1)  Orginal CPR brake discs
 
2)  CPR Powerdisc

Essential requirements

3)  Always replace both the brake discson anaxle at the same time;for best results,useonly new Orginal CPR brake linings, so as to achieve the same braking effect on both wheels on the axle.

  * Take care to ensure that the components are correct for the vehicle type/year of manufacture.

  * Always replace self-loking screws, nuts and individual locking components with new parts

Removal

  * Remove the wheels

  * Unscrew and remove the brake caliper from the Wheel mouting stub or the caliper or the caliper housing from its holder; do not release the brake hose or line
 
4)  With a length of wire, suspend the caliper/housing in the Wheel arch, e.g. from the shock absorber strut. Do not allowit to hang from the hose itself

 
5)  Remove the brake discs ( without using force) in order to prevent subsequent damage to the Wheel hubs, Wheel bearings, sensor or ring gear components. Use the specifiled tools.
   

Cleaning/ýnspections

6)  Clean the flange face/centring shoulder on the Wheel hub so that it is absolutely clean , free of rust, free of burs and smooth, i.e. so that it is bright metal all ower (do not use an angle grinder).
 

7)  With a dial guage, check the hub flange at its greatest diameter for true runout ( standart specification <0.030 mm). Check surface regulartiy with a straightedge; no irregularrities are permitted.

Caution: any secondaryrunout will roughly double the disc runout.
8)  Inspect the brake caliper and all moving parts; piston, siding/ guide elements, lininig in guideways must exhibit freedom of movement and not be worn; seals must be in satisfactory condition.
 
9)  Inspect all the steering transmission components;the steering gear, track rod ends, intermediate levers, steering dampers must not worn or damaged.
10)  Inspect all the Wheel mouting components;the steering bushes, insuleting blocks, rubber stabilizer bushes, shock absorbers, suspension struts must not be soft, worn, cracked or damaged. Front axle adjustment must with the manufacturer’s  specifications.
 
11)  Wheel bearing must not be worn or damaged; they must be correctly adjusted, free of play and properly secured.
 

12)  Remove all corrosion inhibitor. Coating from new brake discs at the flange/contact faces. Inspect the flange faces;they must be clean, free of burrs and undamaget.

CPR Powerdisc:A small amount of burring is left on the peripheral grooves of the contact faces
   

Installation

13) Apply an even ultra- fine film of corrosion inhibiting oil (not paste) to the hup flange.

* If necessary, note the direction of rotation of internally ventilated brake discs;do not displace or remove balancing weights.

* Centre the brake disc and secure with retaining screw/locking device(depending on type)or tighten crosswise in two stages(clockwise)to the specified torque.

* Ýf the Wheel bearing has been removed, inspect it, replace  radial seals if necessary, adjust/secure the Wheel bearing in accordance with specifications.
 

14)  Ýf necessary, check brake disc runout with a dial guage. Secure discs mounted on the hub from outside with Wheel screws/nuts washers, tightening evenly crosswise to the spesified torque. With a 10 mm dial guage, check the runout of the outer rim (the outermost rim of an CPR Powerdisc) relative to the contact face. Deviation, if any, must not exceed 0.06-0.09 mm(max)

* Ýn the event of greater deviation, re-check the cleaning, inspection and mouting points. If possible,  reposition the brake disc in the mouting aperture, then re-check.

Install the brake calipar/housing(do not twist the brake hose) and tighten to the specified torque.
 

15)  Install the wheels, corretly balanced and trued up in both planes( no vertical or lateral runout) tighten evenly, crosswise or in two stages(clockwise) to the specfied torque.

If the hydraulic system has been disconnected, fill the braking system wiþth the specified brake fluid and bleed.
 

Final testing

* Pump the brake pedal repeatedly until pedal travel is satisfactory.

* Check and top-up brake fluid in the reservior to the MAX mark.

* Test the braking system on a test stand or in a road test for leaks, function, effect
 

Breaking in
 

16) Brake in new brake in new brake discs and linings as gently as possible;avoid unnecessary heavy braking for the first 200 km, so as to ensure that the contact faces adjust perfectly to each other.


CPR Powerdisc: Considerably reduced breaking in intervals(approx. 5-10 brakings);somewhat more noticeable/audible only init,ally