Instruction manual

Model Year: MY17

Model Name: GIANT CONDUCT DISC BRAKE

Purpose: FOR GIANT DEALERS ONLY

2016. September

1
CONTENTS

Important Notice & Information .......................................................................................... 3

Spare Parts in Gear ............................................................................................................ 4
Parts List .............................................................................................................................. 5
Brake Lever cable ratio check ........................................................................................... 6
Adjust the brake reach........................................................................................................ 7
Mounting The Caliper & The Master Cylinder Body ........................................................ 8
Cable Installation ................................................................................................................. 9
Hydraulic Hose Assembly ................................................................................................ 10
Connecting the Brake Cable and Master Cylinder ........................................................ 11
Adjusting Hydraulic Hose Length (Only apply to when the housing is too long) ....... 12
Brake Bleeding (Only apply to when the oil shortage) ................................................. 12
Changing Brake Pads ....................................................................................................... 15

2
Important Notice & Information

 This product is compatible with Shimano System only and is designed for use ONLY with Giant Contact
SL, Contact and Connect stem extensions.
 Important: Operating Giant Hydraulic braking system without using authorized GIANT rotor disc will
void your warranty. Using unauthorized rotor disc may lead to unpredictable braking performance, this
may cause serious injuries or possibly death.
 Important: Operating Giant Hydraulic braking system without using authorized GIANT braking pad will
void your warranty. Pad should be replaced when total thickness is less than 2.5mm (friction material
& metal plate)or the pad wear indicator appearance. When the braking pads are worn out please
make sure to replace both pads, this way it insures the same 0.3mm clearance in between the rotor
and the braking pad.

 Please do not press the circled cylinder section before the

brake assembly is complete. Pressing the cylinder before
assembly may cause unexpected braking characteristics.

 Please do not remove the screws from the hydraulic cap

located the circled cylinder section, by removing the screw
may cause unpredictable malfunctions.

3
Spare Parts in Gear

Gear SKU PARTDESC IMAGE

Conduct Hydraulic Disc Brakes - Body-Post

290000031
disc mount version / Without Rotor

Conduct Hydraulic Disc Brakes - Body-Flat disc

290000032
mount version / Without Rotor

Conduct Hydraulic Disc Brakes - Body-Post

290000036
disc mount version / With Rotor 140mm

Conduct Hydraulic Disc Brakes - Body-Post

290000037
disc mount version / With Rotor 160mm

Conduct Hydraulic Disc Brakes - Body-Flat disc

290000038
mount version / With Rotor 140mm

Conduct Hydraulic Disc Brakes - Body-Flat disc

290000039
mount version / With Rotor 160mm

290000033 Conduct Hydraulic Disc Brakes - rotor 140mm

290000034 Conduct Hydraulic Disc Brakes - rotor 160mm

Conduct Hydraulic Disc Brakes - Adapter

410000086
packs-Lights & Computers & GoPro mount

Conduct Hydraulic Disc Brakes - Disc brake

290000035
pad blue color

Conduct Hydraulic Disc Brakes - work shop

380000019
service kit

Conduct Hydraulic Disc Brakes- Inner cable &

370000011
cable housing

4
Parts List

Item Description Qty Item Description Qty

A1 Connector Screws 2 A5 Tubing cutter 1

A2 Connector Cover 2 A6 Bleed Spacer 1

Cable lock
Compression
A3
Sleeve 2 A16 Tool/ratio 1
testing device

2
Cable end
A4 Barb O-Ring 2 A17
Rubber cap

Item Description Qty

A7 Bleeding Syringe 2

A8 Hydraulic Hose A8

A9 Caliper Bolts 2
A9

Brake Caliper
A10
A10 (Flat/Post Mount) (M6 2
X4)

A9

A13 Master Cylinder Body 1

A14 Hosear Brake Casing 2

A15 Brake Cable 2

5
Brake Lever cable ratio check

Bolt
Ideal Area
Brake cable Ratio testing Brake
Braking Lever Cable
housing device

Example of
non-ideal
ratio

Example
of ideal
ratio

Confirm brake lever pull ratio is ideal:

1. Before starting, please be sure that the brake lever is properly installed on the handlebar and
with handlebar tape wrapped.

2. Install the testing device (A16) as shown by pulling the brake cable taut then tighten the bolt
to secure the brake cable to the testing device (brake cable housing is roughly 350mm in length).
For the most accurate result, please ensure there is no gap left between the joints from the
testing device to the braking lever and the brake cable is taut.

3. Pull the brake lever until the lever touches the handlebar and check for acceptable ratio by
referring to the black mark on the test device (A16):
4. IDEAL = the black area is partially covered by testing device body when the lever is pulled to
the bar (see item B in the figure)
NOT IDEAL = the black area is not covered, even partially, by the testing device body when the
lever is pulled to the bar (see item A in the figure)

Warning!
Operating Giant's Hydraulic Braking System without enough braking lever ratio could
dramatically affect the braking characteristics, and cause possible injury or even death.

6
Adjust the brake reach
If the brake reach need to be adjusted after product installation, please follow below steps:
(Note: the range of brake reach adjustment should be less than 3mm)

1. Assemble the cable lock

tool after brake cable
assembly.

2. Lock tight the brake cable

and align it with 0 mark on
the scale of cable lock tool.
(★ Note: there should
not be any clearance
★
between cylinder body and
cable lock tool. )

★Note: Please make

sure below two parts
are 100% matched.

3. Adjust brake reach with

Allen key. The range of
adjustment should be less
than 3mm.
Warning!
Adjustment over than 3mm
might cause malfunction to
brake system and serious
injuries.
4. Remove the cable lock
tool, cut the remaining
cable and apply the cap.

7
Mounting The Caliper & The Master Cylinder Body

Description

For flat mount or post mount adapters, hold the

adapter so that the stamped “UP” is oriented upwards.
Assemble the adapter and front caliper together,
tightening torque is 5-7 Nm(4mm)
Tightening torque is 6-8 Nm(5mm) for post mount.
5-7Nm (4mm)

Align caliper with frame/fork mounting holes.

Attach the caliper to the fork or frame using two
mounting bolts, but do not fully tighten at this time.

Assemble the master cylinder body to stem extension

being sure that the hydraulic hoses are facing
downwards
Tighten Stem bolts following the sequence shown,
fastening torque is 6 Nm.

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Cable Installation
Brake Housing

The housing assembly (A14) is composed of two parts (A & B). The role of Part A is to prevent damage to the
control unit structure from the hosear, compressionless housing. When adjusting length, only adjust the length
of Part B and do not modify Part A (Please Keep part A as short as possible for the best braking characteristics).
Part B is hosear, compressionless brake housing to maintain key braking performance and feel. Do not arbitrarily
change.
Note

The metallic, flexible housing serves as a safety

adapter that prevents the control unit housing
Confirm that the housing is cut evenly, not frayed from being damaged by the non compression
and wire strands are not exposed. cable housing and also helps reduce cable friction
for smooth operation.

Connect Master Cylinder Body and Lever

Notice:
1. Please insert the flexible cable housing into the brake lever.
2. Ensure the compressionless cable housing is at the proper lengt
3. Cable housing caps labeled with safety marks are pre-installed on the end of the included compressionless
cables. After completing the brake cable assembly please ensure that the safety mark is pushed all the way
into the master cylinder, the safety mark will not be visible on a well installed unit.
4. Please confirm that the safety mark remains covered by the housing stop on the unit AFTER the handlebar
tape has been properly installed
5. NOTE: Brake cable housing that is too long will result in a cable
loop, this will affect the braking characteristics and performance.
(Indicated by red hose)
WARNING! Brake cable housing that is too short (visible housing cap
safety mark) will cause serious device malfunction, and cause injury
and possible death while operation. (Indicated by SOMETHING
OTHER THAN orange hose)

9
Hydraulic Hose Assembly

1. Use 2mm wrench to remove the oil screw stopper 2. Remove the pre-installed end plug from A13

A3
A1
A2

3. A1/A2/A3/A4 Assembled on hydraulic hose. Please

ensure the convex ring section (circled part A3) is 4. Use an 8mm wrench to tighten A1 (max
pointed outwards in order for the hydraulic brake to torque 7.0Nm)
function properly .

Right
Brake Left
Brake

5. Repeat this step to connect the hydraulic

Push A2 into position
hose to the remaining port

10
Connecting the Brake Cable and Master Cylinder
Description

1. Loosen brake cable screw in A13

2. Insert brake cable through control, cable housing and
A13
3. Pull brake cable taut and tighten the brake cable screw
(T15 max torque 4.5Nm)
4. Cut off excess cable and install cable ends to prevent
fraying of the cable

5. Confirm brake cables are securely fastened

6. pull the brake lever a minimum of 10 times to ensure no
air remains in the hydraulic hose
7. Confirm assembly is complete and fully installed
8. Pull the brake lever firmly and hold to self-align the
caliper on the rotor while tightening the caliper
mounting bolts with a torque of 5-7 Nm Tightening
torque is 6-8 Nm(5mm) for post mount.
9. Confirm brake function
10. Please recheck all the functions after the handlebar tape
is wrapped.

11. Once the brake cables are installed and the system is A B A17
confirmed as functioning, please cut the excess brake
cable to approximately 30-50mm in length (A), fit a
standard cable tip (B) and crimp to secure.
Now install A17 over the cable tip and you are done.
For easiest installation, we recommend cutting the cable
with a bike cable cutter and crimp the cable tip with side
cutters or pliers.

11
Adjusting Hydraulic Hose Length (Only apply to when the housing is too long)

1. Using the tubing cutter to reduce hose length 2. A1/A2/A3 as assembled on the hydraulic hose，Please
ensure the convex ring section (circled part A3) is
pointed outwards in order for the hydraulic brake to
function properly.

4. Using the tubing cutter to push A4 to the hydraulic

3. A4 Pre-installation position
hose.

Brake Bleeding (Only apply to when the oil shortage)

Front/前
Right Brake Left Brake

NOTE: The hydraulic hose is serviced by the bleed port on the opposite side of the
master cylinder (left hose = right bleed port, for example)

12
 A6

1. Remove the wheel and brake pad assembly. 2. Please remove the oil filling screw and fill
Insert A6 bleed spacer into caliper 20cc of mineral oil to A7 before attaching it to
the caliper.

3. Remove the appropriate bleed port screw 4. After attaching the first A7 to the caliper, fill
the second A7 with 5cc of mineral oil before
attaching it to A13. Make sure both A7 units
are attached properly before the bleeding
process.

5. Press A7 (attached to caliper) to inject the mineral oil. (We suggest turning A13 to an 45-90
degree angle while the bleeding process. )
6. To make the bleeding process more effective, it is ideal to operate the braking lever while
injecting mineral with A7.

13
7. Once all air bubbles have risen to the top of the
syringe at the master cylinder (A13), proceed to
8. To make the bleeding process be more effective,
use the syringe at the master cylinder to push the
it is suggested to operate (pull and release) the
mineral oil back into the system. To aid in the
brake lever while using the master cylinder
bleeding process, we suggest orienting the master
syringe to push mineral oil into the system.
cylinder (A13) so the bleed port is the highest part
of the system.

9. Remove A7
Install bleed port screw (torque 6 - 7Nm) 10. Clean the surface with isopropyl alcohol.
Install wheel according to wheel or bicycle owner's Remove bleed spacer( A6 )
manual (with correct sized rotor installed) Install the brake pad assembly

11. Remove A7 from A13 12. Pull brake lever to confirm correct function of the
Install bleed port screw (torque 1.5 - 2Nm) brake

14
Changing Brake Pads

 Important: Operating Giant Hydraulic braking system without out using authorized GIANT brake pads
will void your warranty.
 When the brake pads are worn out please make sure to replace both pads, this way it insures the
same 0.3mm clearance in between the rotor and the brake pad. Uneven clearance may cause major
braking failure and result in serious injury.

 Pad should be replaced when total thickness is less

than 2.5mm (friction material & metal plate)or the
pad wear indicator appearance.

· Loosen the brake pad assembly bolt with a 3mm

hex wrench.
· Pull the cotter pin from the brake pad retaining
bolt – be careful not to lose this piece
· Set the bolt and cotter pin aside. Be careful to
save the spring assembly for later use.
· Remove the pads from the bottom end of the
caliper.
· Install new pads and spring assembly into the
calipers in a reverse order to the removal
process.
· Reinsert brake pad retainer bolt into the caliper
and re-attach the cotter pin. Tighten the brake
pad assembly bolt.
· Repeat for other caliper and adjust cable tension
or pad alignment if necessary.

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