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Formula SAEPS-78PB-DA
Shock, Double Adjustable
TECHNICAL MANUAL
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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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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
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