technical manual - Gates Carbon Drive

Transcription

TECHNICAL MANUAL
®
2012
gatescarbondrive.com
®
: introduction
The Carbon Drive system is the brainchild of the
Gates Corporation; an engineered products company
with a legacy of creating long-lasting, superiorperforming power transmission products. From
driving 6000 horsepower blower enhanced racing
engines to working with industry leaders such as
BMW, Harley-Davidson, and Bombardier, Gates
has been offering its drive-train expertise to the
automotive, industrial and engine powered world
since 1911. Gates is proud to bring its unparalleled
standards, unwavering product support and proven
product development capacity to the bicycle market.
CenterTrack
The CenterTrack system provides maximum drivetrain
performance for all environments and bike types.
Higher tensile strength, a slimmer profile and improved
dirt- and debris-shedding abilities. Dirt and grime
simply fall away, making CenterTrack technology ideal
for muddy or snowy conditions. The sprockets are the
slimmest ever produced, and this slender profile allows
for additional chainstay clearance - making it easier
than ever to integrate with the latest generation of
internally geared hubs and frame designs.
• Front Sprockets - Forged/CNC Alloy
• Rear Sprockets - Stainless Steel
revision: 04
page.
2
CDX
The original system that started it all. Lightweight,
with exceptional durability in all environments
including MTB, Trekking, Pavement and Urban.
CDX provides the broadest line of sprocket and belt
options currently avaliable.
•
•
•
•
Patented Mud Port design
Armour-GK tooth coating
Front Sprocket - Forged/CNC Alloy
Rear Sprocket - Forged/CNC Alloy
For all MTB applications Gates recommends the use of
12mm wide Carbon Drive belts.
revision: 04
page.
3
CDC
Designed specifically to provide quiet, smooth,
and durable performance for Pavement, and
Commuter bikes.
•
•
•
•
Patented Mud Ports design
Hard Ano tooth coating - Front
Front Sprocket - Forged/CNC Alloy
Rear Sprocket - Steel
Insert CDC specific
product image
revision: 04
page.
4
: contacts
Gates has staff located around the world to provide integration support for engineers, custom frame
builders and large scale manufacturers. Initial inquiries should be directed to one of the following
contact locations.
For North America:
For Europe:
For Asia:
For South America:
Gates Carbon Drive
[email protected]
Gates Carbon Drive
[email protected]
Gates Carbon Drive
[email protected]
Gates Carbon Drive
[email protected]
331 Corporate Circle, Suite A
Golden CO 80401
Tel: 720.524.7206
Külftalstr. 18
31093 Lübbrechtsen
Germany
Tel: +49.5185.60266-50
No. 6, Lane 105
Shiangshang North Rd.
West District, Taichung City
Taiwan, 403
Tel: +886.4.2301.6876
Rua Florida, 1703-11° andar
São Paulo - SP
Tel: +5511.5105.8100
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5
//: Table of Contents
sect.
1
Anatomy of the Belt
CDX/CDC-Alfine 8
CDX/CDC-Nexus 8
sect.
2
Belt Line Drawings
CDX/CDC-Nexus 7
CenterTrack
sect.
3
Sprocket Drawings
Rear-Shimano 9 Spline
Rear-Nexus / Alfine
Front
sect.
4
sect.
5
Belt Installation + Alignment
Belt Tensioning
Rear Triangle Stiffness
sect.
6
Frame Engineering
Dropout Design
Alignment Specification
sect.
7
sect.
8
sect.
9
revision: 04
page.
6
Belt Handling
Glossary of Terms
Troubleshooting Guide
Belt Anatomy
//: Reference Ribbed Back Belt
reduces bending resistance,
maximizing system efficiency
Carbon Fiber
Tensile Cords
provides the incredible
core strength of the
belt
Curvilinear Tooth Profile
specifically designed to maximize engagement between
belt and cog with minimum
amount of friction.
Nylon Tooth Jacket
tough flexible fabric
layer that adds strength
and wear resistance to
the teeth
Core Compound
advanced polyurethane
chemistry enables resistance
to weather, oxidation, and
wear
revision: 04
page.
7
SHIMANO ALFINE 8
SG-S500/SG-S501
//: Belt Line Specification
MODEL NUMBER
SHEET
1 OF 2
REV
05
10.5 MM
FLANGE-TO-FLANGE
DISTANCE FROM REAR SPROCKET INNER
FLANGE SURFACE TO FRONT SPROCKET
INNER FLANGE SURFACE
48.7±0.5
FRONT SPROCKET MOUNTING DISTANCE
DISTANCE FROM FRAME CENTERLINE
TO CRANK ARM+SPROCKET MOUNTING
SURFACE REQUIRED TO ACHIEVE
44.85MM BELT LINE
44.85mm
BELT LINE
5.25 mm
BELT LINE LOCATION
MEASURED AT CENTER OF BELT
FROM INNER EDGE OF FLANGE
WHEN ASSEMBLED AND ALIGNED
24.3
67.5
135 (O.L.D)
187
NOTES:
1.
SHIMANO CHAINLINE SPEC: 41.8MM (FOR ALFINE CHAIN DRIVEN SYSTEM)
revision: 04
page.
8
SHIMANO ALFINE 8
SG-S500/SG-S501
MODEL NUMBER
SHEET
2 OF 2
REV
05
CL
44.85 MM
BELT LINE
5.250
4.60 (EDGE OF 68MM BB SHELL
TO INSIDE EDGE OF SPROCKET)
68
104.10 (60T SPROCKET)
2MM MINIMUM CLEARANCE
WITH FRAME
WITH FRAME
5.250
CL
44.85 MM
BELT LINE
NOTES:
1.
SHIMANO CHAINLINE SPEC: 41.8MM (FOR ALFINE CHAIN DRIVEN SYSTEM)
revision: 04
page.
9
SHIMANO NEXUS 8
SG-8R31
MODEL NUMBER
SHEET
1 OF 2
REV
02
10.5 MM
FLANGE-TO-FLANGE
49.2±0.5
45.35MM BELT LINE
45.35mm
BELT LINE
5.25 mm
BELT LINE LOCATION
22.3
66
132 (O.L.D)
184
NOTES:
1.
SHIMANO CHAINLINE SPEC: 42.7MM (FOR NEXUS SG-8R31 CHAIN DRIVEN SYSTEM)
revision: 04
page.
10
SHIMANO NEXUS 8
SG-8R31
MODEL NUMBER
SHEET
2 OF 2
REV
02
CL
45.35 MM
BELT LINE
5.250
68
WITH FRAME
WITH FRAME
5.250
CL
45.35 MM
BELT LINE
NOTES:
1.
SHIMANO CHAINLINE SPEC: 42.7MM (FOR NEXUS SG-8R31 CHAIN DRIVEN SYSTEM)
revision: 04
page.
11
SHIMANO NEXUS 7
SG-7R46
MODEL NUMBER
SHEET
1 OF 2
REV
02
10.5 MM
FLANGE-TO-FLANGE
46.9
45.35MM BELT LINE
5.25
43.05
BELT LINE
5.25
BELT LINE LOCATION
23.6
65
130(O.L.D.)
182
NOTES:
1.
SHIMANO CHAINLINE SPEC: 40.3MM FOR NEXUS SG-7R46 CHAIN DRIVEN SYSTEM (WITH 18-23T REAR)
revision: 04
page.
12
SHIMANO NEXUS 7
SG-7R46
MODEL NUMBER
SHEET
2 OF 2
REV
02
CL
43.05 MM
BELT LINE
5.25
BELT LINE LOCATION
68
WITH FRAME
WITH FRAME
5.25
BELT LINE LOCATION
CL
43.05 MM
BELT LINE
NOTES:
1.
SHIMANO CHAINLINE SPEC: 40.3MM FOR NEXUS SG-7R46 CHAIN DRIVEN SYSTEM (WITH 18-23T REAR)
revision: 04
page.
13
CenterTrack
CL
DIM “B”
DISTANCE FROM FRAME CENTERLINE TO OUTSIDE
OF CRANK ARM MOUNTING SURFACE, REQUIRED
TO ACHIEVE LISTED BELT LINE
FRAME CENTERLINE
Graphic Logo Position
Belt Line specifications, as listed in the
table below, defined with product logos/
graphics on front and rear sprockets facing
outward, away from frame centerline
DIM “A”
BELT LINE
O.L.D
CenterTrack //: INTERNAL GEAR HUB BELTLINE
revision: 04
page.
14
Manufacturer
Hub Description
Hub Model Number
O.L.D.
DIM “A”
Belt Line
DIM “B”
Sprocket Mount Distance
Shimano
Alfine 11
SG-S700
135
43.65
43.65
Shimano
Alfine 8
SG-S501
135
43.65
43.65
Shimano
Nexus 8
SG-8R36/8R31
132
44.55
44.55
Shimano
Nexus 7
SG-7R46
130
42.15
42.15
Shimano
Nexus 3
SG-3D55
135
43.85
43.85
Shimano
Nexus 3
SG-3C41
120
43.05
43.05
NuVinci
CVP
N360
135
45.53
45.53
FRONT
//: Sprocket Dimensions CenterTrack
Mount Tab
Width
BCD
Inner Arm Diameter
Tooth Outer Diameter
Mounting Web Thickness
Flange Offset:
Mount Surface
Flange Offset:
Centerline
Sprocket Width
CenterTrack //: FRONT
Teeth
# of Bolt
Mounting
Inner Arm Tooth Mounting Web Sprocket Flange Offset: Flange Offset: Tooth
Holes Part Number Arm Width BCD Diameter O.D.
Thickness
Width
Mount Surface
Centerline
Pitch
39
4
CT11394AA
23
104
88.0
134.8
3.1
11
3.1
1.55
11
42
4
CT11424AA
TBD
104
88.0
TBD
3.1
11
3.1
1.55
11
46
4
CT11464AA
16.2
104
88.0
159.3
3.1
11
3.1
1.55
11
50
4
CT11504AA
21
104
88.0
173.2
3.1
11
3.1
1.55
11
55
4
CT11554AA
18
104
88.0
190.7
3.1
11
3.1
1.55
11
46
5
CT11465AA
16.2
130
114.5
159.3
3.1
11
3.1
1.55
11
50
5
CT11505AA
17.3
130
114.5
173.2
3.1
11
3.1
1.55
11
55
5
CT11555AA
17.3
130
114.5
190.7
3.1
11
3.1
1.55
11
60
5
CT11605AA
18
130
114.5
208.2
3.1
11
3.1
1.55
11
revision: 04
page.
15
9-SPLINE
//: Sprocket Dimensions
CenterTrack
Flange Offset:
Mount Surface
Flange Offset:
Sprocket Width
Centerline
CenterTrack //: 9 SPLINE
Teeth
Part Number
Sprocket
Width
Flange Offset:
Flange Offset:
20
CT1120SMN
68.3
2.5
11.0
3.0
1.75
22
CT1122SMN
75.3
2.5
11.0
3.0
1.75
24
CT1124SMN
82.3
2.5
11.0
3.0
1.75
26
CT1126SMN
89.3
2.5
11.0
3.0
1.75
28
CT1128SMN
96.3
2.5
11.0
3.0
1.75
30
CT1130SMN
103.3
2.5
11.0
3.0
1.75
revision: 04
page.
16
Mount Surface
Centerline
SHIMANO NEXUS/ALFINE
//: Sprocket Dimensions
CenterTrack
Flange Offset:
Mount Surface
Flange Offset:
Sprocket Width
Centerline
CenterTrack //: SHIMANO ALFINE/NEXUS
Teeth
Part Number
Sprocket
Width
Flange Offset:
Flange Offset:
22
CT1122NMN
75.3
2.85
11.0
2.0
.575
24
CT1124NMN
82.3
2.85
11.0
2.0
.575
Mount Surface
Centerline
revision: 04
page.
17
9-SPLINE
//: Sprocket Dimensions CDX
Flange Inner Diameter
Flange Outer Diameter
Flange Thickness
Sprocket Width
CDX //: 9 SPLINE
Teeth
Part Number
Flange
Outer Diameter
Flange
Inner Diameter
Tooth
Outer Diameter
Mounting Web
Thickness
Sprocket
Width
Belt Ride
Area
Flange
Thickness
Tooth
Pitch
20
CDX1120SAF10
74
57
68.3
5.3
15.2
11.5
1.85
11
22
CDX1122SAF10
80
64
75.3
5.3
15.2
11.5
1.85
11
24
CDX1124SAF10
86
68
82.3
5.3
15.2
11.5
25
CDX1125SAF10
89.5
68
85.8
5.3
15.2
11.5
1.85
11
28
CDX1128SAF10
100
78
96.3
5.3
15.2
11.5
1.85
11
32
CDX1132SAF10
115
93
110.3
5.3
15.2
11.5
1.85
11
discontinued
model
1.85
11
discontinued
model
*For all MTB applications Gates recommends the use of 12mm wide Carbon Drive belts.
revision: 04
page.
18
SHIMANO NEXUS/ALFINE
//: Sprocket Dimensions CDX / CDC
CDX
CDX
Flange Inner Diameter
Web Offset From Flange
Flange Thickness
Belt Ride Area
Sprocket Width
CDX / CDC //: SHIMANO NEXUS/ALFINE
Teeth
Part Number
Flange
Outer Diameter
Flange
Inner Diameter
Tooth
Outer Diameter
Mounting Web
Thickness
Sprocket Belt Ride
Width
Area
Flange
Thickness
Web Offset
From Flange
24
CDX1124NAF10
86
71
82.3
3.0
13.35
11.5
1.85
5.45
24
CDC1124NPN10
86
71
82.3
3.0
13.35
11.5
1.85
5.45
24
CDC1124NPN10-SNO
86
71
82.3
3.0
13.35
11.5
1.85
5.45
24
CDC1124NPN10-2.5
86
71
82.3
3.0
13.35
11.5
1.85
2.95
CDC
CDC
NOTE: Inner sprocket engagement features (shown in RED)
found on CDC rear sprocket are visually different from CDX
rear sprocket. All functional geometry is identical.
revision: 04
page.
19
FRONT
//: Sprocket Dimensions CDX
Mounting Arm
Width
BCD
Inner Arm Diameter
Flange Thickness
Sprocket Width
CDX //: FRONT
Mounting
Arm Width
BCD
Inner Arm
Diameter
Flange
O.D.
Tooth
O.D.
Mounting Web
Thickness
Sprocket
Belt Ride
Flange
Width
Area
Thickness
Teeth
Part Number
# of Bolt
Holes
Tooth
Pitch
39
CDX11394AF10
4
16.2
104
88.0
138.4
134.8
3.1
13.1
11.5
1.60
11
46
CDX11464AF10
4
16.2
104
88.0
164.0
159.3
3.1
13.1
11.5
1.60
11
50
CDX11504AF10
4
16.2
104
88.0
178.4
173.2
3.0
13.1
11.5
1.60
11
55
CDX11554AF10
4
17.3
104
88.0
196.0
190.7
3.0
13.1
11.5
1.60
11
46
CDX11465AF10
5
17.3
130
114.5
164.0
159.3
3.0
13.1
11.5
1.60
11
50
CDX11505AF10
5
17.3
130
115.6
178.4
173.2
3.1
13.1
11.5
1.60
11
55
CDX11555AF10
5
17.3
130
115.6
196.0
190.7
3.0
13.1
11.5
1.60
11
60
CDX11605AF10
5
17.3
130
115.6
213.8
208.2
3.0
13.1
11.5
1.60
11
For all MTB applications Gates recommends the use of 12mm wide Carbon Drive belts.
revision: 04
page.
20
FRONT
//: Sprocket Dimensions CDC
Mounting Arm
Width
BCD
Inner Arm Diameter
Flange Thickness
Sprocket Width
CDC //: FRONT
Teeth
Part Number
# of Bolt
Holes
Mounting
Arm Width
BCD
Inner Arm
Diameter
Flange
O.D.
Tooth
O.D.
Mounting Web Sprocket
Thickness
Width
Belt Ride
Area
Flange
Thickness
Tooth
Pitch
46
CDC11464AA10
4
16.2
104
88.0
164.0
159.3
3.1
50
CDC11504AA10
4
16.2
104
88.0
178.4
173.2
3.0
13.1
11.5
1.60
11
13.1
11.5
1.60
11
50
CDC11505AA10
5
17.3
130
115.6
178.4
173.2
55
CDC11555AA10
5
17.3
130
115.6
196.0
190.7
3.1
13.1
11.5
1.60
11
3.0
13.1
11.5
1.60
11
60
CDC11605AA10
5
17.3
130
115.6
213.8
208.2
3.0
13.1
11.5
1.60
11
69
CDC08695AA10
5
17.3
130
115.6
178.4
174.1
3.0
13.1
11.5
1.60
8
74
CDC08745AA10
5
19.5
130
115.6
190.9
186.8
3.0
13.1
11.5
1.6
8
revision: 04
page.
21
//: Design - General Belt and Sprocket Selection
Sprocket selection is impacted by the target gear ratio,
frame chain stay length and available belt lengths.
To simplify the selection process, refer to the drive
calculator on the Carbon Drive website (http://www.
gates.com/Carbondrivesystem/Calculator/) or click on
the belt drive calculator image.
Center Distance Adjustment
To allow for belt installation and tensioning, adjustment in the chainstay length or “Center Distance” is required. To install
a belt, there must be enough room so the belt can slip over the sprockets, achieved by decreasing the Center Distance
between sprockets. See page 30 Figure C for a visual example of Center Distance slackening. It is important to note
that the belt must be installed loose, not rolled or pried onto the sprockets while under tension.
Once the belt is installed onto the sprockets, there must be a way to take up the slack in the drive. If only one ratio
is desired for the application, a minimum range of movement of 12mm is needed – 10mm shorter than nominal for
installation room, and 2mm longer than nominal for tensioning and tolerance take-up. More Center Distance range may
be desired to enable the bike to use different sprockets enabling multiple gear ratio combinations.
Center distance adjustments are typically made through rear axle movement with a sliding dropout, horizontal dropout or
bb axle movement with an eccentric bottom bracket. When using an eccentric bottom bracket pay close attention to both
the sprocket selection, chainstay length and Center Distance due to the limited range of adjustment typical eccentric bb
shells provide.
Suspension Frame Considerations
In the earliest possible stages of designing a Carbon Drive rear suspension frame there are critical engineering factors
which must be taken into consideration. In general, full suspension frame designs result in some form of chain growth.
Chain growth being defined as a change in the resting distance between the axis of the bottom bracket axle and the
axis of the rear hub axle. Because the belt does not have the ability to stretch and the tension in the belt must remain
constant, even the smallest amount of chain growth during suspension travel would be detrimental to the system integrity.
Devices which compensate for drive train slack such as spring loaded idlers or chain guides are not approved for use
with the belt drive.
If a full suspension frame design which utilizes the Carbon Drive system is desired, please contact Carbon Drive Systems
([email protected]) for engineering and development assistance.
Brakes
Gates recommends that hand brakes are used as the primary braking system. Gates does not recommend the use of
brake systems that incorporate the use of the belt drive as the only brake system, such as coaster brakes and fixed
gears. If belt drive brake systems are installed, Gates recommends a hand brake as a secondary braking system.
revision: 04
page.
22
//: Frame Design Rear Triangle Stiffness
Rear Triangle Stiffness
The stiffness of a frame’s rear triangle plays a major role
in the ride quality of the frame as well as the performance
of the belt drive system. If the rear triangle of a frame is
too flexible, it is possible the chainstays/seatstays may
deflect far enough to enable tooth jumping, accelerated
wear, drivetrain noise, or in extreme cases, belt derailment.
Excessively high rear triangle stiffness can result in an
uncomfortable ride quality therefore a balance must be
struck between comfort and adequate stiffness required to
deliver optimum drivetrain performance.
BELT
PULLING
FORCE
Gates engineers have developed a method for directly
measuring and quanitifying rear triangle stiffness as it
relates to belt drive performance. This frame stiffness
evaluation service is offered by Gates to all frame engineers
as a product development tool. It is highly recommended
to submit frames for evaluation as early in the frame
development process as possible.
In order to provide accurate monitoring and evaluation of
the frame stiffness data at all stages of the development
process, Gates offers testing of prototype, pilot production
and mass production frames.
Frame testing requires
submission of two complete framesets to one of our three
engineering development centers located in Taiwan, USA
and Germany.
Please feel free to contact Carbon Drive Systems for
details on how to submit frames for stiffness engineering
evaluations. Email: [email protected]
REAR TRIANGLE DEFLECTION
direction & magnitude will vary
revision: 04
page.
23
//: Frame Design There are many different styles of dropouts available but most
generally fall into two categories – horizontal and vertical.
Horizontal Dropouts almost always have some sort of center
distance adjustment, allowing the use of various belt lengths
and sprocket combinations. A key factor to consider is the need
to realign and tension the belt every time you take the belt off
or need to remove the rear wheel. Component selection is also
important when using horizontal dropouts and may be more
limited. For example, a standard 5mm quick release does not
produce the necessary clamping force to keep the rear wheel
from moving under heavy loading, therefore features such as
positive tensioning stops must be built into the dropouts or
secondary axle tension devices may be required.
Vertical Dropouts do not possess, by themselves, a center
distance change, or tension adjustment capability. This
means a secondary tension mechanism is required (eccentric
bottom bracket, eccentric hub, or dropout slider). The benefit
to a vertical dropout is that once tension and alignment of the
belt have been set (assuming the mounting hardware has
been properly tightened), the rear wheel can be released, and
reinstalled without having to start over with the alignment and
tensioning process. Furthermore, quick release type skewers
can be used, because the clamping force of the skewer is not
holding the belt tension.
revision: 04
page.
24
Dropouts
Alignment
//: Frame Design There are 3 primary types of rear triangle
alignment which directly impact the performance of the belt drive system.
Centerline Offset
The distance between the center plane of the
frame and the inside face of the dropout.
Axis Alignment - Vertical Plane
Refers to the parallel relationship between the axis
of the bottom bracket and the axis of the rear hub
in the vertical plane.
Axis Alignment - Horizontal Plane
Refers to the parallel relationship between the axis
of the bottom bracket and the axis of the rear hub
in the horizontal plane.
reference feature:
centerline offset
frame centerline
1/2 dropout spacing
distance +/- 1.0mm
revision: 04
page.
25
Alignment
//: Frame Design ver
tica
l pl
ane
l
horizonta
plane
axis:
bottom bracket
axis:
rear axle
Axis Alignment - Horizontal Plane
Horizontal Plane-Axis Rotation:
+/- 0.3 Degrees
revision: 04
page.
26
reference feature:
bottom bracket axis
Alignment
//: Frame Design ver
tica
l pl
ane
l
horizonta
plane
axis:
bottom bracket
axis:
rear axle
Axis Alignment - Vertical Plane
Vertical Plane-Axis Rotation:
+/- 0.3 Degrees
parallel axis
reference feature:
bottom bracket axis
revision: 04
page.
27
//: Belt Handling + Compatibility
Gates Carbon Drive™ Belts are extremely durable and offer long life when properly handled. However, caution must be
used before and during installation to avoid damaging the carbon tensile cords that make up the backbone of the belt’s
strength. Excessive bending and twisting creates crimps which can lead to belt breakage under high load.
Do not back bend
Do not crimp
Do not use as a chainwhip
Do not twist
Always use Gates Carbon Drive belts
with authentic Gates Carbon Drive sprockets.
Gates engineers have invested significant time designing,
developing and testing the belt and sprocket tooth profiles
to perform optimally together. The unique design of
Gates Carbon Drive sprocket profile is patent pending.
Gates will not warranty the belts or sprockets if used
with a substitute part from another manufacturer. Always
use Gates Carbon Drive belts with authentic
Gates Carbon Drive sprockets.
revision: 04
page.
28
Do not bundle
Do not invert
//: Belt Installation + Alignment
NOTE: These instructions are for a frame with horizontal dropouts. The concept applies to all belt drive frame types but
specific steps of the setup may vary. Please consult your frame manufacturer’s instructions for additional belt installation and
alignment directions that are specific to your particular frame.
To achieve correct belt alignment, proper spacing of rear sprocket is required to align the centerplane of the rear sprocket
with the center plane of the front sprocket. For more information please refer to the Belt Line Specification section.
Procedure:
1. Install belt through frame break (Figure: A) . The frame break is the separation feature in the frame that allows
for belt installation. This process will vary between manufacturers. Refer to bike manufacturer’s instruction
manual for specific details on your frame’s separation features.
2. Place belt over the crankset and rest on the bottom bracket shell of the frame. This will allow enough belt slack
to bring the belt behind the rear wheel sprocket during wheel installation. (Figure: B)
Figure: A
3. Place wheel into dropouts. Minimize center-to-center distance between axle and bottom bracket by sliding wheel
as far forward in the dropout as possible.
Figure: B
revision: 04
page.
29
4.
5.
6.
7.
Slip belt onto rear sprocket.
Slip belt onto front sprocket. Belt should now be loose but engaging both sprockets. (Figure: C)
If needed, loosen disc brake caliper mounting hardware.
Tighten tensioner bolt(s) on drive side until belt approaches proper tension.
8. Adjust tensioner bolt(s) on non-drive side until wheel is roughly centered between stays.
9. Back pedal and forward pedal 10-15 times and check alignment of belt on rear sprocket. Edge of belt should
slightly touch or come just short of touching inside flange of sprocket (within 1mm) as seen in Figure D.
Adjust tensioner bolt(s) as needed. Figure E shows incorrect belt alignment.
Correct Alignment
Figure: D
Incorrect Alignment
Figure: E
NOTE : wheel may not be perfectly centered between stays after correct belt alignment is achieved.
Some variance is possible due to frame alignment, wheel dish or incorrect crank/bb length combination.
revision: 04
page.
30
*
WARNING: when installing the belt, do not pry the belt onto sprocket or “roll” the belt on by rotating cranks.
Doing so could damage the belt and lead to failure. Belt must be installed loosely and then tension when in place.
Do not pry
Do not roll
//: Retaining Ring Specification - Internal Gear Hubs Only
Gates requires a retaining ring replacement for the standard Shimano® Retaining Ring part #FW7030 for
some Alfine® and Nexus® applications due to the dimensional differences between rear sprockets. The
replacement Gates retaining ring is part #SR144 and can be ordered directly from Gates. See the table
below to determine when to use the Gates Carbon Drive retaining ring vs. the stock Shimano retaining
ring.
Shimano Part # FW7030
Gates Part # SR144
Thickness: 2.0mm
End Detail: Flat, w/o Gap
Thickness: 1.44mm
End Detail: Angled, w/ Gap
INTERNAL GEAR HUB MODEL
Sprocket Part Number
ALFINE 11
ALFINE 8
NEXUS 8
NEXUS 7
NEXUS 3
CDX1124NAF10
N/A
Gates:
SR144
Gates:
SR144
Gates:
SR144
Gates:
SR144
CDC1124NPN10
N/A
Gates:
SR144
Gates:
SR144
Gates:
SR144
Gates:
SR144
CT1124NMN
Shimano:
FW7030
Shimano:
FW7030
Shimano:
FW7030
Shimano:
FW7030
Shimano:
FW7030
revision: 04
page.
31
Carbon Drive Krikit
//: Belt Tensioning
The Gates Carbon Drive Krikit gauge is used to measure belt tension.
Indicator Arm
Finger Strap
KG Scale
kilograms
LBS Scale
Click Pad
pounds
Krikit Gauge Procedure
Proper belt tension is critical to maintain optimum drive operation. The following
instructions explain how to properly use the Carbon Drive Krikit Tension Gauge
1 . Place index finger in the
rubber Finger Strap, on top of the
Click Pad, as shown.
2. Verify Indicator Arm is
positioned completely down
revision: 04
page.
32
Carbon Drive Krikit
//: Belt Tensioning
3. Place the bottom of the
gauge onto the backside of the belt
in the middle of the total belt span,
making sure that the Gauge Lip
is positioned against the outside
edge of the belt, as shown.
Gauge Lip
4. Press down on tester click
pad slowly and steadily with one
finger until the tester clicks. Notice
that the Indicator Arm should move
upward as the pressure is applied
downward. When the gauge clicks,
release the pressure. It is critical
that only one finger is used to apply
pressure to the gauge.
*
WARNING: Do not touch the
Krikit gauge with a second
finger. This process is a one
finger operation.
revision: 04
page.
33
Carbon Drive Krikit
//: Belt Tensioning
5.
Carefully remove tester from belt. Use caution to not move the Indicator Arm after lifting the tool away from the belt.
measurement point
the intersection of lines
A
and
B
A
B
Tension Reading: 20 KG
6.
Rotate crank one-quarter turn and repeat previous steps 1-6. Due to tolerances of supporting drivetrain
components it is likely that different tensions will be measured at different positions in the crank revolution. Repeat rotation
and measurement no less than 3 times. Average the measurements and follow drive setup tension recommendations.
Note: These guidelines are a Gates Recommended Procedure for adjustment of belt tension. In all cases please refer to your individual
bicycle manufacturer’s instructions for confirmation of recommended tensions specific to your specific bicycle’s drivetrain design.
revision: 04
page.
34
//: Belt Tensioning
Sonic Tension Meter 507C
The Gates Sonic Tension Meter measures belt tension by analyzing the harmonic characteristics of a vibrating belt.
Simply strum the belt like a guitar string and the meter will take a reading and provide a highly accuracy tension
measurement.
Compact Size
About the size of a cellular telephone, the Sonic Tension
Meter can easily be operated by one person for fast, accurate
readings
Straightforward operation
Belts vibrate at a particular natural frequency based on mass
and span length.
To operate the 507C meter:
1. Enter the belt width, span length and a belt mass constant
using the built-in keypad.
2. Hold the meter sensor next to the belt span and lightly
strum the belt to make it vibrate.
3. Press the “MEASURE” button and the meter quickly
converts the vibration into belt tension. Readings are
displayed on a backlight LCD screen.
Intelligent Features
This small, lightweight and user friendly meter features:
1. LCD screen with backlight
2. 20 memory registers for belt constants
3. Auto gain control automatically adjusts meter sensitivity
4. Variable frequency range filters
5. Frequency range from 10 - 5000 hertz
6. Output readings measurable in hertz, pounds, kilograms
and newtons
Sonic Tension Meter 507C with
Standard Cord Sensor
Available Option
Flexible Sensor - a semi-rigid sensor arm that can be bent
and repositioned for convenient one-handed operation.
507C Sonic Tension Meters can be purchased direct from
Gates.
revision: 04
page.
35
//: Glossary of Terms
Axial Crank Run-Out
the amount of right to left crank arm tab movement relative to the centerline of the
frame when rotating the cranks. Also referred to as wobble.
Belt Alignment
refers to the parallel (side to side) and angular (toe in - toe out) alignment of the belt
between the front and rear sprocket positions. Proper aligment is critical in order to
maintain proper system performance.
Belt Frequency
a term used in tensioning the belt. The natural frequency of a belt depends on the
tension inside of the belt and distance between sprockets; the higher the tension the
higher the frequency. Measurement of the belt frequency requires the Sonic Tension Meter.
Belt Installation
Distance
the minimum distance between center of the front sprocket and rear sprocket
needed to install the belt on the sprockets loosely. Initial installation of the belt
loosely on the sprockets is required in order to avoid damaging the belt.
Belt Line
defined as the distance of a point on the belt in relation to the centerline of the
frame. The point on the belt is typically a defined distance from the inside edge of
the sprocket flange.
Belt pitch
the distance from the center of one tooth to the center of the next tooth. This
measurement is typically different than a chain.
Belt tension
the amount of tension experienced inside of a loaded belt. Belts require a higher
installation tension than chains and are sensitive to incorrect tensioning. Proper
installation tension keeps the belt from skipping teeth and increases the life of the
belt.
Diameter Over Teeth
the outer most diameter (OD) of the sprocket teeth
Force-Deflection
Measurement
a term used to explain a type of tension measurement process. This process
involves deflecting the belt a specific distance for a given amount of force applied.
Frame Break
feature of the frame enabling a “break” in the frame structure allowing belt
installation into the rear triangle. Unlike a chain a belt is continuous and cannot be
separated therefore a separation in the frame is required for belt installation.
Frame Stiffness
refers to a frame’s resistance to flex for a given load applied. Stiffness plays a vital
role in the operation of a belt drive. Too much flex can cause skipping mis-alignment
noise and wear.
Gear inches
a system of measurement used to compare gear ratios based on the distance a bike
travels during one pedal revolution.
Krikit gauge
Profile
revision: 04
page.
listed alphabetically
36
a handheld tool used to set proper belt tension.
refers to the shape of the belt tooth and sprocket groove.
//:Glossary of Terms
//:
Radial Crank Run-Out
the amount of “out-of-roundness” of crank arm tabs when rotating the cranks. Also
referred to as Eccentricity. This type of run out is usually detected through tension
readings in the belt
Rear 9-spline Flange
a flange component that is assembled on the hub cassette body next to the unflanged side of the rear sprocket to keep the belt running between two flange
surfaces.
Skipping
occurs when the belt tooth misses an engagement with a sprocket tooth resulting in
a “skipped” tooth engagement.
Snubber
a device typically used on Rohloff drivetrains to increase belt wrap on the rear
sprocket to help prevent the belt from skipping. A typical place for a snubber would
be on the entry point of the belt into the rear sprocket (slack side)
Sonic tension meter
high precision electronic tool used to set proper belt tension
Sprocket
using belt drive terminology the term sprocket is used in place of rear cog and front
chainring.
Sprocket Clearance
distance from the closest edge of a front or rear sprocket to the frame. Belt drive
sprockets are wider than chain rings so clearance requirements must be considered.
Sprocket diameter
There are a few diameters associated with front and rear sprockets. The first is
flange diameter which is the largest diameter of the sprocket body. The second is
diameter over teeth which is measured over the tips of the sprocket teeth. If trying
to identify an unmarked sprocket the best way is to count the number of teeth.
Strap wrench
a tool used to hold the rear sprocket in order to remove the rear cassette lockring.
A strap wrench is the equivalent of a chain whip used for removing cogs on standard
chain drive systems.
Synchronous
refers to drive systems using toothed belts in mesh with grooved sprockets.
Tensioned Center
Distance
the distance between the center of the front sprocket and rear sprocket at proper
belt tension for a given drive ratio.
revision: 04
page.
37
//:Troubleshooting Guide
//:
If a problem occurs with the drive system, please use the following troubleshooting chart to help determine a symptom, possible cause and corrective action. Of course if you
have any questions, please contact us at: [email protected]
[email protected]
SYMPTOM
POSSIBLE CAUSES
Belt squeaking
Mis-alignment of the drive system
Improper belt tension
Belt running off sprockets
Worn sprocket
Replace sprocket
Chainring bolts coming loose
Tighten chainring bolts
Mis alignment of the drive system
- Check to see if the rear wheel has moved.
- Check to see if the tensioning device has been effected.
- Reposition rear wheel in dropouts.
- Re-tension the belt
- Reposition rear wheel in dropouts
Tighten crankset bolts
Cassette lock ring coming loose
Tighten cassette lock ring
Belt system has lost its tension
Worn sprocket
38
- Check to make sure sprockets are properly aligned
- Verify the correct amount of spacers been used for the rear
sprocket.
- Check to make sure the belt is not being pinched between
sprocket flanges.
- Realign drive system and tension belt
Crankset coming loose
Rear wheel has moved in dropout
page.
- Check to see if the tensioning device has been effected.
Replace sprocket
Rear wheel has moved in dropout
revision: 04
- Check to make sure sprockets are properly aligned.
sprocket
sprocket flange.
- Realign drive system and tension belt
Bent sprocket flange
Belt tooth jumping on sprockets
CORRECTIVE ACTION
- Check to see if the rear wheel has moved
- Check to see if the tensioning device has been effected
Replace sprocket
//:Troubleshooting Guide
//:
Broken belt
Improper belt handling, storage or
installation
Debris or object in drive system
Belt ran off rear sprocket
Tension loss in drive system
Change in distance between sprockets
Excessive variation of tension readings in
the belt after proper installation
(std 55 +/-15 Hz)
Non-concentric assembly of
sprocket/crank arm
Crank arm run out
Belt tooth wear
Belt running off non-flanged side of
sprocket/mis alignment
Excessive belt edge wear
- Follow belt handling instructions and installation tips
- Never roll or pry belt onto sprockets
- Replace belt
- Clean any debris from sprocket
- Replace belt
- Verify the correct amount of spacers have been used for the
rear sprocket.
k t
- Realign drive system and tension belt.
- Check to see if the tensioning device has been affected.
- Re-tension the belt.
- Loosen chainring bolts and Reposition sprocket on crank arm
tabs
- Re-tighten chainring bolts
Replace crank arm set
- Check to make sure the tension is not too high.
- Check to see if the tensioning device has been affected.
- Verify the correct amount of spacers have been used for the
rear sprocket.
- Check
Ch k to
t make
k sure the
th belt
b lt is
i nott being
b i pinched
i h d between
b t
sprocket flanges.
Worn sprocket
Replace sprocket
Damaged sprocket teeth
Replace sprocket
Excessive debris in drive system
Clean any debris from sprocket
Mis alignment of the drive system
Sprocket flange damage
sprocket.
sprocket flanges.
- Check to see if the rear wheel has moved
- Check to see if the tensioning device has been effected
Replace sprocket
revision: 04
page.
39
®
gatescarbondrive.com
GATES CORPORATION
[email protected]
720-524-7206
17572
February 2012

technical manual - Gates Carbon Drive

Transcription

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