更换轿车和轻型商用车制动卡钳的说明
请仔细阅读并遵循所有说明。您会在制动钳包中找到相同的说明。请记住在整个产品生命周期中保留它们。如果您出售车辆，请将它们交给新车主。
这些安装说明是标准维修工作的指南，并没有考虑到不同制动系统可能具有的任何特殊性。必须详细遵循车辆和制动系统制造商发布的特定说明。
本文件提供了更换制动钳的说明：
1. 单制动盘卡钳
2. 双盘固定卡钳
3. 带径向安装刹车片的浮动卡钳，2x60/68型。
2. 双盘固定卡钳
3. 带径向安装刹车片的浮动卡钳，2x60/68型。
除非另有说明，本说明书上的所有信息均适用于所有三种类型的制动钳。
更换程序
在开始更换之前，请确定用于更换的备件适合车辆的品牌和型号。
- 拆下车轮。
- 记下所有部分或完全拆卸的组件的位置，以便正确回装。
1. 从车辆中的端子上断开磨损指示器电缆（点1）（如果存在），将其与底盘和制动钳上的所有附件松开。
2. 对于装有安全开口销（点2）的型号，请使用钳子将其拆下。
3. 如果是双盘制动卡钳，请使用钳子拆下弹簧（点3）。
4. 使用锤子和销钉起子拔出销钉（点4）。用手完全拉出，确保弹簧（点5）保持在合适的位置。
5. 拆下弹簧（点5）。检查液位。打开制动液储液罐盖。
小心！下面描述的活塞回拉的步骤导致储液器中的制动液液位上升。确保制动液的液位不会导致溢出泄漏，因为这会损坏车辆的喷漆部件。
A B 型固定制动钳
1. 使用牵引器或其他合适的工具稍微拉开活塞，压住刹车片（点6）。
活塞拉回之后，必须将制动钳从制动盘上松开。
2. 如果制动钳的设计允许，请拆下刹车片。否则，请在拆卸制动钳后将其拆下。如果您打算重复使用刹车片，请用记号笔在刹车片上标记制动盘的旋转方向。
C 型浮动制动钳
1. 取出刹车片，同时将制动卡钳在导向套上前后滑动（点7）。滑动卡钳体会将刹车片稍微拉离制动盘，从而更容易拆卸。
如果制动盘磨损产生的凹痕阻碍刹车片的取出，请拆卸制动卡钳体：
1. 使用扳手拆卸螺丝（点8）
2. 使用螺丝刀将导向衬套从专用座中撬出。
3. 充分取出导向衬套（点7），将其从制动卡钳支架（点9）上拆下。
4. 将制动卡钳体（点10）与卡钳支架（点9）完全分离，并使用S形挂钩将其挂入车辆底盘。
5. 取出刹车片。
6. 如果您打算重复使用刹车片，请用记号笔在刹车片上标记制动盘的旋转方向。
7. 对于后制动卡钳（带驻车机构），断开驻车控制电缆（点11）。
危险！制动液管路必须保持松弛且不拉伸。如果拉伸管路，它们可能会断裂且制动液可能会泄漏。
适用于所有类型的制动钳
1. 关闭制动液储液罐盖。
2. 在乘客舱内座椅和制动踏板之间放置一个垫片（点12），以确保踏板在这些操作期间保持踩下状态。
警告! 这样可以关闭制动液压回路，避免制动液泄漏。
小心！在下面描述的所有阶段中，确保制动液不会接触到车辆上可能损坏的部件，尤其是喷漆部件。立即用厨房毛巾擦去意外溅出或泄漏的制动液并用水清洗。
警告! 这样可以关闭制动液压回路，避免制动液泄漏。
小心！在下面描述的所有阶段中，确保制动液不会接触到车辆上可能损坏的部件，尤其是喷漆部件。立即用厨房毛巾擦去意外溅出或泄漏的制动液并用水清洗。
3. 充分松开制动钳上的供给管路（点13），以便能够用手将其完全拧下，但要避免任何制动液泄漏。
4. 使用开口扳手拧下紧固螺丝（点14），然后从轴上拆下制动卡钳。
5. 小心！对于双盘制动卡钳，仅拆卸轴紧固螺丝。请勿拆卸将半卡钳连接在一起的螺丝（点15）。
6. 将供应管道（点13）与制动钳完全分离。
7. 立即擦掉泄漏的制动液。
8. 保持供应管道升高，以防止任何意外的液体泄漏。
9. 拉开要更换的卡钳。
9. 拉开要更换的卡钳。
装配程序
1. 将刹车片（点16）插入新制动钳。
警告! 刹车片上印有的箭头必须指向光盘旋转方向。
危险！插入刹车片时摩擦材料必须面向制动盘。
2. 警告！如果制动卡钳的设计允许，也可以在安装卡钳后插入刹车片，即在“拧紧紧固螺丝”步骤之后。
危险! 确保摩擦表面没有沾上油脂，否则必须用砂纸清除所有油脂痕迹。
3. 将弹簧（点5）和销（点4）重新插入制动卡钳和刹车片的专用安座中。必须使用锤子和销钉起子将销钉完全打入。
安装弹簧时请注意方向。
4. 检查弹簧是否正确定位。
5. 对于配备安全开口销（点2）的型号，使用钳子重新定位它们。
6. 检查开口销是否正确定位。
7. 使用脱脂产品（例如溶剂 SE 47）清洁制动盘（点18）上的制动表面（点17）。
8. 将新制动卡钳放置在轴上，将制动盘（点18）插入刹车片之间。
9. 使用开口扳手拧紧紧固螺丝（点14），并采用车辆制造商推荐的扭矩拧紧。
或者，使用以下推荐的拧紧扭矩作为参考：
| 螺丝类型 | M12x1,25 | M12x1,5 | M14x1,5 |
| 锁紧扭力 | 115 Nm | 125 Nm | 180 Nm |
10. 将磨损指示器电缆（如有）重新连接到车辆中的终端以及底盘和制动钳上的任何附件上。
11. 重新连接制动液供给管路（点13）。
12. 拆下之前放置在乘客舱内的垫片，从而松开制动器踏板并允许回路重新打开。
13. 对于C型后制动卡钳（带驻车机构），重新连接驻车控制电缆（点11）。
14. 拆下控制杆锁定销（点19）。
15. 在车内拉起驻车制动器。重复该过程几次，直到制动机构杆的行程重新达到最小值。
16. 打开制动液储液罐盖。
17. 取下保护帽（点20）并将透明管连接到制动钳上的放气塞（点21），其末端应放置在容器中以收集所有液体。
18. 打开放气塞（点21）。
19. 反复踩下车辆制动踏板，直至制动液开始从放气塞溢出。
20. 踩下踏板，关闭放气塞。松开踏板，等待几秒钟，然后重复该过程，直到没有任何气泡的液体溢出，直到制动踏板恢复正常的阻力和行程。
21. 使用表中规定的扭矩拧紧放气塞：
| 放气塞 | M6x1 | M6x1 | M6x1 | M6x1 |
| 锁紧扭力 | 5÷7 Nm | 7÷10 Nm | 17÷20 Nm | 18÷22 Nm |
22. 拆下透明管并将保护帽重新放置在放气塞上。
23. 对任何其他放气塞重复放气过程。
24. 放气过程结束后，使用适当的工具（例如伸缩器）将制动钳中的活塞完全拉回，然后按照制造商的建议加满液位。
25. 关闭制动液储液罐盖。
26. 发动机运转时，用力踩下车辆制动踏板，检查制动钳是否有液体泄漏或回路中是否存在异常压力损失，并且后制动灯是否亮起。
危险！如果液体从制动钳泄漏，请重复本文档中列出的所有步骤，以查明原因并解决问题。
27. 如果卡钳带有内置驻车制动器，请将驻车制动电缆端子连接至制动卡钳上的相应位置。反复拉动并松开驾驶舱驻车制动器。
28. 重新装上车轮。
29. 如果刹车片是新的，请将其磨合；按照备用垫提供的说明进行操作。
Here the instructions for the replacement of brake calipers:
Floating calipers with central spring
Floating calipers with 2 or 4 side springs and residual torque reducing springs.
All the information on this instruction sheet applies to both types of calipers, unless otherwise specified.
Replacement procedure
Before commencing replacement, ascertain that the spare parts used for replacement are suitable for the make and model of the vehicle.
- Remove the wheel
- Make a note of the position of all the partially or fully disassembled components for correct reassembly.
1. Disconnect the wear indicator (point 1), where present, from the terminal in the vehicle, releasing it from the shim (point 2) that secures it to the caliper and from any attachments on the chassis.
2. Remove the protective caps (point 3) from the guiding bushes.
3. If the cap has a lip (point 4), snap off the cap by pulling on the lip (point 4) with your fingers.
4. If the cap is made of hard plastic (point 5), prise if off with a screwdriver. Removing the cap will break it.
WARNING! Do not reuse the disassembled hard plastic cap.
CAUTION! The guiding bush to disassemble must be the one that allows the caliper body to turn without causing the brake fluid supply line to stretch.
WARNING! There are two types of guiding bushes:
- with separate screw
- with incorporated screw
- with incorporated screw
5. Loosen and completely remove the screw (point 6) or incorporated guiding bush (point 7) using a spann
WARNING! If there are any brake pads glued to the caliper, detach them using a screwdriver.
DANGER! Opening the caliper body may cause the residual torque reducing springs to spring open.
6. In the case of a non-incorporated guiding bush (point 8), pull the guiding bush out of the caliper bracket (point 9) prising it out of its seat with a screwdriver.
7. When replacing the caliper on rear wheels with suspension and leaf springs, both the guiding bushes (point 8) must be removed to separate the caliper body (point 10) completely from the caliper bracket (point 9).
8. Pull the caliper body (point 10) away from the caliper bracket (point 9) by twisting it around the other guiding bush until the pads come out of the caliper bracket. Attach the caliper body to the vehicle chassis using appropriate supports.
9. Remove the pads (point 11) and springs (point 12) without causing any damage so you can reassemble them onto the new caliper.
10. Use a marker to mark the direction of rotation of the disc on the pads to avoid reassembling them incorrectly.
11. If they are still in position, remove the residual torque reducing springs (point 13).
12. Place a spacer (point 14) inside the passenger compartment between the seat and the brake pedal to make sure the pedal remains pressed for the duration of these operations.
WARNING! This allows the brake hydraulic circuit to be closed, avoiding any brake fluid from leaking.
CAUTION! During all the phases described below, make sure the brake fluid does not come into contact with parts of the vehicle which would be damaged, especially painted parts. Promptly wipe off any accidental brake fluid splashes or leaks with kitchen towel and clean with water.
WARNING! This allows the brake hydraulic circuit to be closed, avoiding any brake fluid from leaking.
CAUTION! During all the phases described below, make sure the brake fluid does not come into contact with parts of the vehicle which would be damaged, especially painted parts. Promptly wipe off any accidental brake fluid splashes or leaks with kitchen towel and clean with water.
13. Loosen the supply line (point 15) on the caliper enough to be able to screw it off completely by hand, as this will avoid any brake fluid leaking out.
14. Unscrew the fixing bolts (point 16) using an open-ended spanner and remove the caliper bracket (point 9) from the hub bracket.
15. Detach the supply line (point 15) completely from the caliper body.
16. Promptly wipe off any brake fluid leaks.
17. Keep the supply line raised to prevent any fluid leaks.
18. In the case of calipers with an incorporated parking brake, disconnect the parking brake cable from its seat on the caliper.
19. Pull away the caliper to be replaced.
20. Clean the braking surfaces (point 17) on the disc using a degreasing product (e.g. Solvent SE47).
Caliper fitting procedure
CAUTION! Do not disassemble the protective cap from the fluid inlet hole on the new caliper until you connect the supply line to it.
Lubricate the bushes and dust covers using the grease provided before fitting the new caliper.
WARNING! EUH210 - Safety data sheet available upon request.
WARNING! EUH208 - Contains N-alkylated benzotriazole. May cause an allergic reaction.
1. Remove the protective caps from the bushes, where present.
2. Loosen the screws or guiding bushes with incorporated screw.
3. In the case of separate screws, take the screws out completely.
4. Pull the caliper body away from the caliper support.
WARNING! To avoid damaging the dust covers, pull out the bushes from the side of the cover.
5. Remove the covers.
6. Thoroughly clean all the components to be fitted, the bush seats and the cover seats using appropriate products (e.g. a damp cloth).
7. Clean the mounting faces on the hub bracket.
8. Position the new caliper bracket (point 18) by inserting it in the disc.
9. Insert and approach the two fixing bolts (points 19 and 20).
10. Tighten the fixing bolt on the disc entry side (point 19) (in forward gear) applying the tightening torque recommended by the vehicle manufacturer.
11. Tighten the second fixing bolt 20 (on the disc exit side) applying the tightening torque recommended by the vehicle manufacturer.
Use the following recommended tightening torques for reference:
| Type of screw | Tightening torque |
| M12x1,25 | 115 Nm |
| M12x1,5 | 125 Nm |
| M14x1,5 | 180 Nm |
| M16x1,5 | 210 Nm |
12. Grease the entire inner surface of the covers (point 21) and the contact profile (point 22) with the caliper body evenly.
13. Insert the covers (point 21) in the seats (point 23) on the caliper body.
CAUTION! Using your finger, check the cover has been inserted and seated in the caliper body correctly.
14. Grease the external surface of the bushes (point 24) and their seats (point 25) in the caliper body, insert the bushes in the caliper body from the side opposite the cover.
15. Push the bushes (point 24) until the covers (point 21) fit in their seat (point 26).
16. Remove any excess grease.
17. Fit the caliper body onto the caliper bracket threading through and screwing on the screw or the incorporated bush on the disc exit side (in forward gear).
18. Pull the caliper body (point 27) away from the caliper bracket (point 18) by twisting it around the guiding bush until the pads go into the caliper bracket. Attach the caliper body to the vehicle chassis using appropriate supports.
CAUTION! Do not use the guiding bush seat as a point of attachment.
Fitting the pads
1. Where envisaged, fit the side springs (point 12) in the caliper bracket, exerting the right amount of pressure to attach them securely.
2. In the case of calipers with four springs, always fit the springs with the vanes facing the outside of the caliper bracket.
CAUTION! Observe the correct fitting direction.
WARNING! IF there are any pads with an adhesive side, then new pads must be fitted; follow the instructions provided with the spare pads.
CAUTION! The pad with a wear indicator must be fitted back into the position it was originally in before being disassembled.
CAUTION! Observe the correct fitting direction.
WARNING! IF there are any pads with an adhesive side, then new pads must be fitted; follow the instructions provided with the spare pads.
CAUTION! The pad with a wear indicator must be fitted back into the position it was originally in before being disassembled.
3. Reinsert the pads (point 11) in the caliper bracket (point 18); for type B calipers, use a screwdriver to prise open the side springs (point 12).
WARNING! Any arrows stamped on the pads must be pointing in the disc rotation direction.
DANGER! Pads must be inserted with the friction material facing the disc.
WARNING! Any arrows stamped on the pads must be pointing in the disc rotation direction.
DANGER! Pads must be inserted with the friction material facing the disc.
4. Thread the wear indicator cable (point 1) through the dedicated duct as follows:
For type A calipers - in the spring (point 28).
For type B calipers - in the caliper body (point 27).
4. Close the caliper carefully, by twisting the caliper body (point 27) around the screwed-on guiding bush. If there are any pads with an adhesive side, take care not to create contacts between the caliper body and the pad before you have completed the caliper body fitting.
CAUTION! Close the caliper carefully, making sure the protective covers on the bushes are not damaged by knocking against the caliper bracket.
CAUTION! Close the caliper carefully, making sure the protective covers on the bushes are not damaged by knocking against the caliper bracket.
5. Move the caliper body (point 27) towards the caliper bracket (point 18).
6. Reinsert the guiding bush (point 29) in the caliper bracket seat.
7. Insert and screw in a new screw (point 30), where present.
8. When replacing the caliper on rear wheels with suspension and leaf springs, the caliper body (point 27) must be repositioned on the caliper bracket (point 18), then reinsert both guiding bushes (point 29) and insert and tighten two new screws (point 30), where present.
9. If it is not screwed in yet, tighten the guiding bush fastening screw or the incorporated guiding bush on the disc entry side (in forward gear). Next, tighten the other screw or the other incorporated guiding bush at the same torque.
10. Tighten at the tightening torque specified in the following table:
| Type | Tightening torque | |
| Fastening screw | (M8 – CH6) | 32 ÷ 36 Nm |
| Guiding bush with incorporated screw | (M8 – CH6) | 32 ÷ 36 Nm |
| Guiding bush with incorporated screw | (M10 – CH8) | 65 ÷ 75 Nm |
DANGER! Observe the tightening sequence described; failing to could compromise the proper functioning of the caliper.
11. In the case of residual torque reducing springs (point 31) hook the spring under the plate (point 32) of the pad and hook the underside of the plate on the other pad with the aid of a hollow tip screwdriver.
DANGER! Incorrect attachment of the spring could cause it to spring open.
CAUTION! Observe the correct fitting direction.
12. Carefully clean the parts (point 33) to make sure they stay in place and fit new protective caps (point 34), greasing their internal surface and the caliper body seat with grease provided in the spare part kit.
13. Turn the protective cap (point 34) so that it adheres fully to the seat (point 35).
14. Reconnect the wear indicator, where present, to the terminal in the vehicle, securing it with a light pressure to the shim present on the caliper and securing any attachments on the chassis.
15. Remove the protective cap from the brake fluid inlet hole (point 36).
16. Reconnect the brake fluid supply line.
17. Remove the spacer you previously placed inside the passenger compartment, thereby releasing the pedal from the brake and allowing the hydraulic circuit to reopen.
18. Open the brake fluid reservoir cap.
19. Remove the protective cap (point 37) and connect a transparent tube to the bleeder plug (point 38) on the caliper, the ends of which should be placed in a container to collect any fluid.
20. Open the bleeder plug (point 38).
21. Repeatedly press the vehicle brake pedal until brake fluid starts to flow out of the bleeder plug.
22. Holding down the pedal, close the bleeder plug. Release the pedal, wait a few seconds, then repeat the process until fluid without any air bubbles flows out and until the usual resistance and travel of the brake pedal are restored.
23. Tighten the bleeder plug applying the tightening torque specified in the table:
| Bleeder plug | M6x1 | M8x1,25 | M10x1 | M12x1 |
| Tightening torque | 5÷7 Nm | 7÷10 Nm | 17÷20 Nm | 18÷22 Nm |
24. Remove the transparent tube and reposition the protective cap on the bleeder plug.
25. Repeat the bleeding procedure for any other bleeder plugs.
26. After the bleeding process, pull back the pistons in the caliper completely using an appropriate tool (such as a retractor) and then top up the fluid level, as recommended by the manufacturer.
27. Close the brake fluid reservoir cap.
28. With the engine running, apply strong pressure to the vehicle brake pedal and check there are no fluid leaks from the caliper or abnormal pressure losses in the circuit and that the rear brake lights come on.
DANGER! If fluid is leaking from the caliper, repeat all the steps set out in this document to pinpoint the cause and remedy the problem.
29. In the case of calipers with an incorporated parking brake, connect the parking brake cable terminal to its seat on the caliper.
30. Pull and release the cabin parking brake repeatedly.
31. Refit the wheel.
32. If the pads are new, run them in; follow the instructions provided with the spare pads.
Here the instructions for the replacement of components for commercial vehicle floating calipers (type ECS53 and ECS60) with incorporated electric parking mechanism:
1. Actuator unit
2. Pads
3. Caliper body (without pads and caliper bracket)
4. Caliper bracket
2. Pads
3. Caliper body (without pads and caliper bracket)
4. Caliper bracket
WARNING! Read this document before replacing the spare parts contained in the pack. Only perform those steps required for replacing the spare part or parts contained in the pack.
Replacement procedure
Before commencing replacement, ascertain that the spare parts used for replacement are suitable for the make and model of the vehicle.
WARNING! In the event of an electrical failure, disassemble the actuator unit and pull the piston back, turning the torx screw clockwise with a suitable spanner.
WARNING! In the event of an electrical failure, disassemble the actuator unit and pull the piston back, turning the torx screw clockwise with a suitable spanner.
- Make a note of the position of all the partially or fully disassembled components for correct reassembly.
1. Connect the diagnostics tool (On Board Diagnosis - OBD) to the vehicle and put it in maintenance mode procedure as described by the vehicle manufacturer.
CAUTION! Make sure the spare part is compatible with the vehicle software.
2. Remove the wheel.
3. Release the actuator unit electricity supply cable from the cable gland.
4. For caliper type ECS60 loosen and remove the cable gland (point 5).
5. Disconnect the electricity supply cable (point 6) from the actuator unit.
WARNING! The connector may be fitted with a safety latch.
WARNING! The connector may be fitted with a safety latch.
Disassembling the actuator unit
WARNING! Proceed with disassembling the actuator unit only if a separate spare part is available.
1. Loosen the fastening screws (point 7) from the actuator unit (point 1).
2. Remove the actuator unit (point 1).
3. Remove the seal (point 8).
Disassembling the pads
CAUTION! Do not damage any components you intend to re-use.
DANGER! Do not cause the brake fluid supply line to stretch.
DANGER! Do not cause the brake fluid supply line to stretch.
1. Disconnect the wear indicator (point 9), where present, from the terminal in the vehicle, releasing it from the shim that secures it to the caliper and from any attachments on the chassis.
2. Remove the protective cap (point 10) from the secondary bush (forward drive revolution disc exit side).
3. If the cap is made of hard plastic (point 11), prise if off with a screwdriver. Removing the cap will break it.
WARNING! Do not reuse the disassembled hard plastic cap.
4. Loosen and remove the secondary screw (point 12).
5. For caliper type ECS60 use a screwdriver to prise the bush out of the groove to release it from the caliper bracket.
6. Remove the protective cap (point 14) from the primary bush (forward drive revolution disc entry side).
7. Loosen the primary screw (point 15) completely and remove it.
WARNING! Use a screwdriver to prise the guiding bushes out from the grooves.
8. Take out the primary guiding bush (point 16) enough to release it from the caliper bracket.
9. Pull the caliper body (point 3) away from the caliper bracket (point 4) taking care not to cause the brake fluid supply line to stretch.
10. Attach the caliper body to the vehicle chassis using appropriate supports.
CAUTION! Do not use the bush seat as a point of attachment.
11. Remove the pads (point 17) and springs (point 18) without causing any damage so you can reassemble them onto the new caliper.
12. If they are still in position, remove the residual torque reducing springs (point 19).
WARNING! For the correct refitting of the same pads, mark some arrows (where not present) on the pads with a marker to indicate the direction of rotation of the disc.
Disassembling the caliper body
1. Place a spacer (point 20) inside the passenger compartment between the seat and the brake pedal to make sure the pedal remains pressed for the duration of these operations.
AWARNING! This allows the brake hydraulic circuit to be closed, avoiding any brake fluid from leaking.
CAUTION! During all the phases described below, make sure the brake fluid does not come into contact with parts of the vehicle which would be damaged, especially painted parts. Promptly wipe off any accidental brake fluid splashes or leaks with kitchen towel and clean with water.
2. Loosen the supply line (point 21) on the caliper enough to be able to screw it off completely by hand, as this will avoid any brake fluid leaking out.
3. Detach the supply line (point 21) completely from the caliper body.
4. Promptly wipe off any brake fluid leaks.
5. Keep the supply line raised to prevent any fluid leaks.
6. Pull away the caliper body (point 3).
Disassembling the caliper bracket
CAUTION! During disassembly, keep the caliper bracket in position to avoid it accidentally dropping.
1. Loosen the fastening screws (point 22).
2. Remove the caliper bracket (point 4) from the hub bracket.
Fitting procedure
Reassemble the new spare components.
1. Thoroughly clean all the components to be fitted (whether new or removed previously), the bush seats and the spring seats using appropriate products (e.g. a damp cloth).
DANGER! Make sure the components are intact, replace them with new ones if damaged.
2. Clean the mounting faces (point 23) on the hub bracket.
3. Clean the braking surfaces (point 24) on the disc using a degreasing product (e.g. Solvent SE47).
Fitting the caliper bracket
1. Position the new caliper bracket (point 25) on the hub bracket.
2. Insert and tighten the fastening screws (point 26) at the tightening torque recommended by the vehicle manufacturer.
Fitting the pads and caliper body
1. Reinsert the springs (point 27), placing them the right way round in their seats.
2. For caliper type ECS52 with four springs, always fit the springs with the vanes (point 28) facing the outside of the caliper bracket.
WARNING! IF there are any pads with an adhesive side, then new pads must be fitted; follow the instructions provided with the spare pads.
CAUTION! The pad with a wear indicator must be fitted back into the position it was originally in before being disassembled.
DANGER! Pads must be inserted with the friction material facing the disc.
3. Reinsert the pads (point 29) in the caliper bracket (point 25); use a screwdriver to prise open the side springs (point 27).
4. In the case of residual torque reducing springs (point 30) hook the spring under the plate (point 31) of the pad and hook the underside of the plate on the other pad with the aid of a hollow tip screwdriver.
DANGER! Incorrect attachment of the spring could cause it to spring open.
DANGER! Incorrect attachment of the spring could cause it to spring open.
CAUTION! Observe the correct fitting direction.
CAUTION! If the caliper body is new, do not disassemble the protective cap from the fluid inlet hole on the new caliper until you connect the supply line to it.
6. Position the caliper body (point 32) by inserting it in the disc, so that the guiding bushes coincide with the holes on the caliper bracket.
CAUTION! Do not damage the covers.
7. Push the guiding bushes (point 33) into their seats on the caliper bracket.
8. Insert and tighten the screws (point 34) using a tightening torque of 32 ÷ 36 Nm.
9. Position the caps (point 35).
CAUTION! Before removing the protective cap, leave the supply point as high as possible, making sure none of the brake fluid inside the caliper leaks out.
10. Reconnect the wear indicator cable, where present, to the terminal in the vehicle, securing it with a light pressure to the shim on the caliper, where present, and securing any attachments on the chassis.
Connecting the brake fluid supply line
1. Remove the protective cap (point 36) from the brake fluid inlet hole.
2. Reconnect the brake fluid supply line (point 21).
3. Remove the spacer you previously placed inside the passenger compartment, thereby releasing the pedal from the brake and allowing the circuit to reopen.
4. Remove the protective cap (point 37) from the bleeder plug (point 38).
5. Connect a transparent tube to the bleeder plug (point 38) on the caliper, the ends of which should be placed in a container to collect any fluid.
6. Open the bleeder plug (point 38).
7. Repeatedly press the vehicle brake pedal until brake fluid starts to flow out of the bleeder plug.
8. Holding down the pedal, close the bleeder plug. Release the pedal, wait a few seconds, then repeat the process until fluid without any air bubbles flows out and until the usual resistance and travel of the brake pedal are restored.
9. Tighten the bleeder plug (point 38) applying the tightening torque specified in the following table:
| Bleeder type | M10x1 |
| Tightening torque | 12÷16 Nm |
10. Remove the transparent tube.
11. Repeat the bleeding procedure for any other bleeder plugs.
12. Reposition the protective cap (point 37).
13. After the bleeding process, pull back the pistons in the caliper completely using an appropriate tool (such as a retractor) and then top up the fluid level, as recommended by the manufacturer.
14. With the engine running, apply strong pressure to the vehicle brake pedal and check there are no fluid leaks from the caliper or abnormal pressure losses in the circuit and that the rear brake lights come on.
DANGER! If fluid is leaking from the caliper, repeat all the steps set out in this document to pinpoint the cause and remedy the problem.
Fitting the actuator unit
WARNING! The actuator unit may be supplied already fitted to the caliper body.
Reassemble the new spare components.
- Clean any components you removed previously before reassembling them.
CAUTION! Always use new screws with thread locker. Always fit a new seal.
DANGER! Make sure the components are intact, replace them with new ones if damaged
1. Clean the contact surface on the caliper and on the actuator unit.
2. Remove any thread locker residue from threaded screw seats.
3. Clean and lubricate the seal (point 39) with the grease supplied.
4. Lubricate the internal diameter of the actuator unit coupling with the grease supplied.
WARNING! EUH210 - Safety data sheet available upon request.
WARNING! EUH208 - Contains N-alkylated benzotriazole. May cause an allergic reaction.
5. Position the seal (point 39) in its seat (point 40) on the caliper body.
6. Fit the actuator unit (point 41) on the torx screw (point 42) on the caliper body.
7. Turn the actuator unit (point 41) so that the holes (point 43) of the fastening screws (point 44) coincide with their original fitting position.
CAUTION! Avoid pinching the seal (point 39) when fitting the actuator unit on the caliper body.
8. Insert and tighten the fastening screws (point 44) at a tightening torque of 7 ÷ 10 Nm.
9. Remove the protective cap (point 45), where present, and connect the electrical supply cable (point 6).
10. Where removed previously, screw on the cable gland (point 5).
11. Secure the actuator unit electricity supply cable (point 6) to the cable gland (point 5).
Final phases
1. Refit the wheel.
2. Perform the reset procedure (Assembly check).
3. If necessary, reset the counters (Reset Internal Counters) as prescribed by the vehicle manufacturer.
4. If required by the vehicle manufacturer, run in the pads.
5. Disconnect the diagnostics device. (On Board Diagnosis – OBD).
Here the instructions for the replacement of the caliper body for floating calipers with 2 or 4 side springs and residual torque reducing springs.
When replacing only the fastening screws, only refer to the relevant parts.
Replacement procedure
Before commencing replacement, ascertain that the spare parts used for replacement are suitable for the make and model of the vehicle.
- Make a note of the position of all the partially or fully disassembled components for correct reassembly.
- Remove the wheel.
For ECS calipers
WARNING! In the event of an electrical failure, disassemble the actuator unit (point 5) and pull the piston back, turning the torx screw clockwise with a suitable spanner
1. Connect the diagnostics tool (On Board Diagnosis - OBD) to the vehicle and put it in maintenance mode procedure as described by the vehicle manufacturer.
CAUTION! Without this operation, the piston cannot be pulled back with the retractor or another suitable tool.
CAUTION! Make sure the spare part is compatible with the vehicle software.
2. Disconnect the electricity supply cable (point 2) from the actuator unit.
WARNING! The connector may be fitted with a safety latch.
For all types of calipers
1. For calipers with a parking brake, detach the control cable (point 3) from the caliper.
2. Disconnect the wear indicator (point 4), where present, from the terminal in the vehicle, releasing it from the shim (point 5) that secures it to the caliper and from any attachments on the chassis.
3. Remove the protective caps (point 6) from the guiding bushes.
4. If the cap has a lip (point 7), snap off the cap by pulling on the lip (point 7) with your fingers.
5. If the cap is made of hard plastic (point 8), prise if off with a screwdriver. Removing the cap will break it.
WARNING! Do not reuse the disassembled hard plastic cap.
CAUTION! The guiding bush to disassemble must be the one that allows the caliper body to turn without causing the brake fluid supply line to stretch.
WARNING! There are two types of guiding bushes: with separate screw, with incorporated screw.
WARNING! Do not reuse the disassembled hard plastic cap.
CAUTION! The guiding bush to disassemble must be the one that allows the caliper body to turn without causing the brake fluid supply line to stretch.
WARNING! There are two types of guiding bushes: with separate screw, with incorporated screw.
6. Loosen and completely remove the screw (point 9) or incorporated guiding bush (point 10) using a spanner.
7. In the case of a non-incorporated guiding bush (point 11), pull the guiding bush out of the caliper bracket (point 12) prising it out of its seat with a screwdriver.
8. When replacing the caliper on rear wheels with suspension and leaf springs, both the guiding bushes 11 must be removed to separate the caliper body (point 13) completely from the caliper bracket (point 12).
WARNING! If there are any brake pads glued to the caliper, detach them using a screwdriver and take care not to damage any rubber parts of the caliper.
DANGER! Opening the caliper body may cause the residual torque reducing springs to spring open.
9. Pull the caliper body (point 13) away from the caliper bracket (point 12) by twisting it around the other guiding bush until the pads (point 14) come out of the caliper bracket. Attach the caliper body to the vehicle chassis using appropriate supports. Do not use the bush seat as a point of attachment.
11. Remove the pads (point 14) without causing any damage.
12. Use a marker to mark the direction of rotation of the disc on the pads to avoid reassembling them incorrectly.
14. If they are still in position, remove the residual torque reducing springs (point 15).
15. Place a spacer (point 16) inside the passenger compartment between the seat and the brake pedal to make sure the pedal remains pressed for the duration of these operations.
WARNING! This allows the brake hydraulic circuit to be closed, avoiding any brake fluid from leaking.
CAUTION! During all the phases described below, make sure the brake fluid does not come into contact with parts of the vehicle which would be damaged, especially painted parts. Promptly wipe off any accidental brake fluid splashes or leaks with kitchen towel and clean with water.
CAUTION! During all the phases described below, make sure the brake fluid does not come into contact with parts of the vehicle which would be damaged, especially painted parts. Promptly wipe off any accidental brake fluid splashes or leaks with kitchen towel and clean with water.
16. Loosen the supply line (point 17) on the caliper enough to be able to screw it off completely by hand, as this will avoid any brake fluid leaking out.
17. Loosen completely and remove the screw (point 9) or incorporated guiding bush (point 10).
18. In the case of a non-incorporated guiding bush (point 11), pull the guiding bush out of the caliper bracket (point 12) prising it out of its seat with a screwdriver.
19. Pull the caliper body (point 13) away from the caliper bracket (point 12) taking care not to cause the brake fluid supply line to stretch.
20. Detach the supply line (point 17) completely from the caliper body.
21. Promptly wipe off any brake fluid leaks.
22. Keep the supply line raised to prevent any brake fluid leaks.
23. Pull away the caliper to be replaced.
24. In the case of calipers with an incorporated parking brake, disconnect the parking brake cable from its seat on the caliper.
25. Clean the braking surfaces on the disc using a degreasing product (e.g. Solvent SE47).
Fitting the pads
CAUTION! If there are any pads with an adhesive side, then new pads must be fitted; follow the instructions provided with the spare pads.
1.Check the springs are correctly positioned. In the case of calipers with four springs, make sure the vanes are always facing the outside of the caliper bracket.
CAUTION! Incorrect spring positioning could possibly cause injury.
2. Insert the pads (point 14) in the caliper bracket (point 12). Use a screwdriver to press the side springs.
WARNING! Any arrows stamped on the pads must be pointing in the disc rotation direction.
DANGER! Pads must be inserted with the friction material facing the disc.
CAUTION! The pad with a wear indicator must be fitted back into the position it was originally in before being disassembled.
WARNING! Any arrows stamped on the pads must be pointing in the disc rotation direction.
DANGER! Pads must be inserted with the friction material facing the disc.
CAUTION! The pad with a wear indicator must be fitted back into the position it was originally in before being disassembled.
3. Where present, attach the wear indicator terminal (point 20) to the pad opposite the pistons, replacing it if necessary.
CAUTION! When attaching the wear indicator terminal, make sure the most protruding part is facing the friction surface on the pad.
CAUTION! When attaching the wear indicator terminal, make sure the most protruding part is facing the friction surface on the pad.
Fitting the caliper body
CAUTION! For calipers with a parking brake - while the caliper body is disassembled from the brake disc and/or the brake pads are absent, do not move the piston either hydraulically or using the lever as this could damage the spring and/or cause the brake fluid to leak.
1. On the caliper bracket, wipe the fitting areas (point 21) with the caliper body (guide seats) with a damp cloth.
CAUTION! Do not use products which could damage the protective covers, such as nitro-tetrachloroethylene thinner, petrol, etc.
2. Clean and uniformly grease the entire internal surface of the covers, the external surface of the guiding bushes and their seats in the caliper body.
3. Position the new caliper body (point 22), setting one of the two guiding bushes (point 10) in the seat on the caliper bracket (point 12).
CAUTION! Don’t remove the protective cap from the brake fluid inlet hole until the tube is connected definitively.
CAUTION! Don’t remove the protective cap from the brake fluid inlet hole until the tube is connected definitively.
4. In the case of a non-incorporated guiding bush (point 11), fit and tighten a new screw (point 23).
5. Close the caliper carefully, by twisting the caliper body (point 22) around the seated guiding bush.
CAUTION! Close the caliper carefully, making sure the protective covers on the bushes are not damaged by knocking against the caliper support. Replace the covers if necessary.
WARNING! If there are any pads with an adhesive side, take care not to create contacts between the body and the pad before you have completed the caliper body fitting.
6. Thread the wear indicator probe (point 20) through the dedicated hole in the caliper body (point 22).
7. Reinsert the other guiding bush (point 10) in the caliper bracket seat (point 12).
8. In the case of a non-incorporated guiding bush (point 11), fit and tighten a new screw (point 24).
CAUTION! When replacing the caliper bracket on rear wheels with suspension and leaf springs, the caliper body must be repositioned on the caliper bracket, then reinsert both guiding bushes and insert and tighten two new screws.
9. Tighten the guiding bush fastening screw or the incorporated guiding bush (point 24) on the disc entry side (in forward gear). Next, tighten the other screw or the incorporated guiding bush (point 25) at the same torque.
10. Tighten at the tightening torque specified in the following table:
| Type | Tightening torque | |
| Fastening screw | (M8 – CH6) | 32 ÷ 36 Nm |
| Guiding bush with incorporated screw | (M8 – CH6) | 32 ÷ 36 Nm |
| Guiding bush with incorporated screw | (M10 – CH8) | 65 ÷ 75 Nm |
DANGER! Observe the tightening sequence described; failing to could compromise the proper functioning of the caliper.
11. In the case of residual torque reducing springs (point 26) hook the spring under the plate (point 27) of the pad and hook the underside of the plate on the other pad with the aid of a hollow tip screwdriver.
DANGER! Incorrect attachment of the spring could cause it to spring open.
CAUTION! Observe the correct fitting direction.
12. Carefully clean the part (point 28) to make sure it stays in place and fit new protective caps (point 29), greasing their internal surface and the caliper body seat with grease provided in the spare part kit.
WARNING! EUH210 - Safety data sheet available upon request.
WARNING! EUH208 - Contains N-alkylated benzotriazole. May cause an allergic reaction.
WARNING! EUH208 - Contains N-alkylated benzotriazole. May cause an allergic reaction.
13. Turn the protective caps (point 29) so that they adhere fully to the seat (point 30).
14. Reconnect the wear indicator, where present, to the terminal in the vehicle, securing it with a light pressure to the shim present on the caliper and securing any attachments on the chassis.
15. Remove the protective cap from the brake fluid inlet hole.
16. Reconnect the brake fluid supply line.
17. Remove the spacer you previously placed inside the passenger compartment, thereby releasing the pedal from the brake and allowing the circuit to reopen.
For calipers with a parking brake
CAUTION! Before assembling the piston with the pads, make sure the caliper bracket, pads and disc are present.
- Use the lever to assemble the piston with the pads.
CAUTION! Hydraulic operation is only permitted when the piston is less than 1 mm from the pads.
For all types of calipers
1. Connect a transparent tube to the bleeder plug (point 31) on the caliper, the ends of which should be placed in a container to collect any fluid.
2. Open the bleeder plug (point 31).
3. Repeatedly press the vehicle brake pedal until brake fluid starts to flow out of the bleeder plug.
4. Holding down the pedal, close the bleeder plug. Release the pedal, wait a few seconds, then repeat the process until fluid without any air bubbles flows out and until the usual resistance and travel of the brake pedal are restored.
5. Tighten the bleeder plug (point 31) applying the tightening torque specified in the table:
| Bleeder plug | M6x1 | M8x1,25 | M10x1 | M12x1 |
| Tightening torque | 5÷7 Nm | 7÷10 Nm | 17÷20 Nm | 18÷22 Nm |
6. Remove the transparent tube.
7. Repeat the bleeding procedure for any other bleeder plugs.
8. After the bleeding process, pull back the pistons in the caliper completely using an appropriate tool (such as a retractor) and then top up the fluid level, as recommended by the manufacturer.
9. Close the brake fluid reservoir cap.
10. With the engine running, apply strong pressure to the vehicle brake pedal and check there are no fluid leaks from the caliper or abnormal pressure losses in the circuit and that the rear brake lights come on.
DANGER! If fluid is leaking from the caliper, repeat all the steps set out in this document to pinpoint the cause and remedy the problem.
For calipers with a parking brake
- Reconnect the wear indicator, where present, to the terminal in the vehicle, securing it with a light pressure to the shim present on the caliper and securing any attachments on the chassis.
- Restore the correct tension to the control cable.
- Repeatedly operate the parking brake lever in the vehicle cab until the usual stroke has been re-established.
For ECS calipers
1. Remove the protective cap (where present) and connect the electrical supply cable (point 2).
2. Perform the reset procedure (Assembly check).
3. If necessary, reset the counters (Reset Internal Counters) as prescribed by the vehicle manufacturer.
4. If required by the vehicle manufacturer, run in the pads.
5. Disconnect the diagnostics device (On Board Diagnosis - OBD).
For all types of calipers
1. Refit the wheel.
2. If the pads are new, run them in; follow the instructions provided with the spare pads.
2. If the pads are new, run them in; follow the instructions provided with the spare pads.
保修限制
本保修涵盖货物交付后两年内发生的所有合规的缺陷。消费者必须在发现缺陷之日起两个月内向卖方报告合规的缺陷，但不影响自交付货物起二十六个月内采取旨在纠正缺陷行动的时效期限。根据《消费者权益保护法》第 130 条的规定，如果货物存在合格缺陷，用户有权要求修理或更换货物，或要求适当降价或终止合同。
本保修构成与本产品相关的唯一保修，并取代任何其他口头和书面保修。
如果出现缺陷，用户需要：
- 在六十天内以书面形式通知制造商和经销商；同时，用户应提供在产品上或在退回的部件上发现的缺陷描述，以及原始用户的购买证明，其中应注明产品和购买日期（无论是零售购买还是由经销商出售作为产品安装的一部分）；
- 通过分销链将被认为有缺陷的产品发送至 Brembo S.p.A. 位于 via Brembo 25 -24035 Curno (BG) - Italy 的总部。
保修不适用于以下情况：
- 由于不正确使用、事故、火灾、化学腐蚀、用于预定用途之外的用途、非法使用、使用与规定型号不同的型号、不正确安装、违反制造商指示的安装或未按照制造商提供的说明对产品进行维护而部分或全部造成的产品损坏；
- 与舒适性、噪音、振动或恶劣的骑行特性有关的投诉。
该产品是针对Brembo目录和/或Brembo产品经销商指定的特定型号和用途而设计和生产的，两者均可在Brembo网站 (www.brembo.com) 上查阅。产品的使用应遵守安装产品的车辆所在州和/或国家的现行法律，包括但不限于遵守《公路法》的规定，并在获得州和/或国家要求的任何授权/批准、许可或执照后使用。
对于在欧盟成员国境内销售的产品，这些保修限制符合1985年7月25日欧盟理事会 85/374/EEC指令的规定。
对于在美国境内销售的产品，这些保修限制遵循所有适用的联邦或州法律。
一般和安全信息
该 Brembo 产品的设计符合所有适用的安全标准。产品的用必须与其设计和制造的特定用途相符。将产品用于任何其他目的，或任何修改或篡改产品可能影响产品的性能，并可能导致产品不安全。
此类修改或不当使用将使受限的保修失效，并可能使使用产品的个人对他人造成的人身伤害或财产损失承担责任。
在这些说明中，“危险！“警告是指如果不遵守，很可能导致严重伤害甚至死亡的程序。“注意”表示如果不遵守，可能会导致物理损坏的程序，而“警告！”是指如果不遵守，可能会导致车辆损坏的程序。
危险！
在开始更换之前，请确定备件适合车辆的品牌和型号。本产品对于安装该产品的车辆的安全操作至关重要，只能由经过培训和/或具有安装和使用本产品经验的熟练、合格人员进行安装。
安装人员必须配备行业的专用工具，并具备处理车辆维修的知识和经验。不正确或不适当的安装，无论是由于未严格、完整地遵守这些说明或其他原因造成的，都将使有限保修失效，并可能使安装人员在发生人身伤害或财产损失时承担责任。
对于因更换产品安装不当而导致车辆操作人员造成的任何损坏或伤害，Brembo不承担任何责任。
本产品替换的旧产品不得安装在任何其他产品上。这可能会导致财产损失和人身伤害，包括死亡。
务必检查储液罐中的制动液液位是否在储液罐上指示的最低液位和最高液位之间。液位不正确可能会导致制动液泄漏或制动系统效率降低。储液罐中制动液过多或过少都可能导致制动器无法正常工作，从而导致人身伤害，包括死亡。
小心！
更换的部件必须依法处置。
避免剧烈撞击和/或损坏产品及其零部件至关重要，因为这可能损害其效率并可能导致它们发生故障。如有必要，更换任何损坏的零件或组件。为避免受伤，我们建议如下：
- 使用合适的装备防止吸入零件清洁过程中产生的灰尘。
- 在拆卸和组装具有锋利边缘的组件时，请务必戴手套。
- 请勿让皮肤表面与刹车片和制动蹄的摩擦材料直接接触，因为这可能会导致擦伤。
- 使用压缩空气拆卸制动钳活塞时，请勿将手放入刹车片安座中，否则可能会导致手被压伤。
- 避免直接接触制动液，因为它可能会刺激皮肤和眼睛。如果意外接触，请按照车辆或制动液制造商的说明彻底清洁。
- 请勿使电气元件积聚静电荷或遭受撞击，否则可能会损坏塑料部件。
- 保护拆卸下来的电气元件免受潮湿。
- 确保所有电气触点连接正确，检查警告灯是否亮起。如果警告灯不亮，可能会导致制动系统效率降低或制动信号失灵。
- 避免油脂和其他润滑剂与制动盘、制动鼓、刹车片和制动蹄的制动表面接触，因为这可能会影响制动系统的效率并造成严重的物理损坏。
- 请勿使用锋利的工具安装橡胶部件，因为这可能会损坏它们。确保更换所有损坏的部件。
保修限制
本保修涵盖货物交付后两年内发生的所有合规的缺陷。消费者必须在发现缺陷之日起两个月内向卖方报告合规的缺陷，但不影响自交付货物起二十六个月内采取旨在纠正缺陷行动的时效期限。根据《消费者权益保护法》第 130 条的规定，如果货物存在合格缺陷，用户有权要求修理或更换货物，或要求适当降价或终止合同。
本保修构成与本产品相关的唯一保修，并取代任何其他口头和书面保修。
