Zurich INSTALLATION INSTRUCTIONS TRP Cycling Components 688 W. Amidan Dr. 4X-1 Ogden, UT 84404 Toll Free: 1-877-807-4162 Direct: 1-650-965-4442 Email: email@example.com Web: www.trpcycling.com SAFETY WARNINGS WARNING - This braking system was designed for use on a single rider bicycle. Use of this system on any other vehicle or apparatus will void the warranty, possibly causing you great personal harm or injury. WARNING - Disc brakes, calipers and rotors get VERY HOT during regular use. DO NOT touch or attempt to service the rotor or caliper assembly until you’ve allowed for sufficient cooling to occur. WARNING - These disc brakes offer a significant increase in performance over traditional cable actuated systems. Follow the break-in recommendations listed in this manual, allow yourself time to learn and become accustomed to the braking characteristics. WARNING - Leaking oil indicates a potential BRAKE FAILURE. If your system is leaking oil stop immediately and determine the nature of the problem. DO NOT continue to ride a leaking system. WARNING - If your bike is involved in a fall or crash, fully check the brake function including: the lever, caliper and rotor are securely attached to the bike, pads are correctly installed and functioning, the cable, (if applicable) is operating smoothly and the lever feels firm when applying the brake. Always have a qualified mechanic check the brakes if you have any doubts. WARNING - Pad thickness must be at least 0.8mm of pad material. Confirm this before each ride. Keep pads clean and free of oil or hydraulic fluid. If pads become contaminated, discard and replace. CAUTION - Read this manual completely before attempting to install or work on your TRP brakes. If you are unfamiliar with any element of assembly or maintenance of this braking system please consult a qualified mechanic for assistance. CAUTION - Only use TRP or TEKTRO branded replacement Mineral Oil when servicing the brakes. Other disc brake fluids, ESPECIALLY DOT based oils, will harm the system and compromise braking performance. CAUTION - Cleanliness is a very important part of any maintenance of a TRP disc brake. If the pads or rotor become contaminated with oil, or if the system becomes contaminated with impurities, braking performance will be greatly impaired. CAUTION - As with any oil, precautions in handling and clean up of any spills should be handled according to accepted best practices as governed by your state or country. Our Mineral oil is non-toxic, but clean up any spills promptly and completely. If Mineral Oil gets in your eyes IMMEDIATELY FLUSH WITH WATER for several minutes and go to the hospital. If Mineral oil gets on your skin RINSE IMMEDIATELY with soap and water. Do not inhale Mineral Oil, it is harmful. If inhaled move to a well ventilated environment and proceed to the hospital for appropriate care. If you ingest Mineral oil it may cause vomiting and/or diarrhea. TRP hydraulic disc brakes are warranteed against manufacturing defects in materials and / or workmanship for a period of two years from the date of original retail purchase. Not covered under this warranty is damage resulting from improper installation, adjustment or maintenance, lack of maintenance, alterations, crashes or use judged by Tektro to be excessive or abusive. For warranty related questions or more information please contact a TRP Service Center or email at firstname.lastname@example.org Zurich IS Mount Brake signal wire nut, 7mm wrench Brake signal wire cap Zurich Post Mount For Post Mount adaptors, hold the adaptor so that the Clamp bolt, 4mm hex stamped ‘UP’ is oriented upwards, or furthest from the hub axle. Reach adjust knob/screw Mounting bolts, (post mount shown) Adaptor, (A-11 shown) INSTALLATION & ADJUSTMENT TOOLS AND EQUIPMENT REQUIRED 5 The following tools are necessary to install the Tektro hydraulic disc brake: 2mm hex wrench 7mm open end wrench 4mm hex wrench T25 Torx® wrench 5mm hex wrench Birzman Pad Gap Tool (optional) 2 3 4 MOUNTING THE ROTOR TO THE HUB 1 6 Attach the rotor to the hub with the supplied Torx® bolts and tighten in an alternating pattern with A-1. Rotor torquing sequence a T25 Torx® wrench. Final tightening torque: 4-6 Nm (35-53 in-lb). [ref. A-1] NOTE - The rotor must be installed with the “rotation” arrows pointing in the same direction as the forward rotation of the wheel. Front caliper Attach the adaptor to the fork in correct direction for your rotor. [IS adaptors] Tighten the two M6 bolts to a torque of 6-8 Nm (53-72 in-lb.) Attach the caliper to the adaptor with two M6 bolts. adjust ad adj ust us sstt reach re each ch adjus a ad adjust djust jus ust Do not tighten at this stage. Rear caliper Attach adapter to frame and tighten the M6 bolts to 6-8 Nm (53-72 in-lb) torque. Then attach caliper to the adaptor with M6 bolts. Do not tighten yet. B-1 reach adjust on models with 2mm hex reach adjust screw. ALIGNMENT With the caliper mounting bolts still loose, squeeze the brake lever. The caliper will correctly center itself to the rotor. You may also use a disc brake gap or alignment tool such as the one made by Birzman. Maintaining pressure on the brake lever, tighten the caliper mounting bolts. Final tightening torque: 6-8Nm (53-71 in-lb). Remove the disc brake gap tool and spin the wheel to check for rubbing or noise from contact between rotor and brake pads. Repeat alignment cut ho hose se at lever er er process with the disc brake gap tool if needed. MOUNTING THE BRAKE LEVERS Loosen the 4mm hex head clamp bolt on the lever and position lever on handlebar. Place the levers in an appropriate position and tighten to 4-6Nm (35-53 in-lb). Check the routing of the hose. As with all hydraulic hose, there should be no kinks or bends that C-1 Cut Zurich hose to length at the lever. collapse the housing. Once you have the lever assembly positioned appropriately, you can adjust the reach of the blade. Zurich Comp models have a knob and Zurich models have a 2mm hex set screw. [ref. B-1] MODIFYING HOSE LENGTH Pull to remove the plastic cap and unscrew the compression nut with the 7mm open end wrench. Pull on the hose to free it from the lever. [ref C-1] Some fluid may drip out. Measure the cut length making sure you have enough free length for full rotation of your handlebars. Cut the hose to the desired length using a hydraulic hose cutter. (Zurich uses a banjo fitting on the hose end at the caliper, which is not replaceable. This is the reason for cutting the hose at the lever. ) Important: Slide on the plastic cap, compression nut, then the olive with the tapered end oriented to engage the compression nut. [ref C-2] C-2 Install cap, nut and olive before installing the barb! Install the barb ensuring that it is fully seated within the cut end of hydraulic tubing. Reinsert the hose into the caliper and tighten the compression nut to 4-6Nm (35-53in-lbs). GENERAL MAINTENANCE PAD REPLACEMENT Pads should be replaced if they become contaminated or have less than 2.5mm thickness (Pad friction material & metal backing plate). (See D-1) BEFORE RIDING Check the pads for wear or contamination. Check the hose for cracking, wear or deformation. Replace if necessary. Check that the brake system is operating correctly. AFTER RIDING 2.5 mm Remove any mud or contamination from the rotor slot on the caliper. Clean the caliper body with a cloth. AT REGULAR INTERVALS Check the oil level in the reservoir. Lubricate the brake lever pivot with grease. Check to make sure that all the bolts are tightened to the correct torque specifications. Pad wear Indicator D-1. Wear indicators Instructions on bleeding the brakes can be found on www.trpbrakes.com or on www.youtube.com/user/TRPBrakes For questions about setup, usage or general inquiries, please contact TRP by e-mail at email@example.com or by phone toll free in US, 877-807-4162 or outside US 1-801-648-7079.