Formula Brake Workshop Presentation for Specialized Custom Brakes

Report
Welcome to the Formula
Brake Workshop
Overview
Overview
Technical Workshop
•
•
•
•
•
•
•
•
•
•
•
•
•
Formula history
Specialized brake models
Functionality of master cylinder
Brake system components R1 S,
TH1 R
Why we use DOT4
Requirements for a working brake
Troubleshooting
Lever blade replacement
Hose trimming
Pad replacement
Bleeding procedure
Master cylinder rebuild
Caliper piston cleaning
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
2
About Formula Brakes
• Founded in 1987 and still a family owned
company.
• Early expertise in motorcycle components.
• Headquarter in Prato , Italy.
• Two facilities for production in Tuscany.
• Subsidiaries in Taiwan, France, Germany, USA
and Canada.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
3
About Formula Brakes
• Disc brakes for MTB since 1993.
• First to successfully produce and distribute
disc brakes for MTB.
• Focus on quality, weight and performance
• Lightest and strongest brakes.
• All current models feature a radial flip-flop
master cylinder and 1 piece calipers.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
4
4
R1 S
•
•
•
•
•
•
•
•
Forged radial master cylinder (MC).
High capacity integrated reservoir.
Removable handlebar clamp.
Flip-Flop master cylinder assembly.
Aluminium forged lever blade.
Hard anodized MC piston.
Lever integrated tool free reach adjust.
Lever throw adjustment via FCS valve.
• One-piece PM caliper body with 22mm
pistons.
• Top and bottom vented caliper eliminates
overheating effects.
• Top-loading pads simplify pad changes.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
5
THE ONE R
•
•
•
•
•
•
•
High capacity, integrated reservoir.
Removable handlebar clamp.
Flip-Flop master cylinder assembly.
Hard anodized MC piston.
Aluminium forged lever blade.
Lever integrated tool free reach adjust.
Lever throw adjust via FCS valve.
• Patent-pending forged one-piece post
mount style caliper.
• 24 mm caliper pistons provide amazing
stopping power.
• Top and bottom vented caliper eliminates
overheating effects.
• Top-loading pads simplify pad changes.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
6
Functionality of the Master Cylinder
• Animation M/C
• Cross section R1 S Pump with FCS
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
7
Functionality of FCS
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
8
R1 S Master Cylinder
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
9
R1 S M/C spare parts
Description
Position
Code
R1 S Complete: R1x front brake 85cm
FD86085XMY
R1 S Complete: R1x rear brake 170cm
FD86170XMY
(Left-XO) R1 Complete master cylinder
All the parts (Exc. 27)
FD53286-00
(Right-XO) R1 Complete master cylinder
All the parts (Exc. 27)
FD53287-00
R1 Complete master cylinder body
1-2-3
FD40168-20
Complete black lever kit (TFRA Red)
9-10-11-14-15-16-21-22-23-24-25-26
FD10066-20
27
FD10055-20
4-5-6-7-8-10-(grease/grasso)
FD40116-20
19-20
FD40049-20
(Black) Master cylinder clamp and screws
17-18-18
FD40172-20
X0 Left Master cylinder clamp and screws
----
FD40182-20
X0 Right master cylinder clamp and screws
----
FD40183-20
FCS Kit (Red anodized)
Piston kit
Screw reservoir kit
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
10
R1 S Caliper
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
11
R1 S Caliper Spare Parts
Description
Position
Code
All the parts (Exc. 7-8-9)
FD52091-00
1
FD-C284-04
Screws kit
6-7-8
FD40127-10
Piston kit
3-3-(grease/grasso)
FD40128-10
ORing Kit
4-9-10-10
FD40129-10
2-2-11
FD40103-10
12(50 pcs)
FD40130-10
Rx Complete caliper (red anodized cap)
Rx caliper body
Sintered brake pads kit “Mega/The one/R1/Rx” (BOX)
Screw pads Seeger Kit (50 pcs)
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
12
THE ONE R Master Cylinder
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
13
THE ONE R M/C Spare Parts
Description
Position
THE ONE S Complete:T heOne fr front brake
90cm without disc/adaptor
THE ONE S Complete: TheOne fr front brake
175cm without disc/adaptor
Code
FD86090XER
FD86175XER
(Left-XO) RX Complete master cylinder
All the parts (Exc. 11 – 28)
FD53300-00
(Right-XO) RX Complete master cylinder
All the parts (Exc. 11 – 28)
FD53301-00
Rx Complete master cylinder body Black
27-10-5-11-12
FD40173-20
Complete black lever kit (TFRA Red)
FCS Kit (Red anodized)
14-15-16-17-18-19-20-21-22-23-24-25FD10060-20
26
28
FD10055-20
6-8-9-7-13-20
FD40131-20
11-12
FD40132-20
(Left) Master cylinder clamp and screws
1-2(2 Pcs.)
FD40178-20
(Right) Master cylinder clamp and screws
1-2(2 Pcs.)
FD40179-20
X0 Left Master cylinder clamp and screws
----
FD40180-20
X0 Right master cylinder clamp and screws
----
FD40181-20
Piston kit
Screw reservoir kit
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
14
THE ONE R Caliper
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
15
THE ONE R Caliper Spare Parts
Description
Position
Code
All the parts (Exc. 10-11-12)
FD52084-00
6-7-10-11
FD40163-10
3-3(grease)
FD40166-10
2-2-5-12
FD40117-10
8-8-9
FD40103-10
7 (50 pcs)
FD40130-10
Disc Ø160mm - 6 bolt (Solid)
3
FD50696-00
Disc Ø180mm - 6 bolt (Solid)
3
FD50697-00
Disc Ø203mm - 6 bolt (Solid)
3
FD54001-00
3-4-5-6
FD40018-40
All the parts
FD50140-00
Adaptor for rear Ø160mm I.S.
5
FD40144-10
Front adaptor P.M. for Ø180mm P.M. 6”
9
FD40148-10
Front adaptor P.M. for Ø203mm P.M. 6”
11
FD40150-10
The One Complete caliper
Screws kit
Piston kit (2 pcs)
O-Ring Kit
Sintered brake pads kit “Mega/The one/R1/Rx” (BOX)
Screw pads Seeger Kit (50 pcs)
Hose joint kit
70 cm Complete hydraulic hose
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
16
Why we use DOT4
DOT4
•
•
•
•
•
Low level of compressibility  stable performance / Lever feel.
Constant viscosity  consistent lever feel.
Higher dry and wet boiling point than mineral oil  fade resistant.
Less hygroscopic than DOT 5.1  Requires less bleeding/service.
Recommended bleed of the system every 6 to 12 months.
Recommended fluids for brake service
•
•
•
•
Use DOT4 Brake fluid only!
High percent Isopropyl alcohol for cleaning the system and the discs.
Brake cleaner only for cleaning and mobilizing the caliper pistons.
Silicone grease for seals and parts. NO TEFLON BASED GREASE.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
17
Requirements for proper function
First engagement of caliper pistons
•
•
When brand new or after long periods non-actuation, caliper pistons can stick to
the quadrings limiting their free movement. To free the pistons, pull the brake
lever several times and then reset them by pushing them back into caliper body.
Adjust pistons with included spacer.
Checking the lever stroke
•
The lever stroke of Formula Brakes is around 20mm. The cause of an excessively
short stroke is most frequently excessive fluid in the system caused by expansion.
Even when not in use, the hydroscopic nature of DOT fluid causes it to expand over
time and the system will need to be equalized by burping out excess fluid before
the correct amount of free-stroke is realized.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
18
Requirements for proper function
Mounting points
•
•
•
•
Frame and Fork mounting points must be properly aligned, faced and free of paint.
Always use medium strength thread-locker for mounting fasteners.
Always use washers under bolt heads for caliper mounting.
Always torque all fasteners to spec.
Cleaning
•
Rotors must be free of grease or oils for proper function. Before the initial use,
clean the rotors with a high % isopropyl alcohol on a clean rag.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
19
Troubleshooting
Caliper pistons don‘t reset all the way
1.
2.
3.
4.
Excess fluid in the system.
Dry and/or heavily dirty caliper pistons.
Friction at quadrings is too low.
Caliper oxidation.
Inconsistent lever contact point
1.
2.
3.
4.
5.
6.
Air in the system
Dry and/or heavily dirty caliper pistons.
Friction at quadrings is too high.
Caliper oxidation.
Leaking membrane.
Pump piston damage.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
20
Troubleshooting
Lever blade does not fully return
1.
2.
3.
Seals experienced expansion after exposure to non-approved oil or grease
(WD40, Triflow etc.).
Lever pivot contaminated.
Lever blade fixing screws over-torqued causing binding.
Rotor rub
1.
2.
3.
4.
Check caliper pistons to ensure proper movement and retraction.
Check rotors trueness.
Check to ensure wheel is fully seated in dropouts.
Check mounting points of Caliper, adapter and rotor for correct alignment.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
21
Troubleshooting
Brake squeals
1.
2.
3.
4.
5.
6.
7.
8.
Contaminated pads/rotor.
Caliper pistons retraction limited.
Pads not properly bedded in.
Bent pad spring contacting rotor when pistons actuating.
Rotors overheated and glazed (brake track is black/discolored).
Frequency vibration on frame, wheels or fork.
Pad type not appropriate for riding style.
Wet conditions.
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
22
Contact Information
Formula USA
Formula North America
Charlie Schneider
405 East D Street, ste c
Petaluma, CA 94952
Tel:
707. 540.6137
Email: [email protected]
Christoph Vogl
414 Hwy 21 Bypass
Fort Mill, SC 29715
Tel:
803.547.7010
Email:
[email protected]
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011
23

similar documents