2010 Ps 78pb Da Manual

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Formula SAEPS-78PB-DA

Shock, Double Adjustable

TECHNICAL MANUAL

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PS78PBDA DoubleAdjustable 2009/2010

2

Introduction

ThankyouforyourpurchasefromPenskeRacingShocks!

AllofthefundamentalattributesfoundinanyPenskeRacingShockhavebeenincorporatedintothe

FormulaSAEshocksincluding:

Separatecompressionandreboundadjustment

Lowfrictionshaftandpistonseals

Anodized,aluminumbodiesandcomponentsforsuperiordurabilityandperformance

DurableACMEthreadbodythatallowsquickadjustmentofspringpreload(.100perturn)

WinningheritagePenskeRacingShockscontinuetohelpourcustomerswinracesand

championshipsin

all

forms

of

Motorsport.

MadeinU.S.A.TheFormulaSAEshockshavebeen100%designed,machined,assembled,and

testedforqualityintheUnitedStates.

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TableofContents:

Introduction.................................................................................................................................................. 2

TableofContents:......................................................................................................................................... 3

BasicTerminology:........................................................................................................................................ 4

GettingStarted:............................................................................................................................................. 5

Adjusters:...................................................................................................................................................... 5

TrackTuning:................................................................................................................................................. 6

Troubleshooting:........................................................................................................................................... 6

DisassemblyInstructions:............................................................................................................................. 7

AssemblyInstructions:.................................................................................................................................. 7

DynoGraphOverview:.................................................................................................................................. 8

TechnicalSupport:...................................................................................................................................... 12

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4

BasicTerminology:

SHAFT

COMPRESSION

ADJUSTER

REBOUNDADJUSTER

BUMPRUBBER

BODY

RIDEHEIGHTADJUSTER

INFLATIONVALVE

SHAFTBEARING

RESERVOIRBODY

RESERVOIRCAP

BODYCAP

SPRINGRETAINER

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GettingStarted:

TheFormulaSAEshocksaresetfromthefactoryatrecommendedstartingsettingsforyourapplication.

Theyarepressurizedandreadytogo. ThestartingpressurefortheFormulaSAEshockswillvary

depending

on

the

specified

valving

codes

used

and

can

range

from

50

200

psi.

Adjusters:

CompressionAdjuster(Screwdriver):15clicks

(stiffer=clockwise;0=fullhard, 15=fullsoft)

ReboundAdjuster(1/6Pin): 45clicks

(stiffer=clockwise;0=fullhard, 45=fullsoft)

AdjustmentRange:

COMPRESSION

(15

Clicks)

Thecompressionadjusterhasmosteffectinthe010in/secvelocityrangeoftheshock.

AdjustmentRange:REBOUND(45Clicks)

Thereboundadjusterhasmosteffectinthe05in/secvelocityrangeoftheshock.

FactorySettings:

Adjusters:

5(Compression)

10 (Rebound)

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TrackTuning:

CompressionAdjuster:

Theideaistosetthecompressiondampingforcestosuitthebumpsincriticalareas,suchascorners,

cornerexitsandbrakingzones.

Step1 Setthereboundadjusteratfullsoft.

Step2 Startingwiththecompressionsettingatfullsoft,drivealapthenreturntoincreasethebump

settings.Continuethisprocessofaddingbumpcontroltominimizetheupsetsuntilthecarbecomes

harsh,losestirecomplianceandtraction.Atthispointyouknowthatyouhavegonetoofaronthe

compressionsettings;backoffoneclick.

ReboundAdjuster:

Theideaistotightenupthecar,stabilizetheplatformandeliminatethefloating"Cadillacfeeling".This

willalsoreducetherateofbodyroll.

Step1Set

the

rebound

adjuster

at

full

soft.

Step2 Add5clicksofreboundadjustmentatatime,thenreturntocontinuetheprocessuntilthecar

becomes"skittish"ortherearwheelshopunderbraking.Atthispointyouknowyouhavegonetoofar

onthereboundsettings,backoffoneclickatatimeforfinalbalance.

GasPressure:

Wedonotrecommendalteringthefactorygaspressuresetting.

Troubleshooting:

SignsofFluid:

Iftheareaaroundtheshaftbearingandshaftexhibitsasmallamountofmoisture,thisisnormal. In

ordertoreducefrictioninthesystem,sealsqueezesareslightlyrelaxedwhichservesthepurposeto

allowasmallamountoffluidtobewickedontotheshaftwhenthestrutoperates. Ifyouseeexcessive

amountoffluidthatmaypoolonthetopoftheshaftbearing,youmayhaveasealproblem. Contact

yourPenskerepresentativeatonce.

LossofGasPressure:

Iftheshockforsomereasonlosesitsgascharge,atelltalesignofreducedornogaspressureisthatthe

shock(withoutaspring)whencompressed,willnotreturntoitsfullyextendedposition.

FailureofShafttoExtend:

Iftheshockhaslostpressureorlostexcessivefluid,youmayfindthatthestrutshaftdoesnotextend

fullywhencompressed. Insomesituations,youmayneedtophysicallypulltheshaftoutinorderfor

ittoreachfullextension.

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DisassemblyInstructions:

1.Adjustthereboundadjustertofullsoftanddepressurizethereservoir.

2.Clampthebodycapeyeletinavisewiththeshaftpointingup.

3.Unscrewtheshaftbearingassemblyandremovetheshaftassembly.

4.Draintheoil.(Pleasedisposeofproperly)

5.Pushthereservoirendcapupintothereservoirbody.

6.Usingascribe,prythewireretainingringoutofthereservoirbodyandremovethereservoirendcap.

7.Removethereservoirwithastrapwrench.

8.Pushthefloatingpistonoutofthereservoirbody.

9.Clampthe9/16widetopoutplateinavise,makingsureyoudonotclamptheshims.

10.Removetheringnutwithan11mmsocket.

11.Usesolventtocleanallparts,thendryandinspectthem.NOTE:Brakecleaneruseisdiscouraged

duetothepossibledamagingeffectsonsealsandwipers.

12.Inspectandreplacetheoringsandsealsasneeded.

AssemblyInstructions:

1.Reassembletheshaftandpistonassembly.Besuretoaddsufficientconstantstobeabletoproperly

torquetheringnutto80inlbs.

2.Threadthereservoirbodyontothepiggybackhousingwithastrapwrench.

3.Withtheshockreturnedtothevise,openthecompressionadjustertofullsoftandfilltheremote

reservoirtothetopwithoil.

4.Lookintotheshockbody.Whentheoillevelisabovethefittingport,fillthereservoirtothetopwith

oil.

5.Beforetheoillowers,insertthefloatingpistonwiththedishsidefacingdown*Makesurethequad

ringisnottwisted.

6.Replacethereservoirendcapandsnapring.

11.Pressurizetheremotereservoirtorepositionthefloatingpiston(approx.150psi).

12.Filltheshockbodywithoiltothebottomofthethreads(1/2"fromthetopofthebody).

13.Insertthepiston/shaftassemblywiththepistonbandintotheshockbody,pushingthepistonjust

belowthesurfaceoftheoil,untilthe4shaftbleedholeportsarecovered.

14.Itisveryimportanttoremoveasmuchairaspossiblefromthepistonassembly.Todothis,startby

movingtheshaftupslowlyandpushingdownafewtimesusinga.5" 1"stroke,beingsuretokeepthe

twoportsintheshaftbelowthesurfaceoftheoil,orairwillbesuckedbackintothepistonassembly.

Lightlytaptheeyeletafewtimeswithamallettoassurethatalltheairisreleasedfromthepiston.

NOTE:thisstepisveryimportant;takeyourtime,repeatasneeded.

15.Slowly

pull

up

on

the

shaft

assembly

until

the

four

ports

are

just

below

the

surface

of

the

oil.

Top

off

withoiltofilltheshockbody.

16.Slidetheshaftbearingdownwithoutmovingtheshaftuntiltheoringcontactsthebody.Threadthe

shaftbearingintothebodyuntilthereisapproximately1/10leftofexposedthread.Depressurizethe

reservoir,andtightentheshaftbearing.

17.Pressurizetheshocktotherecommendedpressure.Pleasecallifyouhaveanyquestionsonspecific

pressures.

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DynoGraphOverview:

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TechnicalSupport:

KAZTechnologies

2976AmbassadorCourt

WestBloomfield,MI48322

734.367.0895

www.kaztechnologies.com

PenskeRacingShocksMainHeadquarters

150FranklinStreet

Reading,PA 19602

UnitedStates

610.375.6180

www.penskeshocks.com

PenskeRacingShocks Midwest

12666U.S.Route12

Brooklyn,MI49230

UnitedStates

517.592.6681

Rev.20100209

Documents

2010 Ps 78pb Da Manual