Power Unit -to-chassis mounting points As per FIA F4 - 2nd Gen Technical Regulations the Power Unit-to-chassis mounting points are arranged in accordance with the following Drawing: RELEASE 2.1.0...

  • Page 61: Controls And Display

    3.6 C ONTROLS AND ISPLAY 3.6.1 Cockpit Controls • [1] Main power switch: Position 1: Main OFF Position 2: Master switch ON Position 3: Ignition ON IGNITION ON (KILL OFF) MAIN ON (KILL ON) MAIN OFF • [2] Starter button (YELLOW) •...
  • Page 62 RELEASE 2.1.0...

  • Page 63: Steering Wheel Controls

    3.6.2 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 (4 seconds) will reset chassis sensors (steering angle, accelerometers). •...

  • Page 64: Steering Wheel Display

    3.6.3 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: High 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 65: Page #1: Driver Page

    3.6.3.1 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 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.
  • Page 66 In the logged data are available the channel: • DashAlarm: bitmapped, triggers value 1 on relevant bit if one of the alarms has been shown. Please refer to the table below showing bitmap configuration for the channel above: DashAlarm RELEASE 2.1.0...

  • Page 67: Page #2: Setting Page

    3.6.3.2 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 68 • 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 RELEASE 2.1.0...

  • Page 69: Page #3: Logger Page

    Acc Y: lateral acceleration [mg] from external accelerometer All the listed channels except wheel speeds are set to zero when ACK button is pressed longer than 1 second. Damper position sensors and external accelerometer are optional parts. Please refer to the T-421 Spare parts catalogue.

  • Page 70: Page #4: Electric Power Distribution

    3.6.3.4 Page #4: Electric Power Distribution This page shows the power system of the car, each box contains the current drawn by the relevant line. The background of the boxes is • White: if the relevant power line is not commanded •...

  • Page 71: Page #5: Engine Warmup

    3.6.3.5 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: Fuel temperature [°C] (if available from ECU) •...

  • Page 72: Page #6: Gearbox Page

    3.6.3.6 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 73: Driver Installation

    3.7 D RIVER INSTALLATION 3.7.1 Steering Wheel Longitudinal Adjustment The longitudinal position of the steering wheel is limited by FIA regulation. The spacers ① allow the adjustment of the steering wheel depth, each spacer add 13mm and can be stack up to two.

  • Page 74: Steering Wheel Vertical Adjustment

    3.7.2 Steering Wheel Vertical Adjustment The steering wheel height is adjustable adding or removing spacers from the column bracket. Std: 1 shim (0 mm) Min: no shim (+5 mm) Max: 3 shim (-10 mm) After any stack setting, it is reminded to check the correct alignment of the forward column bracket. Adjust its vertical position if necessary.

  • Page 75: Gearshift Paddles

    3.7.3 Gearshift paddles Please find below the standard delivery configuration for the gearshift paddles. The steering wheel comes with the paddle TSW0203006 on the RH side and with the TSW0203005 on the LH side TSW0203006 TSW0203005 To improve driver ergonomics the paddles may be considered as alternative items. Please find in the picture below a possible configuration with paddles reverted compared to the standard delivery configuration.
  • Page 76 It is necessary that the longer tip of the paddle faces upwards, the configurations below must not be used. NOT ALLOWED NOT ALLOWED RELEASE 2.1.0...

  • Page 77: Pedals

    3.8 P EDALS The three pedals may be placed independently, all of these are “standalone”. RELEASE 2.1.0...

  • Page 78: Brake Pedal

    3.8.1.1 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 correctly in position and far from their contact. It is recommended to replace the balance bar and the pedal base every 10’000 km.

  • Page 79: Throttle Pedal

    3.8.1.2 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 meet the calibration thresholds.

  • Page 80: Throttle Pedal Learning

    3.8.1.3 Throttle pedal learning 1. Adjust the pedal potentiometer position according to the threshold for the rest and full stroke position stated in the engine manual. 2. Switch OFF the car IGN. ON MAIN ON MAIN OFF 3. Push and hold the throttle pedal to full stroke 4.
  • Page 81 6. On the bottom right corner of the dash will be displayed the message below During this waiting period the throttle body is commanded by the ECU from full closed to full stroke, then back to full closed. It is possible to hear it moving. 7.

  • Page 82: Clutch Pedal

    3.8.1.4 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 compared to the optional master cylinders available: Master cylinder...

  • Page 83: Heel Rest

    3.8.2 Heel rest An heel rest may be fitted, provided that it fulfills just the functions listed below • support the driver’s heel • allow to raise the driver’s feet The heel rest should be made of homogeneous material. While manufacturing the heel rest make sure that it does not put any sharp edge in place. Please find in the drawing below the pedal board mounting holes pattern for reference RELEASE 2.1.0...
  • Page 84 To assure pedals and heel rest stability it is recommended to bolt the heel rest on the unused holes placed rearwards of the pedals. Please refer in the picture below to the blue highlighted area RELEASE 2.1.0...
  • Page 85 If not possible to bolt the heel rest on the unused holes: • it should be held on the same bolts used to fit the pedals. • it should be placed between the pedal base and the internal chassis floor in a way that the bottom surface of the pedal bases are fully supported by the heel rest.

  • Page 86: Brake Bias

    3.8.3 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 Brake pressure (Front and Rear) and Brake Bias, defined as ������������...

  • Page 87: Aerodynamics

    ERODYNAMICS 4.1 G ENERAL OTES Drag [SCx]: total drag (including wheels) of the car resolved to the tire contact point. Downforce [SCz]: total downforce generated by the car. Front downforce: downforce acting at the front contact patches. Rear downforce: downforce acting at the rear contact patches. Balance %F: percentage of the total downforce acting at the front contact patches.

  • Page 88: Aerodynamic Sensitivity Definition

    4.2.2 Aerodynamic sensitivity definition All maps’ points are percentual variations with respect to the aerodynamic datum point (shown in par.4.2.1). So, if the datum point is: ���� = 100% �� ���� = 100% �� %�� = 40% A variation of (e.g.) -15% of all the coefficients will bring to: ̃...

  • Page 89: Wing Sensitivity

    TATUUS recall that, by FIA Technical Regulation, the use of gurney flaps on any of the rear aerofoils is currently not allowed. 4.5 W ENSITIVITY The following tables report the percentage changes from the datum point resulting from the change of flap angles (FW = Front Wing Angle / RW = Rear Top Wing Angle).

  • Page 90: Wing Sensitivity With Fw Gurney Flaps H15 Not Installed

    4.5.2 Wing Sensitivity with FW gurney flaps h15 NOT installed → -20.8% -6.0% +9.2% -23.9% -9.1% +6.0% ↓ -27.0% -12.1% +3.0% -29.9% -15.1% +0.1% -32.7% -17.8% -2.7% -35.3% -20.5% -5.4% -37.9% -23.1% -7.9% -40.3% -25.5% -10.4% -42.6% -27.8% -12.7% -44.8% -29.9% -14.8% -46.8%...

  • Page 91: Ride Height Sensitivity

    4.6 R EIGHT ENSITIVITY The Ride Height Sensitivity is referred to a configuration with gurney flaps 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 2.1.0...
  • Page 92 RELEASE 2.1.0...
  • Page 93 RELEASE 2.1.0...

  • Page 94: 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 95: Front Wishbones Brackets Assembly

    RONT WISHBONES BRACKETS ASSEMBLY During the assembly pay attention to the orientation of the wishbones brackets studs (items #1 below), the thread undercut side is the one that must be assembled in the chassis. CHASSIS Thread undercut RELEASE 2.1.0...

  • Page 96: Geometry Adjustments

    5.3 G EOMETRY DJUSTMENTS 5.3.1 Ride height adjustment Act on the adjustment element ① on the pushrod to modify the ride height of the car. Refer to the table below for the effect of the adjustments on the front and rear ride height. Ride height adjustment Front Ride Height change Rear Ride Height change...

  • Page 97: Camber Adjustment

    5.3.2 Camber adjustment Front camber is set changing the shims stack between Ackermann and the upright: Camber Front Rear adjustment Camber change Camber change +1 mm +0.42 deg (+25’) +0.3 deg (+18’) Max camber shim 13 mm 11 mm Min camber shim 0 mm 0 mm Warning:...

  • Page 98: Toe Adjustment

    5.3.3 Toe adjustment Toe can be adjusted by the steering arm length Toe adjustment Front Rear Total Toe Change Total Toe Change +1 turn +1.12 deg (+1°07’) +1 deg RELEASE 2.1.0...

  • Page 99: Caster Adjustment

    5.3.4 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 9.4° of caster angle. Caster adjustment Front Rear Caster Change +1turn +0.47 deg (+28’12”’)

  • Page 100: Ump Adjustment

    5.3.5 UMP adjustment The front pushrod is directly installed on the upright, its pick-up point can be adjusted longitudinally (laser marked arrow forward/rearward) 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 steering effort.

  • Page 101: Vertical Stiffness

    5.4 V ERTICAL STIFFNESS 5.4.1 Front vertical stiffness The table below resumes stiffness options available and relevant stiffness at the wheel: Spring stiffness [lb/in] 1000 1100 Ground stiffness [daN/mm] 10.3 13.2 14.7 16.2 Motion ratio (wheel/damper): 1.1 Springs can be preloaded acting on the damper/spring platform, the pitch of the thread is 1.5mm. 5.4.2 Rear vertical stiffness The table below resumes stiffness options available:...

  • Page 102: Dampers

    5.5 D AMPERS ANDREANI Formula Light damper is based on mono tube design for competition purposes, the 2-Way adjustment mechanisms allow maximum control over the damping forces generated. Technical specification FL Full length 320 mm Stroke 48 mm SL Spring max length 109 mm ID Spring inner diam 36 mm...

  • Page 103: Cleaning

    Curve Compression Position Rebound Position BLUE Compression Rebound Table 1The graph illustrated is to be considered indicative. The curves produced may undergo variations based on the test conditions. 5.5.3 Cleaning Clean the shock absorber externally with a soft detergent. Use compressed air. Be careful that all dirt is removed.

  • Page 104: Compression Damping Curve

    5.5.6 Compression damping curve RELEASE 2.1.0...

  • Page 105: Rebound Damping Curve

    5.5.7 Rebound damping curve RELEASE 2.1.0...

  • Page 106: Rolling Stiffness

    5.6 R OLLING STIFFNESS 5.6.1 Front roll stiffness The motion ratio of the front anti-roll bar is: Blade length [mm] 129.5 119.5 109.5  /  [deg/deg] 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] 22.0...

  • Page 107: Suspension Geometry

    5.7 S USPENSION EOMETRY 5.7.1 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 108: Rear Suspension Geometry

    5.7.2 Rear suspension geometry -370,0 141,0 169,2 -11,5 669,0 163,0 -10,0 115,4 164,7 -280,7 146,1 325,4 -85,0 615,1 348,5 95,0 101,0 336,8 47,7 614,9 353,1 84,6 213,5 340,4 735,0 249,0 735,0 -485,0 135,0 381,1 -206,3 43,3 419,0 -180,0 123,5 385,9 -180,0 85,3 293,5...
  • Page 109 Pick up nomenclature according to the following image. The following table summarize the pickup point coordinates of the standard configuration (BE23). 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 110: Anti-Effects

    5.7.3 Anti-effects The following tables show the anti-effects of the car for the ensuing settings: • Front wheel hub: 253mm over reference plane • Rear wheel hub: 249mm over reference plane The RC height is related to the reference plane. 5.7.3.1 Front Pick Up position...
  • Page 111 Pick Up position RC height (mm) α [°] α [°] anti_Lift anti_Squat AD13 -17,6 AD14 -55,6 11,6 AD23 -19,4 -0,6 AD24 -57,5 AE13 -5,7 AE14 -43,6 AE23 -7,5 AE24 -45,6 BD13 -9,0 -0,4 BD14 -46,4 13,4 BD23 -10,8 -1,5 BD24 -48,3 -0,3 BE13...

  • Page 112: Optional Damper Sensors

    Wheel/Pot: 2 [mm/mm] Spring/Pot: 1,8 [mm/mm] Spring/Pot: 1,6 [mm/mm] For the optional sensors and adaptor looms, please refer to the T-421 spare parts catalog. For the analog spare input configuration in data logging, please refer to the engine manufacturer. Warning: Please refer to the sporting regulation about the installation and use of the damper sensors in the official events.

  • Page 113: Suspension Maintenance

    5.9 S USPENSION AINTENANCE 5.9.1 Upright Maintenance 5.9.2 Upright Disassembly The upright can be disassembled for inspection: 1. Remove the seeger [g] and the wheel axle [f]. 2. Apply unlock spray. 3. Using the special tool [e] (pn. 3391010, available on Spare Part Catalogue), unscrew and remove the ring nut [d].
  • Page 114 4. Press the hub out. It is suggested to do this operation with a hydraulic press. Pictures below shows the procedure using a TATUUS’ special tool available upon request (ref p/n 3391005). 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 115 5. For the final phase of the extraction remove the hub with a drift punch through the 4mm holes [A]. RELEASE 2.1.0...
  • Page 116 6. Remove the bearing retention ring (a). 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 2.1.0...

  • Page 117: Upright Assembly

    5.9.3 Upright Assembly Here below the assembling 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 118 6. Fit the ring nut [d] 7. Using the special tool [e] (pn. 3391010, available on Spare Parts List) tight the ring nut to 500Nm. 8. Insert the wheel axle [f] and secure the seeger [g]. RELEASE 2.1.0...
  • Page 119 RELEASE 2.1.0...

  • Page 120: Steering

    TEERING 6.1 S TEERING EOMETRY Standard ratio: 8 teeth pinion Pinion primitive diameter: 17.3 mm Steering ratio: 11.7 °/° 6.2 S TEERING AINTENANCE The steering rack must be periodically inspected: • rack pinion play: the preload can be set acting on the bush [2], its position should be regularly inspected to follow system wearing, periodically inspect bush [3];...
  • Page 121 Rack end assy: allow some preload [2-3] to avoid any free play during the setting up, periodically change the bush [1]. RELEASE 2.1.0...

  • Page 122: Wheels And Tires

    HEELS IRES 7.1 W HEELS Front wheels: OZ Wheels 8.0”x13” Rear wheels: OZ Wheels 10.0”x13” 7.2 W HEEL Wheel nut tightening torque: 220 Nm 7.3 T IRES Refer to the documentation provided by the championship tire manufacturer. RELEASE 2.1.0...

  • Page 123: Brake System

    RAKE YSTEM 8.1 B RAKE YSTEM ETUP Master cylinder suggested configuration: FRONT ø REAR ø Standard 19.05 mm 20.64mm The following table shows the front brake balance when the balance bar is set at the mid adjustment (master cylinders have the same distance from trunnion): REAR 5/8”...

  • Page 124: Brake System Bedding-In

    8.2 B RAKE YSTEM 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 125: Fuel System

    YSTEM 9.1 F Premier FT3/99 Rubber bladders should be used for no more than 5 years after the date of manufacture, unless inspected and recertified by the manufacturer for a period of up to another 2 years. Fuel cell contains a maximum of approximately 45 liters Before installing the bladder, make sure that the chassis compartment is free of sharp edges and clean.

  • Page 126: Fuel Drain Procedure

    9.2 F UEL DRAIN PROCEDURE • Main switch in ON position IGN. ON MAIN ON MAIN OFF ○ • Double click MARK button 6 to activate fuel pump (for fuel drain purpose). ○ • Single click MARK button 6 to deactivate fuel pump. RELEASE 2.1.0...

  • Page 127: Fuel Coupling

    9.3 F OUPLING The feeding line to the engine is equipped with a safety dry-break: Staubli SPT08.3655/L/JV SPT08.7655/L/JV The fuel tank port is equipped with a dry break • Filling Port: Staubli N00916298 (on board) • Mating Port: o Staubli N009 161 98 (fuel bottle) o Staubli SPT12.1658/L/JV (fuel machine) RELEASE 2.1.0...

  • Page 128: Fuel Machine Options

    9.4 F ACHINE PTIONS An optional system can be installed to have a breather valve dry coupled. 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. RELEASE 2.1.0...

  • Page 129: Oil System

    10 O YSTEM The oil tank is located within the gearbox bellhousing. Some oil may overflow into the catch tank, so regularly drain and clean it to optimize oil level. It is recommended to follow the procedure below in order to have a consistent level measurement: •...

  • Page 130: Electric System

    11 E LECTRIC YSTEM 11.1 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 131 33-25-040 Fuse Jump Battery loom 33-25-043 RELEASE 2.1.0...

  • Page 132: Main Switch

    11.2.2 Main switch The master switch is actuated by the cockpit panel and emergency switches, connection schematics: • +12V Generator (loom 33-25-040) • +12V Chassis loom ring (“Main Switch” on Chassis Loom) • +12V Battery (loom 21-16-18-019) • Main switch coil supply (“TYCO Main Switch” on Chassis Loom) •...

  • Page 133: Battery

    11.2.3 Battery The car is equipped with 14 Ah AGM battery. The battery is a crucial component interacting with engine and gearbox management systems. Pay particular attention to its charge level especially if you are running reset procedures. It is particularly important to keep the SOC (state of charge) of the battery at an high rate, running with the battery at low SOC may reduce its performance and affect the battery SOH (state of health).

  • Page 134: Jump Battery

    11.2.5 Jump battery It is suggested the use of a jump battery during the engine crank and during the garage/pits and grid operations. The car is equipped with Lithium battery. A specific Jump battery suitable with Lithium batteries is necessary. The rear wing pillar has a double thread suitable for the Anderson SB50 plug.

  • Page 135: Fire-Up/Switch-Off Procedures

    11.2.6 Fire-UP/Switch-OFF Procedures The following procedures best practices are suggested with the aim to reduce the risks of damages to the electronics due to hard electrical spikes. Best Practices in Fire-UP/Switch-OFF Whenever is possible plug-in the jump battery BEFORE toggling the Main switch in MAIN ON position. It is recommended to switch-off the engine by pushing Start button on the Steering wheel, alternatively toggle the Main switch in the middle position (MAIN ON).

  • Page 136: Power-Box

    11.2.7 Power-box The car is equipped with a Power Distribution Module, usually referred to as power-box. The Power-box manages the current distribution on the power lines listed on the following paragraphs. 16 power lines are available. The lines are subdivided in 2 groups: HP lines (total of 6) and LP lines (total of 10). Some of the lines are merged in order to meet the power requirements of the devices connected.
  • Page 137 The powerbox features an on board led indicator panel. Please find it reported in picture below First row led strip • LS1, LS2 : not used • IN1 – IN6: show the status of the input activation. With reference to paragraph Error! Reference source not found.
  • Page 138 Please find in the following picture the powerbox line connection map: RELEASE 2.1.0...

  • Page 139: Wiring

    11.3 W IRING RELEASE 2.1.0...

  • Page 140: Electrical Schematics

    11.4 E LECTRICAL CHEMATICS Refer to PDF files available in the Tatuus’ sharezone for electrical schematics. 11.4.1 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.

  • Page 141: Can Termination

    Please find below a table showing which device is connected to can line and which are the connectors where the can line is available. CAN-line CAN Numbering CAN name CAN-0 CAN-1 CAN-Cortex Type Powerbox device Steering wheel device device device CAN AUX CHASSIS LOOM connector CAN AUX GBOX LOOM...

  • Page 142: Sensors

    Please refer to the T-421 spare parts catalogue. • GPS unit An optional 10Hz unit compatible with data logging system, standard and high gain antennas are available. Please refer to the T-421 spare parts catalogue. Dedicated connection is available at the RELEASE 2.1.0...

  • Page 143: Video System

    front end of the chassis. The antenna may be installed on the front damper deck below the Kevlar patch of the damper cover. For optional sensors and devices allowed use please refer to the Sporting Regulation of the relevant Championship. 11.4.5 Video system AIM smarty cam GP HD 2.2 is supplied together with the car.

  • Page 144: Engine

    12 E NGINE For any technical information contact the engine suppliers RELEASE 2.1.0...

  • Page 145: Transmission

    13 T RANSMISSION 13.1 S ADEV EARBOX F4-21 car is equipped with a 6 gears sequential gearbox, not limited slip differential: the SADEV SLR75-14 13.2 R ATIO HART Final drive Ref. Secondary shaft Crown wheel Reverse gear Primary shaft Idler Secondary shaft RELEASE 2.1.0...

  • Page 146: Standard Stages Chart

    13.3 S TANDARD TAGES HART Gear Ratio 12/30 2.50 16/30 1.88 18/27 1.50 20/25 1.25 25/26 1.04 23/20 0.87 RELEASE 2.1.0...

  • Page 147: Optional Stages Chart

    13.4 O PTIONAL TAGES HART Gear Ratio 12/30 2.50 16/30 1.88 18/27 1.50 20/25 1.25 24/26 1.08 21/20 0.952 RELEASE 2.1.0...
  • Page 148 RELEASE 2.1.0...

  • Page 149: Lubrication

    13.5 L UBRICATION 13.5.1 Particular Precautions No additives should be added to the oil. The resulting consequences are not in any circumstances covered by SADEV. When topping up the rear differential oil, do not mix any other oil with that already in the box. 13.5.2 Storage And Use Be particularly careful with any oil bottles which are open when used: •...
  • Page 150 RELEASE 2.1.0...

  • Page 151: Sadev Factory Rebuild

    13.6 S ADEV ACTORY EBUILD • The gearboxes are delivered plumbed and numbered. • SADEV will adopt a careful attitude when receiving a gearbox without any ‘SADEV ‘seals. This will also be valid if the gearbox shows minor or major damages. 13.6.1 Returning Gearboxes For Servicing At the time the gearboxes return to SADEV, follow the Receiving procedure as described below: •...

  • Page 152: Glued Components

    13.8 G LUED OMPONENTS Glued components and tightening torque are shown in the 3D exploded view, refer to paragraph 13.12. 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. 13.9 S PECIAL TOOLS IMAGE...

  • Page 153: Information About Disassembly

    13.10 I NFORMATION ABOUT DISASSEMBLY Before any intervention Unless otherwise stated, all interventions are done with gearbox in neutral, drained and disassembled of the car. Arrange you a clean and large enough surface to put parts during disassembly. It is very important to mark the mounting direction of each part during disassembly. When they were run in a direction of rotation, reusing them in the opposite direction may cause premature damage.
  • Page 154 ○ ○ • Remove the circlips 2 and the nut stopping washers 3 from the primary and secondary shafts, then engage two gears. • Mount the anti-splay plate FOUT9019004 on the primary and secondary shafts. • Loosen the 2 nuts: use FOUT1910110 tool for the primary shaft use FOUT9003276 tool for the secondary shaft.
  • Page 155 RELEASE 2.1.0...

  • Page 156: Gears Refitting

    • Remove the anti-splay plate, then remove each component, noting the order of assembly. 13.11.2 Gears refitting • Clean and check the condition of parts. • Lightly lubricate the forks and the needle roller bearing cages using gearbox oil. • Replace each gears in the reverse order from removal.

  • Page 157: Selector Shaft Disassembly

    13.11.3 Selector shaft disassembly • Engage reverse gear. ○ • Remove the push pin of the selector ratchet ○ • Unscrew the 3 M6 screws then remove the selector closing block RELEASE 2.1.0...
  • Page 158 • Hold the selector shaft rachet with a magnet (Facom tool ref.827.1). • Remove the selector assembly. Check the components. RELEASE 2.1.0...

  • Page 159: Selector Shaft Refitting

    13.11.4 Selector shaft refitting • Engage the reverse gear. Check the O'ring. • Set in place the rachet into the selector axle. • Insert the selector axle assembly in the main housing. • Refit the selector closing block with the 3 M6 screws (loctite 243; torque 15N.m). •...

  • Page 160: Barrel And Reverse Gear Rocker Removal

    13.11.5 Barrel and reverse gear rocker removal • Remove all gears. "see paragraph 13.11.1" and the primary shaft. ○ • Remove the reverse gear rocker: hold the special nut with a flat wrench 1 , loosen the external ○ pin bolt with an Allen key •...

  • Page 161: Differential Removal

    13.11.7 Differential removal • Drain the gearbox. • Disconnect the sensor and unscrew the 5 M10 nuts and the 5CHC M10x30 screws. • Remove the rear housing. • Extract the differential. RELEASE 2.1.0...
  • Page 162 RELEASE 2.1.0...

  • Page 163: Differential Block Disassembly

    13.11.8 Differential block disassembly ○ • Remove the circlips ○ • Remove the cover ○ • Remove the outside circlip "wire locking" • Remove the gear axles from the case, extract the planet gears and the sun gears from the cage. RELEASE 2.1.0...

  • Page 164: Differential Block Reassembly

    13.11.9 Differential block reassembly • Clean and degrease the parts, check their wear and replace if necessary. • Reassemble the parts, use gearbox oil to lubricate, respect the reverse order of disassembly. • Use safety wire to secure the circlip. RELEASE 2.1.0...

  • Page 165: Crown Wheel And Differential Bearings Replacement

    13.11.10 Crown wheel and differential bearings replacement ○ • Remove the bearings (extractor needed) ○ ○ • Untighten the M10x1.00 bolts 2 (heat if necessary). Remove the crown wheel ○ • Remove the EKAGRIP wedge • Clean and degrease the wheel crown, use an M10 x 1.0 tap drill. •...

  • Page 166: Remove The Secondary Shaft

    13.11.11 Remove the secondary shaft • Drain the gearbox through the lower drain plug. (see paragraph 13.5.6 ). • Remove the primary gears and secondary gears (see paragraph 13.11.1). • Remove the differential case (see paragraph 13.11.7). ○ • Using a mallet, remove the secondary shaft ○...

  • Page 167: Secondary Shaft Advancement, Shim Calculation

    13.11.12 Secondary shaft advancement, shim calculation. Operation to find the thickness (D) of the advancement shim on the secondary shaft: • Note the smallest dimension marked in the main housing (A) (ex 133.50). • Note the thickness of the two secondary shaft bearings (B) (ex 33.94). RELEASE 2.1.0...

  • Page 168: Secondary Shaft Reassembly

    • Note the value engraved on the secondary shaft (C) (ex 95.94) A - (B + C) = D Ex: 133.50 - (33.94 + 95.94) = 3.62 Choose the shim from the F19102051 set, assemble the shim being the closest as possible to the calculated thickness (ex 3.60mm).
  • Page 169 • Refit the bearings flange on the housing, tighten the 6 M8 bolts (Loctite 270; torque 25N.m). • Set it in place the secondary shaft through the bearings using a plastic mallet. O-RING Ø68x2 M8x20 QJ207 Bearing Berings flange F1910205 Shim Secondary shaft NU207 Inner ring NU207 Bearing...

  • Page 170: Differential Centering, Shim Calculation

    13.11.14 Differential centering, shim calculation Operation to find the total thickness (Z) of the shims to centering the differential case and the crown wheel. • Note the highest dimension marked in the main housing (X) (ex. 170.75). • Note the highest distance between the external races of the bearings assembled on the differential case (Y) (ex.165.85).

  • Page 171: Differential Centering, Final Drive Backlash

    13.11.15 Differential centering, final drive backlash • Mount all parts except the stages, keep the reverse gear on the secondary shaft. Tighten the secure nut on the secondary shaft (180 N.m). • Check the gear backlash using a dial indicator placed on the secure nut (F9072203). •...
  • Page 172 RELEASE 2.1.0...

  • Page 173: Exploded Views

    13.12 E XPLODED IEWS Refer to spare catalogue for part numbers 13.12.1 Primary Shaft Torque Item Part number Description Glue (daN*m) F1910108 G.C. 15,0 0103012 NU 1007 ECP Bearing F9072103 Plug 0103015 NU 304 ECP Bearing RELEASE 2.1.0...

  • Page 174: Secondary Shaft

    13.12.2 Secondary Shaft Torque Item Part number Description Glue (daN*m) 0301561 CHC M8x18 bolt F9072208 Secondary nut C.G. 18,0 0103012 NU 1007 ECP Bearing RELEASE 2.1.0...

  • Page 175: Differential

    13.12.3 Differential Torque Item Part number Description Glue (daN*m) F0085941 Crown screw RELEASE 2.1.0...

  • Page 176: Selector

    13.12.4 Selector Torque Item Part number Description Glue (DaN m) 0101088 61907 Bearing 0101128 61905 Bearing F0077108 Reverse gear pin 0304006 CZHC M10x35 Bolt 0301421 CHC M8x20 Bolt F0085135 Reverse gear screw 0301169 CHC M8x25 Bolt RELEASE 2.1.0...

  • Page 177: Selector Axle

    13.12.5 Selector Axle Torque Item Part number Description Glue (DaN m) 0301422 CHC M16x16 Bolt F0059021 Shoulder screw 0301138 CHC M5x12 Bolt RELEASE 2.1.0...

  • Page 178: Housing

    13.12.6 Housing Torque Item Part number Description Glue (DaN m) F90570000 Bearing casing 12867 F0085126 Revere axle 12867 F0085135 Free wheel nut F9047008 Stud closing plate F9047030 Stud RELEASE 2.1.0...

  • Page 179: Transmission

    13.12.7 Transmission Torque Item Part number Description Glue (DaN m) F1910706 Drive shaft stop 0301490 CHC M5x25 Bolt RELEASE 2.1.0...

  • Page 180: Shift System

    14 S HIFT YSTEM 14.1 S YSTEM VERVIEW The T421 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): Marelli GCC, this unit manage the actuator (ESA) control •...

  • Page 181: Esa Settings

    14.1.3 ESA settings • Engage the 1 gear by acting manually on the selector axle of the gearbox Gear shift down (18mm) Gear shift up (18mm) • Go to the page #2 of the dash display: Setting page. Check the Gear Pot (gear barrel absolute position ) value is 1630mV +/- 10mV •...

  • Page 182: Esa Warnings

    14.1.4 ESA Warnings In the first page of the display are shown also the following warning messages related to the barrel sensor: • F: barrel sensor position out of mechanical range. The barrel is stuck in a not engaged position between two gears.

  • Page 183: Esa Maintenance

    14.1.5 ESA Maintenance It is reminded to regularly check the AV mounting of the ESA: The rubber ring (pn. ORN08x3,5) should be inspected each 1’000 km and must be replaced before 3’000 14.1.6 Damped Shaft Assy Eighteen Belleville washer are included in the damped shaft assy (pn. 3322012). The Belleville washers must follow the stacking order: >...

  • Page 184: Esa Rocker Bolts

    14.1.7 ESA rocker bolts Please find below specification for ESA rocker bolts, tightening torque and prescription for installation Item Description ISO14580-M5X8-CL 12.9 Hexalobular socket screws M5, length 8 mm, grade 12.9 ISO7089-5 Washer 5.3x10x1 Bolts should be fitted with Loctite 270, applying a tightening torque of 4.5 Nm. If bolts are removed for maintenance please make sure of cleaning them with isopropyl alcohol before applying Loctite.

  • Page 185: Electronic & Software

    15 E & S LECTRONIC OFTWARE Refer to engine supplier docs. RELEASE 2.1.0...
  • Page 186 16 A NNEXES 16.1 T IGHTENING ORQUE 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...

Table of Contents

Save PDF