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DT SWISS D 232, Technical Manual

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Summary of Contents for D 232

Page 1: ...D 232 D 232 ONE TECHNICAL MANUAL V2020 05 ...

Page 2: ...2 1 GENERAL 3 2 OVERVIEW 6 3 SERVICE KITS 7 4 SERVICE AND CARE 13 5 TROUBLE SHOOTING 14 6 SMALL SERVICE 17 7 FULL SERVICE 24 ...

Page 3: ...ous situation that may result in damage to property 1 3 TARGET GROUP This manual is intended for the user of the component and dealers This manual offers the experienced user the possibility to carry out minor service work himself If you have any doubts about your own abilities you should definitely contact a specialist or a DT Swiss Service Center Any warranty claims will lapse if work is not car...

Page 4: ...NFORMATION Unless otherwise specified moving parts threads O rings and seals must be greased before assembly CLEANING For an optimal result of the maintenance works every component that will be disassembled must be cleaned Only use cleaners which do not damage the components Especially the cleaning of O rings and sealings requires mild cleaners Observe the instructions for use of the respective cl...

Page 5: ...nner Only print this manual if electronic usage is not possible 1 10 EXCLUSION OF LIABILITY The activities listed in this manual may only be carried out by persons with sufficient specialist knowledge The user is liable for any damage or consequential damage caused by wrongly maintained or installed components If you have doubts please contact your region s DT Swiss pro level service center 1 11 W...

Page 6: ... release piston D232 LATCH SYSTEM KIT 10 coil spring release piston D232 LATCH SYSTEM KIT 11 guide for release piston D232 LATCH SYSTEM KIT 12 raster ring D232 LATCH SYSTEM KIT 13 O ring D232 GUIDING KIT 14 lock nut D232 SLIDER TUBE NUT KIT 15 guide ring D232 GUIDING KIT 16 guide key D232 D232 ONE SLIDER TUBE KIT 17 latch 5x D232 LATCH SYSTEM KIT D232 BALL REPL KIT 18 seat tube D232 D232 ONE SEAT ...

Page 7: ...KIT Item No DWKD232S30507S 1x guide key 1x slider tube carbon 1x spring guide The spring guide is pre assembled in the slider tube D232 LATCH SYSTEM KIT Item No DWKD232X30510S 1x upper stop for release piston 1x release piston 1x coil spring release piston 1x guide for release piston 1x raster ring 5x latch D232 QUICK CONNECTOR CAP KIT Ø27 2 Item No DWKD232X30511S 1x lower seat tube cover Ø27 2 mm...

Page 8: ...o DWKD232X30514S 1x lower seat tube cover Ø27 2 mm 1x O ring Ø18 x 2 5 mm D232 ONE QUICK CONNECTOR CAP KIT Ø30 9 Item No DWKD232X30513S 1x lower seat tube cover Ø30 9 mm 1x O ring Ø22 x 2 5 mm D232 QUICK CONNECTOR KIT Item No DWKD232X30515S 1x quickrelease housing 1x O ring Ø6 x 1 5 mm 1x quickrelease slider 2x threaded pin M4 x 4 mm 1x Internal actuating spoke ...

Page 9: ...10 mm 2x O ring Ø23 x 3 mm 1x outer coil spring guide Ø27 5 x 20 9 x 27 mm D232 ONE CARBON SEAT CLAMP KIT Item No DWKD232C30518S 1x upper seat clamp carbon 1x lower seat clamp carbon 2x barrel nut 1x seat clamp screw Ti M6 Ø10 x 36 mm 1x seat clamp screw Ti M6 Ø10 x 46 mm D232 ALUMINIUM SEAT CLAMP KIT Item No DWKD232S30519S 1x upper seat clamp aluminium 1x lower seat clamp aluminium 2x barrel nut ...

Page 10: ... 1x seat clamp screw Ti M6 Ø10 x 36 mm 1x seat clamp screw Ti M6 Ø10 x 46 mm D232 STEEL SEAT CLAMP SCREW KIT Item No DWKD232N30521S 2x barrel nut 1x seat clamp screw M6 Ø10 x 36 mm 1x seat clamp screw M6 Ø10 x 46 mm D232 REPLACEMENT SPRING Item No DWKD232N30522S 1x coil spring ...

Page 11: ... Service Center D232 SEAT TUBE REPLACEMENT Ø30 9 Item No DWKD232S30524S Only available for DT Swiss Service Center D232 ONE SEAT TUBE REPLACEMENT Ø27 2 Item No DWKD232C30525S Only available for DT Swiss Service Center D232 ONE SEAT TUBE REPLACEMENT Ø30 9 Item No DWKD232C30526S Only available for DT Swiss Service Center ...

Page 12: ...L REPLACEMENT KIT Item No DWKD232N30527S 10 x latch Only available for DT Swiss Service Center L1 REMOTE LEVER Art Nr LL1XX4LXXXSA29724S 1x remote lever 1x shifting cable Ø1 1 mm length 2100 mm 2x cable end crimp ...

Page 13: ...xtreme operating conditions Check the seat post for damage and cracks If there is any damage contact the DT Swiss Service Center Before and after every ride and after a crash Check the fastening is correct check tightening torques Before each ride Check the functionality Before each ride Seat post care see below After each ride 4 3 CARE The following care and cleaning instructions must be observed...

Page 14: ...w increase tension of the cable cable torn replace cable cable unhooked from the quickconnector dismount the seat post and attach the cable quickconnector damaged replace quickconnector kit details see 7 on page 24 lower seat tube cover damaged install new seat tube cover details see 7 on page 24 connection of quickconnector and actuating spoke loose clamp actuating spoke to quickconnector details...

Page 15: ...all service details see 6 on page 17 cable tension too high reduce the tension of the cable tension of the actuating spoke on the quickconnector too high reduce tension of the actuating spoke details see Mounting the Quickconnector on page 34 release piston jammed disassemble the seat post completely clean all parts replace latch system kit details see 7 on page 24 wear of the locking mechanism we...

Page 16: ...y clean all parts replace latch system kit details see 7 on page 24 incorrect use of the seat post seat post is lowered under full load relieve the seat post briefly while operating the remote lever play of the remote lever cable tension too low increase tension of the cable guide of the remote lever defective replace remote lever details see user manual at www dtswiss com strong radial play in di...

Page 17: ...ds upwards Seat post makes noises while riding Shift cable runs sluggishly high actuating forces on remote lever shift cable blocked Preparatory Steps Make sure that the seat post is in the extended position If not extend the seat post by pressing the remote lever Clean the seat post Check all functions of the seat post If malfunctions occur observe the information in the table in chap 5 Trouble S...

Page 18: ...18 2 Pull the slider tube off the seat tube 3 Pull the coil spring out of the seat tube 4 Remove the guide ring from the upper end of the seat tube ...

Page 19: ...te the remote lever and slide the raster ring downwards when the remote lever is pushed 6 Take the five latches out of the recesses in the seat tube TIP A magnet makes it easier to remove the latches 7 Pull the spring guide out of the seat tube ...

Page 20: ... Clean all parts with an appropriate cleaner We recommend one of the following cleaners Motorex Rex Motorex Swissclean Motorex OPAL 2400 3000 OPAL OPAL 5000 2 Check all parts for excessive wear and replace worn parts if necessary ...

Page 21: ...ng guide into the seat tube 3 Generously grease the recesses for the latches in the seat tube 4 Insert the five latches into the recesses in the seat tube 5 Grease the entire area around the latches 6 Press the remote lever and simultaneously slide the raster ring over the latches 7 Grease the entire area around the raster ring GREASE GREASE GREASE ...

Page 22: ...e area around the guide ring 11 Make sure that the entire sliding area of the seat post is greased 12 Grease the spring and the inner surface of the slider tube 13 Push the coil spring into the seat tube 14 Slide the slider tube onto the seat tube Make sure that the guide key slides into the guide groove of the slider tube GREASE GREASE ...

Page 23: ...ush the seat post down Release the remote lever once the seat post is no longer in the top fixed position It must be possible to push the seat post down with slight resistance The seat post must latch in the lowered position with a noticeable click 3 Briefly actuate the remote lever while the seat post is fixed in the lower position Do not apply a load to the saddle while doing so The seat post mu...

Page 24: ... in the extended position If not extend the seat post by pressing the remote lever Clean the seat post Check all functions of the seat post If malfunctions occur observe the information in the table in chap 5 Trouble Shooting on page 14 DISMANTLE SADDLE AND SEAT CLAMP 1 Unscrew both saddle clamp bolts 2 Pull the saddle upwards with the upper seat clamp 3 Remove the barrel nuts from the upper seat ...

Page 25: ...ully to relieve the tension 2 If present release the cable clamps on the bike frame 3 Open the seat post clamp pull the seat post carefully out of the bike frame while feeding the cable at the same time 4 Pull the cable housing on the quickconnector downwards and detach the cable housing 5 Detach the cable from the quickconnector ...

Page 26: ...26 7 2 DISASSEMBLING THE SEAT POST 1 Unscrew the lock nut from the slider tube by hand 2 Pull the slider tube off the seat tube 3 Pull the coil spring from the seat tube 4 Remove the guide ring ...

Page 27: ...g a M3 screw with a minimum thread length of 5 mm 6 Slide a 6 mm Allen key from above into the stop of the release piston and press the release piston slightly downwards 7 Push the raster ring upwards with the release piston pressed down and remove the raster ring from the seat tube ...

Page 28: ... Take the five latches out of the recesses in the seat tube TIP A magnet makes it easier to remove the latches 9 Slide the lock nut and O ring off the seat tube 10 Pull the spring guide out of the seat tube ...

Page 29: ...QUICKCONNECTOR 1 Unscrew the clamping screw of the actuating spoke a few turns 2 Pull the quickconnector with the slider down 3 Remove the seat tube cover 4 Push the actuating spoke upwards and pull the actuating spoke out of the seat tube from the top ...

Page 30: ...HE RELEASE PISTON FROM THE SEAT TUBE 1 Screw the stop of the release piston out of the seat tube using an 8 mm Allen key 2 Take the release piston the spring and the guide of the release piston out of the seat tube ...

Page 31: ...its on page 7 1 universal grease Slick Honey as required The service kit only needs to be replaced if there is a seat post malfunction see Trouble Shooting on page 14 In case of malfunction all parts of the required service kit should be replaced 1 Grease the inner surface of the lock nut the sliding surface of the seat tube and the O ring 2 Slide the lock nut and O ring onto the seat tube ...

Page 32: ...oting on page 14 In case of malfunction all parts of the required service kit should be replaced 1 Grease the guide spring release piston and inner surface of the seat tube 2 Insert the guide spring and release piston into the seat tube 3 Push the stop for the release piston into the seat tube and tighten the stop with an 8 mm hex key to a torque of 4 Nm The recess of the stop must point upwards 4...

Page 33: ...cesses for the latches and insert the latches 6 Slide a 6 mm hex key from the top into the stop of the release piston and press the release piston slightly downwards 7 Slide the raster ring upwards over the latches with the release piston pressed down ...

Page 34: ...see Service Kits on page 7 1 universal grease Slick Honey as required The service kit only needs to be replaced if there is a seat post malfunction see Trouble Shooting on page 14 In case of malfunction all parts of the required service kit should be replaced 1 Push the actuating spoke from the top through the release piston If the lower seat tube cover is replaced a new O ring must first be fitte...

Page 35: ... the slider fully in the direction of the seat tube and pull the actuating spoke down as far as possible without actuating the release piston 7 Clamp the actuating spoke with the clamping screw in the slider using a 2 mm hex key The tension of the actuating spoke must be neither too high nor too low The slider must not have axial play The raster ring must have no play on the latches If there is pl...

Page 36: ...ould be replaced at every full service annually or after 200 operating hours 1 Grease the O ring 2 Slide the O ring onto the seat tube and pull the O ring over the raster ring 3 Grease the guide ring and the groove for the guide ring in the seat tube 4 Place the guide ring on the seat tube 5 Grease the inner and outer surface of the coil spring guide 6 Insert the coil spring guide into the seat tu...

Page 37: ...s a seat post malfunction see Trouble Shooting on page 14 In case of malfunction all parts of the required service kit should be replaced 1 Lightly grease the guide key and the groove in the seat tube 2 Place the guide key in the groove in the seat tube and press the guide key completely into the groove in the seat tube with light hammer strokes with a plastic hammer Caution If the guide key is no...

Page 38: ... kit only needs to be replaced if there is a seat post malfunction see Trouble Shooting on page 14 In case of malfunction all parts of the required service kit should be replaced 1 Grease the coil spring and push the coil spring into the spring guide of the seat tube 2 Grease the inner surface of the slider tube and the guide parts of the seat tube and slide the slider tube onto the seat tube The ...

Page 39: ...me 4 Close the seat post clamp 5 If available clamp the cable housing with the cable clamps of the bike frame 6 Tension the cable by turning the cable adjuster on the remote lever MOUNTING THE REMOTE LEVER ON THE HANDLEBARS 1 Using a 3 mm hex key loosen the fixing screw on the clamp and attach the remote lever on the desired side of the handlebars 2 Tighten the fixing screw with a max tightening o...

Page 40: ...below the upper seat clamp B 5 Pull up the upper seat clamp and the saddle and push the lower seat clamp in underneath the saddle C from the side 6 Tighten the seat clamp screws alternately until the desired saddle tilt has been adjusted When tightening the seat clamp screws make sure that the barrel nuts are not twisted and lie in the recesses of the upper saddle clamp 7 Tighten the seat clamp sc...

Page 41: ...SS DEUTSCHLAND GmbH Pixeler Strasse 56 D 33378 Rheda Wiedenbrück Germany info de dtswiss com DT SWISS POLSKA Sp z o o ul Towarowa 36 PL 64 600 Oborniki Poland info pl dtswiss com DT SWISS AG Längfeldweg 101 CH 2504 Biel Bienne info ch dtswiss com DT SWISS INC 2493 Industrial Blvd USA Grand Junction CO 81505 info us dtswiss com DT SWISS FRANCE S A S Parc d Activites de la Sarrée Route de Gourdon F ...

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