Formula

SAE

PS-78PB-DA

Shock, Double Adjustable

TECHNICAL MANUAL

PS78PBDA DoubleAdjustable 2009/2010

Introduction
ThankyouforyourpurchasefromPenskeRacingShocks!
AllofthefundamentalattributesfoundinanyPenskeRacingShockhavebeenincorporatedintothe
FormulaSAEshocksincluding:

Separatecompressionandreboundadjustment

Lowfrictionshaftandpistonseals

Anodized,aluminumbodiesandcomponentsforsuperiordurabilityandperformance

DurableACMEthreadbodythatallowsquickadjustmentofspringpreload(.100perturn)

WinningheritagePenskeRacingShockscontinuetohelpourcustomerswinracesand
championshipsinallformsofMotorsport.

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

PS78PBDA DoubleAdjustable 2009/2010

TableofContents:
Introduction..................................................................................................................................................2
TableofContents:.........................................................................................................................................3
BasicTerminology:........................................................................................................................................4
GettingStarted:.............................................................................................................................................5
Adjusters:......................................................................................................................................................5
TrackTuning:.................................................................................................................................................6
Troubleshooting:...........................................................................................................................................6
DisassemblyInstructions:.............................................................................................................................7
AssemblyInstructions:..................................................................................................................................7
DynoGraphOverview:..................................................................................................................................8
TechnicalSupport:......................................................................................................................................12

PS78PBDA DoubleAdjustable 2009/2010

BasicTerminology:
BODYCAP

COMPRESSIONADJUSTER

RIDEHEIGHTADJUSTER

RESERVOIRBODY

RESERVOIRCAP
INFLATIONVALVE
BODY
SHAFTBEARING

SHAFT
BUMPRUBBER
SPRINGRETAINER
REBOUNDADJUSTER

PS78PBDA DoubleAdjustable 2009/2010

GettingStarted:
TheFormulaSAEshocksaresetfromthefactoryatrecommendedstartingsettingsforyourapplication.
Theyarepressurizedandreadytogo.ThestartingpressurefortheFormulaSAEshockswillvary
dependingonthespecifiedvalvingcodesusedandcanrangefrom50200psi.

Adjusters:

CompressionAdjuster(Screwdriver):15clicks
(stiffer=clockwise;0=fullhard,15=fullsoft)

ReboundAdjuster(1/6Pin):45clicks
(stiffer=clockwise;0=fullhard,45=fullsoft)

AdjustmentRange:COMPRESSION(15Clicks)
Thecompressionadjusterhasmosteffectinthe010in/secvelocityrangeoftheshock.

AdjustmentRange:REBOUND(45Clicks)
Thereboundadjusterhasmosteffectinthe05in/secvelocityrangeoftheshock.

FactorySettings:
Adjusters:

5(Compression)

10(Rebound)

PS78PBDA DoubleAdjustable 2009/2010

TrackTuning:
CompressionAdjuster:

Theideaistosetthecompressiondampingforcestosuitthebumpsincriticalareas,suchascorners,
cornerexitsandbrakingzones.
Step1Setthereboundadjusteratfullsoft.
Step2Startingwiththecompressionsettingatfullsoft,drivealapthenreturntoincreasethebump
settings.Continuethisprocessofaddingbumpcontroltominimizetheupsetsuntilthecarbecomes
harsh,losestirecomplianceandtraction.Atthispointyouknowthatyouhavegonetoofaronthe
compressionsettings;backoffoneclick.

ReboundAdjuster:
Theideaistotightenupthecar,stabilizetheplatformandeliminatethefloating"Cadillacfeeling".This
willalsoreducetherateofbodyroll.
Step1Setthereboundadjusteratfullsoft.
Step2Add5clicksofreboundadjustmentatatime,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.

PS78PBDA DoubleAdjustable 2009/2010

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.Slowlypullupontheshaftassemblyuntilthefourportsarejustbelowthesurfaceoftheoil.Topoff
withoiltofilltheshockbody.
16.Slidetheshaftbearingdownwithoutmovingtheshaftuntiltheoringcontactsthebody.Threadthe
shaftbearingintothebodyuntilthereisapproximately1/10leftofexposedthread.Depressurizethe
reservoir,andtightentheshaftbearing.
17.Pressurizetheshocktotherecommendedpressure.Pleasecallifyouhaveanyquestionsonspecific
pressures.

PS78PBDA DoubleAdjustable 2009/2010

DynoGraphOverview:

PS78PBDA DoubleAdjustable 2009/2010

PS78PBDA DoubleAdjustable 2009/2010

10

PS78PBDA DoubleAdjustable 2009/2010

11

PS78PBDA DoubleAdjustable 2009/2010

TechnicalSupport:

KAZTechnologies
2976AmbassadorCourt
WestBloomfield,MI48322
734.367.0895
www.kaztechnologies.com

PenskeRacingShocksMainHeadquarters
150FranklinStreet
Reading,PA19602
UnitedStates
610.375.6180
www.penskeshocks.com

PenskeRacingShocksMidwest
12666U.S.Route12
Brooklyn,MI49230
UnitedStates
517.592.6681

Rev.20100209

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