D IS C B R A K E

H Y D R AU L I C S Y S T E M
1 1s / 12s / 13s

CAMPAGN OLO.COM
 WARNING!
Always wear protective gloves and glasses while working on the bicycle.

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 INDEX

1 SAFETY RECOMMENDATIONS 4

2 TECHNICAL SPECIFICATIONS 6

3 COMPATIBILITY 9

4 INTERFACE WITH THE FRAME 10

5 ASSEMBLY 14

6 EXTRAORDINARY MAINTENANCE 44

7 ORDINARY MAINTENANCE 53

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 DISC BRAKE HYDRAULIC SYSTEM

THIS TECHNICAL MANUAL IS INTENDED FOR USE BY PROFESSIONAL MECHANICS.

Anyone who is not professionally qualified to assemble bicycles should not attempt to install and operate on the components
because of the risk of carrying out incorrect operations that could cause the components to malfunction with the consequent
risk of accidents, physical injury or even death.
The actual product may differ from what is illustrated, as the specific purpose of these instructions is to explain the
procedures for installing and adjusting the component.

Info for professional mechanics: Although the User Manual that comes with the product is intended mainly for the end user, it is vital that pro-
fessional mechanics also read and understand it so that they are adequately prepared to explain the product to customers, making certain that
all care is taken to ensure its safe and proper use.

1 - SAFETY RECOMMENDATIONS
WARNING!
With Campagnolo brakes® braking is different and more powerful compared to standard braking systems.
Improper use of this braking system could result in loss of control of the bicycle, accidents, physical injury or even death.
Please read and comply with all warnings and instructions.

Because each bicycle may handle differently, ensure that you are familiar with the braking technique (including brake lever pressure to be exerted
and the controls) and functions of the particular bicycle in question. We advise you to use the recommended riding and braking techniques, where
possible in a safe, unobstructed area, at least until you have familiarised yourself with the new braking system.
• If you apply excessive pressure to the front and/or rear brake, the wheel may lock and the bicycle may suddenly fall forward, putting you at risk
of serious injury.

• Never touch the disc brake rotor, even when the bicycle is statio-
nary. The rotor itself may be very hot, and could cause serious burns.
You are also reminded to take great care when the bicycle is moving,
as the rotor is sharp and could cause serious injury to the fingers if
inserted into the rotor openings while in motion (Fig.1).
• If any of the following conditions occur, stop using the bicycle
immediately:
- Any cracks or damage are visible on the rotor, even if these are
minimal
- The rotor is worn beyond the prescribed limits
- The brake system is leaking fluid

Fig.1

Failure to observe the above indications could lead to accidents, physical injury or even death.

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• If leaked oil comes into contact with the eyes, it may cause irritation: rinse with water and seek immediate medical attention.
• If leaked oil comes into contact with the skin, it may cause irritation: wash thoroughly using soap and water.
• Inhalation or ingestion of mineral oil vapours may cause nausea. Cover your nose and mouth and immediately go to a well-ventilated area. If
necessary, seek professional medical attention.
• Never make any modifications to any Campagnolo® product.
• Any bent or damaged parts following impact or accidents must be replaced with original Campagnolo® parts.
• Wear close fitting and highly visible clothing (fluorescent colours or light colours).
• Avoid cycling at night because it is difficult for others to see you and obstacles on the road are difficult to distinguish. If using the bicycle at
night, ensure that it is fitted with suitable lights and reflectors.
• Never use a bicycle or component with which you are not completely familiar or the use and maintenance operations of which are unknown.
Second hand parts may have been used incorrectly or may be ruined, therefore they could break unexpectedly, causing an accident.
• If the bicycle is used in the wet remember that the braking power and tyre grip decrease significantly, making it more difficult to control.
Therefore pay closer attention when riding on wet surfaces in order to prevent possible accidents.
• Always wear a correctly-fastened protective helmet and ensure that this is ANSI or SNELL approved.

WARNING!

Only original discs, pads and oil that are supplied with the Campagnolo drivetrain or original replacement parts must be
used; failure to respect the above requirements could result in accidents, physical injuries or even death.

1 . 1 - BEFORE US I N G T HE BI C YC L E
DO NOT USE YOUR BICYCLE IF IT DOES NOT PASS THIS TEST – CORRECT ANY FAULTY SITUATIONS BEFORE USING THE BICYCLE.
• Make sure that all of the bicycle components, including (but not exclusively) brakes, pedals, handgrips, handlebars, frame and seat unit are in
perfect condition and ready for use.
• Make sure that none of the bicycle components are bent, damaged or out of alignment.
• Check to ensure that all of the locking and fixing devices on the bicycle are properly adjusted. Bounce the bicycle on the ground to check
whether you can see or hear any loose parts.
• Check all reflectors are securely mounted and are clean.
• Make sure the wheels are perfectly centred. Spin the wheel to ensure that it does not wobble up and down or from side to side.
• Spin the wheel to check that it rotates freely and to ensure that the brake pads are not touching the rotor when the brake levers are not
depressed.
• Before using the bicycle, always check that the front and rear brakes are working correctly by testing the brake levers several times, ensu-
ring that the front and rear rotors engage correctly.

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2 - TECHNICAL SPECIFICATIONS
Ergopower Ultra-Shift /Power-Shift mechanical and electronic commands with adjustable free stroke (AMS - where available) and brake lever
position.

E R G O P OW E R H O U SING S CABLE BRAKE H O S E

UP / DOWN
C O N T R OL L EVE R S R E A R D E R A IL L E U R R E A R D E R A IL L E U R (EXT ERN AL Ø )
POWER-SHIFT 13s Ø 4.1 mm
Campagnolo maximum smoothness

Ø 4.1 mm
Campagnolo maximum smoothness

GROUPS E T S C A LIP ER S PADS DI SCS OI L

SR / RE / C

Campagnolo
organic pads
(with wear indicators)

GROUPS E T S C A LIP ER S PADS DI SCS OI L

SR / RE /
Campagnolo
organic pads
(with wear indicators)

EKAR 13s
Campagnolo
organic pads
(with wear indicators)

WARNING!
Only original discs, pads and oil that are supplied with the Campagnolo drivetrain or original replacement parts must be used;
failure to respect the above requirements could result in accidents, physical injuries or even death.

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2 . 1 - DISC SEL E C T I ON
WARNING!
This braking system cannot be used by cyclists who weigh more than 109 kg (240 lbs), or where the overall weight of the cyclist, the
bike and any bags or accessories installed exceeds a total weight of 120 kg (265 lbs).

Use 140 mm or 160 mm discs in accordance with your weight and the overall weight of the bicycle, bags/panniers or other accessories installed.
When selecting the disc, the weight limits must be respected (your weight and the total weight):

C YC LIS T W EIG HT OVERALL WEI GHT:

DI S C D I A M E T E R ( m m )
( K G / LB S ) CYCLI ST + BI KE + ACCESSORI ES ( K G / LB S )

140 or 160 82/180 90/198

109/240 120/265

WARNING!
Failure to respect the above mentioned weight limits could result in loss of control of the bicycle, accidents, physical injury or even
death.

a CAUTION!
Failure to respect the above-mentioned weight limits will void the product warranty.

WARNING!
When using a 160 mm disc at the rear, please remember that braking power will be increased, and accordingly, may result in an
increased risk of rear wheel locking.
Practice braking in a safe place until you are familiar with the braking power obtained with a rear disc of different sizes.

WARNING!
Campagnolo S.r.l. does not authorise the modification of the disc through the use of adapters for converting the AFS/6 screw disc
locking system.
The use of adapters for converting the AFS/6 screw disc locking system, could result in loss of control of the bicycle, accidents,
physical injury or even death.

a CAUTION!
The use of adapters for converting AFS/6 screws, will void the product warranty.

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2.2 - SEMI-FLOATING ROTORS
Semi-floating discs are identified by the code C3:

DI S C DIA M E T E R ( m m) PRODUCT CODE

140 DB-140C3

DB-160C3

These types of rotors are made with a central carrier, joined to the hub, and the outer braking rim which is connected via rivets.
To allow the braking rim to expand without losing rotor plane, when at high temperatures there is play between the central carrier and the braking
rim.
This rotational play is normal and must not exceed 1 mm.

outer rotor rivet central carrier 1 mm max play

S ay
l pl
na
tio
ta
ro

Section S-S

The force that must be used in order to make the play occur may vary significantly between one disc and another, but this a normal consequence
of the use of rivets and does not affect the correct operation of the discs themselves.

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3 - COMPATIBILITY
3 . 1 - MEC HA NI C A L GROUP S E T
E RGOP OW E R C R A NK S ET - C H A I N RI N G
REAR DERAI LLEUR FRON T DERAI LLEU R
C ONT RO L L E V E R S M A R K ING
POWER-SHIFT ULTRA-TORQUE
EKAR 13s
(EKAR 13s) (EKAR 13s)

SUPER RECORD SUPER RECORD

ULTRA-TORQUE
RECORD RECORD
(F / G)
(FG) (FG)

3 . 2 - EP S GROUP S E T
E RGOP OW E R
ULTRA-SHIFT 12s EPS ULTRA-SHIFT 11s EPS
C ONT RO L L E V E R S

C RA NK S E T ULTRA-TORQUE 12s ULTRA-TORQUE H11

C HA I NR IN G M A R K IN G F/G H

RE A R D E R A IL L E U R

F RONT D E R A I L L E U R

I NTE RFA C E U N I T

W I RE L ES S F O R M

P OWE R U N I T

* In the case of frames with thru-axles, use a rear derailleur produced in 2017 or later - these are concave shaped, ensuring perfect clearance
between the rear derailleur and the frame.

WARNING!
Combinations other than those provided for in the above table could cause the drivetrain to malfunction and potentially be the
cause of accidents, physical injury or even death.

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4 - INTERFACE WITH THE FRAME
4 . 1 - I NTERFA C E WI T H HA N DL E BAR FO R ER G O POW ER M ECH AN ICAL / E PS
CO NTROLS
WARNING!
Combinations other than those provided for in the above table could cause the drivetrain to malfunction and potentially be the cause
of accidents, physical injury or even death.

OK! R -65
R = 60 - 75
75 mm
NO!
NO!

R
R= 60
65- 75
- 7 mm
5
Fig.1

OK! NO!
R = 60 - 75 mm

Fig.2

• Do not lodge the upper part of the command in the rectilinear section of the handlebar (Fig. 1 / Fig. 2).
• Lodge the command in the curved section measuring R = 60 - 75 mm with a diameter = 23.8 - 24.2 mm (including any ovalization) to gua-
rantee more effective fastening (Fig. 1/Fig. 2).

CAUTION
a Make sure that the curved section of the handlebar where the command is to be fixed, has a sufficiently rough surface to ensure
a better grip.

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 α

Fig.3 Fig.4

CAUTION

a The cable routing illustrated in Figure 3 seriously compromises the drivetrain’s gear shift and derailing performance.
DO NOT USE HANDLEBAR BENDS WITH THIS KIND OF ROUTING.

• Make sure that angle α is sufficiently wide to ensure that the housing is mounted correctly and the cable runs through it easily (Fig. 4).

4. 2 - MI NI MUM C HA I N S TAY L E N G T H

LL
Fig.5
L = 410 mm min.

4. 3 - I NFORM AT I ON A BOUT T HE B EN D R AD IU S O F H Y D R AU LIC H O S ES

The recommended minimum bend radius of the hose is 15 mm.

! The presence of wrinkles on the outer hose wall does not indicate loss of functionality.
If there are evident signs of crushing or major dents on the outer surface of the hose, replace it, even if no loss of functio-
nality has been identified.

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4. 4 - FORK SP E C I F I C AT I ON S F OR T H E FR O N T CALIPER

Dropout angle
I = 40° max
A

Nm
is 6 - 8
H
torque
x 0,8 - 6
caliper
2xM5
Brake
8 min 8 min

2x Ø min
n 140 min
6,5 min

THIS AREA MUST HAVE NO PRONG SHAPE

le positio

HIGHER THAN Ø 13 AREA 2x 10 m

in
on of ho

0.1 CZ A
5
70 ±0,1
Suggesti
R5
6,5 min

4 x R5 max
5
23,5 ±0,1

1,7 ±0,4
11 ±0,15

SECTION A - A

Fig.6

Note: measurements are expressed in mm

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4 . 5 - LEFT- HAN D C HA I N S TAY F OR R EAR CALIPER

B B
A

16 ±0,15
SUGGESTION OF HOLE POSITION 130 min

A C
C

REAR MOUNT THICKNESS

10, 15, 20, 30, 35 ±0,5
0.1 CZ A

B
6,5 min
26 min 6,5 min
26,5 min

THIS AREA MUST HAVE NO

PRONG SHAPE HIGHER THAN
SECTION A - A
SECTION B - B Ø 13 AREA

BRAKE CALIPER FIXING BOLT CON-

2 x Ø 11 min 2 x Ø 11 min TACT FACE IS Ø 11
BRAKE CALIPER FIXING BOLT
2 x Ø 5,2 ±0,1 TIGHTENING TORQUE IS 6-8 Nm
2 x Ø 5,2 ±0,1
15,5 max
5,55 ±0,4

0,15 B

A
34 ±0,15 36,5 ±0,15

Fig.7

Note: measurements are expressed in mm

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5 - ASSEMBLY

5 . 1 - TOOLS FOR I N S TA L L I N G A ND B LEED IN G T H E H Y D R AU LIC S Y S T EM

WARNING!

Campagnolo spare parts must only be installed by qualified mechanics with specialised skills, tools and adequate
experience, following the installation instructions precisely. Installation by unqualified persons may cause malfunctions,
accidents and serious or even fatal injury.

Generic tools:

1,5 ALLEN WRENCH FLAT SCREWDRIVER

mm
Screwdriver

2 ALLEN WRENCH PHILLIPS SCREWDRIVER

mm
Screwdriver

2,5 ALLEN WRENCH FIXED WRENCH

mm
8 mm

3 ALLEN WRENCH T10 TORX WRENCH T10

mm

4 ALLEN WRENCH T20 TORX WRENCH T20

mm

5 ALLEN WRENCH T25 TORX WRENCH T25

mm

6 ALLEN WRENCH
mm

8 ALLEN WRENCH
mm

!
Tools supplied by other manufacturers for components that are similar to Campagnolo® components may not be compati-
ble with the Campagnolo® components. Similarly, tools supplied by Campagnolo S.r.l. may not be compatible with compo-
nents from other manufacturers. Always check with your mechanic or with the tool manufacturer to ensure compatibility
before using tools from one manufacturer on components from another manufacturer.

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In addition to standard workshop tools, the following are also required:

➜ MAGURA HYDRAULIC HOSE CUTTER

➜ JAGWIRE NEEDLE DRIVER TOOL

➜ MAGURA TORQUE SCREWDRIVER WITH OPEN BIT ADAPTER

➜ TORQUE WRENCH - 4-20 NM (WITH 8 MM BUSH AND 5 MM HEX BIT)

➜ CAMPAGNOLO OIL LEVEL TOOL UT-DB010 ( FOR INJECTING THE CORRECT AMOUNT OF OIL INTO THE SYSTEM)

➜ CAMPAGNOLO DB-100 BLEEDING TOOL (FOR FILLING AND BLEEDING THE SYSTEM)

➜ MINERAL OIL (SEE TABLE PAG. 6)

DANGER!

Use solely mineral oil in accordance with the table (page 6).
The use of DOT oil or oil other than the oil indicated in the table (page 6) could irreparably damage the rubber seals.
Failure to observe the above conditions could result in accidents, physical injury or death.

5 . 2 - A SSEMBL I N G T HE C A MPA GN O LO B LEED K IT

• Fit the short tube with the M6 threaded connector

onto the syringe with a hole.
• Fit the long tube with the M4 threaded connector onto
the syringe with no hole.

Fig.1

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5 . 3 - P REPA RIN G T HE F RA ME
• Remove all traces of paint from the areas where the callipers are to be installed on the fork and the left-hand chain stay. Also remove all traces of
paint from the bottom part of the holes on the chain stay, where the rear calliper screw heads rest. (Fig.1 - 1.1).

5 . 3 . 1 - FRONT F ORK

THIS AREA MUST HAVE NO PRONG CALIPER SUPPORT SURFACES

SHAPE REMOVE PAINT RESIDUES CALIPER SUPPORT
HIGHER THAN Ø 13 AREA SURFACES
REMOVE PAINT RESIDUES

Fig.1 SECTION A - A

Note: measurements are expressed in mm

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5 . 3 . 2 - REAR FORK

B B
CALIPER SUPPORT SURFACES
REMOVE PAINT RESIDUES

C
C

SECTION B - B
CALIPER SUPPORT SURFACES
REMOVE PAINT RESIDUES

THIS AREA MUST HAVE NO PRONG SHAPE

HIGHER THAN Ø 13 AREA

SECTION C - C

FIXING BOLT SUPPORT

SURFACES
REMOVE PAINT RESIDUES
Fig.1.1

Note: measurements are expressed in mm

• Using the frame cutter tool make sure the calliper

contact surface on the fork and the left-hand chain
stay are perpendicular to the discs, grinding the chain
stay if necessary in order to achieve this (Fig.2).

Fig.2

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5 . 4 - I NSTA LLI N G T HE E RGOP OW ER CO M M AND S

!
Always check the tables in the technical manual that provide information on product compatibility with previous
Campagnolo product ranges.

• For instructions on how to install the cables and sheaths for the operation of the rear derailleur and the Ergopower Ultra Shift and Power
Shift front derailleur, please refer to the “Ergopower commands” chapter of the technical manual, which is available on our website www.cam-
pagnolo.com.
• For instructions on how to install the Ergopower EPS and connect them to the EPS V3 interface, please refer to the “Assembly of the EPS
groupset” chapter of the technical manual, which is available on our website www.campagnolo.com.

5 . 5 - MOUNTIN G T HE DI S C ON TO T H E W H EEL
WARNING!

Only original discs, pads and oil that are supplied with the Campagnolo drivetrain or original replacement parts must
be used; failure to respect the above requirements could result in accidents, physical injuries or even death.

1) Position the disc on the hub so that the knurled

surface is visible (Fig.1).

Fig.1

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2) Insert the washer and locknut to hold the disk in
place (Fig.2).

Fig.2

3) Screw on the locknut (Fig.3).

Fig.3

4) Tighten the locknut (Fig. 4).

40 Nm
(354 in.lbs)

Fig.4

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5 . 6 - I NSTA LLI N G T HE F RON T DI SC B R AK E H Y D R AU LIC S Y S T EM
(F OR SYSTEM WI T HOUT OI L )
If the wheel has been mounted onto the bicycle, remove it beforehand in order to prevent soiling of the disc due to potential oil leaks from the
system during the mounting and bleeding phase. If the disc becomes soiled you then have to clean and degrease it.

1) Identify the front and rear callipers on the basis of

their geometry and distance from the screw holes on FRONT REAR
the frame (70 mm) (Fig.1 - Fig.2).

Fig.1 Fig.2

2) Remove the transportation block, the securing pin

and the pad fastener screw (Fig.3).
2,5
mm

Fig.3

3) Fit the oil level tool (which has a width of 10.5 mm).
If necessary, push the pistons back into the calliper 2,5
using the transportation block (Fig.4). mm
4) Fix the tool in place by screwing the pad fastener
screw back on (Fig.5).

Fig.4 Fig.5

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5) The length of hose must now be removed from the
calliper: loosen the nut, remove the nut and then the 5
hose (Fig.6). mm
6) Temporarily install the calliper onto the fork with two 8 mm
screws supplied (Fig.7).

Fig.6 Fig.7

7) Once the command has been installed on the

handlebar, insert the hydraulic hose into the hole pre-
sent on the left chain stay of the fork (Fig.8).
The barb driver on the end of the hose can be used
to guide the hose via a rear derailleur hose mounted
onto it (Fig.8). Insert the cable into the top hole and
once it has been threaded through the bottom hole
pull on it so that the hose can slide through the lower
area of the fork.

Fig.8

8) Assess the correct length of the hose by observing

its position in the handlebar area and bearing in mind
that the part entering the calliper should measure 11
mm in length from the cut end of the hose (Fig. 9).
Once the barb (with the head measuring 4 mm in
length) has been inserted, the part of the hose and
barb entering the calliper should measure approxima-
tely 15 mm.
We recommend that the length is greater than what is
required in case subsequent operations (11 and/or 14)
are not completed successfully.

9) Use the cutter, making sure that the cut is at a 90°

angle to the hose (Fig. 10).

Fig.9 Fig.10

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10) Insert part of the barb into the hose and push it in
using the driver tool (Fig. 11).

11) Check that the end of the hose touches the barb
and that the olive can be inserted on the hose (Fig.12).
If it is not possible, check to see whether the length of
barb inserted is excessive, causing the hose to bulge
out.
This situation - which would cause the incorrect posi-
tioning of the olive - is solved by returning to step 8 in
the procedure, cutting the end of the hose and refit-
ting the barb.

Fig.11 Fig.12

12) Insert the olive into the caliper (Fig. 13).

13) Hand-tighten the nut on the calliper so as to screw

it on safely and with precision without the constraint
of the hose (Fig. 14).

Fig.13 Fig.14

14) Insert the hose into the calliper and tighten the
nut ensuring that the hose is properly inserted into the
calliper (Fig. 15).
8 mm
15) Once it has been sufficiently tightened, unscrew
the nut in order to extract the hose and check that
the chamfering on the olive allows the barb to protru-
de from the olive itself (Fig.16). If this is not the case,
you must return to step 8 and cut the end of the hose,
otherwise the seal between the hose and barb would
not be effective.

Fig.15 Fig.16

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16) Insert the hose into the calliper once again, screw
on and tighten the nut again to the prescribed torque,
taking care not to damage the hose with the tool (Fig.
17). 8 mm
4 Nm
17) Now proceed with bleeding the hydraulic system. (35 in.lbs)

Fig.17

5 . 7 - NSTA LLI N G T HE RE A R DI S C B R AK E H Y D R AU LIC S Y S T EM

(F OR SYSTEM WI T HOUT OI L )
• If the hydraulic hose passes through the bottom bra-
cket shell and no other separate routing is required,
the axle cover cylinder needs to be installed in the
bottom bracket (supplied with hydraulic component
set - Fig.1).

• If the wheel has been mounted onto the bicycle,

remove it, in order to prevent potential oil leaks from
the system during the mounting and bleeding phase
from soiling the disc (which you would then have to
clean and degrease).

Fig.1

DANGER!
Take care to ensure that no lubricants, oils, solvents or waxes for polishing the frame are deposited on the brake pads
or discs. If this occurs, the braking power will be reduced or lost completely. In these circumstances, the bike must not
be used. Do not attempt to clean the pads, but instead simply replace these, and clean the discs with a degreasing agent.
Failure to observe the above instructions could cause accidents, physical injury or even death.

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1) Identify the front and rear callipers on the
basis of their geometry and distance from the REAR FRONT
fixing holes on the frame (34 mm) (Fig. 2/Fig. 2.1).

Fig.2 Fig.2.1

2) Remove the transportation block, the securing

pin and the pad fastener screw (Fig.3). 2,5
mm

Fig.3

3) IInsert the oil level tool (which has a width of

10.5 mm). If necessary, push the pistons back into 2,5
the calliper using the transportation block (Fig.4). mm

4) Fix the tool in place by screwing the pad faste-

ner screw back on (Fig.5).

Fig.4 Fig.5

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 24 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

5) The length of hose must now be removed from the
calliper: loosen the nut, remove the nut and then the
hose (Fig.6).
8 mm

6) Once the command has been installed on the

handlebar, insert the hydraulic hose into the hole
present on the left chain stay of the fork (Fig.7).

Fig.6 Fig.7

The barb driver on the end of the hose can be used

to guide the hose via a rear derailleur hose mounted
onto it.
Insert the cable into the hole on the frame (Fig. 8)
and once it has been threaded through the chain
stay pull on it so that the hose runs through the
frame (Fig. 9).

Fig.8 Fig.9

7) Assess the correct length of the hose by obser-

ving its position in the handlebar area and bearing
in mind that the part entering the calliper should
measure 11 mm in length from the cut end of the
hose (Fig. 10).
Once the barb (with the head measuring 4 mm in
length) has been inserted, the part of the hose and
barb entering the calliper should measure approxi-
mately 15 mm.

!
We recommend that the length is greater
than what is required in case subsequent
operations (10 and/or 13) are not completed
successfully.

8) Use the cutter, making sure that the cut is at a 90°

angle to the hose (Fig. 11). Fig.10 Fig.11

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 25 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

9) Insert part of the barb into the hose and push it in
using the driver tool (Fig. 12).

10) Check that the end of the hose touches the

barb and that the olive can be inserted on the hose
(Fig.13).
If it is not possible, check to see whether the length
of barb inserted is excessive, causing the hose to
bulge out.
This situation - which would cause the incorrect
positioning of the olive - is solved by returning to
step 7 in the procedure, cutting the end of the hose
and refitting the barb.

Fig.12 Fig.13

11) Holding the rear calliper, insert the olive into the
calliper and hand-tighten the nut on the calliper so
as to screw it on safely and accurately, without the
constraint of the hose (Fig. 14). 8 mm

12) Insert the hose into the calliper and tighten the
nut ensuring that the hose is properly inserted into
the calliper (Fig. 15).

Fig.14 Fig.15

13) Once it has been sufficiently tightened, unscrew

the nut in order to extract the hose and check that
the chamfering on the olive allows the barb to pro-
trude from the olive itself (Fig.16).

If this is not the case, you must return to

!
step 7 and cut the end of the hose, other-
wise the seal between the hose and barb
would not be effective.

Fig.16

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 26 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

16) Insert the hose into the calliper once again,
screw on and tighten the nut again to the prescribed
torque, taking care not to damage the hose with the
8 mm
tool (Fig. 17).
4 Nm
(35 in.lbs)

Fig.17 Fig.18

17) Temporarily install the calliper onto the left-hand

chain stay fitting the two Campagnolo screws fol- HEIGHT OF SCREW SEAT ON
lowing the indications in the table on the right, which
L SCREW (mm)
FRAME (mm)
ensures that the screws are inserted at least 5 mm
into the calliper. 10-14 19
18) Now proceed with bleeding the hydraulic system. 15-19 24
20-24 29
25-29 34
30-34 39
35 44

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 27 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

5 . 7 - I NSTA LLI N G T HE F RON T DI SC B R AK E H Y D R AU LIC S Y S T EM
(F OR SYSTEM WI T H OI L )
If the wheel has been mounted onto the bicycle, remove it beforehand in order to prevent soiling of the disc due to potential oil leaks from the
system during the mounting and bleeding phase. If the disc becomes soiled you then have to clean and degrease it.

From the EPS 12s disc brake groupset onwards, there is oil in the Ergopower controls, or more specifically, in the master cylin-

!
der and in the hose that is connected to it.
The caliper that is in the Ergopower controls package but is not connected to the hose is also filled with oil. Do not separate the
pads, in order to prevent the oil in the caliper from leaking.

This configuration makes it possible to avoid having to bleed the system at the end of installation.
If the installation procedure that requires you to use the pin for locking the brake lever to prevent the oil in the expansion chamber from lea-
king is carried out correctly during assembly, bleeding the system can be avoided.

1) Insert the lever locking pin in the hole on the inner

side of the Ergopower (Fig.1).
2) Keep the locking pin pressed down and at the
same time, move the brake lever until the locking pin
slides into the hole on the lever itself, thus stopping
it from moving (Fig.2).

Fig.1 Fig.2

3) Once the command has been installed on the

handlebar, insert the hydraulic hose into the hole
present on the left chain stay of the fork (Fig.3).
The barb driver on the end of the hose can be used
to guide the hose via a rear derailleur hose mounted
onto it (Fig.3). Insert the cable into the top hole and
once it has been threaded through the bottom hole
pull on it so that the hose can slide through the
lower area of the fork.

Fig.3

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 28 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

4) Temporarily install the calliper onto the fork with
two screws supplied (Fig.4).

5) Cut the hose to the correct length, considering

that approximately 19 mm of the hose must be posi-
tioned inside the caliper (the hose must be measu-
red from the end of the nut on the caliper that has
just been screwed in) (Fig. 5).
We recommend that the length is greater than
what is required in case subsequent operations
(7 and/or 9) are not completed successfully.

Fig.4 Fig.5

6) Use the cutter, making sure that the cut is at a 90°

angle to the hose (Fig. 6).
7) Insert part of the barb into the hose and push it in
using the driver tool (Fig. 7).
Check that the end of the hose is in contact with the
barb.

!
Ensure that the barb has not been inserted far,
causing the hose to reinflate.

Fig.6 Fig.7

8) Remove the yellow cap from the caliper (Fig.8).

Fig.8

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 29 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

9) Insert the hose into the caliper and tighten the nut,
ensuring that the hose is properly inserted into the
caliper (Fig. 9).
8 mm

WARNING!
It is not necessary to insert the olive into the
caliper, as this comes pre-assembled inside
the caliper itself.

10) Once it has been sufficiently tightened, unscrew

the nut in order to extract the hose and check that
the chamfering on the olive allows the barb to pro-
trude from the olive itself (Fig.10)

Fig.9 Fig.10

!
If this is not the case, you must return to
step 5 and cut the end of the hose, other-
wise the seal between the hose and barb
would not be effective.

11) Insert the hose into the calliper once again,

screw on and tighten the nut again to the prescribed
torque, taking care not to damage the hose with the
tool (Fig. 11).

Fig.11

12) If oil has leaked onto the hose, remove any

residues using a clean cloth with some methylated
spirit.

13) Exert a small amount of pressure with the brake

lever and remove the locking pin (Fig. 12).

Fig.12

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 30 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

14) Separate the pads with the transport kit or with a fla-
thead screwdriver (Fig. 13).

WARNING!
Place it on the metal part of the pads and
NOT on the braking surface.

15) Fit the wheel, inserting the disc into the caliper.

16) At this point, check the effectiveness of the braking.

Fig.13

!
If the lever feels “spongy”, air may have got into the system, or an excessive quantity of oil may have leaked out. In the latter case,
the system needs bleeding.

17) To adjust the brake lever free stroke (where applicable) and adjust the brake lever position (closer to or further from the handlebar), refer to
the Ergopower DB controls User Manual.

Pay particular attention if there are mechanical Ergopower controls (not EPS): in this case, depending on the brake lever position, it

!
may be necessary to adjust the rear and front derailleur external operating lever position as well, to avoid its interference or exces-
sive distance from the brake lever. In this case too, refer to the Ergopower DB controls User Manual.

5. 9 - I NSTA LLI N G T HE RE A R DI S C B R AK E H Y D R AU LIC S Y S T EM

(F O R SY STEM WI T H OI L )
• If the hydraulic hose passes through the bottom bracket
shell and no other separate routing is required, the axle
cover cylinder needs to be installed in the bottom bracket
(supplied with hydraulic component set - Fig.1).

• If the wheel has been mounted onto the bicycle,

remove it, in order to prevent potential oil leaks from the
system during the mounting and bleeding phase from
soiling the disc (which you would then have to clean and
degrease).

Fig.1

WARNING!
Take care to ensure that no lubricants, oils, solvents or waxes for polishing the frame are deposited on the brake pads or discs.
If this occurs, the braking power will be reduced or lost completely. In these circumstances, the bike must not be used. Do not
attempt to clean the pads, but instead simply replace these, and clean the discs with a degreasing agent. Failure to observe the
above instructions could cause accidents, physical injury or even death.

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 31 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

 From the EPS 12s disc brake groupset onwards,
there is oil in the Ergopower controls, or more spe-

!
cifically, in the master cylinder and in the hose that
is connected to it.
The caliper that is in the Ergopower controls
package but is not connected to the hose is also
filled with oil. Do not separate the pads, in order to
prevent the oil in the caliper from leaking.

This configuration makes it possible to avoid having

to bleed the system at the end of installation.
If the installation procedure that requires you to use
the pin for locking the brake lever to prevent the oil
in the expansion chamber from leaking is carried out Fig.2 Fig.2.1
correctly during assembly, bleeding the system can
be avoided.

1) Insert the lever locking pin in the hole on the inner

side of the Ergopower (Fig.2).

2) Keep the locking pin pressed down and at the

same time, move the brake lever until the locking pin
slides into the hole on the lever itself, thus stopping
it from moving (Fig.2.1).

Fig.3 Fig.4

3) Once the command has been installed on the

handlebar, insert the hydraulic hose into the hole
present on the left chain stay of the fork (Fig. 3).
The barb driver on the end of the hose can be used
to guide the hose via a rear derailleur hose mounted
onto it.
Insert the cable into the hole on the frame (Fig. 4)
and once it has been threaded through the chain
stay pull on it so that the hose runs through the
frame (Fig. 5).

Fig.5

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 32 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

4) Cut the hose to the correct length, considering
that approximately 19 mm of the hose must be posi-
tioned inside the caliper (the hose must be measu-
red from the end of the nut on the caliper that has
just been screwed in) (Fig. 6).

We recommend that the length is greater

!
than what is required in case subsequent
operations (6 and/or 9) are not completed
successfully.

5) Use the cutter, making sure that the cut is at a 90°

angle to the hose (Fig. 7).

Fig.6 Fig.7

6) Insert part of the barb into the hose and push it in

using the driver tool (Fig. 8).
Check that the end of the hose is in contact with the
barb.

!
Ensure that the barb has not been inserted
far, causing the hose to reinflate.

7) Remove the yellow cap from the caliper, keeping

it vertical in order to prevent the oil from coming out
(Fig. 9).

Fig.8 Fig.9

8) Insert the hose into the caliper and tighten the

nut, ensuring that the hose is properly inserted into
the caliper (Fig. 10).
8 mm

WARNING!
It is not necessary to insert the olive into
the caliper, as this comes pre-assembled
inside the caliper itself.

Fig.10

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 33 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

9) Once it has been sufficiently tightened, unscrew
the nut in order to extract the hose and check that
the chamfering on the olive allows the barb to pro-
trude from the olive itself (Fig.11). If this is not the
case, you must return to step 4 and cut the end of
the hose, otherwise the seal between the hose and
barb would not be effective.

10) Insert the hose into the caliper once again, screw
on and tighten the nut again to the prescribed torque,
taking care not to damage the hose with the tool
(Fig. 12).

Fig.11 Fig.12

11) Temporarily install the calliper onto the left-hand

chain stay fitting the two Campagnolo screws fol-
lowing the indications in the table on the right, which
ensures that the screws are inserted at least 5 mm
into the calliper.

Fig.13

HEIGHT OF SCREW SEAT ON FRAME

L SCREW (mm)
(mm)

10-14 19
15-19 24
20-24 29
25-29 34
30-34 39
35 44

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 34 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

12) If oil has leaked onto the hose, remove any residues
using a clean cloth with some methylated spirit.

13) Exert a small amount of pressure with the brake

lever and remove the locking pin (Fig. 14).

14) Separate the pads with the transport kit or with a

flathead screwdriver (Fig. 15).

Fig.14 Fig.15

WARNING!
Place it on the metal part of the pads and NOT on the braking surface.

15) Fit the wheel, inserting the disc into the caliper.

16) At this point, check the effectiveness of the braking.

!
If the lever feels “spongy”, air may have got into the system, or an excessive quantity of oil may have leaked out. In the latter case,
the system needs bleeding.

17) To adjust the brake lever free stroke (where applicable) and adjust the brake lever position (closer to or further from the handlebar),
refer to the Ergopower DB controls User Manual.

Pay particular attention if there are mechanical Ergopower controls (not EPS): in this case, depending on the brake lever position, it

!
may be necessary to adjust the rear and front derailleur external operating lever position as well, to avoid its interference or exces-
sive distance from the brake lever. In this case too, refer to the Ergopower DB controls User Manual.

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 35 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

5 . 1 0 - BLEEDI NG THE F RONT/RE AR D IS C B R A K E H YD R A U LIC S YS TEM
Introduction: The images illustrating this procedure relate to the installation of the left-side command and the front caliper but they are also
relevant for the installation of the right-hand command and the rear caliper.

1) The new command features adjustable free stroke

(AMS - when available) set to the short position (S).
This means that less oil is used to fill the system if
2,5
mm
the long position (L) is set.
Always check that the idle stroke is set to the S
position before bleeding (Fig. 1).

2) Fit the oil level tool (which has a width of 10.5

mm). If necessary, push the pistons back into the
caliper using the transportation block (Fig.2).

Fig.1 Fig.2

3) Fix the tool in place by screwing the pad fastener

screw back on (Fig.3).
2,5 2,5
4) Remove screw from the bleed valve (Fig.4). mm mm

Fig.3 Fig.4
3) Fill the syringe without the hole with Campagnolo
mineral oil (for the correct oil, refer to the table on
page 6) and, with the hose longer than (M4 thread)
about ¾ of its capacity, screw the syringe onto the
bleed valve (Fig.5).

DANGER!
Use solely mineral oil in accordance with
the table (page 6).
The use of DOT oil or oil other than the
oil indicated in the table (page 6) could
irreparably damage the rubber seals.
Failure to observe the above conditions
could result in accidents, physical injury
or death.

Fig.5

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 36 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

6) The valve is currently closed: open the valve by
turning the nut on the valve itself anticlockwise by
approximately ¼ turn (Fig.6 - Fig. 7).
8 mm 8 mm

WARNING!
Do not turn the valve by more than half
a turn to prevent damage to the O-ring
inside.

Fig.6 Fig.7

7) Lift the command cover and remove the bleed

screws on the command (Fig. 8).
2,5
mm

Fig.8

8) Screw on the empty syringe with the short hose

(M6 thread) (Fig. 9) so that the piston is positioned
above the lateral hole (Fig.10).

Fig.9 Fig.10

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 37 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

8) Push the plunger of the syringe connected to the
calliper (Fig. 11) to expel all the air trapped in the
system until the oil exiting from the command bleed
valve has filled the syringe by at least 50 %. Ensure
that the bottom syringe is not left without oil, so as
to prevent air from entering the calliper.
If the system is not new, aspirate the oil already in
the system, remove the syringe, plug the hole on the
syringe and dispose of the used oil in accordance
with local/regional/national legislation. Then recon-
nect the syringe and refill with new oil.

9) Slowly aspirate oil with the syringe connected to

the calliper, watching for air bubbles, until the syrin-
ge is at least 50% full. Ensure that the top syringe is
not left without oil, so as to prevent air from entering
the calliper (Fig.12).
Repeat this pushing and aspiration procedure until
the oil contains no more air (2 or 3 times approx.). Fig.11 Fig.12

10) While pressing down on the syringe plunger, pull

the brake lever and release without accompanying,
in order to eliminate any trapped air in the command
area (in the master cylinder) (Fig.13).

11) While aspirating with the syringe, pull the brake

lever several times as if you were braking to expel
any remaining air in the caliper (Fig.14).

Fig.13 Fig.14

12) When no more air comes out of the system, use

the syringe connected to the clamp to insert oil in
the syringe connected to the control unit (topping up
the oil level by approx. 1 cm), then close the clamp 8 mm
bleed valve by turning the key clockwise (Fig.15).

13) Remove the syringe from the command, ensuring

there is no oil leakage by sealing the lateral hole on
the bleed syringe with one finger (Fig.16).

Fig.15 Fig.16

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 38 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

14) Check that there is oil in the screw seat and
tighten the bleed screw (Fig.17).
2,5
mm
WARNING! 0,5 Nm
(4,4 in.lbs)
Do not exceed the specified tightening
torque, as this may damage the hydrau-
lic system.

15) Use alcohol or a specific product for braking

systems to clean the upper part of the control unit,
where some oil has seeped out (Fig.18).

NB

!
Fig.17 Fig.18
to avoid contaminating the oil in the hydraulic
system, tighten the bleed screw before clea-
ning the control unit area.

16) Remove the oil between the valve and the syringe
connection, aspiring with the syringe to prevent any
remaining oil underneath the valve screw from lea-
king once this is in place in its seat (Fig.19).

17) Remove the syringe from the caliper (Fig.20).

Fig.19 Fig.20

18) Fit the bleed valve screw (Fig.21).

19) Torque tighten the bleed valve (Fig.22).

2,5
mm
8 mm
0,5 Nm 4 Nm
(4,4 in.lbs) (35 in.lbs)

Fig.21 Fig.22

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 39 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

20) Using alcohol, clean away any oil from the caliper
(Fig. 23).

21) Refit the wheel and align the calliper with the
disc, with the centring tool still in the calliper: this
is to provisionally align the caliper with the disc
(Fig.24).

Fig.23 Fig.24

22) Unscrew the pad pivot that holds the oil level tool
in place and remove the oil level tool (Fig.25).
2,5
mm
23) Position the pads so that the metal support is in
contact with the pistons (Fig.26).

Fig.25 Fig.26

24) Mount and tighten the pad pivot (Fig.27).

25) Position the securing pin on the pivot (Fig.28).

Fig.27 Fig.28

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 40 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

26) Align the calliper with the disc keeping the brake
lever pressed and tighten the two calliper screws 4
(Fig. 29). mm
6 Nm
(53 in.lbs)

27) To adjust the brake lever free stroke (where

applicable) and adjust the brake lever position (clo-
ser to or further from the handlebar), refer to the
Ergopower DB controls User Manual.

Fig.29

Pay particular attention if there are mechanical Ergopower controls (not EPS): in this case, depending on the brake lever position, it

!
may be necessary to adjust the rear and front derailleur external operating lever position as well, to avoid its interference or exces-
sive distance from the brake lever. In this case too, refer to the Ergopower DB controls User Manual.

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 41 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

5 . 1 1 - INSTA L L I N G T HE F RON T SPACER FO R U S IN G T H E 140 m m R EAR
CAL IPER
Using the front spacer, it is possible to install the 140 mm rear calliper at the front, enabling you to use the 140 mm or 160 mm disc, depending
on how the spacer is installed on the calliper.

5 . 1 1 . 1 - US I NG A 140 mm DISC
Install the front spacer on the 140 mm rear cal-
liper so that when the spacer is installed on the 4
fork, the indication 140 mm UP is visible from mm
the outside of the fork (Fig. 1).
6 Nm
Tighten the screws included with the spacer, to (53 in.lbs)
a torque of 6 Nm (53 in.lbs).

Fig.1

5 . 1 1 . 2 - US I NG A 160 mm DISC
Install the front spacer on the 140 mm rear cal-
liper so that when the spacer is installed on the 4
fork, the indication 140 mm UP is visible from mm
outside of the fork (Fig. 2).
Tighten the screws included with the spacer, to 6 Nm
a torque of 6 Nm (53 in.lbs). (53 in.lbs)

Fig.2

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 42 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

5 . 1 2 - INSTA L L I N G RE A R C A L I P ER S PACER 140 m m FO R U S E W IT H D ISC
D. 1 60 mm

Install the front spacer on the 140 mm rear

calliper so that when the spacer is installed 4
on the fork, the indication 140 mm UP is visi- mm
ble from the outside of the fork (Fig. 3).
Tighten the screws included with the spacer, 6 Nm
(53 in.lbs)
to a torque of 6 Nm (53 in.lbs).

Fig.3

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 43 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

6 - EXTRAORDINARY MAINTENANCE

6 . 1 - TOOLS FOR E XT RA ORDI N A RY M AINT EN AN CE PR O CED U R ES ( i n add i ti o n

to those invol ve d in mo unt ing a n d b l eed i n g th e h y d rau l i c s y s tem )
- Standard workshop tools.
- N°2 - T10 Torx wrench.

6 . 2 - REP LA C I N G T HE L E F T-HA N D B R AK E LEVER

WARNING!
Faults or malfunctions in the brake system could lead to a sudden increase in the brake lever stroke, which could result in
poor braking performance and cause accidents, personal injury or even death.

6 . 2 . 1 - DI SA SS E MBLY
1) Hold the axle in place from the inside (Fig.1). T10 T10

2) Remove the axle screw from the outer side (Fig.2).

Fig.1 Fig.2

3) Remove the brake level (Fig. 3).

Fig.3

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 44 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

6 . 2 . 2 - A SSEMBLY
1) Identify the left-hand brake lever thanks to its upper
geometry and the presence of a deep groove near the
hole on the inner side (Fig.4).

2) Install the smooth bush (i.e. with no teeth) on the

inner surface of the lever (Fig.5).

Fig.4 Fig.5

3) Install the bush with teeth on the outer surface of

the lever (Fig. 6).
NOTE: From the 2019 range, this bearing will be
smooth, without teeth.

4) Install the check ring on the outer bush so that

the teeth are positioned to act as a check when the
pivot is inserted (Fig. 7).

!
We recommend applying a small amount of gre-
ase to the check ring, to prevent it from falling
during assembly.

Fig.6 Fig.7

5) Fit the spring in the hole on the command body

(Fig. 8).

!
We recommend applying a small amount of gre-
ase to the spring, to prevent it from falling during
assembly.

6) Insert the lever in the command body (Fig. 9).

Fig.8 Fig.9

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 45 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

7) Hold the bushes and ring in position while you
insert a screwdriver from the outer side of the com-
mand (Fig. 10).

8) Insert the pivot from the inner side, drawing back

the screwdriver at the same time (Fig. 11).

Fig.10 Fig.11

9) Hold the axle in place from the inside (Fig.12).

T10 T10
10) Screw on the pivot screw (Fig. 13).

1 Nm
(9 in.lbs)

Fig.12 Fig.13

6. 3 - REP LA C IN G T HE RI GHT-HA N D B R AK E LEVER

For instructions on how to assemble, disassemble and replace the right-hand brake lever, please refer to the procedure described in para-
graph “6.2 REPLACING THE LEFT-HAND BRAKE LEVER”, as the images contained within have the sole purpose of explaining extraordinary
maintenance operations.

WARNING!

Faults or malfunctions in the brake system could lead to a sudden increase in the brake lever stroke, which could result
in poor braking performance and cause accidents, personal injury or even death.

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6 . 4 - REP LA C IN G T HE HYDRA UL I C H O S E
6 . 4 . 1 - DI S AS S EMBLY
1) Remove the screw from the valve present on the
caliper (Fig. 1).

2) Install the long-tubed syringe (M4 connection) on

the caliper (Fig. 2).

Fig.1 Fig.2

3) Open the valve by turning the nut on the valve

itself anticlockwise by approximately ¼ turn (Fig.3 -
Fig. 4).
8 mm 8 mm

Fig.3 Fig.4

4) Lift the command cover and remove the bleed

screws on the command (Fig. 5).

5) Drain the oil from the hydraulic system (Fig. 6).

Fig.5 Fig.6

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 47 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

6) Loosen the nut on the calliper and remove the
hose from the calliper (Fig. 7).

8 mm
7) Lift the command cover to reveal the hose. Screwdriver

In the case of commands for mechanical units, iden-

tify the plate that holds the hydraulic hose in posi-
tion and loosen its screw (Fig. 8).

Fig.7 Fig.8

8) Remove the hose from the groove on the com-

mand body (Fig. 9).

9) Loosen the screw that connects the hose with the

banjo to the master cylinder (Fig. 10).

Fig.9 Fig.10

10) Remove the hydraulic hose from beneath the

command cover (Fig. 11).
T25

Fig.11

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6 . 4 . 2 - AS S EMBLY
11) Let the hydraulic hose slide beneath the command
cover to reach the front or rear calliper (Fig. 12).
T25
12) Tighten the screw that connects the hose with the
banjo to the master cylinder, checking that the two 3 Nm
O-rings are present on the inner and outer sides of the (26 in.lbs)
banjo (Fig. 13).

Fig.12 Fig.13

13) Position the hydraulic hose in the groove provided

on the command (Fig. 14).
Screwdriver
14) In the case of commands for mechanical units,
identify the plate that holds the hydraulic hose in posi-
tion and tighten its screw (Fig. 15).

Fig.14 Fig.15

6 . 5 - REP LA C IN G T HE HYDRA UL I C S Y S T EM ( M AS T ER CY LIND ER AND H OSE )

Should you need to replace the hydraulic system for the command body, please follow the procedure on the next page carefully.

WARNING!

Faults or malfunctions in the brake system could lead to a sudden increase in the brake lever stroke, which could result
in poor braking performance and cause accidents, personal injury or even death.

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6 . 5 . 1 - DI S AS S E M BLY
Disassemble the brake lever as described in chapter “6.2 - Replacing the left-hand brake lever/ DISASSEMBLY”” or “6.3 - Replacing the right-
hand brake lever””.

15) Lift or remove the command cover. In the case of

commands for mechanical units, identify the plate
that holds the hydraulic hose in position and loosen T6
its screw (Fig. 1). Screwdriver

16) Remove the hose from the groove on the com-

mand body (Fig. 2).

Fig.1 Fig.2

17) Push in the area shown in Figure 3 to remove the

master cylinder from the body; at the same time, keep
your finger on the rear spring to avoid losing it (Fig. 4).

18) Loosen the nut on the calliper and remove the

hose from the calliper (Fig. 5).

Fig.3 Fig.4

If there is still oil in the system and you wish to pre-

vent it from leaking or if you wish to reuse the oil in
the system, follow the procedure described in chapter
“6.4 - Replacing the hydraulic hose”, up to and inclu-
ding point 5.

Fig.5

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6 . 5 . 2 - AS S EMBLY

19) Insert the hydraulic component in the command

body with the spring installed on the rear side (Fig.
6).

20) Press simultaneously on the master cylinder and

the spring, making sure the spring is correctly posi-
tioned (Fig. 7).

Fig.6 Fig.7

21) Insert the tube in the groove present on the

command body (Fig. 8). In the case of commands for
mechanical units, identify the plate that holds the
hydraulic hose in position and tighten its screw (Fig. Screwdriver

9).

22) Assemble the brake lever as described in chapter

“6.2 - Replacing the left-hand brake lever/ASSEMBLY”
or “6.3 - Replacing the right-hand lever/ASSEMBLY”.

Fig.7 Fig.8

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6 . 6 - REP LA C IN G T HE MA S T E R C Y LIN D ER

Should you need to replace the master cylinder, we recommend you follow the procedure described in chapter “6.5 - Replacing the hydraulic
system (master cylinder and hose)/DISASSEMBLY”.

1) Loosen the screw that connects the hose with the

banjo to the master cylinder (Fig.1).
T25 T25
2) If necessary, remove also the lockscrew from the
opposite side of the hose and fit it on the other side of 3 Nm
the master cylinder (Fig. 2). (26 in.lbs)

Fig.1 Fig.2

3) Check that the two O-rings are present on the two

sides of the banjo and intact (Fig. 3).
T25
4) Refit the screws to hold the hose with the banjo in
place (Fig. 4). 3 Nm
(26 in.lbs)

Follow the procedure described in chapter “5.4 -

Replacing the hydraulic system (master cylinder and
hose)/ASSEMBLY”.

Fig.3 Fig.4

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7 - ORDINARY MAINTENANCE
Campagnolo S.r.l. recommends that you check your bicycle at least once a year to ensure that the braking system along with all other parts of
the bike are functioning correctly. However, depending on how the bicycle is used, more frequent inspections may be necessary.

7 . 1 - P ERI ODI C I N S P E C T I ON
Before each use and after a fall or collision, check that
the bicycle components do not exhibit any of the fol-
lowing problems:
NO!
NO!
Ergopower commands that are loose or not correctly
positioned on the handlebar (Fig. 1).
• Ergopower commands, cables and sheaths that are
damaged and no longer operating the front derailleur,
rear derailleur and brakes correctly.
• Command levers that are jammed and do not return to
OK!
SÌ!
the original position, or levers that are damaged.
• Command covers that are broken or damaged, which
could cause the hands to slip.
• Cuts or damage to the brake system tubing
• Broken or damaged brake pads
• Excessive wear of the brake pads, where the wear indi- NO!
NO!
cator on one or more of the pads is no longer visible (Fig.
2).
• Incorrect position of the screw holding the pads in Fig.1 Fig.2
position and/or missing securing pin at the end of the
screw (Fig. 3/Fig. 4).
• discs with excessive wear: thickness of disc measured
at a distance of 4 mm from the outer edge (Fig. 5) must
not be less than 1.65 mm.

WARNING!
If when using the brakes you notice an unu-
sual noise, check the wear and the position
of the pads - these could be excessively
worn, or fitted incorrectly, thus reducing
braking performance.
Fig.3 Fig.4

CAUTION

a Using a different brand of break pads instead

of original Campagnolo® break pads, automa-
tically voids the product warranty.

4 mm

Fig.5

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7 . 2 - PA D REP L A C E ME N T P ROC E D U R E
• Move the pads apart using the specific tool (Fig. 1).
• Pull the securing pin out of the pivot (Fig. 2).

Fig.1 Fig.2

• Unscrew the pivot using an Allen wrench (Fig. 3).

• Remove the pads and the spring (where present) (Fig.
4).

Fig.3 Fig.4

• Check that the pad you are inserting into the caliper is
positioned correctly. The metal support must be in con-
tact with the piston and the friction area of the pad must
be in contact with the disc (Fig. 5).
• Insert the new pads, aligning the holes in the pads
with the holes in the calipers, and screw the pivot until it
stops (Fig. 6).

Fig.5 Fig.6

D I S C BRAKE HYDRAUL IC SYSTE M - R ev. 0 4 / 0 5 - 2 0 2 2 54 C AM PAG NO L O CO M P O NE NT S - T E C HNI C A L M A NUA L

• Insert the securing pin in the pivot (Fig. 7).

After refitting the wheel with the disc,

!
operate the brake lever several times
until the disc is locked.
If the disc touches one of the two pads,
centre the caliper again.

Fig.7

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7 . 3 - LUBRI C AT I ON A N D C L E A N I NG
The duration of the components is variable based on the conditions of use, frequency and quality of maintenance. To ensure the components
are well maintained, these must be cleaned frequently, especially in more extreme usage conditions (e.g. after every time the bicycle is
washed, or ridden on wet, dusty or muddy roads, etc.).

WARNING!

Take care to ensure that no lubricants, oils, solvents or waxes for polishing the frame are deposited on the brake pads
or discs. If this occurs, the braking power will be reduced or lost completely. In these circumstances, the bike must not
be used. Do not attempt to clean the pads, but instead simply replace these, and clean the discs with a degreasing agent.
Failure to observe the above instructions could cause accidents, physical injury or even death.

• Make sure the pads are not embedded with any debris (stones, broken glass, etc.); if this is the case, remove this.

WARNING!
Do not use products to reduce the noise when braking - these products also reduce the braking power, and as such, can
lead to accidents, physical injury or even death.

• Use cleaning products that are compatible with braking systems which use mineral oil. Do not use cleaning products for systems which use
DOT oil, as these can damage the rubber seals irreparably.
• Never wash your bicycle using pressurised water. Pressurised water - even from a normal garden hose - may infiltrate through the seals and
into your Campagnolo®, components, causing irreparable damage to them. Wash your bicycle and the Campagnolo® components by delicately
cleaning with water and neutral soap.
• Check that any holes present in the bottom bracket shell are not obstructed and let water drain from the frame.

WARNING!
Saline conditions (such as roads in winter and in coastal areas) may cause galvanic corrosion in the majority of the
exposed components of the bicycle. To prevent damage, malfunctions and the consequent risk of accident, carefully rinse,
clean and dry all components that are subject to corrosion.

7 . 3 . 1 - PROCEDU RE F OR CL E ANING A N D LU B R IC ATIN G ER G O P OW ER C O MMA N D S

The gear command and front derailleur sheaths are pre-lubricated and need no additional lubrication.

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7 . 4 - TRA NSP ORTAT I ON
• If you need to remove the wheels from the bike,
ensure that you have inserted the transport tool (Fig.
1/Fig. 2) which prevents the brake pads from coming
together if the brake lever is accidentally engaged,
making it impossible to insert the disc.
If this occurs, proper conditions must be restored
immediately.
• The braking system can be transported by air; no
adjustments need to be made.

!
Make sure that the brake system tubing is
protected and cannot become bent.

Fig.1 Fig.2

• After transportation:
- Check that there are no oil leaks.
- Check that no component of the bicycle is damaged, particularly the cables and hoses that form part of the braking system.
- Engage the brake lever 4-5 tines in a safe place to ensure that the front and rear brake systems are working properly

!
Do not expose the product to temperatures below -10 ° C (5 ° F) or above 60 ° C (131 ° F). For this reason, do not leave these com-
ponents in locked cars parked in the sun and do not store them near radiators or other heat sources. Do not store carbon or pla-
stic products in direct sunlight.

Campagnolo S.r.l. reserves the right to change the content of this manual without notice. The most updated version will be available on www.cam-
pagnolo.com.

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