Gates Belt Ruler - G-Boxx
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1. U nN Ive rS al Transmissions Universal transmissions GmbH Kulftalstr 18 31093 Lubbrechtsen Germany phone 49 5185 60266 50 info carbondrive net www carbondrivesystems com GATES belt ruler and tension tester User manual Thank you for choosing the Carbon Drive equipment to install the drive system correctly On the following pages a testing method will introduced to check easily the correct belt line and the belt tension Please read this manual carefully before you start with the first measurements lf you got any additional questions to the measurement procedure feel free to contact us info carbondrive net fig 1 Multi purpose tool to check the belt line and the belt tension rae BASICS a ee PaSa Checking the beltline Adjustment of the belt line Checking the belt tension Measurement 005 Content Basics Beltline A correct aligned belt line is absolutely required to receive a secure and carefree system The correct beltline is also important to receive the high efficiency of the system The beltline is specified by the used hub type The Position of the front sprocket needs to be aligned depending on the hub type The fine adjustments are also necessary in order to compensate the frame or component tolerances The front sprocket and the rear pulley should aligned in a way that they are located on one plane An incorrect aligned beltline is shown on fig 2 The displacement a2. d correctly fig 11 Belt tension low Red array is shown in the indicator opening
3. e horizontal dropouts or the eccentric bottom bracket If the belt tension wont be increased fast belt wearing can occur The stress on the D bearings of the rear hub and the bottom bracket will also raise to a level where high wearing is possible P The belt tension is to low fig 11 Please decrease the tension of the belt via the horizontal dropouts or the eccentric bottom bracket Lack of belt tension can lead to so called ratcheting which means that the belt will jump over the teeth of the rear pulley Ratcheting can damage the carbon tensile cords i Important Initial setting The carbon fibers on the inside of the belt are in an unstressed state before the first assembly If the belt is mounted for the first time and tensioned for the first time the carbon fibers move to their working position tensioned This process causes a minimal change in length of the belt This is called initial settling To compensate this settling behavior the belt will be tensioned about 15 above the optimum belt tension The belt tension during first assembly can also be easily verified with the belt ruler Prior to delivery of the bike to the customer the tension indicator should show 50 yellow and 50 green in the indicator opening i Tip The belt ruler can be positioned on top of the belt while tensioning the belt via the horizontal dropouts or the eccentric BB Unit This is an easy way to notice when the belt is tensione
4. embly stand The testing weight is not necessary to check the beltline Please remove the weight before measuring As a first step the fine adjustment of the measurement device needs to be done Via the adjustment bar the device can be adjusted in order to match the device to different chain stay length Please loose the two M8 cylinder head bolts which are fixing the adjustment bar fig 4 Pos 1 Afterwards the length can be adjusted in a way that the testing needle reaches the inside flange of the rear pulley The testing needle is an indicator if the belt line is aligned correctly The needle has to be proper adjusted to the different beltlines as well Please loose the M5 cylinder head bolt to adjust the testing needle fig 4 Pos 2 ED Pos 2 Pos 1 fig 4 Fastening bolts to adjust the belt ruler The beltline is specified by the used hub Three possible beltlines are listed in the chart below Chart 1 Chart 1 Measurements at the testing needle Measurement at the Hub type testing needle Rohloff Speedhub 10 0mm Shimano Nexus 12 0mm Alfine 9Spline freewheel body 13 0mm Please adjust the testing needle to the used hub type The value D should be measured at the surfaces which are shown in fig 5 The belt ruler is now adjusted properly Please follow the next step to check the belt line To check the belt line the belt ruler needs to be positioned at the mounted front sprocket
5. of the sprockets will lead the belt to run of the sprockets This procedure could damage the belt and might cause a dangerous crash Displacements of the sprockets can also increase the friction of the system and therefore decrease the efficiency oS sm me me fig 2 Incorrect aligned beltline Displacement shown through a Belt tension Proper belt tension is absolutely required to receive a secure and durable drive system A belt tension against the specification can lead to an increased wearing Lack of belt tension can lead to so called ratcheting which means that the belt will jump over the teeth of the rear pulley Ratcheting could damage the carbon tensile cords my Part list Nr Quantity Description te tension indicator o e mmn l e e pen 0 cylinder head bolt M5 x 12mm Ea 1 dowel 6 x 14mm Se The measurement device is already pre assembled To make the individual adjustments please use the following tools Tools are not included in delivery 1x 6mm Allen key 1x 4mm Allen key ae Checking the beltline The measurement device can be used on a fully equipped bicycle It is useful to fix the bike in an assembly stand in order to get an ergonomic position to check the beltline Please consider that the chain stays are aligned parallel to the ground fig 3 Please pay attention to the secure stand of the assembly stand fig 3 Bicycle fixed in an ass
6. t Poll N answit eto SY 2 pes 10x1 6x1 mm j Mounting Shim for Bottom 1 pcs 10x16x0 5mm j Bracket if required D pcs 41x35x1mm 1 pcs 41x35x0 5mm i 7 i r j Bearing Cup 1 Bottom Bracket Axle Za fig 8 belt line alignment via bottom bracket spacer Checking the belt tension The checking of the belt tension can perfomed at an assembled bike as well The procedure can be done in an assembly stand or directly at the bicycle To prepare the measurement device the provided testing weight needs to screw on the measurement shaft fig 9 fig 9 Preparation for the tension measurement Measurement The belt ruler has to be positioned on top of the drive section tight span to check the belt tension In order to receive reliable test results the belt ruler should applied in a way that the tension indicator pushes in the middle of the drive section A force from about 10N is introduced perpendicular on top of the belt The generated deflection is a measurement of the pre tension of the Carbon Drive system The array of the tension will be shown through the indicator opening The following tension arrays will be shown The Carbon Drive System is correctly tensioned fig 10 There are no tension adjustments necessary Low wearing and the highest efficiency are accomplished in this array The belt tension is too high Please decrease the belt tension via the adjustabl
7. with its parallel face fig 6 lf the belt line is already adjusted the face of the testing needle should touch the inside of the flange of the rear sprocket fig 6 test setup to check the belt line In the case that the belt line is not aligned properly please use the following procedure to receive the correct adjustment Ea Adjustment of the belt line The beltline can be adjusted by using the washer set The washer set is included in the front sprocket delivery It consists of washers with two different thicknesses to be able to fine adjust the belt line The needed washers are mounted between the surface oft he crank arm and the front sprocket fig 7 Some bottom bracket units e g Shimano Hollowtech or Truvativ GXP allow the fine adjustment via washers between the bottom bracket shell and the BB housing fig 8 Please pay attention to the instructions for installation of the bottom bracket which is supplied by the BB manufacturer Crank Arm Chain ring Nut Mounting Shims Sa if required H Front Sprocket Ria fig 7 Assembly of the front sprocket i lf your bike is equipped with an eccentric bottom bracket you can set the belt line by adjusting the bottom bracket unit axial in the bottom bracket housing Please pay attention to the instructions for installation of the eccentric bottom bracket which is supplied by the bike manufacturer ED ai I Washer set Crank with Bel
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