Campagnolo PRJ330 Ergopower Calipers Controls User Manual

Campagnolo PRJ330 Ergopower Calipers Controls

Product Information

The PRJ330 Ergopower Controls + Calipers is a component of the Campagnolo PRJ330 groupset. It is a wireless groupset designed for bicycles. The controls and calipers are essential parts of the disc brake system.

General Information and Compatibility

It is important to read the user manual carefully as it contains important instructions for installation, adjustment, and maintenance of the product. The manual is an integral part of the product and should be kept in a safe place for future reference.

Information and Technical Support

If you require installation assistance or have a technical problem, you can refer to the diagram provided in the manual. Additionally, you can scan the QR code provided to access more detailed information, frequently asked questions, and find your nearest Campagnolo Pro Shop on the Campagnolo website. For specialized mechanics, there is a technical manual available on the Campagnolo website that provides detailed assembly, disassembly, adjustment, and maintenance procedures. You can access it by scanning the QR code provided in the manual.

Product Usage Instructions

1. Always wear protective gloves and goggles when working on your bike.
2. Ensure that you have read and understood the user manual.
3. Refer to the provided diagram for installation, adjustment, and maintenance procedures.
4. If you require technical support or have a problem, consult with a trusted mechanic or visit the Campagnolo website to find a Pro Shop in your area.
5. If you cannot find a Pro Shop, contact the Campagnolo Service Center in your country.
6. If you encounter any issues with the product, contact the store that sold you the product.
7. Only use original discs, pads, and oil supplied with the Campagnolo drivetrain or original replacement parts.

Following these instructions will ensure the best performance of your PRJ330 drivetrain and maintain safety, performance, longevity, and functionality. Failure to follow these instructions may result in accidents, physical injuries, or even death.

Product Compatibility

The assembly of the PRJ330 groupset components should only be performed by a Campagnolo Pro-Shop or a mechanic specialized in the assembly of Campagnolo wireless groupsets. Any tampering with or incorrect installation of any part of the disc brake system, even just one component, will void the warranty. It is important to check the tables in the technical manual for information on product compatibility with previous Campagnolo product ranges.

Safety Recommendations

To ensure safety, performance, longevity, and functionality are not compromised, it is essential to use the components of the PRJ330 drivetrain with those of the Campagnolo 12-speed PRJ330 mechanical drivetrain (cranksets and sprocket boxes). Under no circumstances should the PRJ330 components be used with non-Campagnolo components. The calipers of this brake system are only compatible with the flat mount frame caliper assembly system.

WARNING

• Always use protective gloves and goggles when working on your bike.

GENERAL INFORMATION AND COMPATIBILITY

WARNING: Read the instructions in this manual carefully. This manual is an integral part of the product and must be kept in a safe place for future reference.

MECHANICAL EXPERTISE

Most bicycle maintenance and repair work requires specific skills and experience and the use of appropriate tools. Basic mechanical skills and aptitude may not be adequate for working correctly on your bicycle. If you have any doubts about your ability to carry out the operations, contact qualified personnel.

“ACCIDENT”

This manual draws your attention to the possibility of accidents in certain situations. Please note that any accident may cause damage to the bicycle and its components, and may result in severe or even fatal injury to yourself or others.

DESIGNATED USE

This Campagnolo® product is designed and manufactured exclusively for use on racing bicycles ridden on smooth tarmac roads or on the track. Any other use of this product, off-road or on trails, for example, is not permitted.

LIFE CYCLE – WEAR – NEED FOR INSPECTION

The life cycle of Campagnolo® components depends on many factors, such as the weight of the user and the conditions of use. Impacts, blows, falls and improper use in general could compromise the structural integrity of the components, significantly reducing the life cycle; some components are also subject to wear over time. Please have your bicycle inspected regularly by a qualified mechanic, to check for the presence of cracks, deformations or other signs of fatigue or wear (to detect cracks on the parts, use a liquid penetrant or other microfracture detector). If any deformations, cracks or signs of impact or fatigue are found on inspection, regardless of how minor, the part affected must be replaced immediately; also excessively worn components must be replaced immediately. The frequency of inspection depends on many factors; contact your authorised Campagnolo S.r.l. representative to help you to select the interval that is right for you.

If you weigh more than 82 kg/180 lbs, you should be especially careful and have your bike inspected more frequently (compared to those who weigh less than 82 kg/180 lbs) to check for cracks, deformations and other signs of fatigue or wear. Check with your mechanic that the Campagnolo® components that you have chosen are suitable for the intended use, and determine how frequently these components need to be inspected together with your mechanic. Read the instructions in this manual carefully. This manual is an integral part of the product and must be kept in a safe place for future reference.

WARNING

Dear Customer,

We are writing to remind you that in order to get the best performance out of your PRJ330 drivetrain and ensure safety, performance, longevity and functionality are not compromised, it is absolutely essential to use the components of the PRJ330 drivetrain with those of the Campagnolo 12-speed PRJ330 mechanical drivetrain (cranksets and sprocket boxes); under no circumstances must the PRJ330 components be used with non-Campagnolo components.

The user of this Campagnolo® product expressly acknowledges that the use of the bicycle may involve risks that include the breakage of a bicycle component, as well as other risks which could lead to accidents, physical injury or death. By purchasing and using this Campagnolo® product, the user expressly, voluntarily and knowingly accepts and/or takes on these risks and agrees not to hold Campagnolo S.r.l. liable for any damage that could result from this use.

INFORMATION AND TECHNICAL SUPPORT

• Refer to the diagram on the following page when performing installation or adjustments or if you have a technical problem. Scan this QR CODE to access the search page to find your closest Campagnolo Pro Shop, or go to www.campagnolo.com.
• Scan this QR CODE to access more detailed information and frequently asked questions at www.campagnolo.com
• NOTE FOR SPECIALISED MECHANICS: Please remember that all the assembly, disassembly, adjustment and maintenance procedures are described in the technical manual, which is available on our website www.campagnolo.com. Scan this QR CODE to access the first page directly.

WARNING

The assembly of the components of the PRJ330 groupset must be carried out exclusively by a Campagnolo Pro-Shop or a mechanic specialised in the assembly of Campagnolo wireless groupsets. Any tampering with or incorrect or incomplete installation of any part of the disc brake system, even of only one component of the PRJ330 groupset, will automatically void the warranty.

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

WARNING

• In order to get the best performance out of your PRJ330 drivetrain and ensure safety, performance, longevity and functionality are not compromised, it is absolutely essential to use the components of the PRJ330 drivetrain with those of the Campagnolo 12-speed PRJ330 mechanical drivetrain (cranksets and sprocket boxes); under no circumstances must the PRJ330 components be used with non- Campagnolo components.
• THE CALIPERS OF THIS BRAKE SYSTEM ARE ONLY COMPATIBLE WITH THE FLAT MOUNT FRAME CALIPER ASSEMBLY SYSTEM.

SAFETY RECOMMENDATIONS

WARNING

• With these 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. For more information regarding the use of this product, we recommend that you contact an authorised Campagnolo dealer. You can also refer to Chapter 5 – OPERATION AND ADJUSTMENTS, and use the riding and braking techniques recommended (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 stationary. 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.
•  If any of the following conditions occur, stop using the bicycle immediately and consult a qualified mechanic or a Campagnolo Pro Shop (as indicated in Chapter 2 – INFORMATION AND TECHNICAL SUPPORT):
  • Any cracks or damage are visible on the disc, even if these are minimal
  • the disc is worn beyond the prescribed limits (as indicated in Chapter 5, OPERATION and ADJUSTMENTS)
  • The brake system is leaking fluid. Failure to observe the above indications could lead to accidents, physical injury or even death.
• 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.
• This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved.
• Children shall not play with the appliance.

BEFORE USING THE BICYCLE

DO NOT USE YOUR BICYCLE IF IT DOES NOT PASS THIS TEST – CORRECT ANY FAULTS BEFORE USING THE BICYCLE BY VISITING A SPECIALIST MECHANIC OR A PROFESSIONAL CAMPAGNOLO SHOP.

• 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 disc 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, ensuring that the front and rear disc rotors engage correctly.

For any other questions or comments, please contact your nearest Campagnolo Pro Shop. You can find a list of Campagnolo Pro Shops on the website: www.campagnolo.com.

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.
• 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.

OPERATION AND ADJUSTMENT

The Ergopower controls operate the front derailleur, rear derailleur and brakes. The components of the Ergopower controls are:

• A – Brake lever (Fig.1)
• B- Upper lever (Fig.1)
• C- Lower lever (Fig.1)
• D – Communication LEDs (Fig.3)
• E – Ergopower MODE button (Fig.3)
• F – Power button (Fig.3)
• G – Battery compartment (Fig.4)

The braking system components are:

• rotor (E – Fig.2)
• calliper (F – Fig.2)
• Pad (G – Fig.5)
• Clip (X – Fig.5)
• Brake pad locking screw (H – Fig.5)
• Brake pad screw cotter pin (I – Fig.5)

OPERATION AND ADJUSTMENT OF THE BRAKES

• Moving the lever A (Fig. 1) operates the brake: check which wheel corresponds to which lever by operating each of these one at a time.

BRAKE PAD AND DISC RUN-IN PERIOD

• The brake pads are subject to a break-in period. During this period the braking power is limited but will progressively increase.

WARNING: Failure to follow the above instructions could result in loss of control of the bicycle and cause an accident, personal injury or death.

CORRECT USE OF THE BRAKES

In order for the brake system to operate correctly, the brakes must be applied and released frequently, to allow the brake system to cool down. Where the brakes are operated continuously without allowing the heat generated during braking to dissipate, this can cause overheating of the braking system oil and components, reducing the efficiency of the braking system as a whole.

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.

ADJUSTING THE POSITION OF THE BRAKE LEVER

• To change the position of the brake lever, insert a 2.5 mm Allen wrench into the front hole to reach the grub screw and adjust its position (Fig.6).

DISC SELECTION

• As far as choosing 140 mm or 160 mm discs is concerned, this depends on your weight and the overall weight of you, the bicycle and any bags/panniers or other accessories installed.
• When selecting the disc, the weight limits must be respected(your weight and the total weight).
• 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).

Disc (mm)| Cyclist weight (kg/lbs)| Overall weight: cyclist + bike + accessories (kg/lbs)
---|---|---
140 or 160| up to 82/180| up to 90/198
160| up to 109/240| up to 120/265

WARNING

• Make sure that, when the brake levers are operated until the end of their stroke, the outer levers of the rear derailleur and front derailleur do not come into contact with the handlebar itself, with the belt already positioned, limiting the stroke of the brake levers and therefore the braking power. If this should happen, reposition the brake levers further apart than you have done and check again.
• Failure to respect the abovementioned weight limits could result in loss of control of the bicycle, accidents, physical injury or even death.

USE OF THE DISCS WITH AFS/6 SCREW ADAPTERS

• 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.

BRAKE PADS: WEAR INDICATOR AND CHECKS

WARNING: If when using the brakes you notice an unusual noise, check the wear and the position of the pads – these could be excessively worn, or fitted incorrectly, thus reducing braking performance.

For each pad, check that the W pad wear indicator (Fig.7) is present, that the pad is properly positioned with the metal support Q (Fig. 7) in contact with the piston, and that the R friction area of the pad (Fig.7) is in contact with the disc. If this is not the case, consult a qualified mechanic or a Campagnolo Pro Shop (as indicated in Chapter 2 – “INFORMATION AND TECHNICAL SUPPORT”).

WARNING

• Use in wet, muddy, sandy or dusty conditions may drastically reduce the lifetime of the brake pads, causing earlier wear than if they were used on clean asphalt roads. As such, it is important to check very frequently that the W brake wear indicator (Fig. 7) is visible on the pads. If it is not visible, ask your mechanic to replace the pads.
• Failure to follow the above instructions could result in loss of control of the bicycle and cause an accident, personal injury or death.
• Only use original Campagnolo® pads – in addition to having different friction surfaces which can alter the effectiveness of braking, a pad made from a different support material (for example, aluminium rather than steel) could result in increased transmission of heat to the calliper, causing the brake system to overheat which in turn could lead to accidents, injury or death.
• Using a different brand of brake pads instead of original Campagnolo® brake pads, automatically voids the product warranty.

OPERATION AND ADJUSTMENT OF THE BRAKES

Right-hand Ergopower control

• By pressing the lower lever, the rear derailleur shifts up (Fig.8).
• By pressing the upper lever, the rear derailleur shifts down (Fig.9).

Left-hand Ergopower Control

• By pressing the lower lever, the front derailleur shifts up (Fig.10).
• By pressing on the upper lever, the front derailleur shifts down (Fig.11).
• The functions of the levers can be customised using the MyCampy app.

SWITCHING ON THE ERGOPOWER CONTROLS

• Quickly press the “power” button (Fig. 12). The LED lights up twice in green and then flashes blue rapidly.
• If the controls have already been paired with the rear derailleur, they try to connect to it.

WARNING: If the Ergopower controls have not been paired to the rear derailleur, they attempt to connect to it for 30 seconds and then go into Low Power mode. If no connection is made, shake the controls or move one of the levers to make them try to pair with the rear derailleur once again.

ACTIVATING/DEACTIVATING LOW POWER MODE (DORMANT)

• Ergopower controls enter Low Power mode automatically after 30 min without use or vibrations.
• To deactivate Low Power mode, simply operate the controls or subject them to a vibration. The LED lights up 1x green and then flashes blue rapidly until they connect to the rear derailleur.

BATTERY INSERTION/REPLACEMENT

• Lift up the rubber hood on the outside of the Ergopower.
• Use a coin to turn the battery cover to the Open arrow (Fig.13) and remove.
• Extract the battery (if present) and insert a CR 2032 battery with the + side upwards (Fig. 14).
• Replace the cover and turn it to the Closed arrow (Fig. 15).
• Reposition the rubber hoods.

DANGER

• Keep the battery out of reach of children.
• Do not put the battery in your mouth.
• If swallowed, consult a doctor immediately.
• Do not use any sharp or pointed object to remove the batteries.

Note: to switch on the Ergopower controls, refer to chapter 5.3.

SWITCHING OFF THE ERGOPOWER CONTROLS

• Press the “power” button for 3 seconds until the red LED light comes on (Fig. 16).

STATE OF CHARGE AND BATTERY LIFE

To view the charge level of the battery, quickly press the MODE button of the Ergopower control (Fig.17) and look at the colour of the LED on the control itself.

• Blue colour: battery charge ok
• Red colour: replace the battery as soon as possible

The battery charge level can also be viewed by operating the levers and observing the colour of the LED on the Ergopower controls.
Battery life under normal use is XXXX km/years

APP MYCAMPY

• Additional information and customisation features are available in the MyCampy app.

PERIODIC INSPECTION

Before each use and after a fall or collision, check that the bicycle components do not exhibit any of the following problems:

• Ergopower commands that are loose or not correctly positioned on the handlebar (Fig. 18).
• Ergopower commands that are damaged and no longer operating the front derailleur, rear derailleur and brakes correctly.
• 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 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 indicator on one or more of the pads is no longer visible (Fig. 19).
• Incorrect position of the screw holding the pads in position and/or missing cotter pin at the end of the screw (Fig. 20)
• Discs with excessive wear (disc thickness of less than 1.65 mm, measured at any point on the braking surface).

If one or more of these problems are found or in the event of any doubts with regard to the correct operation of the component, contact a specialised mechanic as indicated in Chapter 2, “Information and technical support”.

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.

MAINTENANCE/CLEANING/TRANSPORT/STORAGE

FIRMWARE UPDATE PROCEDURE

• Press the MODE button on the Ergopower control: the LED lights up pink and then BLUE; at this point release the button.
• The LED lights up GREEN: quickly press the MODE button on the Ergopower control.
• The rear derailleur will wait for an update for 2 minutes. The LED flashes green. Next, follow the instructions in the MyCampy app.
• If you do not want to update the firmware, turn off the control.

WARNING: The GREEN LED lights up only once. If you do not press the MODE button, the cycle ends without any change being made.

CLEANING

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 conditions could result in accidents, physical injury or 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 the seals and get into your Campagnolo®, components, causing irreparable damage to them. Wash your bicycle and the Campagnolo® components by delicately cleaning with water and neutral soap.
• IMPORTANT : when cleaning the bicycle, only use environmentally-friendly and neutral products without caustic substances which are safe to use for you and for the environment.
• 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 bicycle components. To prevent damage, malfunctions and the consequent risk of accident, carefully rinse, clean and dry all components that are subject to corrosion.

• Cleaning and user maintenance shall not be made by children without supervision.

TRANSPORTATION

When transporting the bicycle, it is best not to remove the batteries for the rear derailleur and front derailleur. Therefore there is no need to turn off the Ergopower controls. In case of vibrations, the components of the groupset will not turn on because the levers of the Ergopower controls are not activated. If it is necessary to remove the batteries for the rear and front derailleur, turn off the Ergopower controls (as indicated in Chapter 5.6) to avoid running down the batteries unnecessarily.

• If you need to remove the wheels from the bike, ensure that you have inserted the transport tool (Fig. 21/22) 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, consult a qualified mechanic or a Campagnolo Pro Shop to have this issue rectified.
• 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.
• 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.

STORAGE

• If the bicycle is not used for a long time, it is best to turn off the Ergopower controls as indicated in Chapter 5.6 and remove the batteries as indicated in Chapter 5.5
• 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 components in locked cars parked in the sun and do not store them near radiators or other heat sources. Do not store carbon or plastic products in direct sunlight.

PERIODIC MAINTENANCE AND SAFETY INSTRUCTIONS

For all information and requirements relating to the product, the instructions provided in the sections “3 – SAFETY RECOMMENDATIONS”, “4 – BEFORE USING THE BICYCLE” and “6 – PERIODIC INSPECTION” must be followed. Campagnolo recommends that you take your bike to a Campagnolo Pro-Shop or mechanic specialised in assembling Campagnolo® components at least once a year, to check that the brake system and all other parts of the bicycle are working correctly.However, depending on how the bicycle is used, more frequent inspections may be necessary. Ask your mechanic to help you choose the best maintenance programme for you. A mechanical expert may be better trained and qualified to check the function of the system than even the most experienced of users.

SAVE THESE INSTRUCTIONS

CAMPAGNOLO.COM

References

• Olo | Enable Hospitality
• Wheels and groupsets for racing and gravel bikes | Campagnolo

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