Formula FD40292-20 - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document outlines the service manual for the Formula CURA retrofitting kit for E-Bikes, specifically detailing the upgrade process for the CURA standard brake system to be compatible with E-Bike applications. The manual is designed to guide users and service technicians through the necessary steps for installing the CURA E-Bike upgrade kit, ensuring proper functionality and safety.

Function Description:

The Formula CURA retrofitting kit for E-Bikes is designed to adapt the existing CURA standard brake system for use on electric bicycles. This upgrade typically involves modifying the brake lever assembly to incorporate a reed sensor and a magnet, which are crucial components for integrating the brake system with the E-Bike's electrical system. The reed sensor, when activated by the magnet, signals the E-Bike's motor to cut power, providing a safety feature that ensures the motor disengages when the brakes are applied. This is a standard requirement for E-Bike brake systems to prevent accidental acceleration while braking and to comply with safety regulations. The kit facilitates the seamless integration of a high-performance hydraulic disc brake system with the specific demands of an E-Bike, offering reliable stopping power and enhanced safety.

Important Technical Specifications:

The manual provides a parts list for the "KIT UPGRADE CURA EBIKE (HIGO)," identified by part number FD40292-20. This kit includes several key components:

O-Ring (Position 1): A sealing component for the bleeding screw.
Bleeding Screw (Position 2): A specialized screw for bleeding the brake system, designed to accommodate the O-Ring.
Knob (Position 3): Used to tighten the bleeding screw assembly.
Reed Sensor (Position 4): The electrical component that detects the magnet's presence and sends a signal to the E-Bike's motor.
Magnet (Position 5): Placed within the piston assembly of the brake lever, it activates the reed sensor when the brake lever is pulled.

The installation process involves specific torque values for critical components:

Bleeding Screw: 2 Nm, using a 3 mm tool.
Lever Pivot: 3 Nm, using a 3 mm tool (Allen key).

Required tools for the upgrade include:

Torque wrench with a 3 mm tool.
Allen key (3 mm).
Torx T10 key.
Formula mineral oil (for bleeding the brake system).

The brake system operates with Formula mineral oil, emphasizing the importance of using the manufacturer's recommended fluid for optimal performance and longevity.

Usage Features:

The CURA retrofitting kit enhances the safety and functionality of E-Bikes by providing a reliable brake cut-off mechanism. When the rider pulls the brake lever, the magnet within the piston assembly moves closer to the reed sensor, triggering the sensor. This, in turn, sends a signal to the E-Bike's controller, instructing the motor to cease power output. This feature is crucial for preventing situations where the motor might continue to provide assistance while the rider is attempting to slow down or stop, which could lead to loss of control or accidents. The CURA brake system itself is known for its strong braking power and modulation, which are essential characteristics for E-Bikes that often carry more weight and achieve higher speeds than traditional bicycles. The retrofitting ensures that these performance characteristics are maintained while integrating the necessary E-Bike safety features. The HIGO connector type, implied by the kit name "HIGO," suggests compatibility with common E-Bike electrical systems.

Maintenance Features:

The manual highlights several important maintenance considerations to ensure the longevity and performance of the CURA brake system, especially after the E-Bike upgrade:

Frequent Servicing: Products used in extreme conditions require more frequent servicing. This is particularly relevant for E-Bikes, which often experience higher loads and speeds.
Recommended Cleaning Methods: Avoid using unrecommended high-pressure washing methods, as these can damage components and reduce the lifespan of the product.
Genuine Spare Parts and Lubricants: Formula strongly recommends using only ORIGINAL spare parts and lubricant products. The use of unrecommended spare parts, solvents, and lubricants can significantly reduce the life span of the products.
Professional Consultation: For servicing activities, Formula recommends consulting servicing technicians. This ensures that complex procedures are performed correctly and safely.
Personal Protective Equipment (PPE): When working on the brake system, always wear nitrile gloves and safety glasses. This protects against exposure to brake fluid and potential injuries.
Proper Waste Disposal: Ensure correct disposal of waste materials and liquids, particularly brake fluid, which is an environmental hazard.
Bleeding Procedure: The manual refers to a video on Formula's YouTube Channel for the correct bleeding procedure ("Bleeding CURA"). This indicates that proper bleeding is a critical maintenance task after installation or if air enters the system, and visual guidance is available for users.
Torque Specifications: Adhering to specified torque values for the bleeding screw (2 Nm) and lever pivot (3 Nm) is crucial for preventing damage to components and ensuring secure assembly.
Dust Seal Handling: When reinstalling the dust seal, use a non-sharpened tool to avoid damaging the seal, which is vital for protecting internal components from dirt and moisture.

Overall, the Formula CURA retrofitting kit for E-Bikes provides a comprehensive solution for upgrading standard CURA brakes to meet E-Bike requirements, emphasizing safety, performance, and proper maintenance practices.