DT SWISS ROAD 2013 SPLINE RC 38 Technical Manual
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DT SWISS ROAD 2013 SPLINE RC 38 Technical Manual

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WHEELS
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SPLINE
Technical Manual english
V2013.11_EN

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Summary of Contents for DT SWISS ROAD 2013 SPLINE RC 38

  • Page 1 WHEELS ® SPLINE Technical Manual english V2013.11_EN...

  • Page 2: Table Of Contents

    General General Maintenance Information ........6 Safety Conversion of the Hub Converting the Hub [Inserted Adapters] .
  • Page 3 Technical Data Spoke Tension ............74 Tolerances .
  • Page 4 The cover page and the footing are providing information about the type of product and manual as well as the version of the manual. The backside provides a list of the DT Swiss service centers. A list of all DT Swiss service centers can be found at www.dtswiss.com.
  • Page 5 Biel/Switzerland. Swiss law shall apply. Submit any warranty claims to your retailer or a DT Swiss service center. Any defects recognised by DT Swiss AG as a warranty claim will be repaired or replaced by a DT Swiss service center.
  • Page 6 To take advantage of this warranty, the product or part must be returned for examination, postage prepaid, to the dealer where you bought the product or to a DT Swiss service center. Proof of purchase date and an expla- nation of the complaint must accompany the product. If our inspection discloses a defect, DT Swiss will either repair or replace the product or refund the purchase price, if we cannot readily and quickly provide a repair or replacement.

  • Page 7: General Maintenance Information

    The operations described in this manual should only be done by professionals. The user is liable for any damage or consequential damage which is caused by wrong maintained or wrong installed components. If you have doubts, please contact a DT Swiss service center. ®...

  • Page 8: Safety

    • The components must not be changed or modified. • The component must not be used if it is damaged or there are any signs of damage. If in any doubt, consult a DT Swiss service center. DANGER Risk of death caused by incorrectly assembled or faulty wheels and hubs! •...

  • Page 9: Conversion Of The Hub

    3 Conversion of the Hub The hubs can be converted to the following axle version: Wheels 2013 Wheel Front Wheel Option Rear Wheel Option ROAD 2013 ● ● RC 38 ● ● R 28 ● ● R 23 MTB 2013 ●...
  • Page 10 Wheels 2014 Wheel Front Wheel Option Rear Wheel Option ROAD 2014 ● ● RC 28 ● ● RC 38 ● ● RC 46 ● ● RC 55 ● ● R 23 ● ● R 28 MTB 2014 ◐ ○ ● ◐...

  • Page 11: Converting The Hub [Inserted Adapters]

    Converting the Hub [Inserted Adapters] Preparatory Steps Link Rear wheel: Remove the cassette if necessary. see instructions of the manufacturer Required Material Specification Amount universal grease as required NOTE Risk of damage of the adapters! To avoid damages, only use grind clamping jaws, aluminium clamping jaws or special tools to clamp the adapters.
  • Page 12 Cleaning and Greasing the Adapter 1. Clean both adapters and the accessible parts of the hub with a dry cloth. 2. Grease the bearing and the contact surface of the adapter. Putting on the Adapters 1. Put the left and the right adapter onto the hub. Caution: If the adapters have different lengths, the shorter adapter must be put to the drive side.
  • Page 13 2. Push in the adapters by hand. Closing Steps Link Rear wheel: Put on the cassette if necessary (see instructions of the manufacturer). ® SPLINE Technical Manual...

  • Page 14: Converting The Hub [Pressed On Adapters]

    Converting the Hub [Pressed on Adapters] Preparatory Steps Link not required Required Material Specification Amount multi purpose grease as required adapter adapter 15 mm to QR NOTE Limited conversion options! Hubs with pressed on adapters can‘t be converted to a different axle diameter by changing the adapters. Only the 15 mm version can be converted by inserting a special adapter.

  • Page 15: Maintenance Of The Hub

    The description of a big hub service can be found in the Technical Manual of the desired hub at www.dtswiss.com. Hub Technologies The following table provides an overview of all hub technologies which are part of DT Swiss SPLINE wheels. The link in the header directly forwards you to the required chapter. Front Wheel...
  • Page 16 ● EX 1750 ● ● ● E 1900 Service Intervals The following periodic maintenance and service works are recommended by DT Swiss: Action Interval Small service (see following) • normal operating conditions: 6 months • extreme operating conditions (frequent rides in...

  • Page 17: Safety

    Wrong maintenance, wrong assembly or wrong spare parts can lead to unpredictable errors. • Maintenance must only be done by professionals. • Only use original spare parts or spare parts released by DT Swiss. • In case of any doubts, contact a DT Swiss service center.

  • Page 18: Maintenance Of The Front Wheel Hub [Inserted Adapters Version 1]

    Maintenance of the Front Wheel Hub [Inserted Adapters Version 1] figure 4.1: Overview: front wheel with inserted adapters (version 1) 1 adapter left 3 axle 5 adapter right 2 ball bearing 4 hub shell Preparatory Steps Link not required Required Material Specification Amount multi purpose grease...
  • Page 19 Cleaning and Greasing the Parts 1. Clean the hub, the bearings and the adapters (see Cleaning, p.6). 2. Check the bearings. If the hub doesn‘t turn smoothly, change the bea- rings (see Technical Manual at www.dtswiss.com). 3. Grease the bearings (fig.4.1/2) and the contact sur- face of both adapters (fig.4.1/1, 5) with multi pur- pose grease.

  • Page 20: Maintenance Of The Front Wheel Hub [Inserted Adapters Version 2]

    Maintenance of the Front Wheel Hub [Inserted Adapters Version 2] figure 4.2: Overview: front wheel with inserted adapters (version 2) 1 adapter 3 axle 5 sticker 2 ball bearing 4 hub shell Preparatory Steps Link not required Required Material Specification Amount multi purpose grease as required...
  • Page 21 Cleaning and Greasing the Parts 1. Clean the hub, the bearings and the adapters (see Cleaning, p.6). 2. Check the bearings. If the hub doesn‘t turn smoothly, change the bea- rings (see Technical Manual at www.dtswiss.com). 3. Grease the bearings and the contact surface of both adapters (fig.4.2/1) with multi purpose grease.

  • Page 22: Maintenance Of The Front Wheel Hub [Pressed On Adapters]

    Maintenance of the Front Wheel Hub [Pressed on Adapters] figure 4.3: Overview: front wheel with pressed on adapters 1 cover 4 axle 7 sticker 2 adapter left 5 o-ring 8 adapter right 3 ball bearing 6 hub shell Preparatory Steps Link not required Required Material...
  • Page 23 Removing the Adapters NOTE Risk of damage to the adapters and the ball bearings! The mounting pin must not touch the ball bearing while disassembling the adapters. 1. Plug the mounting pin of the tool set into one of the adapters (fig.4.3/2/8). 2.
  • Page 24 Cleaning and Greasing the Parts 1. Clean the adapters (fig.4.3/2, 8), the covers (fig.4.3/1) and the accessible parts of the hub (see Cleaning, p.6). 2. Grease the bearings (fig.4.3/3). 3. Check the bearings. If the hub doesn‘t turn smoothly, change the bea- rings (see Technical Manual at www.dtswiss.com).
  • Page 25 Putting on the Left Adapter 1. Put the cover (fig.4.3/1) and the left adapter (fig.4.3/2) onto the hub. 2. Put the small diameter of the mounting bushing of the tool set onto the left adapter (fig.4.3/2). 3. Slide the mounting pin into the mounting bus- hing.
  • Page 26 Putting on the Right Adapter 1. Put the right adapter (fig.4.3/8) and the cover (fig.4.3/1) onto the hub. 2. Put the big diameter of the mounting bushing of the tool set onto the right adapter. 3. Slide the mounting pin into the mounting bus- hing.

  • Page 27: Maintenance Of The Rear Wheel Hub [Ratchet System®]

    DT Swiss special grease NOTE Risk of damage of the adapters! To avoid damages, only use grind clamping jaws, aluminium clamping jaws or special tools to clamp the adapters.
  • Page 28 ® Removing Adapters, Rotor and the Ratchet System 1. Clamp the left adapter (fig.4.4/1) into a vice. 2. Pull off the wheel, respectively the hub. 3. Clamp the left adapter (Abb.4-4/13) into a vice. 4. Pull off the wheel, respectively the hub. Take care that the rotor does not fall off.
  • Page 29 Cleaning and Checking the Parts 1. Clean all parts of the hub (see Cleaning, p.6). 2. Check all parts for damages and wear. 3. Check the bearings. If the hub doesn‘t turn smoothly, change the bea- rings (see Technical Manual at www.dtswiss.com). 4.
  • Page 30 DT Swiss special grease. For an optimal functionality, a thin layer of grease is sufficient. 2. Grease the toothing of the rotor using DT Swiss special grease. 3. Grease the bearing on the drive side using multi purpose grease.
  • Page 31 5. Put on both star ratchets (fig.4.4/11) and the se- cond spring (fig.4.4/10). The small diameter of the spring must be placed on the star ratchet. Putting on the Rotor and the Adapters 1. Grease the rotor and put it onto the hub. 2.
  • Page 32 5. Push the adapters in by hand. Closing Steps Link see instructions of Mount the cassette. the manufacturer ® SPLINE Technical Manual...

  • Page 33: Maintenance Of The Rear Wheel Hub [Two Pawl System]

    Maintenance of the Rear Wheel Hub [Two Pawl System] figure 4.5: Overview: Two Pawl System 1 knurled disc 6 hub shell 11 needle cage 2 adapter right 7 sticker 12 bearing shell 3 ball bearing 8 pawl carrier 13 ball bearing 4 axle 9 pawl 14 rotor...
  • Page 34 Removing Adapters, Rotor and Rotor Sealing 1. Clamp the axle at the non drive side into a vice using the axle holder. 2. Loosen the knurled disc (fig.4.5/1) on the drive side using a 17 mm wrench. 3. Clamp the axle at the drive side into a vice using the axle holder.
  • Page 35 7. Remove the adapter (fig.4.5/2). 8. Remove the rotor sealing. ® SPLINE Technical Manual...
  • Page 36 Removing the Pawl, the Spring and the Needle Cage 1. Lever the spring (fig.4.5/10) out of the groove. Caution: If the spring is bent or damaged, it must be exchanged. 2. Slide the spring (fig.4.5/10) upwards over the bea- ring shell (fig.4.5/12) and remove it. 3.
  • Page 37 Cleaning and Checking the Parts 1. Clean the spring (fig.4.5/10), pawl (fig.4.5/9), needle cage (fig.4.5/11) and all accessible parts of the hub (see Cleaning, p.6). 2. Check the bearings. If the hub doesn‘t turn smoothly, change the bea- rings (see Technical Manual at www.dtswiss.com). 3.
  • Page 38 Mounting the Needle Cage, the Pawl and the Spring 1. Grease the needle cage (fig.4.5/11) and the need- les using multi purpose grease. 2. Grease the bearing shell (fig.4.5/12), the inner sur- face of the hub shell, the axle and the thread using multi purpose grease.
  • Page 39 6. Slide a new spring (fig.4.5/10) onto the bearing shell (fig.4.5/12). The spring must not be damaged while mounting! 7. Slide the spring (fig.4.5/10) onto the pawls (fig.4.5/9). 8. Check, if the spring sits inside the groove over the complete circumference. 9.
  • Page 40 Mounting the Rotor and the Rotor Sealing 1. Grease the rotor sealing using multi purpose gre- ase. 2. Mount the rotor sealing. The sealing lip must face to the rotor (see picture). 3. Fill the seat of the needle cage with multi purpose grease.
  • Page 41 Mounting the Adapters 1. Grease the bearings and the inner surface of the adapters. 2. Put the right adapter (fig.4.5/15) onto the drive side. 3. Put the left adapter (fig.4.5/2) on the non drive side of the hub. 4. Attach both knurled discs (fig.4.5/1) and tighten them by hand.
  • Page 42 Closing Steps Link Mount the cassette see instructions of the manufacturer ® SPLINE Technical Manual...

  • Page 43: Maintenance Of The Rear Wheel Hub [Three Pawl System]

    Maintenance of the Rear Wheel Hub [Three Pawl System] figure 4.6: Overview Three Pawl System 1 adapter left 4 hub shell 7 rotor 2 ball bearing 5 ring nut 8 adapter right 3 axle 6 spacer Preparatory Steps Link Remove cassette. see instructions of the manufacturer Required Material...
  • Page 44 5. Pull the rotor (fig.4.6/7) off the hub. 6. Pull the spacer (fig.4.6/6) off the axle. Removing Pawls, Spring and Rotor Sealing 1. Remove the spring using a small, flat screwdriver. 2. Remove the pawls. 3. Remove the rotor sealing. 4.
  • Page 45 Cleaning and Checking the Parts 1. Clean all parts of the hub (see Cleaning, p.6). 2. Check all parts for wear and damages. 3. Check the bearings. If the hub doesn‘t turn smoothly, change the bea- rings (see Technical Manual at www.dtswiss.com). 4.
  • Page 46 2. Slightly grease the rotor (fig.4.6/7) and the rotor sealing. 3. Mount the pawls. Grease the pawls generously. This way, the pawls stuck in the correct position. 4. Mount the spring. The open end of the spring must be positioned at the pin.
  • Page 47 Mounting the Spacer, the Rotor and the Adapters 1. Grease the bearing and the axle. 2. Slide the spacer (fig.4.6/6) onto the axle. 3. Slide the rotor (fig.4.6/7) onto the hub while per- forming a rotary motion. 4. Check if the rotor can be turned easily and if the pawls lock.
  • Page 48 6. Put on both adapters (fig.4.6/1, 8) and push them in by hand. Caution: The shorter adapter must be attached on the drive side. Closing Steps Link Mount the cassette. see instructions of the manufacturer ® SPLINE Technical Manual...

  • Page 49: Maintenance Of The Wheel

    Wrong maintenance, wrong assembly or wrong spare parts can lead to unpredictable errors. • Maintenance must only be done by professionals. • Only use original spare parts or spare parts released by DT Swiss. • In case of any doubts, contact a DT Swiss service center.

  • Page 50: Special Tools

    Special Tools Pos. Description spokey square spoke holder 1 - 1,3 mm spoke holder NEW AERO spoke holder 0,8 -1 mm spoke holder AEROLITE nipple wrench hex nipple wrench torx spoke holder DT universal tensiometer DT Tensio screw clamp axle holder Park Tool * These tools are available as new and old versions.

  • Page 51: Truing The Wheel

    Truing the Wheel Preparatory Steps Dismount the wheel. Dismount the tire and if necessary the tube and the rim tape. NOTE Functional impairment / risk of damage due to wrong tools! ® Only use the special tools intended for SPLINE wheels (see chap.5.2, p.49).
  • Page 52 3. Slide the nipple wrench onto the nipple. To avoid damages to the nipples, slide the nipple wrench as far as possible onto the nipple. Wheels with bladed spokes: 4. Slide the spoke holder onto the spoke. To avoid damages of the spoke, slide the spoke holder as far as possible into the nipple wrench.

  • Page 53: Changing A Single Spoke [Mtb]

    Changing a Single Spoke [MTB] Preparatory Steps Dismount the wheel. Dismount the tire and if necessary the tube and the rim tape. Clean the wheel and check for damages. If four or more spokes have to be replaced, the whole wheel should be rebuild. NOTE Risk of damage to the bladed spokes and the nipples! •...
  • Page 54 NOTE Caution! Normally, the spoke has to be replaced because it is broken. If the spoke to be replaced is still intact, it can be cut using a cutter or s.th. similar. 2. If necessary, cut the spoke: a) Release the spoke using a screw clamp. b) Cut the spoke.
  • Page 55 Only for spokes in the inner spoke holes of the hub flange. 6. Put the spoke (green) opposite the head of the spoke (red) that needs to be replaced into the middle of the spoke tree. NOTE Risk of damages to the spoke and the hub! Take care not to damage the paint of the spoke and the hub while removing the spoke.
  • Page 56 ® Attaching a New Spoke [Conventional SPLINE Wheels] For attaching a new spoke on a SPLINE ONE wheel, see Attaching a New Spoke [SPLINE ONE]. 1. Slide the new spoke through the spoke hole. Push the opposite spoke beside slightly. 2.
  • Page 57 Wheels]. NOTE Caution! SPLINE ONE wheels must only be build with DT Swiss Squorx nipples and special washers (PHR washers). 1. Grease the contact surface of the PHR washer and the Squorx nipple. 2. Slide the PHR washer onto the nipple.
  • Page 58 6. Screw the Squorx nipple onto the spoke until the thread disappears. Closing Steps Link True the wheel. chap.5.3, p.50 Mount tire and if necessary rim tape and tube or tubeless system. Mount the wheel if necessary. ® SPLINE Technical Manual...

  • Page 59: Changing A Single Spoke [Road]

    Changing a Single Spoke [ROAD] NOTE Risk of damage to the bladed spokes and the nipples! • Bladed spokes must be hold with the spoke holder while turning the nipple. • Whenever possible there should be used the universal spoke holder (see chap.5.2, p.49) to avoid dama- ges to the spokes.
  • Page 60 2. If necessary, loosen the spoke by hand. a) Slide the spoke holder onto the spoke. b) Unscrew the nipple using the nipple wrench. Take care that the nipple does not fall into the rim profile. Closing Steps Link Replace the spoke. see following ®...

  • Page 61: Changing A Single Spoke On The Front Wheel [Slotted Hub]

    5.5.2 Changing a Single Spoke on the Front Wheel [Slotted Hub] Preparatory Steps Link Dismount the wheel. Dismount the tire and if necessary the tube and the rim tape. Clean the wheel and check for damages. Loosen the spoke. chap.5.5.1, p.58 1.
  • Page 62 5. Screw on a new nipple. 6. Tighten the spoke. 7. Check the bearing: Clean and grease the bearing if it is badly soiled. 8. Put on the adapter. Closing Steps Link True the wheel. chap.5.3, p.50 Mount tire and if necessary rim tape and tube. Mount the wheel if necessary.

  • Page 63: Removing A Single Spoke On The Front Wheel [Non-Slotted Hub]

    5.5.3 Removing a Single Spoke on the Front Wheel [Non-Slotted Hub] Preparatory Steps Link Dismount the wheel. Dismount the tire and if necessary the tube and the rim tape. Clean the wheel and check for damages. Loosen the spoke. chap.5.5.1, p.58 1.
  • Page 64 5. Screw on a new nipple. 6. Tighten the spoke. 7. Check the bearing: Clean and grease the bearing if it is badly soiled. 8. Put on the adapter. Closing Steps Link True the wheel. chap.5.3, p.50 Mount tire and if necessary rim tape and tube. Mount the wheel if necessary.

  • Page 65: Changing A Single Spoke On The Rear Wheel

    5.5.4 Changing a Single Spoke on the Rear Wheel Preparatory Steps Link Dismount the wheel. Dismount the tire and if necessary the tube and the rim tape. Clean the wheel and check for damages. Loosen the spoke. chap.5.5.1, p.58 Removing the Spoke 1.
  • Page 66 2. Screw on a new nipple. 3. Tighten the spoke. Closing Steps Link True the wheel. chap.5.3, p.50 Mount tire and if necessary rim tape and tube. Mount the wheel if necessary. ® SPLINE Technical Manual...

  • Page 67: Rebuilding The Wheel [Road]

    Rebuilding the Wheel [ROAD] Preparatory Steps All spokes are available in the correct lengths. 5.6.1 Putting on the Spokes on the Front Wheel 1. Slide all spokes through the spoke holes on the first side of the hub. 2. Slide all spokes through the spoke holes on the se- cond side of the hub.

  • Page 68: Putting On The Spokes On The Rear Wheel

    5.6.2 Putting on the Spokes on the Rear Wheel General: The crossing of the spokes must always be like shown in the picture. 1. Slide all spokes through the spoke holes on the first side of the hub. For easier handling, first put the spokes into the inner side of the hub.

  • Page 69: Connecting The "Spoke Tree" To The Rim

    5.6.3 Connecting the «Spoke Tree» to the Rim 1. Position the «spoke tree» in the way that there is no spoke crossing above the valve hole. Check the positioning of the stickers on the hub and on the rim. 2. Screw the nipple onto the spoke until the thread disappears.
  • Page 70 Increasing the Spoke Tension 1. Increase the spoke tension (see chap.6.1, p.74) by using appropriate tools (see chap.5.2, p.49). Caution: The figure shows a wheel with bladed spo- kes. Closing Steps Link True the wheel. chap.5.3, p.50 ® SPLINE Technical Manual...

  • Page 71: Rebuilding The Wheel [Mtb]

    Rebuilding the Wheel [MTB] Preparatory Steps All spokes are available in the correct lengths. Putting on the Spokes General: The crossing of the spokes must always be like shown in the picture. 1. Slide all spokes through the spoke holes on the first side of the hub.
  • Page 72 3. Position the «spoke tree» in the way that there is no spoke crossing above the valve hole. > Check the positioning of the stickers on the hub and on the rim. ® Putting on the Nipple [Conventional SPLINE Wheels] Attaching of a nipple on a SPLINE ONE Wheel, see Putting on the Nipple [SPLINE ONE Wheels].
  • Page 73 Wheels]. NOTE Caution! SPLINE ONE wheels must only be build with DT Swiss Squorx nipples and special washers (PHR washers). 1. Grease the contact surface of the PHR washer and the Squorx nipple. 2. Slide the PHR washer onto the nipple.
  • Page 74 6. Screw the Squorx nipple onto the spoke until the thread disappears. Increasing the Spoke Tension 1. Increase the spoke tension (see chap.6.1, p.74) by using appropriate tools (see chap.5.2, p.49). Caution: The figure shows a wheel with bladed spo- kes.
  • Page 75 6 Technical Data Further technical data, like spoke types, spoke lengths etc. can be found in the DT Swiss Techbook at www.dts- wiss.com. Spoke Tension Max. Tolerated Spoke Tension Min. Tolerated Spoke Tension Average Spoke Tension of the of the Higher Tightened...
  • Page 76 F - 06620 Le Bar sur Loup E-Mail: service.fr@dtswiss.com DT Swiss (Asia) Ltd. No. 26, 21st Road Industrial Park Taichung City E-mail: info@dtswiss-asia.com www.dtswiss.com Subject to technical alterations, errors and misprints excepted. All rights reserved. © by DT Swiss AG...

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