Continental Belt Drive. User manual

Transcription

1 Continental Belt Drive User manual

2

3 1 EN Table of contents 1 Basic information Intended use Warning notices Symbols 3 2 Safety warnings 4 3 Mode of operation of the CBD System components and versions Special warnings regarding timing belts Maintaining the components and handling them safely 9 4 Checking and adjusting the CBD Setting the belt tension Arranging and aligning the sprockets / Checking the belt alignment 12 5 Wear and tear 15 6 Exchanging CBD components Warning notices How to carry out maintenance work on the rear wheel Exchanging the timing belt (without changing the sprockets) Exchanging sprockets Disposing of the CBD components 23

4 CONTINENTAL BELT DRIVE 2 1 Basic information This user manual accompanies the Continental Belt Drive system abbreviated: CBD. The user manual contains important information on using, handling, and adjusting the settings of the CBD and is based on the standards and regulations in force in the European Union. Read the entire user manual carefully especially the safety warnings before using the CBD timing belt drive system. If the warnings in the user manual are not observed, it can lead to severe injury or damage to the CBD. Store the user manual in an easily accessible location for future use. If you give your bicycle or e-bike, mounted with the CBD timing belt drive system or individual CBD components, to a third party, you must also include the user manual with it. 1.1 Intended use The CBD timing belt drive system is designed for use with one-person bicycles and e-bikes that are suitable for being equipped with timing belt drive systems. In this user manual, the term e-bike refers to bicycles with electric motor support in general. To ensure that your e-bike model is suitable for use with the CBD timing belt drive system, contact a bicycle retailer. According to regulation, bicycles or e-bikes equipped with CBD may only be used on paved (with asphalt/concrete/cobblestones) roads or paths. The CBD timing belt drive system is not designed to be used on unpaved paths or off-road. Always take note of the additional user manual and safety warnings for the bicycle or e-bike with which you plan to use the CBD. The manufacturer does not assume liability for damage arising from improper use. Only use the CBD as described in this user manual. Any other use is considered improper and can lead to accidents, severe injuries and damage to the CBD. Avoid misuse and check the functionality of the timing belts and sprockets before each ride. If you notice any defects, these must be repaired by a bicycle retailer immediately. If components of the CBD must be replaced, only original replacement parts may be used this is for your own safety and in order for your bicycle to retain its value. Inspections at regular intervals can reveal material fatigue and prevent accidents.

5 3 EN 1.2 Warning notices The following signal symbols and signal words are used in this user manual to warn about the risk of personal injury or material damages. The warning notices themselves cannot prevent danger. Comply with all warning notices to avoid any risks while using the CBD. Wwarnin The signal word indicates a hazard with a moderate level of risk one that can result in death or severe injury if not avoided. wattentio The signal word indicates the possibility of material damage. 1.3 Symbols The following symbols are used in this user manual, on components of the CBD or on the packaging. Read and observe the user manual. There is additional information here. Products with this symbol fulfill all applicable community regulations of the European Economic Area.

6 CONTINENTAL BELT DRIVE 4 2 Safety warnings The following general safety warnings apply to handling the CBD timing belt drive system: Check the proper functioning of your timing belt drive system before every ride. If you notice any defects or damage, you must immediately check these carefully and have them repaired if necessary. Only use a complete CBD timing belt drive system, consisting of the original Continental sprockets and timing belt, that is suitable for your bicycle or e-bike. Inquire about this at a bicycle retailer if necessary. If components of the CBD need to be exchanged, only use original replacement parts that you receive from a trained bicycle retailer. Your bicycle retailer is able to recognize any signs of wear and tear and can exchange the required components if necessary. For this reason, bring your bicycle or e-bike to be inspected by a bicycle retailer on a regular basis. In addition to the general safety warnings included here, you must absolutely also take note of the warnings in the individual chapters of this user manual to avoid injury and material damage. Possible forms of misuse To use your CBD timing belt drive system safely, rule out the following forms of misuse: Using the bicycle or e-bike for competitions, jumps, stunts or tricks, or on open terrain (e.g. off-road or off-path); Improper repairs and maintenance; Defects due to external interference and structural changes to the condition of the bicycle as delivered. In particular: tuning of the drive or other system-related bicycle components. Misuse of the CBD can lead to nullification of the warranty.

7 5 EN 3 Mode of operation of the CBD The Continental Belt Drive (CBD) system was especially developed to be integrated on bicycles or e-bikes and is therefore a suitable alternative to chain drives System components of the CBD timing belt drive system 3.1 System components and versions Essentially, the timing belt drive system is made up of three components: a front sprocket 1, a rear sprocket 2 and a timing belt 3. All system components are available in different widths for various applications of the CBD. Furthermore, there are other versions of the sprockets in terms of material, sprocket size and mounts. Please take note of the various CBD product lines that can only be used as closed systems. CBD10 10 mm carbon belt 10 mm sprockets made of aluminum/stainless steel suitable for city/trekking bikes and e-bikes

8 CONTINENTAL BELT DRIVE 6 CBD8 8 mm carbon belt 8 mm sprockets made of plastic suitable for city/trekking bikes without electric motor assist 3.2 Special warnings regarding timing belts Inside the timing belt, there are carbon fibers which function as the basic element providing traction. Upper material: Abrasion-proof polymer Optimized tooth profile Carbon fibers providing traction High-modulus PU Composition of the timing belt Due to its design, the timing belt has a certain direction of operation that must be observed. Width length of the timing belt 14M/10 x 1568mm Do not crimp! Continental Belt Drive MADE IN GERMANY Direction of operation Composition of the CBD timing belt Please note: Do not crimp the timing belt! Direction of operation When installing or replacing a timing belt, always take note of the indicated direction of operation.

9 7 EN When handling the timing belt, take note of the following warnings to avoid damaging the timing belt or its functionality. wattentio If you handle the timing belt improperly, the carbon fibers can break, which would cause the timing belt to lose its tensile strength and tear. Risk of damage! Refrain from kinking, bending, twisting, knotting or inverting the timing belt and from using it as a belt whip. Do not lift the timing belt by the sprocket when installing. Do not tamper with the timing belt using (sharp-edged) tools. Do not oil or lubricate the timing belt. Do not try to open or repair the timing belt. Never stand on the timing belt, regardless of whether it is installed. Never use the timing belt to hold the bicycle or e-bike. If the timing belt slips off the sprocket, the timing belt must be replaced no matter what. Contact a bicycle retailer if you are unsure about how to apply or handle the CBD or if you are unsure about its condition.

10 CONTINENTAL BELT DRIVE 8. min. 100 mm Keep the timing belt in its natural shape when transporting it separately. Avoid any tension or other impacts on the timing belt. The minimum curvature of the timing belt (100 mm) must be met, regardless of whether the timing belt is installed or not. Minimum curvature of the timing belt (exterior diameter)

11 9 EN 3.3 Maintaining the components and handling them safely The CBD system components are fundamentally suitable for use throughout the whole year, as they are designed for any weather conditions appropriate for cycling: Use temperature of 40 C to +80 C. Resistant to the effects of UV rays and ozone. Usable under all weather conditions appropriate for cycling (excluding deep snow, ice, storms, etc.). Resistant to various media that are often present when using a bicycle, such as oil or cleaning supplies. To extend the service life of the CBD timing belt drive system, we recommend cleaning mud and dirt from the CBD on a regular basis. The gaps between the sprocket bars have been milled in such a way that particles of dirt are usually pushed out by the teeth moving over them. However, small rocks or twigs can become wedged in the system. Residues on the timing belt or sprockets may cause more wear and tear, as well as noise (e.g. squeaking or creaking). Clear dirt from the belt s teeth and the profiles of the teeth on both drive sprockets using a standard hand brush. Carefully loosen trapped particles or firmly stuck rocks, for example by using a plastic wand. Never use a sharp-edged tool. If the soiling is heavy, use a standard bicycle cleaner (biodegradable). The timing belt is resistant to soapsuds. To deal with these, spray the drive system with bicycle cleaner, let it work for a few minutes and then use a sponge to lather and clean. An old toothbrush, for example, can be helpful for removing stubborn soiling in the gaps or in the profiles of the belt and sprockets. Then rinse the drive system using plenty of water. If you notice any unusual noises while operating the timing belt drive system, first check whether the noise is coming from soiling in the CBD and/or its individual components. Clean all the components. If the noise persists even after thorough cleaning, a thin layer of dry silicone spray can be applied to the interior of the timing belt. This layer will prevent further debris getting trapped, improve the belt s smoothness and reduce noise generation.

12 CONTINENTAL BELT DRIVE 10 4 Checking and adjusting the CBD Wwarnin The adjustment of the timing belt drive system is very important for ensuring that the CBD functions properly. If you do not regularly check the components of the CBD and adjust them if necessary, the timing belt can tear while riding, which could cause you to fall and injure yourself. Risk of injury! Regularly check that the belt alignment, sprocket angle and belt tension are adjusted in accordance with the specifications in this chapter and make any necessary adjustments. While doing so, make sure not to crush, kink or twist the timing belt. 4.1 Setting the belt tension Insufficient tension in the timing belt can cause it to jump. When jumping occurs, the teeth of the timing belt slide over the sprocket and the rider feels a slipping sensation. Jumping poses a risk of injury. If the pre-tension of the timing belt is too high, this can lead to increased wear and tear on the components due to overstressing. Damage to the bottom bracket, as well as to the rear wheel hub bracket, can result. Optimum belt tension is in the range of 75 N 100 N. This corresponds to a maximum sag of 25 mm for the timing belt when a central, vertical load of 5 kg is placed on the upper section of the belt. max. 25 mm 5 kg Belt tension

13 11 EN 1. Hang a 5-kg weight in the center of the timing belt to check the belt tension. The timing belt must have a sag of between 25 mm (maximum) and 16 mm (minimum). 2. If the belt tension is too low or high, adjust the belt tension accordingly by following the information provided by the manufacturer of your bicycle or e-bike. If necessary, inquire about the tension mechanism of your bicycle or e-bike or your frame with its respective manufacturer. 3. After adjusting, check again to make sure that the belt tension is within the given optimum range. 4. After successfully adjusting the belt tension, rotate the pedal a quarter turn and check the belt tension at the corresponding position of the timing belt once more. 5. If necessary, repeat steps 1 4 until the belt tension is within the given optimum range on four consecutive checks. Alternatively, you can adjust the belt tension using a belt-measurement tool. Belt-measurement tool (Parktool Art.No. : BDT-2) The belt tension can be checked by applying the belt-measurement tool. A tension spring weighing 5 kg is built into the center of the tool. The scale indicates the current belt tension: A 6 corresponds to 75 N or 25 mm of deflection for 5 kg in the center of the belt. An 8 corresponds to 100 N or 16 mm of deflection for 5 kg in the center of the belt. Please see the corresponding information from the manufacturer for the exact instructions for using the tools (package insert).

14 CONTINENTAL BELT DRIVE wrranging and aligning the sprockets / Checking the belt alignment The arrangement of the sprockets is very important and can vary from bicycle to bicycle. To prevent the timing belt from slipping off the sprocket, the front sprocket 2 and the rear sprocket 4 are each equipped with a raised section, what are known as the flanged wheels 3, which prevents the timing belt from slipping off. The flanged wheel on the front sprocket is located on the exterior side; the flanged wheel on the rear sprocket is located on the interior side. To ensure that the CBD system will function optimally, the sprockets must be correctly arranged and aligned. This depends on the parallelism and the angle between the two sprockets Max. 0.3 (X and Y axles) Arrangement and alignment of the sprockets The following points are especially important for arranging and aligning the sprockets correctly: The pedal axle 1 and rear wheel axle 5 may have a maximum angle error of 0.3. The tread of the sprockets may have a maximum misalignment of 3 mm (including frame misalignment, hub tolerance, axial rotation of the crank/spider, frame stiffness) The timing belt may not extend beyond the sprocket and may not run against the flanged wheels at an angle. In both of these cases, there is a danger of the timing belt tearing during the ride, which could cause you to fall and injure yourself.

15 13 EN Flanged wheel Belt alignment Max. 3 mm, including all tolerances (frame, stiffness, hub tolerance, rotation) Tolerances for the belt alignment Check the belt alignment before every ride to ensure that the timing belt is running correctly on the sprocket. If you notice the timing belt slipping off the sprocket while checking the belt alignment, the timing belt must be replaced no matter what, as the carbon fibers in the timing belt may already be damaged. 1. To do this, position your bicycle or e-bike in such a way that the rear wheel can rotate freely, e.g. by having another person help you by lifting the back of your bicycle or e-bike by the frame. 2. Make the rear wheel spin by turning the pedals several times. 3. Stand behind the bicycle or e-bike and check (visual inspection) whether the timing belt is running in a constant straight line that is centered on both sprockets. The timing belt must be aligned as follows: The timing belt slightly touches the flanged wheels at the front and rear sprocket. Under no circumstances may the timing belt extend beyond one of the sprockets. The timing belt may not run against flanged wheels at an angle. 4. Contact a bicycle retailer if you notice any discrepancies.

16 CONTINENTAL BELT DRIVE 14 Check belt alignment

17 15 EN 5 Wear and tear The CBD timing belt drive system stands out because of its low belt pre-tension and easy handling; however, even these characteristics cannot fully exclude the possibility of wear and tear relating to age and intensity of use. Check the timing belt and the sprockets for defects before every use. Using a worn-out or damaged component can result in injury or damage to the CBD. If you notice any wear and tear on the timing belt and/or sprockets, find a bicycle retailer who can check the condition of the timing belt drive system and replace the worn parts if necessary. The following overview gives specific examples of wear and tear and the corresponding actions to take. asymmetrical wearing down of the tooth pointy shark tooth cracks or signs of breakage on the tooth broken-off tooth Examples of types of wear and tear on the timing belt exposed carbon fibers

18 CONTINENTAL BELT DRIVE 16 Worn-out timing belt Examples of types of wear and tear on the sprockets

19 17 EN In the table below that, you will find a list of possible types of wear and tear on the CBD and the corresponding maintenance work to be carried out. Possible type of wear and tear The sprocket on the front and/or rear sprocket is bent out of shape. The front and/or rear sprocket is bent out of shape. The tooth profile of the front and/or rear sprocket is visibly damaged (asymmetrical). The rear sprocket wobbles on the hub; the fit has come out/is spinning. Replace sprockets (both) Replace timing belt The front/rear sprocket is shorn off. The sprocket on the front and/or rear sprocket has sharp edges. The timing belt is kinked/bent out of shape. The tooth profile of the timing belt is visibly damaged. The timing belt exhibits tears or porous spots. The timing belt is frayed. The timing belt is torn.

20 CONTINENTAL BELT DRIVE 18 6 Exchanging CBD components This chapter provides information on how to exchange worn-out or damaged components of the CBD timing belt drive system and on what you need to know before beginning any maintenance work on your bicycle or e-bike s rear wheel. 6.1 Warning notices Take note of the following important warnings when exchanging CBD components or doing any maintenance work on the rear wheel. Wwarnin The CBD timing belt drive system may only be used on bicycles and e-bikes that are capable of being equipped with a belt drive system. Improper installation poses a significant risk of accident and injury. Risk of injury! Never install the CBD on bicycles or e-bikes that are not suitable for this purpose. Contact a bicycle retailer if you are unsure whether your bicycle or e-bike is suitable for use with a timing belt drive system. Wwarnin To install the CBD, it is necessary to open the frame of your bicycle or e-bike. An improperly closed frame is unstable and poses a significant risk of accident and injury. Risk of injury! Make sure to close the frame again properly once the installation and/or maintenance work has been completed. Contact a bicycle retailer if you experience problems opening or closing the frame, are not familiar with the process or feel unsure.

21 19 EN Wwarnin You can injure yourself by touching or reaching into the drive system while it is running. Risk of injury! Do not touch or reach into the drive system while it is running. Make sure not to crush your fingers between the moving parts when working with the drive system. Wwarnin Improper installation can impede the CBD s functionality, increasing the risk of falling and/or injury. Risk of injury! When installing and doing maintenance work, make sure that the sprockets are correctly arranged and aligned. Only exchange sprockets and timing belts with original replacement parts from the manufacturer. Contact a bicycle retailer if you experience problems when installing and doing maintenance work on the CBD, are not familiar with the process or feel unsure. wattentio If you handle the timing belt improperly, you can damage it permanently. The timing belt may rip or lose functionality. Risk of damage! Refrain from kinking, bending, twisting, knotting or inverting the timing belt and from using it as a belt whip. Do not lift the timing belt by the sprocket when installing. Do not tamper with the timing belt using (sharp-edged) tools. Do not oil the timing belt.

22 CONTINENTAL BELT DRIVE How to carry out maintenance work on the rear wheel The following illustrates how to dismantle the rear wheel for one type of frame lock. The frame lock and, consequently, the method for dismantling the rear wheel may vary, depending on the model of your bicycle or e-bike. For this reason, familiarize yourself with how to dismantle and reassemble the rear wheel according to the user manual of your bicycle or e-bike. Contact a bicycle retailer if you experience problems dismantling or reassembling the rear wheel or feel unsure. Dismantling the rear wheel 1. Reduce the belt tension by following the information provided by the manufacturer of your bicycle or e-bike. Reduced belt tension 2. Dismantle the rear wheel as described in the user manual from your bicycle s manufacturer without crushing, bending or kinking the timing belt. 3. Remove the timing belt from the rear sprocket by hand and let it hang, free of tension, on the front sprocket or the frame until you put the rear wheel back together again. Remove the timing belt from the rear sprocket / let timing belt hang, free of tension

23 21 EN Reassembling the rear wheel and attaching the timing belt 1. Insert the rear wheel into the rear wheel suspension bracket by following the information provided by the manufacturer of your bicycle or e-bike. 2. Place the timing belt by hand on the front sprocket and let it hang, free of tension. 3. Make sure that the belt tension is reduced. Reduce the belt tension first if necessary by following the information provided by the manufacturer of your bicycle or e-bike. Place the timing belt on the front sprocket / reduced belt tension 4. From above, place the timing belt by hand on the rear sprocket. 5. Carefully rotate the rear wheel backwards with the loosely attached timing belt. When the rear wheel is gently rotated backwards, the timing belt will feed into the sprocket completely with no need to apply force. 6. Fasten the rear wheel by following the information provided by the manufacturer of your bicycle or e-bike. 7. Make sure that the belt line, sprocket s angle and belt tension are adjusted correctly (see chapter Checking and adjusting the CBD ).

24 CONTINENTAL BELT DRIVE Exchanging the timing belt (without changing the sprockets) 1. Open the frame lock as described in the user manual provided by the manufacturer of your bicycle or frame. 2. Remove the timing belt from the rear sprocket. 3. Remove the timing belt from the front sprocket. 4. Feed the obstructed timing belt through the open frame lock and place it aside. Remove the timing belt from the rear sprocket and dispose of it 5. Feed the new timing belt through the open frame lock without crushing, bending or kinking the timing belt. 6. While doing so, take note of the direction of operation as indicated on the timing belt (see the chapter Mode of Operation of the CBD ). 7. Then attach the new timing belt to the front sprocket. 8. Close the frame lock again as described in the user manual provided by the manufacturer of your bicycle or frame. 9. From above, place the timing belt by hand on the rear sprocket. 10. Carefully rotate the rear wheel backwards with the loosely attached timing belt. When the rear wheel is gently rotated backwards, the timing belt will feed into the sprocket completely with no need to apply force. 11. Make sure that the belt line, sprocket s angle and belt tension are adjusted correctly (see chapter Checking and adjusting the CBD ).

25 23 EN 6.4 Exchanging sprockets If wear and tear or another reason makes it necessary to exchange one or both of the sprockets, exchange the complete CBD timing belt drive system, including both sprockets and the timing belt. This is the only way to guarantee that the CBD timing belt drive system will function optimally. You can find a list of possible types of wear and tear in the chapter Wear and tear. Sprockets are installed in the same way as standard chainrings or sprockets. To remove the rear sprocket, there is a sprocket tool used to remove freewheel hubs (equivalent to a chain whip). Read the information on this in the user manual from the manufacturer of your bicycle or e-bike or contact a bicycle retailer. 6.5 Disposing of the CBD components Dispose of the CBD system components at the end of their service life in accordance with the laws and regulations in force in your country.

26

27 Continental Bicycle Systems Contact Continental Bicycle Systems GmbH & Co. KG Ludwig-Erhard-Straße D Eschborn Tel: +49 (0) ContiTech. Engineering Next Level The ContiTech division of the Continental Corporation is one of the world s leading industry specialists. As a technology partner, our name is synonymous with expertise in development and materials for components made of natural rubber and plastics and also in combination with other materials such as metal, fabrics or silicone. By integrating electronic components, we are also generating solutions for the future. Beyond products, systems and services we also provide holistic solutions and have a formative influence on the industrial infrastructure. We see digitalisation and current trends as an opportunity to work with our customers to add sustainable value for both sides and for good. Learn more about the contents of this brochure. The content of this publication is not legally binding and is provided as information only. The trademarks displayed in this publication are the property of Continental AG and/or its affiliates. Copyright 2018 ContiTech AG, Hannover. All rights reserved. For complete information go to: EN