2020赛季国际汽联F4中国锦标赛 用户手册.pdf 
2020赛季国际汽联F4中国锦标赛 用户手册.pdf
附件２ 用户手册 Ａｐｐｅｎｄｉｘ ２ Ｕｓｅｒ Ｍａｎｕａｌ MYGALE M14-F4 GEELY USER MANUAL MYGALE Technopole 58470 Magny-Cours France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 Version: V1.6 0.0 CONTENTS 0.0 CONTENTS ..................................................................................................... 2 1.0 CAR VIEWS ..................................................................................................... 3 2.0 CAR SPECIFICATIONS ........................................................................................ 4 2.1 Dimensions .................................................................................................... 4 2.2 Weight ........................................................................................................ 4 2.3 Supplied Parts: Partners ..................................................................................... 5 3.0 SET UP AND OPTIONS ........................................................................................ 6 3.1 Geometry information (in baseline set-up) .................................................................. 6 3.2 Set Up Adjustment ........................................................................................... 7 3.3 Kinematics – Graphical Representation ..................................................................... 18 3.4 Springs ....................................................................................................... 22 3.5 Dampers...................................................................................................... 23 3.6 Anti-Roll Bars ............................................................................................... 25 3.7 Aero Set Up ................................................................................................. 28 3.8 Brake bias ................................................................................................... 30 3.9 Pedal box adjustment ....................................................................................... 31 3.10 Set-up sheet Baseline Proposal ........................................................................... 40 3.11 Ballast ...................................................................................................... 41 3.12 Paddle shift ................................................................................................ 42 3.13 Gear box ratios ............................................................................................ 46 3.14 Data acquisition ............................................................................................ 47 3.15 Brake pads ................................................................................................. 47 3.16 Steering system adjustments ............................................................................. 48 3.17 Radiator protection grille .................................................................................. 49 4.0 ASSEMBLY AND MAINTENANCE ............................................................................ 50 4.1 Engine ........................................................................................................ 50 4.2 Transmission ................................................................................................. 50 4.3 Steering System ............................................................................................. 52 4.4 Hub Assembly................................................................................................ 54 4.5 Wishbones ................................................................................................... 55 4.6 Heat protection.............................................................................................. 56 4.7 Wheel Cables ................................................................................................ 56 4.8 Brake line protection ........................................................................................ 57 4.9 Electricity.................................................................................................... 57 4.10 Wings ....................................................................................................... 61 4.11 Head restraint ............................................................................................. 61 4.12 Monocoque Chassis, Crash Boxes and main roll structure ............................................... 61 4.13 Bodywork ................................................................................................... 63 4.14 Throttle pedal .............................................................................................. 64 4.15 Extractable seat ........................................................................................... 65 4.16 Fire extinguisher ........................................................................................... 66 4.17 Markings and holograms ................................................................................... 66 4.18 Screws ...................................................................................................... 66 4.19 Fuel system ................................................................................................. 67 4.20 Cooling system.............................................................................................. 71 4.21 Filling fluids ................................................................................................ 74 4.22 Accident data recorder .................................................................................... 75 4.23 Assembly of the starter................................................................................... 76 4.24 Exploitation tools ........................................................................................... 76 5.0 ANNEXES ...................................................................................................... 81 5.1 Tightening torques (general) ................................................................................ 81 5.2 Tightening torques (F4 mounting) ........................................................................... 82 5.3 Positions of adjustable pedal box: ......................................................................... 83 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 2/84 1.0 CAR VIEWS 4475 958 1738 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 3/84 2.0 CAR SPECIFICATIONS 2.1 DIMENSIONS Description Length Height Front ride height Rear ride height Wheelbase Front overhang Rear overhang Front overall width Rear overall width Front track Rear track Front wing assy width Rear wing assy width mm mm mm mm mm mm mm mm mm mm mm mm mm Reference Dimensions 4475 958 20 30 2742 1005 723.5 1725 * 1715 * 1493.5 1430.4 1400 898 * depending tyres 2.2 WEIGHT The minimum allowed weight is specified by sporting regulations of the championship. The weight of the car should be adjusted by mean of appropriate ballast to ensure that the specified minimum weight is reached with the driver at any time during the event MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 4/84 2.3 SUPPLIED PARTS: PARTNERS Gearbox, driveshaft: Sadev Steering rack: Titan Springs, dampers: Sachs Fuell cell, fuel pump: Premier Fuel Brake pads: Ferrodo Brake discs, callipers: Brembo Extinguisher : OMP Harness : TRS Motrosports Rims : Team Dynamics MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 5/84 3.0 SET UP AND OPTIONS 3.1 GEOMETRY INFORMATION (IN BASELINE SET-UP) The standard set up of the car is: dimension FRONT REAR Ride Height mm 24 37 Camber deg -3.3 -2.2 Toe deg 0.00 0.00 Castor deg 8.21 -22.81 Castor Offset (wheel centre) mm 5.64 --- Castor Offset (ground) mm 31.23 --- King Pin deg 15.46 --- King Pin Offset (wheel centre) mm 69.1 --- King Pin Offset (ground) mm 15.4 --- Damper-Spring / Wheel ratio 0.68 0.71 Anti Roll Bar (deg) / Wheel ratio 0.69 0.48 Anti Dive % 14.45 22.13 Ackermann % 19.9 --- Roll Center Z mm 17.8 34.5 Mechanical trail* mm 30.87 Mygale designed the car allowing several adjustments on suspension geometry to give to the teams some freedom in the setup of the car and compensate some tolerances from the manufacturing process. Despite this big range of adjustments, the car must respect the maximum and minimum values imposed by FIA Technical Regulation at all moments of the race weekend. 1 Mechanical Trail The perpendicular distance in side elevation between the steering axis and the centre of tyre contact. It is considered positive when the steering axis is forward of the tyre contact centre and negative when it is rearward. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 6/84 3.2 SET UP ADJUSTMENT Values are theoretical, assembly dispersion is possible. Before start your setup, Mygale advises the teams to check the right position of the ball joints as explained in the technical Bulletin F41-15-BT-04-Ball_joint-V1. A bad adjustment of these components can affect the suspension behaviour. 3.2.1 RIDE HEIGHT CHECK & ADJUSTMENT The reference points for calculating the ride height are shown below. The vehicle reference plane is the lower side of the wood floor. The skid block is below this. The choice of ride height needs to take account of the skid block thickness which is a maximum of 5mm below the reference plane (and minimum 2mm). The diagrams refer to the dimensions from the chassis reference point to the reference plane. At the front two ride height adjustment screws (F.41.35.001) must be fix on the two reference pads which are machined into the upper surface of the monocoque and are accessible with the damper cover removed. At the rear the reference surfaces are machined pads on the gearbox upper surface, at the level of the damper bracket and are accessible with the engine cover removed. Front reference Rear reference The front reference dimension A1 is 441mm. The rear reference dimension A2 is 369mm. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 7/84 B1 A1 165 B2 441 230 A2 X1 369 X2 To set up front and rear ride height values at the level of the front and rear axle centre lines (H1 and H2 respectively), use the following procedure: (Dimensions in mm) 1) Define the ride heights values you want in the front (H1) and in the rear (H2). 2) Calculate the car pitch angle with this values: α = arcsin((H2-H1)/2741.6 in rad. 3) Calculate the distances X1 and X2 in the car to obtain the ride height desired: X1 = A1*cos(α) - B1*sin(α) + H1 X2 = A2*cos(α) + B2*sin(α) + H2 4) Adjust in the car the values X1 and X2 as calculated previously to obtain the ride height. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 8/84 Ride height adjustment: Front ride height adjustment Rear ride height adjustment Lengthen adjuster to raise car. Shorten adjuster to lower car Lengthen adjuster to raise car. Shorten adjuster to lower car Front: Lengths (ball centre to ball centre) for a 20mm ride height: Pushrod 554.6mm. 1 face on the adjuster changes the ride height by 0.95mm. 1 turn on the adjuster changes the ride height by 5.70mm. For 1mm ride height, 1/6 turn on the adjuster. Rear: Lengths (ball centre to ball centre) for a 30mm ride height: Pushrod 527.5mm. 1 face on the adjuster changes the ride height by 1.00mm. 1 turn on the adjuster changes the ride height by 6.00mm. For 1mm ride height, 1/6 turn on the adjuster. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 9/84 3.2.2 CASTOR CHECK & ADJUSTMENT The castor angle is the angle, in side elevation, between the steering axis and the vertical. It is considered positive when the steering axis is inclined rearward. You can check the castor angle in the same way in the front and in the rear suspension. The castor angle can be calculated as follows: Measure the angle of the steering arm plane for the front (or the wishbone mount plane for the rear) to the horizontal; this is the measured castor angle (MCA). Positive inclined down to rear, negative inclined down to front. Calculate the true castor angle (TCA) as following: MCA MCA Horizontal and vertical lines TCA Car direction True castor angle Base settings Base set up length, wishbone ball centre to ball centre TCA Front Castor Angle = MCA + 7.08° 8.21° Rear Castor Angle = MCA - 25.41° -22.81° 556.4mm 578.9mm The Castor angle influences the Castor Offset, the Mechanical Trail and therefore the force to turn the wheel. Castor Offset, (mm) The distance in side elevation between the point where the steering axis intersects the ground, and the centre of tyre contact. The offset is considered positive when the intersection point is forward of the tyre contact centre and negative when it is rearward. (Base setting: FRT=31.23mm) Mechanical Trail, (mm) The perpendicular distance in side elevation between the steering axis and the centre of tyre contact. It is considered positive when the steering axis is forward of the tyre contact centre and negative when it is rearward. (Base setting: FRT=30.87mm) MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 10/84 The Castor Offset is along the ground plane while the Mechanical Trail is perpendicular to the steering axis. Castor adjustment: Adjust the castor angle with the rod end bearings as shown in the following pictures: Front castor adjustment MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 Rear castor adjustment 11/84 3.2.3 CAMBER ADJUSTMENT The Camber Angle is the inclination of the wheel plane to the vertical. It is considered positive when the wheel leans outward at the top and negative when it leans inward. The Camber can be adjusted by releasing the fixing bolts and adding or removing shims between the steering arm and the upright. A change of shim has no influence on the toe setting. Front (Rear similar) Camber shim Steering arm Available shims: Part Number F.41.14.055 F.41.14.056 F.41.14.057 F.41.14.058 Description Camber shim 1 mm Camber shim 1.5 mm Camber shim 2 mm Camber shim 4 mm Front Recommended base setting: Adjustment: Rear Recommended base setting: Adjustment: -3,3°, 2mm of shim 0.325°/mm 1.5mm for 0.5° -2.2°, 4.5mm of shim (2mm + 1.5mm+1mm) 0.300°/mm 1.5mm for 0.5° MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 12/84 3.2.4 TOE CHECK & ADJUSTMENT The toe angle is the angle between a longitudinal axis of the vehicle and the line of intersection of the wheel plane and the road surface. The wheel is ”toed-in” if the forward portion of the wheel is turned towards a central longitudinal axis of the vehicle, and “toed-out” if turned away. A/2 semi forward track wheel To e B/2 semi rearward track wheel T.A. = Toe Angle Checking the distance between the wheel forward and rearward points in the front suspension is possible to measure the Toe. The Toe can be measured with the following formula: Toe = B/2 – A/2 The correlation between degrees and the value B/2-A/2 is : B/2-A/2 (mm) Toe (deg) 18 3 12 2 6 1 0 0 -6 -1 -12 -2 -18 -3 In this table, negative toe corresponds to “toe out”, positive toe corresponds to “toe In”. The Toe angle can be adjusted with the track rod. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 13/84 Rear toe adjustment Front toe adjustment Base starting set up lengths for toe adjustment (ball centre to ball centre) Front trackrod assembly: 474.9mm for toe 0° (and 0mm) ±1 turn on the bearing = ±3.84mm ±1 face turn on the bearing = ±0.64mm For 1mm toe: 1.6 faces bearing Rear trackrod assembly: 478.7mm for toe 0° (and 0mm) ±1 turn on the adjuster = ±4.70mm ±1 face turn on the adjuster = ±0.43mm For 1mm toe: 2.4 faces adjuster MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 14/84 3.2.5 SUSPENSION POINTS Front suspension points Fixation points The following picture shows the mandatory position of the front upright points: Ref. F.41.14.063 (x4) Ref. F.41.14.064 (x2) Steering arm position Spacer Ref. F.41.14.097 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 15/84 Rear suspension points Fixation points Fixation points Fixation points The following picture shows the mandatory position of the rear wishbone brackets: 2nd hole from the bottom Lower position Middle position Upper position MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 16/84 The following picture shows the mandatory position of the rear upright points: Ref. F.41.14.063 (x4) Suspension points spacers’ heights MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 17/84 3.3 KINEMATICS – GRAPHICAL REPRESENTATION All the following graphs represent the kinematics from a ride height of 20/30mm, camber of -3.5°/-2.5° and toe 0°/0° (Front/rear respectively): MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 18/84 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 19/84 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 20/84 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 21/84 Motion ratio Motion ratio (MR) = Damper travel Wheel travel Wheel rate = Spring rate * MR² In baseline position : DAMPER FRONT 0.68 ROLL BAR FRONT 0.69 DAMPER REAR 0.71 ROLL BAR REAR 0.48 3.4 SPRINGS Front and rear suspension springs are common sizes. Part Number Stiffness Stiffness lbs/inch N/mm F.41.14.022 F.41.14.024 F.41.14.026 600 106 800 141 1000 176 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 22/84 3.5 DAMPERS 3.5.1 FRONT SUSPENSION DAMPERS The standard front damper is the Sachs F4 non-adjustable front damper, reference F.41.14.103. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 23/84 3.5.2 REAR SUSPENSION DAMPERS The standard rear damper is the Sachs F4 non-adjustable rear damper, reference F.41.15.029. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 24/84 3.6 ANTI-ROLL BARS The front and rear anti-roll bars each have 5 adjustable positions. To adjust the anti-roll bar the retaining screw of the adjustment clevis must be unscrewed and the clevis moved up or down until the setting position is reached. 3.6.1 ANTI-ROLL BARS ADJUSTMENT Various stiffness of anti-roll bar are available. To eliminate pre-load in the anti-roll bar, the length of the adjuster assembly connecting the anti-roll bar to the rocker should be shortened or lengthened to suit. Shorten/lengthen by turning anti-roll bar link Rear rockers setup recommendation: To avoid an early and undesired contact on the rocker plates, thus limiting available stroke., it is recommended to set-up the rod end bearing on the rocker side with no less than 13 mm of thread remaining visible as per photo below. The rod end bearing on the antiroll bar side can be shorten to avoid inclining the bar too much. 13 mm MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 25/84 Front link adjuster - recommendation: Following the introduction of the front anti intrusion panel, the link of the front anti roll bar must be adjusted to avoid the contact between the anti-roll bar and the panel. The total length of the adjuster link recommended by Mygale is 192 mm as shown on the picture below: MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 26/84 ARB currently available Standart ARB : Ø14 3.6.2 ANTI-ROLL BAR STIFFNESS ARBØ Ø12 Ø14 Ø18 1 221 352 621 2 311 501 912 (Optionnals ARB : Ø12 and Ø18) Position 3 411 681 1257 4 571 928 1764 5 765* 1271 2504 N/mm Here the anti-roll bar rate graph from the different anti-roll bar diameters and positions. Anti roll bar rate = f(blade position) (N/mm) 3000 Anti roll bar rate (N/mm) 2500 2000 D12 1500 D14 D18 1000 500 0 0 1 2 3 4 5 6 Blade position (see picture) * The 5th position with anti-roll bar Ø12 is not recommended due to constant deformation of the bar. Use Ø14 position 3th which is equivalent (see technical bulletin F41-14-BT-04). MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 27/84 3.7 AERO SET UP 3.7.1 FRONT WING Position Convention: Angle of the front wing main plate with the reference plane (red line): Front wing -3° -5°/+2° Standard position Range Front wing set up: - Set up the front wing main plate at the desired position - Adjust the front wing end plate to be parallel to the reference plane 6.5mm -3° Frt Ref plane Rr Evolution of downforce coefficient (SCz), drag coefficient (SCx) and balance with front wing main plane angle: Delta wing angle +1° Delta SCx - Delta SCz +0.06 Delta balance +4.6% Standard specification includes a gurney on the trailing edge on each lateral extremity of the wing (part number F.41.24.009). MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 28/84 3.7.2 REAR WING Position Convention: Angle of the wing main plate with the reference plane (red line): Upper wing +5° 0°/+15° Standard position Range Lower wing 0° 0°/+4° Rear wing set up: - Set up the lower wing at the desired position - Adjust the rear wing end plate to be parallel to the reference plane with a +/-1° tolerance - Set up the upper wing at the desired position by using the adjusting holes +5° Frt Rr Ref plane 0° 12.9mm Frt Ref plane Rr MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 29/84 Details on the rear upper wing positions: Evolution of downforce coefficient (SCz), drag coefficient (SCx) and balance with rear wing angles: Upper wing Lower wing Delta wing angle +2.5° +1° Delta SCx +0.006 +0.001 Delta SCz +0.034 +0.011 Delta balance -2.5% -0.8% 3.8 BRAKE BIAS Range: 17.5 turns Adjustment: more front brake = turn left A spacer is available as optional part for the brake bias control: - F.41.11.057: Length 100mm Teams are allowed to adjust its length to optimize driver comfort. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 30/84 3.9 PEDAL BOX ADJUSTMENT 3.9.1 DRIVER POSITION Before adjust the pedal box, the teams must be sure that the center of gravity of the driver attends the Article 15.3.6 of the F4 Technical Regulation from FIA. In order to achieve the best position, Mygale advises to follow the steps below: 1) Install the driver in the cockpit in a position which the eye is visible from the side and the CoG (point G in picture below – is “the intersection of a vertical line passing through the centre of his ear and a horizontal line passing through the centre of his eye” according with FIA.) of the driver’s head is below the survival cell. The 70 mm of gap from the roll hoop line must be respected too. 2) After adjust the driver’s position, the team can adjust the pedal box and steering wheel, as wheel as other devices that needs to be close to the driver. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 31/84 3.9.2 PEDAL BOX POSITION According to the driver feeling, the width of the brake pedal can be adjusted by the team. It is possible to cut the shaded area below: To prevent the translation of the pedal box’s shaft due to vibration and support’s wear, Mygale is making available a new version of this part (Pedal box shaft – F.41.11.002 and 2 Beta pin – AGO02.02.0001). The right picture below shows the new assembly. For ergonomic reasons, 5 Pedal Box’s positions are available: MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 32/84 Each position has an equipment which is available in option. Position 1: F.41.11.029 Short spacer pedal stop F.41.11.017 Master cylinder rod prolongator, setting 1 Position 2: F.41.11.056 Long spacer pedal stop F.41.11.018 Master prolongator, setting 2 cylinder rod Position 3: F.41.11.031 Short pedal stop rest F.41.11.019 Master prolongator, setting 3 cylinder F.41.11.029 Short spacer pedal stop rod MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 33/84 Position 4: F.41.11.031 Short pedal stop rest F.41.11.056 Long spacer pedal stop F.41.11.020 Master prolongator setting 4 cylinder rod Position 5: F.41.11.032 Long pedal stop rest F.41.11.056 Long spacer pedal stop F.41.11.021 Master prolongator, setting 5 cylinder rod The throttle cable must be cut at the right length once the pedal box is correctly positioned for the driver. Long pedal stop rest reinforcement: Welded reinforcements in the corners done by teams to stiffen the long pedal stop rest are allowed, in areas illustrated in picture. Note now that new parts already include reinforcements. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 34/84 With the introduction of the Front anti-intrusion panel of the FIA safety kit 2018, the following prolongators must be assembled on the brake pedal and clutch pedal to compensate the length of the panel: 2 prolongators for brake pedal reference F.41.11.07 1 prolongator for clutch pedal reference F.41.11.07 3.9.3 SMALL DRIVER OPTION For small drivers, it is also possible to offset the pedal box more rearward, with a maximum of 450mm between brake pedal plate and front end of the monocoque. The following picture shows the maximum rearward position of the pedal box: F.41.11.032 stop rest Long F.41.11.062 Spacer pedal stop 215mm pedal F.41.11.060 Long throttle pedal spacer F.41.11.061.Master cylinder rod prolongator 300mm F.41.11.059 Fixing pedal box offset plate, MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 35/84 450mm 340mm F.41.21.106 Bush, throttle sensor, pedal box offset F.41.21.105 Bracket, throttle sensor, pedal box offset Mygale advises the teams to adjust the driver position with Mygale parts. The use of non-original parts can result in problems due to bad fitting as highlighted in the Technical Bulletin F41-17-BT-04- Master Cylinder_brake_failure-V1. Following the Technical Bulletin F41-11-BT-07, Mygale is making available an adjustable pedal box for the customers interested to change the pedal positions in a faster way. This new product is intended to be used exclusively for test days or race schools, for example when the teams must test different drivers and save time during the pedal box adjustment (modification of pedal box position under 15 minutes). New product: PN: F.41.11.077 - Kit adjustable pedal box MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 36/84 - New throttle sensor (attached to throttle pedal). - New master cylinder rod sets. - New pedal support bracket with pedal stops. - New calibration for Renault engine available. - Calibration for Ford and Geely engines available after request. 3.9.4 BRAKE BIAS MOUNTING The 2 bushes of the brake bias clevises must be mounted with the head downward, to avoid that the clevis touch the thread of the axle and being damaged, and to ensure a full setup range: Head of the bush Clevis Furthermore, ensure that the distance between the 2 clevis is enough big to allow the complete rotation range of the bearing axle and not too big to keep the 2 washers in contact with the sleeve nut and parallel to the car center line: To ensure a full setup range of balance, the nut must be mounted in the position as on following picture: MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 37/84 Following the recent issues regarding the brake bias in the British Championship, Mygale prepared the Technical bulletin F41-11-BT-06 with the following information to prevent future failures with the brake bias: According with our supplier the recent issues happened due to fatigue of the component + excessive wear of the thread. - For the 1st problem (fatigue), we strongly advise our customers to control the mileage of safety components and do not use these components after achieve the recommendation in our Mileage Table. The brake bias must be changed after 15.000 km. The supplier insists that the brake bias has to be changed in case of frontal crash, otherwise safety is not guaranteed. In the picture below (from Mileage Table) it's possible to see the Bias Bar in yellow: - For the 2nd problem (excessive wear in the thread), Mygale would like to reinforce that the bleeding in the brakes must be done by one side at a time. If the team perform the bleeding by axle, the brake bias bar can move to its extreme position like the brake bias in red (picture below), and the force applied in the pedal can damage the thread. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 38/84 3.9.5 THROTTLE PEDAL STOPPER When adjusting the throttle cable, ensure that the mechanical throttle pedal stopper is always reached before the maximum rotational position of the throttle sensor. The throttle sensor is not supposed to work as a stopper, it can so be damaged and also its bracket. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 39/84 3.10 SET-UP SHEET BASELINE PROPOSAL SET-UP SHEET M14-F4 Car Date Circuit Run FRONT REAR LH RH LH RH Weight Included / not included Per wheel Total Weight distribution Ride height Kg Kg % mm 19 30 Geometry Camber Camber shims Toe per wheel (in+/out-) Castor Wheelbase Width ° mm mm ° mm mm 3,3 3.3 2.2 2.2 1 8.2 1 8.2 1 -22.8 1 -22.8 2742 1725 1715 Sachs non adjustable Sachs non adjustable Suspensions Dampers Type Bump Rebound pos pos Springs Stiffness Preload lbs/in mm 800 4.7 Anti-roll bar Diameter Blade set-up mm mm 3 800 4.7 800 0 3 3 800 0 14 14 3 Tyres Type Pressure - cold Pressure - hot bar bar Brakes Master cylinder Balance Pads 0,625 0,75 % DS PERFO DS PERFO DS PERFO DS PERFO Wings Angle (- nose up/+ nose down) Gurney ° -3 10x345 5 (top) / 0 (beam) Clutch Master cylinder 0.75 Gearbox Crownwheel & pinion 1st 2nd 3rd 4th 5th 6th 10/31 14/37 18/35 18/28 21/27 20/22 27/26 Cooling Radiator blanking % Comments MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 40/84 3.11 BALLAST Ballast is used to reach the minimum allowable weight Two ballast fixing locations are provided: inside the splitter and in the cockpit under driver’s legs (bottom view of monocoque). 970.9mm 512.6mm Cockpit ballast fixing points Maximum allowed: 16Kg (bracket and screws included) Splitter ballast fixing points Maximum allowed: 6.5Kg (bracket and screws included Standard ballasts: Monocoque ballast – cockpit (5 Kg/plate) F.41.18.008 - ballast F.41.18.010 – bracket MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 Monocoque ballast – splitter (2 Kg/plate) F.41.18.011 - ballast F.41.18.012 - bracket 41/84 3.12 PADDLE SHIFT An optional kit with a paddle shift system is available to replace the manual shifting system. It includes the GCU, the pneumatic actuator and controller, the steering wheel with shift controllers and the display. 3.12.1 PADDLE SHIFT USER MANUAL - To engage 1st gear (when neutral “N” is displayed on the dashboard) push Neutral (N) together with shift paddle “UP”. Push « UP » 1 Push « N » - To return to neutral (when 1st gear “1” is displayed on the dashboard) push Neutral (N). Pull « DOWN » Push « N » N MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 42/84 - To shift into reverse (when neutral “N” is displayed on the dashboard) push Neutral (N) together with shift paddle “DOWN”. Pull « DOWN » R Push « N » On the Technical bulletin F41-12-BT-11, Mygale describes the correct procedure to engage reverse gear. PROCEDURE TO ENGAGE REVERSE GEAR: A) If the car is running in the track: a1 - Slow down the speed of the car and downshift to 1st gear. a2 - Use the clutch pedal and the brake pedal to stop the car with the engine running. a3 - When the car is completely stopped, downshift to Neutral (clutch pedal still engaged), and after, downshift N --> R a4 - With the reverse gear selected, remove the brake pedal and remove slowly the clutch pedal to move to rearward direction. B) If the car is over the stands or static in the ground: b1 - Make sure that the rear wheels are not spinning (use the brake pedal). b2 - Use the clutch pedal to downshift from N --> R IMPORTANT: 1 - To engage the reverse gear the driver must make use of the clutch pedal (to downshift 1st to Neutral and Neutral to reverse) 2 - To engage the reverse gear, the driver must be sure that the car is static (speed = 0 3 - The driver should not engage reverse gear before be sure that the rear wheels are not spinning in the forward direction (wet conditions or car stucked in the gravel). 4 - When the reverse gear is engaged, the driver must release the clutch pedal in a smooth way (the abrupt release will transfer all the loads to the reverse gear and can damage this 5 - The driver should not rise the rpm of the car over 3500 rpm , as the torque at this rpm can damage the reverse gear. 3.12.2 GEAR-SHIFT PNEUMATIC JACK Rod position on gear-shift pneumatic jack may have to be adjusted: MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 43/84 Due to parts manufacturing tolerances, the teams must adjust the length of the ball joint, and the position of the shaft of the pneumatic jack to ensure a proper functioning of the shifting and avoid mis shifting or over shifting issues. The Technical Bulletin F41-12-BT-07-Gear_shift_actuator_balljoint-V2 explains how to proceed in this task. Below you will see the difference in length between the old model of ball joint and the current model (5 mm shorter). 50 mm The new length of the ball joint will allow a better displacement of the actuator shaft, but each car must be adjusted to avoid over-shifting (jumping of gears). To improve the reliability of the pneumatic paddle shift system and ensure a constant pressure supply from the air tank to the actuator during the shiftings, the air tank has a pressure reducer that reduces the pressure from the tank to 7.0 bar. To have more information please check the Technical Bulletin F41-22-BT-01. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 44/84 To adjust this assembly in the right length, the teams must adjust the shaft manually in a way that after hear the mechanical engaging in the gearbox the shaft will travel just few millimeters (2-3 mm) until achieve the stopper. 1–After some displacement it’s possible to hear the next gear engaging. 2–After the mechanical shift, the shaft must travel few millimeters until the stopper 3.12.3 PADDLE SHIFT WEAR TESTS Use technical bulletins F41-12-BT-08 (Actuator leak test V1) and F41-12-BT-09 (Leak test for air tank V1) to check if the compressor, air tank and air actuator are working well, and if some maintenance or part replacement is required. A seal kit is available in the spare parts catalogue for the actuator. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 45/84 3.13 GEAR BOX RATIOS The standard gearbox build specification is: Differential: free (open with no limited slip) CWP ratio: 10/31 Gear ratios: 1st 14/37 2nd 18/35 3rd 18/28 4th 21/27 5th 20/22 6th 27/26 The gear ratios are drawn on the following graph: 8000 Revs (tr/min) 7000 6000 5000 4000 3000 0 50 100 150 200 250 200 250 Speed (km/h) Shot gear ratios are available in option: Gear ratios (option): 4th 22/29 5th 24/28 6th 22/23 8000 Revs (tr/min) 7000 6000 5000 4000 3000 0 50 100 150 Speed (km/h) MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 46/84 3.14 DATA ACQUISITION The following sensors are included in the data acquisition optional kit: - Steering angle Front wheels speed Acceleration in 3 axes Front and rear brake pressure Lap timer Gear Throttle pedal Smarty camera The data download cable is available as an option in the spare parts catalogue, ref F.41.35.153. 3.15 BRAKE PADS The standard fit brake pads are the Ferrodo DS performance, reference F.41.17.004 are identical front and rear. Other brake pads are available in option: -Ferrodo DS3000 (reference F.41.17.007). -Ferrodo DS1.11 (reference F.41.17.008). New brake pads must always be bedded following Ferrodo bedding recommendation. Heating gradually stepwise, until minimum 500°C is reach. To improve the handling of the brake system as well as the driver’s feeling, Mygale is making available an extension cap for master cylinder (F.41.17.034), and a new option of master cylinder, the master cylinder 0.7” (F.41.17.033). Teams are now allowed to mix the current ones (3/4” and 5/8”). Check the Technical Bulletin F41-17-BT-03- Master Cylinder_options-V1 for more information. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 47/84 3.16 STEERING SYSTEM ADJUSTMENTS The height of the steering column can be adjusted by changing the position of the bracket on the monocoque. Adjustment In addition to the standard steering column, a longer steering column is available as optional part: - F.41.16.001: Standard length - F.41.16.046: Length +80mm - F.41.16.053: Length specified by customer (check the technical note released by Mygale and the 2017 catalogue). Spacers for the steering wheel are also available as optional parts to adjust the longitudinal position of the steering wheel (reference F.41.16.003). Only maximum 3 spacers are homologated. It is also possible to cut the steering rack stop to adjust maximum steering angle: MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 48/84 3.17 RADIATOR PROTECTION GRILLE Radiator grille protections are available as optional parts (ref. F.41.26.081): To ensure that the paddle shift system will work properly, Mygale advises the teams to not blank the left radiator. The lack of fresh air in this side will increase the internal temperature of the compressor (paddle shift system). As a result the compressor will switch off and the driver will not be able to upshift / downshift. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 49/84 4.0 ASSEMBLY AND MAINTENANCE Note: all safety critical components should be checked regularly. 4.1 ENGINE 4.1.1 OVERVIEW 4.1.2 ENGINE OPERATING CONDITIONS 72°C < Water T° < 85°C 80°C < Oil T° < 120°C -> Warm up the engine before driving (Engine temperature 80°C) Poil min = 1.2 bar Rev. limits: 6750 rpm Refer to the engine user manual for all other information. 4.2 TRANSMISSION 4.2.1 GEAR BOX The Sadev SL75-14 LW F4 gearbox is homologated for use in the Mygale M14-F4. No other gearboxes have passed a rear impact crash test. Clutch shaft specification depends on the gearbox manufacturer and the type of engine. For all information regarding build and maintenance gearbox, customers should refer to the Sadev user manuals. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 50/84 To avoid issues with the reverse gear, Mygale advises the teams and drivers to avoid the downshift 1 st gear to Neutral without the use of the clutch pedal. When the driver needs to downshift 1 => N, make use of the clutch pedal. 4.2.2 DRIVE SHAFT The standard fit driveshaft is supplied by Sadev. For safety reasons, right and left driveshafts must not be inverted. Driveshaft angles are given for 2.5° negative camber, face viewed. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 51/84 4.3 STEERING SYSTEM The steering rack and steering column are homologated components which may not be modified. 4.3.1 STEERING RACK Tightening torque to ensure the steering rack movement: 34Nm 4.3.2 STEERING COLUMN The steering column includes a collapsible device homologated with the FIA which must not be modified. The column length must not be altered by adjustment of the length of the collapsible device. The upper and lower parts of the column are joined by a splined sliding section, held together axially by a capscrew which tightens against the collapsible device. If disassembled, must be reassembled with grease. Section of the steering column assembly: 4.3.3 STEERING COLUMN JOINT For safety reasons, it is recommended to thoroughly inspect the steering column joint after each shock or crash. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 52/84 4.3.4 STEERING COLUMN BEARING To avoid steering column bearings going out of their housings, the following recommendations must be followed: 1. Ensure that the steering column can slide freely in the bearing. Sanding of the part might be required to adjust this. (Green surfaces on the picture). Add silicone grease if needed. 2. Bond the spherical bearing in the housing with Loctite 638. For this purpose, the contact surfaces must be slightly scratched and cleaned to optimize bonding. (Red surfaces on the picture). Furthermore, a new revision of the bracket has been introduced with two holes (yellow on picture below) to screw washers to maintain the bearing. 4.3.5 STEERING WHEEL GLASS When removing the steering wheel some drivers or mechanics may push the glass with their fingers. Be careful, pushing too hard could break the sealing and cause glass damage. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 53/84 4.4 HUB ASSEMBLY 4.4.1 FRONT AND REAR HUB ASSEMBLY The uprights, wheel bearings, wheel drive pegs and lock nuts are identical front and rear. - At the front the front stud is fitted in the wheel bearing. - At the rear the driveshaft is fitted directly in the wheel bearing. It is not recommended to engage the wheel nuts with a pneumatic screwdriver. Loctite 270 Loctite 270 Wheel peg Stud nut Wheel stud (70Nm max) Loctite 243 Wheel bearing Upright Brake disc MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 54/84 4.4.2 WHEEL SPEED SENSOR Provision for wheel speed sensors is made on the front uprights (data acquisition kit). The speed sensor bracket and disc are respectively references F.41.21.003 and F.41.21.004. The spacer ref is F.41.21.079. Upright Speed sensor disc Speed sensor bracket Speed sensor Speed sensor spacer To ensure the good working of this sensor, Mygale advises the teams to adjust it 0.75 mm from the target. 4.5 WISHBONES Wishbones are usable only when they are straight. If flexion (distance A on the drawing below) is over than 1mm, the wishbone must not be used. To avoid the flexing, do not ratchet strap the car in the truck, do not lift the car by the wishbone. In the case of a damaged ball, Mygale proposes a staking bearing joint replacement (F.41.14.121). Wishbone primary ball joint is glued with Loctite in its housing, and must be heated for disassembling. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 55/84 To allow an easy access to the pushrod adjuster to set up the ride height, Mygale is adopting a new assembly position for the front pushrod and making available a new rear pushrod. To order the new rear pushrod, please refer to the part number: F.41.15.039.A Rear pushrod EVO. 4.6 HEAT PROTECTION To avoid any damage to the composite bodywork, it is recommended to install a thermal protection on the floor, the sidepod and the engine cover around the exhaust. Thermal protection is also recommended between the monocoque and the engine. 4.7 WHEEL CABLES It is recommended to replace cables if one or more of the following conditions is met: The cable has been on the car for 12 months The car has been in an accident The cable has been damaged, i.e. the braid, tape or mould have been damaged exposing the fibre The cable or cover has been cut out When mounting the wheel cable on the upright, ensure that the cable loop doesn't protrude too much on the outer side of the upright, so that it can't make contact with the brake disc (left figure below). The freedom given to the outer end of the wheel cable must be adjusted accordingly when tightening it against the suspension arm and installing the wheel cable cover (right figure below). MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 56/84 4.8 BRAKE LINE PROTECTION To ensure a good protection for the brake line, it is recommended to replace the heat shrink sheat covering in the area of the wishbone when it is damaged. To prevent wearing damages on electric cables, it is highly recommended to cover the main rear brake line and main clutch line surfaces with heat shrink hose. Length to cover with heat shrink hoses (~600mm) To avoid brake or air line damage, make sure to have the good layout of these hoses. As mentioned on the Technical Bulletin F41-17BT-02, these lines can be damaged if positioned between the gearbox and the rear floor. For the paddle shift system this means that the driver will not be able to gearshift properly. For the brake system, the leak of brake fluid will result in the loss of rear brakes. 4.9 ELECTRICITY 4.9.1 BATTERY To ensure a good life time for the battery, it is recommended to charge it at the reception of the car and to charge it every 6 month when you don’t use it. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 57/84 4.9.2 COCKPIT SWITCH PLATE Starter Rain light Ignition Master switch Spacers F.41.21.104 are available as optional parts to offset the switch plate of 70mm. Teams are also allowed to reduced their lengths to optimize driver comfort. The carbon fiber monocoque is a good conductor, so to avoid issues with the electric system, the teams must check periodically the gap between the switch plate terminals and the monocoque. To increase the protection in this area, the teams can use a tape around this region (red rectangle in the next picture) to avoid the contact wire => carbon fiber For safety reasons, during electric maintenance, Mygale advises the teams to disconnect the cable from the battery (negative first) as described in the Technical Bulletin F41-21-BT-08. Turning off the engine: /!\ When turning off the engine, switch off ignition button in first, and then use the main switch when the car is stopped. If the main switch is used in first, there is a risk of high voltage on the alternator, and to damage it. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 58/84 4.9.3 CABLES LAYOUT Mygale made available the Technical Bulletin F41-21-BT-07, with the description of the complete layout of the cables in the F4. On this document you will be able to find the main problems caused by the wrong position of cables and components and how to solve this problems. 4.9.4 MASTER SWITCH AND CONTACTOR Mygale advises the teams to check the following points when preparing the vehicle for a test / race: -Check if the internal spring of the master switch contactor presents some resistance to move (as good parts). - The cable connecting the contactor trigger to the extinguisher must be free (without tension or interference with other parts). - The small loom connecting the master switch contactor to chassis loom must not be damaged, twisted or disconnected. - The extinguisher must be fixed without any degree of freedom (rotation, or displacement). Master Switch Master Switch Contactor 4.9.5 THROTTLE SENSOR Current batches of the throttle pedal sensor may not have a suitable base setting for the zero position. Since this sensor is a series production component where Mygale cannot define the base specification, we have introduced an adjustment for the zero setting. If the base zero voltage is out of range it will provoke an error with the ECU. To correct the reading of the new throttle sensor, the minimum position of the throttle can be adjusted as the procedure below (the next generation of sensors supplied by Mygale will have a stop screw to adjust the position of the sensor as picture below). MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 59/84 PROCEDURE: 1 - With the main switch OFF, connect the throttle sensor to the car without fitting the throttle sensor into it's bracket (to allow you easy access to tighten the nut and adjust the stop screw). 2 - Tighten the stop screw enough to move the sensor few degrees (clockwise) out of the rest position. 3 - With the main switch of the car ON, check the percentage of throttle using the steering wheel of the car or the software LifeCal. Initially this value must be over 1% before proceed to step 4. 4 - Using the steering wheel or the software LifeCal, adjust the stop screw until you have a value close to 0% (〖0%〗_(-0.0%)^(+0.3%)). MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 60/84 Attention: If go below 0%, the sensor may enter into the default mode, and you will need to restart the procedure from step 1. 5 - With the sensor adjusted close to 0% (〖0%〗_(-0.0%)^(+0.3%)check if the sensor covers all the range from 0 to 100% 6 - Fit the sensor to the bracket, and the complete assembly to the car. 4.10 WINGS For reliability reasons, it is highly recommended to replace the wings every two years. Moreover, it is also recommended to check the wings regularly in order to detect the potentially damaging effects of small hits or contacts on the endplates. To avoid matting or weaken the front wing mounts, it is recommended to tighten them moderately on the crashbox, and to use the medium washer specified in the parts catalogue. 4.11 HEAD RESTRAINT The head restraint must be properly assembled, with the fixations clipped securely. The head restraint must never be able to move freely. According to the regulations, it is not permitted to cover the head restraint with any material other than paint. In the case of a damaged Head Restraint, the aramid skin replacement by Mygale is available (ref.: F.41.19.060). 4.12 MONOCOQUE CHASSIS, CRASH BOXES AND MAIN ROLL STRUCTURE Monocoque and crash box reparations must be performed by an approved entity. Before any modification or reparation, you must contact Mygale. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 61/84 However, the team is allowed to change the nose cap. The nose cap must be properly assembled, with the fixations clipped securely on the main part of the crash box. Moreover, it is important to stick the nose cap on the crash box with four silicone points. In 2018, FIA introduced a new safety kit composed by a Front anti-intrusion panel and a new rear crash box. Front anti-intrusion panel: Rear crash box 2018 All cars delivered by Mygale after 2018 will have the new safety kit assembled. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 62/84 For more information about how to assemble the safety kit on your Mygale F4, please contact our engineering department at engineering@mygale.fr, or consult the document “F4 Customer Information Note – Safety kit 2018 – Front Anti intrusion panel” on our website. To clamp correctly the main roll hoop on the monocoque, we advise to all customers to consult the Technical Bulletin F41-19-BT-10- Roll_structure-V1. The roll hoop must be free of painting on the areas highlighted below and the mechanics must minimize the number of tightening and untightening operations of the fixation screws. 4.13 BODYWORK Bodywork repairs: Teams are allowed to repair fibre glass bodywork components but the total surface of repaired areas must not be more 10% of the total surface of the part. If you have some doubt, don’t hesitate to contact Mygale Bodywork adjustments: To optimize sidepod adjustment, brackets on the floor and on the side of the monocoque can be adjusted. For the engine cover, brackets on the rear face of the monocoque, on the rear roll hoop and on the gearbox can be adjusted. Adjustable brackets are in red on the following drawing: MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 63/84 Adjustable tie rods: In addition, adjustable floor tie rods are available in option to ensure the car fulfills the regulations when the flat floor is worn. 4.14 THROTTLE PEDAL Throttle pedal wear: The intensive use of the throttle pedal could create a wear slacks which allows an angular variation of the pedal. In a case of marked wear, the pedal passes next to the pedal stop. To prevent this issue, control every 2000km the maximum displacement distance of the throttle pedal F.41.11.050 as shown below. If the distance exceeds 5mm it is recommended to change the sleeve nut pedal box F.41.11.007 and potentially the pedal box shaft F.41.11.002. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 64/84 4.15 EXTRACTABLE SEAT In order to fulfil the last requirements of FIA, Mygale developed a new extractable seat (F.41.19.067).as shown in the picture below, included in the 2017 safety kit. The extraction belts are now sewn in the composite seat. The installation of this new seat can be found in the Technical Note “F4 FIA – Mounting of the Safety kit 2017” released by Mygale to all teams. A) If belt bracket is on upper position, just add the seat upper centering plates (1). If not, add the centering plates between the bracket and the monocoque (2), filling then the gap on innward point by 2 D6 small wahsers. Ensure screws does not go through inside the fuel tank volume. B) Ensure the chassis loom is correctly maintained close to the monocoque to not have clash with the seat. C) Ensure lower centering pins are oriented parallel to the car center line, and that a length L exceeds seat thickness. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 65/84 4.16 FIRE EXTINGUISHER The fire extinguisher must be fitted in its support in the monocoque. Be sure that it is solidly attached by its retainer and will not rotate. Check also the master switch contactor cable. ffExtinguisher Support An interior pull handle cable is located on the right of the steering wheel. The exterior cable is located on the right of the rear rollover structure, and also activates the main master switch. Do not forget to add extinguisher and electrical switch stickers in this area, according to regulation. Eventually, Mygale proposes an extinguisher refill (ref: F.41.19.059). A spacer F.41.19.061 of 70mm is available as option in order to make the extinguisher cable handle easier to reach for the driver. Its length can be reduced by 24mm on the hole side of the spacer. 4.17 MARKINGS AND HOLOGRAMS Laser markings and holograms stickers must stay always visible and in any case must not be covered by painting or sticker. Furthermore, the holograms stickers must not be removed. 4.18 SCREWS The screws which are classified as type 2 can be modified but must keep the same class and dimensions as specified in the spares parts catalogue. Concerned screws are those related to safety components: - Front crashbox - Rear roll hoop - Rear crashbox/rear wing mount - Seat belt - Shoulder belt bracket MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 66/84 4.19 FUEL SYSTEM 4.19.1 FUEL TANK The fuel tank matches with the FIA specifications. All required details are issued in the certificate of compliance. (i.e. date of validation) It is recommended to regularly wash the inside of the fuel tank to ensure there is no dirt in the fuel circuit. Mygale advises the team to clean the fuel cell and the fuel system after the first uses. 4.19.2 DRAIN Do not use the car’s fuel pump to drain the tank. It is advisable to use an external pump in order to avoid damaging the on-board unit. An external pump can be attached to the drain hole by removing the dash cap on the fuel tank plate. It is also necessary to open the filler cap while draining. Be careful not to damage the thread by over tightening the cap Capacity: 48 litres IN DRAIN OUT 4.19.3 FUEL ASSEMBLY Overview: The fuel pump assembly is composed of the fuel pump with its connector inside a fuel collector pot and a bracket with two 4.5 bar pressure regulators. Use teflon hoses and clamp screws to connect in line the system. Also for a good sealing ensure that there are fuel resistant heat-shrinkable pieces on the pump, the fuel filter, the regulators bracket hose fittings and the fuel cell rear plate (see drawing on the next page for lines assembly details). F.41.23.034 Fuel pump (250l/h) F.41.23.052 Fuel Filter series F.41.23.036 3.5 Bar fuel pressure regulator X2 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 67/84 Fuel hoses details: When assembling the fuel system, make sure to use the right clamps screws clamps specified in the catalogue and in the drawing to avoid hoses coming lost and fuel issues. Rear tank plate modifications allowed: The rear tank plate is modifiable as a type 2 part. Only hose fittings inside the fuel tank (red in picture) can be modified to suit with the fuel hoses Update kit from former fuel system assembly: Two kits are available in spare parts catalogue to update the fuel system from the former fuel buffer tank to the new collector pot system. F.41.23.057: include the collector pot, regulators bracket and filter sock. Pump, regulators and fuel filter are not included. F.41.23.078: Include the three teflon hoses with clamp screws and heat-shrinkable pieces for sealing. The drain silicone hose is not included. Also, the update needs the new fuel cell with the opening for the pot (F.41.23.073) and the new fuel tank padding (F.41.18.016) MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 68/84 Mounting of the fuel system: When fitting the fuel pump inside the pot, ensure a 13,5mm height between the lower face of the regulators bracket and the upper face of the pump bracket (green in picture below), to keep a 4mm clearance between filter socket and pot bottom. To make sure that the right distance as well as the position of the regulators bracket are been respected, Mygale developed a positioner (F.41.23.087) for the fuel system as showed in the red circle below. The Technical Bulletin F41-23-BT-09- Pump_positionner-V2 shows the details about the installation procedures and the modification allowed in the pump plate. The regulators bracket must be oriented as on shown on below right picture. The fuel collector pot must be mounted like on left below picture, in the rear-left side of the fuel cell as below as possible. Adjust the cutting of the foam padding to ensure this. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 69/84 Use gasket compound Hylomar Blue to seal between collector pot and fuel cell 4.19.4 SEALING After all the gearbox and electric cables are insert in the monocoque, you must add expanded foam in the passage circled in red so as to ensure a sealing. Expanded Foam Mygale is making available a new fuel loom with a different sealing device to avoid the risk of fuel leaking into the cockpit. The Kit fuel pump loom V2 is composed of: - 1 fuel loom with sealed body - 1 housing with O ring - 1 O ring - 1 nut - 1 circlip This kit is been introduced as a running change, and the next cars will be delivered with this update. For customers interested to order the complete kit, please refer to the part number: F.41.23.093.A Kit fuel pump loom V2. The procedure of assembly as well as all modification needed, can be found on the Technical Bulletins F41-21-BT-15 and F41-23-BT-10. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 70/84 4.20 COOLING SYSTEM 4.20.1 MAIN WATER CIRCUIT In order to make the mounting easier, it is allowed to cut or adjust the length of silicone hoses It is recommended to add two cut parts of silicone hose D32 around the water tube that is between the two radiators, to get a better maintaining through the monocoque rear face (blue circles). Warning: The right radiator cap must not be used to bleed the circuit. It is highly recommended to not dismount it. The radiator is delivered in spare part with the cap already assembled. Anyway, it must be manipulated carefully as the thread in the radiator is fragile. When mounting the cap, it is recommended to use sealing paste and tight moderately. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 71/84 4.20.2 HEADER TANK CIRCUIT 4.20.3 OIL CIRCUIT Nota: The two extensions surrounded in red on the picture can be cut by the team. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 72/84 4.20.4 CATCH TANK A catch tank is fitted in the car with its bracket, on the monocoque rear face. To avoid any risk of water return in the gearbox oil due to pressure differential and to damage the gearbox, ensure that the catch tank hoses do not end at the bottom of the catch tank. The recommended position of hoses is 50 mm inside the catch tank, and fitted with collars or rislan to block the movement (see following picture). 50 mm MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 73/84 4.21 FILLING FLUIDS The recommended quantities must always be respected. Designation Brand Engine Oil Quality Quantity For the oil grade, please refer to the Engine user manual or contact the engine builder. 5L Gear box Oil Motul (blue) 75W140 1.5 L Water cooling Castrol Anti freeze 6L (50% extract – 50% water) Brake fluid / Clutch release fluid Castrol SRF 2L* Fuel For the oil grade, please refer to the Engine user manual or contact the engine builder. 48 L * +0.5L more to consider for the bleeding process /!\ When racing in very wet and humid condition, it is highly recommended to replace regularly some fluids, particularly brake and clutch fluids to avoid corrosion. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 74/84 4.22 ACCIDENT DATA RECORDER An ADR (Accident Data Recorder) can be fitted in the car. This ADR can be mounted with its bracket under the extractable seat in front of the battery, as explained on the following picture. The assembly of the ADR and the bracket in the monocoque must be made without rubber washers between these parts. ADR To make sure that your installation is correct, check the Technical Bulletin F41-21-BT-05-Vibration-V1. Mygale advises the use of rubber washer as silent blocks (F.41.20.109) on the master switch and in the contactor to avoid potential vibration issues. The green circles in the picture above shows the position of these rubber washers. For more information about the new installation of the Master Switch, please check the Technical Bulletin F41-21-BT-11-Master Switch Bracket-V2. MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 75/84 4.23 ASSEMBLY OF THE STARTER In the case of a Clutch Housing with a C index (or previous), the team must insert the spacer F.41.12.077.A between the starter and the housing. 4.24 EXPLOITATION TOOLS 4.24.1 JACK BAR About the teams who want to build their own jack bar, Mygale provides some dimensions to them. FRONT DIMENSIONS Front Wing MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 76/84 REAR DIMENSIONS Rear jack bracket MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 77/84 Mygale also proposes its own jack bars. These ones are available on the spare parts catalogue: Front jack bar (F.41.35.008) Rear jack bar evo (F.41.35.245) 4.24.2 SET UP TOOLS Some basic set-up tools are for sale on the spare parts catalogue. Tools to adjust parallelism are available: Front parallelism bar (F.41.35.026) MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 Rear parallelism bar (F.41.35.521) 78/84 We also propose false wheels which help you to set your car. The height of this part is adjustable so as to simulate your real wheel. False wheel (F.41.35.066) Height adjusters can be inserted there The references of the adjusters are: - 1mm adjuster: F.41.35.032 -2 mm adjuster: F.41.35.035 -3 mm adjuster: F.41.35.033 4.24.3 VARIOUS TOOLS Mygale is able to propose useful tools like: Body support trestles (F.41.35.054) MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 Steering wheel support (F.41.35.127) 79/84 Fuel filler cask (F.41.35.105) and it support (F.41.35.110) Holding key (F.41.35.060) and socket to fix your wheels studs (F.41.35.124) Steering rack stops (F.41.35.064) Crashbox support for transportation (F.41.35.231) MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 80/84 5.0 ANNEXES 5.1 TIGHTENING TORQUES (GENERAL) General guideline for tightening torques for steel bolts: METRIC C oa r s e T h r e a d B ol t Thread Pitch M4 0.7 M5 0.8 M6 1 M8 1.25 M10 1.5 M12 1.75 M14 2 F i n e T h r e a d B ol t Thread Pitch M8 1.0 M10 1.0 M10 1.25 M12 1.25 M12 1.5 M14 1.5 M16 1.5 M18 1.5 M20 1.5 IMPERIAL Thread Pitch 1/4 5/16 3/8 7/16 1/2 9/16 5/8 28 TPI 24 TPI 24 TPI 20 TPI 20 TPI 18 TPI 18 TPI 8.8 Torque Nm 2.5 4.9 8.4 20 40 70 110 10.9 Torque Nm 3.5 6.9 11.9 28 55 100 150 12.9 Torque Nm 4.2 8.3 14 34 65 115 180 8.8 Torque Nm 22 44 42 75 70 120 180 260 360 10.9 Torque Nm 30 62 59 105 100 170 250 370 510 12.9 Torque Nm 36 75 72 130 120 200 300 440 610 Grade 5 Torque Lbs-ft 7 14 25 40 60 85 120 Grade 8 Torque Lbs-ft 10 20 35 55 85 120 170 These values should be used where a different torque value is not specified. This data refer to a friction coefficient = 0.1 (lubricated). For different friction values the data can change considerably. For example, considering a friction of 0.14 the preload will decrease by about 7% while the torque force will increase about 25%. Conversion factors: Lbs-ft x 1.356 = Nm Nm x 0.7376 = Lbs-ft MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 81/84 5.2 TIGHTENING TORQUES (F4 MOUNTING) TIGHTENING TORQUES Désignation Size Tightening torque N.m Notes m.Kg (x9.81) Lb.Ft (x par 7.246) Wheel – Suspension - Upright Wheel nut 20 x 1.00 200 20.4 147.5 Wheel peg 12 x 1.5 115 11.7 85 Loctite Wheel bearing 12 x 1.5 115 11.7 85 Loctite Rocker bolts 10 x 1.5 65 6.6 48 Lower wishbone outer bearing 3/8-24 UNF 35 3.6 26 Suspension bearings 8 x 1.25 34 3.5 25 Suspension brackets 8 x 1.25 34 3.5 25 Wheel cables 8 x 1.25 34 3.5 25 Gear box / clutch / Bell housing Clutch 8 x 1.25 34 3.5 25 Bell housing upper 12 x 1.75 115 11.7 85 Bell housing lower 10 x 1.5 65 6.6 48 Gearbox 10 x 1.5 65 6.6 48 7.1 52 Brake Calliper bolt 10 x 1.5 70 Engine Lower engine fitting 10 x 1.5 45 4.6 33.2 Upper engine fitting 8 x 1,25 25 2.6 18.5 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 82/84 5.3 POSITIONS OF ADJUSTABLE PEDAL BOX: MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 83/84 COMPONENTS LIFE CYCLE AND GUARANTEE The components of this vehicle have a limited life cycle and it returns to the holder to assure the maintenance and checking. The maximum mileage of the parts is set to one season (tests and races), and after this period, Mygale recommends to replace all the parts exposed to a possible fatigue weakening. It is strongly recommended to replace all the parts that could be affected / damaged after a major crash or accident. The wear parts have to be replaced according to the holder’s appreciation. Moreover, all the "competition" parts cannot be covered by any contractual guarantee. MYGALE CONTACT LIST Web site: www.mygale.fr Parts sales: spareparts@mygale.fr Technical information: engineering@mygale.fr Telephone: +33 (0)386 21 86 21 Fax : +33 (0)386 21 86 22 MYGALE Technopole - 58470 Magny-Cours - France Tel : +33 (0)3 86 21 86 21 Fax : +33 (0)3 86 21 86 22 84/84