TRICKSTUFF C42 Pump Piccola Carbon HD Carbon User Manual

TRICKSTUFF C42 Pump Piccola Carbon HD Carbon

Product Information

Specifications

• Product: Trickstuff Piccola Pump
• Connector: M5
• Compatible Calipers: C21, C22, C41, C42, MXA
• Designed for use with organic, biodegradable Trickstuff Bionol oil

Product Usage Instructions

Safety
The installation, use, and maintenance of Trickstuff products require careful attention to safety instructions to prevent accidents and injuries.

Warning: Ensure brake pads are not below a thickness of 0.5mm. Brake discs should be free of deformations or cracks.

Warning: Avoid using brakes with deficiencies to prevent accidents and injuries.

Service Kits
To service the brake pump, one service kit is required per brake pump. For a set of brakes, two kits are needed.

Tool Requirement
Have the necessary tools to remove the brake from the bike following the operating instructions.

Oil Recommendation
Use only organic, biodegradable Trickstuff Bionol oil with
Trickstuff brakes. Do not use DOT brake fluids to prevent damage to the brake system.

Service Instructions for Brake Pump

1. Secure your bike in a bike stand and remove the wheels.
2. Push back the caliper pistons fully using appropriate tools.
3. Remove the brake pump from the handlebar including clamps and interfaces.
4. Use a TX25 key to disconnect the brake hose from the pump.

Disassembly of Brake Pump

1. Remove pivot bolts on both sides using a TX15 key.
2. Detach the lever blade from the piston rod using a HEX2mm key.
3. Replace the circlip and dispose of the used one properly.
4. Separate the pump piston from the housing and replace the O-ring.
5. Unscrew the reservoir cap, discard the membrane, and clean any leaking oil.

FAQ

• Can I reuse drained Bionol oil?
  No, drained Bionol oil should not be reused. Always use new Bionol for optimal brake performance.

• How often should I service my Trickstuff Piccola Pump?
  We recommend servicing your Trickstuff Piccola Pump regularly as per the service manual guidelines to ensure optimal brake performance and safety.

SERVICE MANUAL – PICCOLA CARBON PUMP
V2024_02

General information

1. Read the manual completely before using the products and follow the instructions contained in these instructions when installing, using and maintaining the product in order to avoid personal injury and damage to property.
2. The installation and maintenance of Trickstuff products require a basic knowledge of handling bicycle components and should only be performed by qualified bicycle mechanics. During installation or maintenance, clean working conditions must be ensured so that dirt entry into the brake systems is avoided.
3. If any of the instructions in this manual are unclear, do not proceed with installation or maintenance. Contact your local Trickstuff dealer or the Trickstuff support-team.

Safety
The installation, use and maintenance of Trickstuff products requires that you have read and understood the following safety instructions.

1. General safety instructions

   • Always follow the instructions in the manual when working on Trickstuff products.
   • We recommend only Trickstuff products for the use with Trickstuff brakes.
   • When working on the system, pay attention to appropriate personal protective equipment such as gloves and safety goggles.
   • Trickstuff products are to be used exclusively in accordance with their intended use. Otherwise the user assumes the responsibility.
     Warning!
     Improper installation, use and maintenance of components pose a considerable risk and can lead to accidents with serious injuries including death.

2. Brake pads and brake discs

   • Visually inspect the brake pads and rotors before each ride:
   • Worn brake pads and/or brake discs can lead to sudden brake failure.
   • Lubricants such as oil or grease on the brake pad or brake disc can limit the effectiveness of the brake.
   • Corrosion can cause the friction material to detach from the backing plate, resulting in brake failure. Replace brake pads that show signs of rust immediately.
   • Brake pads should not be under a minimum thickness of 0.5mm.
   • Brake discs must not show any deformations or cracks and must be mounted in the correct direction of rotation.
   • Brake discs must have a minimum thickness of 1.6mm.
   • In case of damage to the brake pads and/or brake discs, stop using them immediately and replace them with new brake pads or brake discs.
   • Brake pads may only be used with a compatible caliper.
   • Before working on brake calipers or brake discs, make sure that they are no longer hot and that the brake discs are no longer spinning. Heat and rotation can cause burns, bruises, cuts and other injuries.
   • When installing brake pads, only use the original pad spring, pad retaining bolt and safety clip.
   • Check the functionality of the brake after mounting or replacement of brake pads and/or brake discs.

Brake

Warning!
If the brake is used with deficiencies it can fail and lead to accidents with serious injuries including death.

• Check the brake before and after each use of your bike and check for damages.
• If there is damage or signs of damage, the brakes must not be used. If in doubt, contact your local Trickstuff dealer or the Trickstuff support-team.
• If the brake leaks oil under high or low pressure, do not continue riding and contact the Trickstuff support-team immediately.
• The brake must be compatible with all parts of the bike. The maximum system weight of the brake must not be exceeded.
• Trickstuff brakes are only as good as the pilot who uses them. Proper braking technique is essential. Improper braking can lead to accidents with serious injuries.
  • Permanent braking should be avoided. When braking, do not drag the brake steadily, but brake in bursts if the ground will allow. Continuous heat input from a permanently dragging brake can cause the brake to overheat, preventing sudden braking and thus leading to serious accidents with risk of injury. Likewise, permanent braking on changing ground conditions such as rolling gravel, wet ground, loam, rocks, road markings, etc. can cause loss of control.
  • Excessive pulling of the front brake can lead to rollover.

Tools

• TX6 key
• TX10 key
• TX15 key
• TX25 key
• HEX2mm key
• HEX3mm key
• Circlip pliers Knipex 44 11 J1
• Medium strength thread locker (e.g. Loctite 243)
• Assembly grease (e.g. Interflon assembly grease)
• Brush
• Shop towels

Service-Kits
To service the brake pump, one service kit is required for each brake pump (i.e. two kits for one set of brakes).

• Regular service: KIT SEALS & PISTON PCA PUMP OIL ASM

Overview M4-/M5 connectors

| Caliper| Pump
---|---|---
Product| C21| C22| C41| C42| MXA| DIRETTISSIMA/ MAXIMA| PICCOLA
Connector| M5| M4| M5| M4| M5| M4| M5

You will also need the appropriate tools to remove the brake from the bike in accordance with the operating instructions.
Note: Trickstuff brakes are designed for use with organic, biodegradable Trickstuff “Bionol” oil. Never use DOT brake fluids (e.g. DOT4/5/5.1/etc.), otherwise the seals of the brake system will be damaged and the brake can no longer be used without an inspection.
Note: Only use new Bionol. Drained Bionol should not be reused.

Service brake pump
The following service manual includes service for the whole brake pump assembly, it’s disassembly and exchange of all seals.

Preparation

1. Fix your bike in a bike stand and dismount the wheels.
2. Fully push back the caliper pistons. If you use the wooden Piston-Push-Back-Tool, first remove the brake pads and then push back the caliper pistons. If you use the Triple-B-Tool, first push back the caliper pistons and then remove the brake pads, to avoid damaging the pistons. Take care not to tilt the pistons in this process, if in doubt release the applied force and start over.
3. Remove the brake pump from your handlebar including clamps and interfaces. Use tools according to the respective manual. Note the lever distance to adjust it to the same setting after the service.
4. Use a TX25 key to remove the brake hose from the brake pump.

Disassembly of the brake pump

1. Remove the pivot bolt shown in the image below and its counterpart on the other side usinga TX15 key. The remaining two pivot bolts do not need to be removed.
2. Use a HEX2mm key to remove the lever blade from the piston rod. Use a shop towel to clean the lever blade and put it aside, further service on the lever blade is not necessary.
3. Remove the circlip with circlip pliers (e.g. Knipex 44 11 J1) from the pump housing. The used
4. Remove the pump piston from the pump housing, separate it from the spring and dispose of  it.
5. Remove the bleed bolt from the pump housing using a TX10 key and replace the O-ring.
6. Unscrew the M2-bolt from the reservoir cap using a TX6 key. Take off the cap, remove the membrane and discard it. Soak up leaking oil with a shop towel.
7. Clean pump housing and reservoir cap with warm water and a liberal amount of washing-up liquid. Works best in combination with a soft brush and a lot of clean water for rinsing afterwards. Before assembly, make sure everything is properly dried and no water residue remains. You can dry the pump with compressed air or by putting it on a household radiator for some time.
8. Use a flashlight to check the cylinder surface for cleanliness, scratches and possible damage/debris. If you find your cylinder surface damaged, please contact the Trickstuff Tech-Support.

Assembly of the brake pump

1. First put a new membrane onto your pump housing. Note : The membrane is not square, but rectangular. Check for correct orientation as shown in the image below.

2. Slot the reservoir cap into the according groove of the pump housing, as shown in the image, and push it down. Note : The lid sits correctly, if you can easily close the gap between lid and pump housing manually.

3. Press down on the reservoir cap to hold it in position and install the reservoir cap bolt using a TX6 key and medium strength thread locker (e.g. Loctite 243). Torque it down to 1Nm.
   Note : To check whether the assembly of the membrane was successful, you can apply negative and positive pressure (alternating) to the syringe during bleeding after the service. If the seal is damaged, drawing a vacuum at the brake pump with the bleeding syringe will result in air intake, or positive pressure can result in oil exit. In this case, take off the membrane again and check it for damages optically, then give the assembly another try.

4. Mount a new piston spring on a new pump piston. Apply a small amount of grease (e.g. Interflon Assembly Grease) to the primary seal as shown in the picture.

5. Push the pump piston into the pump housing. This should show only minimal resistance.

6. Put the free stroke spacer on the piston rod. Then mount the new circlip like shown in the image below.
   Note : Circlips have a sharp and a dull outer edge. When mounting the circlip, make sure the sharp edge is engaged, it has to face outwards (“sharp edge facing → right → in picture below).

7. Mount the circlip together with the piston rod and the free stroke spacer into the pump housing. Use circlip-pliers (e.g. Knipex 44 11 J0) for the assembly of the circlip. This step can be a little fiddly, it can be necessary to start over. Best way is to do it like shown in the image below. Check the circlip for correct seating, it „clicks” when it seats itself correctly.

8. Use a HEX2 key to mount the lever blade back on the piston rod.

9. Install the pivot bolts using a TX15 key. New bolts are precoated with medium strength thread locker. If you remount previously used bolts, apply medium strength thread locker (e.g. Loctite

243. and torque to 1Nm.
     Note : Apply thread locker to the inner threads, as shown in the picture below. This way you avoid fixing the bearings to the pivot bolts.

10. Before installing the fittings back on the brake pump, replace both O-rings of the banjo fitting (one per side). Use a TX25 key and 3Nm to finish the installation.
11. Bleed the brake system according to the respective manual and mount it back on your bike Technical changes, errors and misprints excepted.

TRICKSTUFF® GMBH
SCHWABENMATTEN 17A
79292 PFAFFENWEILER
GERMANY
TECH-SUPPORT@TRICKSTUFF.DE

SERVICE MANUAL – PICCOLA PUMP V2024_02. PAGE 25 OF 25

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