Mechanical Disc Brakes - Orbea ALMA Instruction And Maintenance Manual

Inspection
Before using your bike, squeeze the brake levers firmly. The lever should never come in contact
with the handlebar. If the lever touches the handlebar, the system should be purged. This action
must be performed by your authorized dealer, since it requires specific materials and know-how.
Check that there is no oil, grease or other type of dirt on the disc. The disc is an essential part
of the braking system; therefore, it must be kept clean. Remove the brake pads from the cali-
pers when you are going to deep-clean. Do not use cleansers, degreasers or solvents to clean
the disc. Only use isopropyl alcohol.
Once a month, make sure that the disc brakes are not worn. If the brake pads have a thickness
less than 1mm, they should be changed. You must also check that the brake pads are correctly
positioned at a distance between 0.25 and 0.75mm from the disc when the brakes are not
applied. Turn the wheel. When the levers are not depressed, the brake pads should touch the
discs as little as possible.
The torque for disc brake bolts is:
Caliper mount bolts: 11.5-12.5Nm
Caliper bridge bolt: 11.5-12.5Nm
Disc screws: 5-6Nm
Handlebar Master Cylinder Clamp Screw: 3-4Nm
Check there are no crimps or leaks in the hose. Replace any hydraulic part that does not pass
inspection. This replacement requires specific tools and know-how. Therefore it should be done
by an authorized dealer.
Adjustment
Adjusting brake lever reach
- Locate the reach adjustment screw between the lever and the handlebar, near the lever pivot.
- To increase the reach, turn the screw clockwise. To reduce the reach, turn the screw counter-
clockwise.
Aligning the brake with the disc
- Loosen the caliper mount bolt.
- Depress the lever as much as possible and gradually tighten the bolts as specified in the
inspection section.
Removing brake pads
- Remove the wheel.
- With your fingers or needle-nose pliers, pull the tab of the brake pad.
Removing the wheel
Removing the wheel with disc brakes does not require you to take apart the braking system.
Carefully slide the disc out of the brake.
When you are going to replace the wheel, carefully guide the disc between the brake pads. If
you press the edge of the disc against the pads, they can crack or be damaged and need to be
replaced.
Lubrication
Lubricate the pivots every three months with synthetic lubricant, as you would with the chain.
The brake pads do not need to be lubricated.

MECHANICAL DISC BRAKES

Introduction
Instead of a shoe exerting pressure on the rim of wheel, a pad acts on a disc located in the front
or rear hub. The disc fits onto the hub with bolts on the left side. The brake is activated using a
cable that extends out of the lever. The braking system is made up of:
- Brake lever
- Brake cables and housing
- Disc brake pads
Disc brakes can become very hot after use. Be very careful when inspecting them. Like with
other parts of your bike, avoid inserting your fingers in the disc.
WARNING Disc brakes can become very hot and even burn your skin. Moreover, the corners
can be sharp and cut you. Avoid touching the disc and brakes when they are hot or rotating.
Inspection
Before every use, squeeze the brake levers firmly 10 times. The lever should never come in
contact with the handlebar.
Check that there is no oil, grease or other type of dirt on the disc. The disc is an essential part
of the braking system; therefore, it must be kept clean. Remove the brake pads from the cali-
pers when you are going to deep-clean. Do not use cleansers, degreasers or solvents to clean
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