Marzocchi Z3 Air Manual de usuario

Z3 Air

(80)

TRAVEL 80

L.MAX=461 L.L.=451 L.MIN=371

396

Ø30

175 18

100

130

248

±2

±0,1

+0.5

9.2

+0.1

-0.1

Ø30

+0.05

GENERAL

• Special air/oil damped cross-country fork: each leg uses pressu-

rized air blown through a special valve on stanchion caps as

damping medium.

• Rebound damping is controlled by pumping rods fixed to the

bottom of each slider; it can also be adjusted through an adjuster

on rh slider bottom.

• Stanchions fitted into lower Crown by cryofit technique. Full length

bushings guarantee superior rigidity.

• Sliders and arch are an integral assembly for reduced weight and

improved rigidity.

• Parts subjected to friction are cooled and lubricated by a specially

formulated oil.

Steer tube: stainless steel or, on request, EASTON aluminum steer

tube available for 1 1/8” diameter, threadless.

Crown: Forged and CNC-machined BAM

❊

aluminum alloy.

Arch: Cast magnesium alloy.

Stanchions: anodized aluminum with variable butting.

Sliders: Forged and CNC-machined BAM

❊

aluminum alloy. Left

slider comes with supports for disc brake caliper.

Slider bushing: Full length guide bushings composed of a copper

base and impregnated with an anti-friction coating.

Seals: Computer designed oil seals guarantee the highest quality

seals available.

Oil: Specially formulated oil which eliminates foaming and viscosity

breakdown while providing complete stiction-free performance.

Fork leg oil: 85 cc (each leg), type EBH 16 - SAE 7.5.

❊

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

Z3 Air

(100)

TRAVEL 100

L.MAX=481 L.L.=471 L.MIN=371

416

Ø30

175 18

100

130

248

±2

+0.5

9.2

+0.1

-0.1

Ø30

+0.05

GENERAL

• Special air/oil damped cross-country fork: each leg uses pressu-

rized air blown through a special valve on stanchion caps as

damping medium.

• Rebound damping is controlled by pumping rods fixed to the

bottom of each slider; it can also be adjusted through an adjuster

on rh slider bottom.

• Stanchions fitted into lower Crown by cryofit technique. Full length

bushings guarantee superior rigidity.

• Sliders and arch are an integral assembly for reduced weight and

improved rigidity.

• Parts subjected to friction are cooled and lubricated by a specially

formulated oil.

Steer tube: stainless steel or, on request, EASTON aluminum steer

tube available for 1 1/8” diameter, threadless.

Crown: Forged and CNC-machined BAM

❊

aluminum alloy.

Arch: Cast magnesium alloy.

Stanchions: anodized aluminum with variable butting.

Sliders: Forged and CNC-machined BAM

❊

aluminum alloy. Left

slider comes with supports for disc brake caliper.

Slider bushing: Full length guide bushings composed of a copper

base and impregnated with an anti-friction coating.

Seals: Computer designed oil seals guarantee the highest quality

seals available.

Oil: Specially formulated oil which eliminates foaming and viscosity

breakdown while providing complete stiction-free performance.

Fork leg oil: 85 cc (each leg), type EBH 16 - SAE 7.5.

❊

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

Z3 Air

INSTRUCTIONS

GENERAL RULES

1. Where specified, assemble and disas-

semble the shock absorption system

usingtheM

ARZOCCHI

special toolsonly.

2. On reassembling the suspension sys-

tem, always use new seals.

3. Clean all metal parts with a special,

preferablybiodegradablesolvent,such

as trichloroethane or trichloroethylene.

4. Beforereassembling,lubricate allparts

in contact with each other using sili-

conefat spray or a specificoil for seals.

5. Always grease the lip seal rings before

reassembling.

6. Use wrenches with metric size only.

Wrenches with inch size might dam-

age the fastening devices even when

theirsizeissimilartothatofthewrenches

in metric size.

Z3 Air

FAILURES, CAUSES AND REMEDIES

Thisparagraph reports somefailures that mayoccur when usingthe fork.Italso indicatespossible causes andsuggests a remedy.Always

refer to this table before doing any repair work.

FAILURES CAUSES REMEDIES

Oil leaking through the bottom of slider O-rings on pumping rod bottom and/or

adjusting rod damaged. Replace the O-rings

Oil leaking through the top of the slider 1. Oil seal is worn out

2. Stanchion tube is scored

3. Excessive dirt on slider oil seal

1. Replace oil seal

2. Replace crown/stanchions assembly,

oil seals and dust seals

3. Cleantheoilsealseatandreplaceoilseal

Fork has not been used for some time and

is locked out Oil seals and dust seals tend to stick to

stanchions Raise dust seal and lubricate stanchion

tube, dust seal and oil seal

Pressure drop Cap valve damaged Replace cap and/or valve

The fork reaches its end of stroke easily Valve at the bottom of the stanchion dam-

aged Change

Excessive play of stanchions in the sliders Pilot bushings worn out Replace bushings

Fork rebounds too fast in any adjuster

position Dirt inside fork legs Clean carefully and change oil

Adjuster position does not affect fork op-

eration 1. Dirt inside legs

2. O-ring into rh pumping rod damaged 1. Clean carefully and change oil

2. Replace O-ring.

Z3 Air

RECOMMENDATIONS FOR

MAINTENANCE

ARZOCCHI

forks are based on advanced

technology,supported by year-longexpe-

rience in the field of professional moun-

tain biking. In order to achieve best re-

sults, we recommend to check and clean

the area below the dust seal and the

stanchion tube after each use and lubri-

cate with silicone oil.

In general, M

ARZOCCHI

forks can offer top

performance from the start. However, in

some cases a short running-in period is

required (5-10 hours) for inner adjust-

ments. This running-in period will make

fork life longer and ensure fork top per-

formance over time.

IMPORTANT: change oil at least every

100 working hours and check pressure at

least every 10 working hours.

Polished forks should be cleaned with

bodywork polish at regular intervals in

order to preserve their original finish.

INSTALLATION

Installing the fork on a bicycle is a very

delicate operation that should be carried

out with extreme care. The installation

should always be checked by one of our

Technical Service Centers.

WARNING: Steer tube/headset

mounting and adjustment must be

carried out in compliance with the head-

set manufacturer’s instructions. Improper

installation may jeopardize the safety of

the rider.

To replace it, contact one of our Technical

Service Centers with the required tools.

WARNING: In case of improper

installation of the steer tube into the

crown, the rider might lose control of his/

her bicycle, thus jeopardizing his/her

safety.

DISC BRAKE SYSTEM ASSEMBLY

WARNING: If a disc brake sys-

tem is installed, it is absolutely for-

bidden to loosen and remove original

brake supports fixing pins. In fact, apart

from retaining Cantilever or V-brake le-

vers, they also play an important role in

securingsliderbottom toslider-archmono-

lith. If needed, replace these pins with

screws (part no. 532979QF) available

as spare parts.

Tighten the above screws to 15 Nm.

IMPORTANT: screw and pin threading

is treated to ensure hydraulic seal. Never

reuse screws and pins which have been

removed.

Assembling the brake caliper onto the

slider is a very delicate operation that

should be carried out with extreme care.

Improper assembly might overstress the

caliper supports which might break.

When installing the disc brake system, be

sure to properly follow the instructions

given by the manufacturer.

Z3 Air

ADJUSTMENTS

FORK LEG PRESSURIZATION

Blow pressurized air through the valves

(5) on the stanchion caps to set COM-

PRESSION damping. To change the pres-

sure value, remove the protection cap (2)

and depressurize each leg. Fully tighten

the pump connection (C) on cap valve (5)

or pressurize until the required value is

reached. Unscrew the connection and

refit the cap (2). This adjustment is essen-

tial in order to have the right fork response

for the rider’s weight and riding style.

The fork is pre-loaded at the factory to a

standard value of 3 bar.

REBOUND ADJUSTMENT

Each fork leg is equipped with an adjuster

screw (D) for REBOUND damping at

slider bottom.

To adjust, always start from the minimum

damping setting, i.e. with the screw fully

turned counterclockwise. Each adjusting

position can be identified by a click.

IMPORTANT: do not force the adjuster

knob (D) over its limit.

Z3 Air

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DISASSEMBLY

GENERAL

– The reference numbers given in this section relate to the components shown in the fork exploded view.

– Before starting any operation. please read the diagram below. It shows the quickest procedure and the exact disassembling

sequence. Locate the part you need to remove in the diagram, then look at the arrows to determine which other parts you need to

remove first.

DISASSEMBLY DIAGRAM

CROWN AND STANCHIONS

ASSEMBLY CHANGE

PUMPING ROD CHANGE

FOOT BUFFER FIG. 11

CROWN AND STANCHIONS

ASSEMBLY WITH PUMPING ROD

FIG. 5

DUST SEAL FIG. 6

FORK OIL CHANGE

STOP RING FIG. 7

OIL SEAL FIG. 8

UPPER WASHER FIG. 9

PILOT BUSHING FIG. 10

REBOUND SPRING FIG. 12

VALVE ASSEMBLY CHANGE

STOP RING FIG. 14

VALVE ASSEMBLY FIG. 14

FOOT NUT FIG. 4

STANCHION TUBE CAP FIG. 1

PUMPING ROD FIG. 12

PILOT BUSHING AND SEAL

ASSEMBLY CHANGE

BOTTOM ADJUSTER FIG. 3

PUMPING ELEMENT INNER O-RING

FIG. 13

Z3 Air

111

FIG. 1

Depressurize each fork leg (see section

ADJUSTMENT).

Unscrew the caps (5) with a 21 mm

socket wrench.

Removethe caps completewith O-ring (6)

from the stanchions.

FIG. 2

Push the stanchions (1) into the sliders

(11) and let all the oil drain out from the

fork legs.

Pump the stanchions several times to help

oil drain off.

WARNING: Rememberto always

recycle any used oil.

To change the fork leg oil follow the

procedure as described in section

“REASSEMBLY” from Fig. 27 to Fig. 29.

PILOT BUSHING AND SEAL

ASSEMBLY CHANGE

FIG. 3 (only right leg)

Turn fork legs upside down and press

adjuster retainer (28) with a small screw-

driver to release it.

Remove adjuster assembly (28) from the

slider.

Z3 Air

Dx.

Sx.

FIG. 4

Remove foot nuts (26) and (7) with a

15 mm socket wrench.

FIG. 5

Withdraw the crown and stanchions as-

sembly (1) from the sliders.

FIG. 6

Remove the dust seal (19) from the top of

the sliders using a small screwdriver.

Z3 Air

FIG. 7

Remove the stop ring (20) from the sliders

byplacing the screwdriver bit inone ofthe

three openings on the stop ring.

IMPORTANT: when removing the stop

ring, make sure not to damage its seat.

FIG. 8

Fit the slider protector (A) onto the slider

and remove the oil seal (21) with the help

of a large screwdriver.

IMPORTANT: when removing the oil

seal, make sure not to damage its seat.

Once removed the oil seals should not be

used again.

FIG. 9

Remove the upper washer (22) from the

slider.

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