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General Safety Information
WARNING
– To avoid serious injuries:
If a problem occurs with the operation of the sensor
that limits automatic gear shifting, the pedals will
suddenly become easy to turn, and this may cause a
fall.
If you feel that there is a problem with gear shifting
operation when you get onto the bicycle, do not ride
the bicycle, and ask a professional bicycle dealer to
check the operation.
Do not operate the mode switch while riding the
bicycle, otherwise your fingers may get caught in the
wheel or the bicycle may become unstable because
of being ridden with one hand, and this may cause a
fall.
Mode switch
It is important to completely understand the
operation of your bicycle's brake system. Improper
use of your bicycle's brake system may result in a
loss of control or an accident, which could lead to
sever injury. Because each bicycle may handle
differently, be sure to learn the proper braking
technique (including bicycle control characteristics)
and operation of your bicycle. This can be done by
consulting your professional bicycle dealer and the
bicycle owner's manual, and by practicing your riding
and braking technique.
Use a neutral detergent to clean the chain. Do not
use alkaline or acidic detergents that are designed to
remove things such as rust, as they can damage the
chain and cause the chain to break.
Check that the wheels are fastened securely before
riding the bicycle. If the wheels are loose in any way,
they may come off the bicycle and serious injury may
result.
Obtain and read the service instructions carefully
prior to installing the parts. Loose, worn, or damaged
parts may cause serious injury to the rider.
We strongly recommend only using genuine
Shimano replacement parts.
Read these Technical Service Instructions carefully,
and keep them in a safe place for later reference.
CAUTION
– To avoid serious injuries:
The hub dynamo generates an extremely high
voltage. Never touch the connection terminal of the
hub dynamo directly while riding the bicycle or while
the wheel is spinning. Touching the dynamo terminal
may cause an electric shock.
Never put your feet on the bell crank arms, otherwise
it may cause problems when gear shifting.
If using a hub dynamo other than the DH-2N01, it
may damage the automatic unit or cause problems
with gear shifting.
This automatic unit is an automatic gear shifting
system that determines shifting points in accordance
with the bicycle's speed (rotation of the wheels).
Because of this, gear shifting will occur regardless of
the intentions of the rider, and so you may feel
unexpected shifting shocks at the point when shifting
occurs. Make sure that you fully understand the
shifting characteristics and are used to the feel of
shifting before riding the bicycle.
Avoid continuous application of the brakes when
riding down long slopes, as this will cause the
internal brake parts to become very hot, and this
may weaken braking performance. It may also cause
a reduction in the amount of brake grease inside the
brake, and this can lead to problems such as
abnormally sudden braking.
Spin the wheel and confirm that the braking force of
the coaster brake is correct.
If the brake is used frequently, the area around the
brake may become hot. Do not touch the area
around the brake for at least 30 minutes after you
finish riding the bicycle.
Area around the brake
NOTE:
This automatic unit will return the bicycle to first gear
when the bicycle stops.
Check the degree of parallel of the front fork end. If
the front fork end is severely out of parallel,
deformation of the hub axle may cause noise from an
obstruction inside the hub dynamo to be generated.
Install the hub dynamo to the front fork so that the side
with the connection terminal is on the right when
facing toward the front of the bicycle. If the side with
the connection terminal is facing toward the left, the
hub dynamo may not turn properly while riding.
Check that the hub dynamo connection terminal is
securely connected before using the hub dynamo.
For correct operation during gear shifting, a small
amount of noise might be generated between the pawl
inside the hub and the ratchet.
If the wheel becomes stiff and difficult to turn, you
should replace the brake shoes or lubricate with
grease.
Do not disassemble the internal hub mechanism.
Do not apply any lubricant to the inside of the hub,
otherwise the grease will come out and it may cause
problems with conductivity.
The hub dynamo will cause the turning of the wheel to
become slightly heavier because of the magnet inside
the hub.
Do not clean the bicycle with high-pressure sprays. If
moisture gets into the components, it may cause
operating problems or rust.
Do not disassemble any of the units, otherwise they
may not operate correctly.
Use a dry cloth or a cloth that is lightly moistened with
neutral detergent to clean the unit. Solvents such as
thinner will damage the unit's surface.
You should periodically wash the sprockets in a
neutral detergent and then lubricate them again. In
addition, cleaning the chain with neutral detergent and
lubricating it can be a effective way of extending the
useful life of the sprockets and the chain.
If the chain keeps coming off the sprockets during use,
replace the sprockets and the chain.
Each unit has a waterproof design to protect it when
riding in the rain, but do not immerse the units in
water.
For details on installing the bicycle wheels, refer to the
Shimano website at www.shimano.com or contact a
professional bicycle dealer.
Be sure to read the technical service instructions for
the CN-NX01 together with these technical service
instructions.
Parts are not guaranteed against natural wear or
deterioration resulting from normal use.
For any questions regarding methods of handling or
maintenance, please contact the place of purchase.
SI-7CB0A
AI-3S01
SG-3C01
SM-BC01
DH-2N01
CN-NX01
FC-S090
Automatic Unit
Rear Hub
Bell Crank
Hub Dynamo
Chain
Front Chainwheel
Technical Service Instructions
SG-3C01 Rear Hub
SM-BC01 Bell Crank
Installation of the hub to the
frame
Mount the chain onto the sprocket, and then set the hub
axle and the brake arm into the fork end, while making
sure that the projecting parts on the brake arm are
facing the correct way.
Groove in fork end
Projecting part of brake arm
Projecting part of brake arm
Note:
If using a reverse fork end, be sure to use a chain
tensioner at the right side.
Total thickness of fork end
and chain tensioner should
be 4.5 – 9.5 mm.
Lock nut
Fork end
Chain tensioner
Installation of the right-hand
bell crank
After placing the hub unit onto the frame, install the
1.
bell crank parts in the order shown in the illustration
below, and secure them with the hub nut.
Cover fixing stay
Bell crank unit
Pull the link forward when
tightening the hub nut. Be careful
not to bend the bracket with the
wrench or other tool being used.
Do not touch
Wrench
Do not
Do not touch
Tightening torque:
30 – 45 N·m
{260 – 390 in. lbs.}
Insert the push rod into the hub axle.
2.
touch
Link
The correct amount of
protrusion for the push rod is
approximately 14 mm from the
end of the hub axle.
Tighten the cable adjustment bolt of the bell crank
3.
unit, pass the inner cable through the cable
adjustment bolt, and hook the inner cable drum into
the groove in the link.
2
For details on adjusting the SM-BC01 bell crank,
read the "N Position Adjustment" section of the
AI-3S01 service instructions.
Cable adjustment bolt
Hook
Inner cable drum
Knurled
washer
(2 mm)
1
Tighten
Groove in link
Hub nut
(B.C. 3/8")
Installation of the left-hand parts
Place the non-turn washer onto the outside of the
1.
left side of the hub axle. At this time, turn the hub
axle so that the projection of the non-turn washer fits
into the groove of the fork end.
The projecting part should be on the
fork end side.
Install the non-turn washer so that the
projecting part is securely in the fork
end groove on either side of the hub
axle.
Non-turn washer
(color: Yellow)
Install the bicycle wheel to the frame with the hub
2.
nut in the order shown in the illustration below.
Knurled washer (2 mm)
Hub nut (B.C. 3/8")
Tightening torque:
30 – 45 N·m {260 – 390 in. lbs.}
Install the brake arm parts onto the fork end in the
3.
order shown in the illustration below.
Brake arm fixing washer A
Brake arm fixing bolt A
Brake arm fixing
bolt B
Tightening torque:
3 – 5 N·m {26 – 43 in. lbs.}
Attach the hub cover, and secure it with the cover
4.
mounting nut.
Hub cover
10 mm
Allen key
Cover mounting nut (B.C. 3/8")
Tightening torque:
15 – 25 N·m {130 – 217 in. lbs.}
Note:
The cover mounting nut for the rear hub and
the hub nut for the hub dynamo are not
interchangeable.
Brake arm fixing washer B
Brake arm fixing bolt B
FC-S090 Front Chainwheel
Installation of the bottom bracket
Use the special tool (TL-UN74-S) to install the bottom
bracket. First install the main unit, then install the adapter.
Adapter
TL-UN74-S
Main unit
BB-UN26
Tightening torque:
50 – 70 N·m {434 – 608 in. lbs.}
Installation of the front chainwheel
Install the right-hand crank arm by using the special
1.
tool (TL-FC10) to tighten the crank arm mounting
bolt.
TL-FC10
Firmly
tighten
Tightening torque:
35 – 50 N·m
{304 – 434 in. lbs.}
Hook the tab inside the right-hand crank arm cap
2.
into the right-hand crank arm to attach the right-hand
crank arm cap, and then secure it by tightening the
crank arm cap mounting screw.
Tightening torque:
1.5 – 2.0 N·m {13 – 17 in. lbs.}
Right-hand crank arm cap
Crank arm cap
mounting screw
Install the left-hand crank arm by using the special
3.
tool (TL-FC10) in the same way as for the right-hand
crank arm. After that, install the left-hand crank arm
cap as shown in the illustration.
Left-hand crank arm cap
Tab
Tab
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DH-2N01 Hub Dynamo
Connection of the hub
dynamo cables
At the hub dynamo
Insert the hub dynamo cables that are coming out from
the frame into the connector cap as shown in the
illustration, and then install the connector cover. Next,
place the connector cover onto the hub dynamo so that
the side with the black cable is aligned with the ground
connection terminal of the hub dynamo.
Ground cable (black)
Approx.
Approx.
16 mm
16 mm
Connector
cap (gray)
Connector
cover (black)
Ground
connection
terminal
Hub dynamo
connection terminal
Note:
When removing the bicycle wheel, first remove the
connector cover. If the cables are pulled strongly, it
may break the cable wires or cause poor contacts.
Furthermore, when installing the wheel, first secure
the wheel to the front forks and then connect the
connector cover.
Connector cover
Connect
At the automatic unit
At the automatic unit, insert the connection terminals into
the connector cover until they click into place. Insert the
connection terminal for the black cable into the ground
side of the connector cover at this time.
Connector cover
Note:
Bend the cable
wires and run them
along the grooves.
Insert
Bend
Groove
Do not allow the
cable wires to
touch each other.
Note:
Set so that it faces
the right way.
Press in until you
hear a click.
Front fork
Make sure that the
connection terminals
are the right way up.
Installation of the front wheel
Install the wheel following the procedure shown
in the illustration below so that the side with the
hub dynamo connection terminals is on the right
side when looking toward the front of the bicycle.
Note:
Make sure that the connection terminal cables do
not touch the hub shell.
Leave a gap
Non-turn
washer
Hub cover
Front fork
Align the D-shaped
hole in the non-turn
washer with the
D-shaped edge of
the hub axle (at both
left and right).
Non-turn washer
Connection terminal
Align the hollow of
the non-turn washer
with the projecting
part inside the hub
cover.
10 mm
Allen key
Hub nut (M9)
Tightening torque:
20 N·m
{174 in. lbs.}
Note:
Provisionally install the non-turn washers, hub
covers and hub nuts at both the left and right, and
then fully tighten the hub nuts.
If you concentrate on fully tightening or fully
loosening only one hub nut at a time when
tightening or loosening the hub nuts, it will force the
hub axle to turn and this will cause the lock nuts to
loosen or tighten. To avoid this, you should tighten
the left and right nuts each a little bit at a time.
Connection
terminal
D-shaped
Hub axle
AI-3S01 Automatic Unit
Operation of the mode switch
The gear shifting timing can be adjusted to one of five
settings.
If you prefer faster pedaling
(Gear shifting timing is delayed)
If you prefer slower, firmer pedaling
(Gear shifting timing is advanced)
Use a flat-tipped
*
screwdriver or similar
tool to turn the dial.
Used for N position adjustment.
(When the front wheel is turned so that
the system is fully charged, the gear will
shift automatically to 2nd gear.)
N position adjustment
At the main unit
When using the hub dynamo power
supply
Set the mode switch to "N", and then set the winder unit
of the automatic unit to the N position. At this time, turn
the front wheel to fully charge the power. When the
power is fully charged, the gear will shift automatically
from 1st to 2nd gear.
Mode switch
When not using the hub dynamo power
supply
Use a Phillips screwdriver to loosen the two cover
1.
fixing screws, and then remove the main unit cover.
Cover fixing screw
Cover fixing
screw
Insert a 5 mm Allen key into the hexagonal recess in
2.
the winder unit as shown in the illustration, and use it
to turn the winder unit in the direction of the arrow
until it is against the stopper.
5 mm Allen key
Next, turn the winder unit back in the direction of the
3.
arrow until it stops (N position).
N position
Install the main unit cover, and then securely tighten
4.
the two cover fixing screws.
Cover fixing screw
Cover fixing
screw
Main unit
cover
Tightening torque:
0.3 – 0.6 N·m {2.6 – 5.2 in. lbs.}
Note:
If the automatic unit has been removed from the
frame, place the automatic unit securely onto the
mounting rail and then tighten the main unit fixing
screw.
Tightening torque:
1.0 – 1.2 N·m {9 – 10 in. lbs.}
At the bell crank
Use a Phillips screwdriver to loosen the two cover
1.
mounting screws, and then remove the bell crank
cover.
Bell crank cover
Cover mounting
screw
Cover mounting screw
Turn the cable adjustment bolt of the bell crank
3.
counterclockwise so that the end of the hub axle and
the red line on the push rod are aligned.
Cable adjustment bolt
Red line on
push rod
Align the red line with
the end of the hub axle
Rotate the front wheel rapidly and check that the
3.
gears change from 1st to 2nd to 3rd. If the gear does
not change from 2nd to 3rd, stop rotating the front
wheel and turn the cable
adjustment bolt of the bell crank
half a turn clockwise. After
this, check the shifting of
the gears once more.
After adjusting the bell crank, secure the cable
4.
adjustment bolt by tightening
the cable adjustment nut.
Checking operation
Set the mode switch to a position other than "N".
1.
Install the bell crank cover, and then securely tighten
5.
Mode switch
Turn the front wheel to fully charge the power. When
2.
the power is fully charged, the gear will shift
automatically from 2nd to 1st gear.
the two cover fixing screws.
Cover fixing screw
Tightening torque:
1.0 – 1.5 N·m {9 – 13 in. lbs.}
Troubleshooting
For any questions regarding installation or adjustments, please contact the place of purchase.
Symptom
No gear shifting
occurs.
Check
Are the cables connected correctly?
Is the gear shifting cable connected correctly?
Is the gear shifting cable broken?
Does the bell crank move smoothly?
Does the push rod move smoothly?
Is the proper push rod being used?
Does the gear shifting cable work smoothly?
Is the shifting cable winder on the automatic
unit blocked with mud or small stones?
Has the N position been adjusted correctly?
Is the mode switch at the "N" position?
Connect the cables correctly between the automatic
unit and the hub dynamo.
Connect the cable correctly at the automatic unit
and the bell crank.
Replace the cable with a new one.
Replace with a new part, or eliminate the cause of
the problem.
Replace with a new part, or eliminate the cause of
the problem.
Use the proper push rod.
Replace with a new part, or eliminate the cause of
the problem.
Remove the cause of the problem.
Refer to "N position adjustment".
Set the mode switch to a position other than "N".
Remedy
Cable adjustment nut
Tightening torque:
1.5 – 2.5 N·m
{13 – 22 in. lbs.}
Bell crank cover
Cover fixing
screw
Ground side
Black
Hub dynamo cable
Main unit
cover
Note:
If the main unit cover cannot be removed
because the frame is in the way, remove the
entire automatic unit from the mounting rail.
Before carrying out N position adjustment, push the
2.
link of the bell crank to take up any slack in the inner
cable.
These service instructions explain how to use and maintain the
Shimano bicycle parts which have been used on your new
bicycle. For any questions regarding your bicycle or other
matters which are not related to Shimano parts‚ please contact
the place of purchase or the bicycle manufacturer.
Please note: Specifications are subject to change for improvement without
notice. (English)
One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003
Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222
3-77 Oimatsu-cho, Sakai-ku, Sakai, Osaka 590-8577, Japan
C
Sep. 2006 by Shimano Inc. PIT. SZK. Printed in China
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