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(English)
DM-EP800-04
Dealer's Manual
ROAD MTB Trekking
City Touring/
Comfort Bike
DU-EP800
DU-EP800-CRG
FC-M8150
FC-EM900
FC-EM600
SM-CRE80
SM-CRE80-B
SM-CRE80-12
SM-CRE80-12-B
SM-CRE80-12-SB
SM-CRE61
EW-SS300
EW-SS301
EW-SS302
DC-EP800-A
DC-EP800-B
DC-EP800-G
URBAN SPORT E-BIKE
EP800 Series
Page 2
Contents
Contents ...................................................................................2
IMPORTANT NOTICE ..................................................................4
TO ENSURE SAFETY ................................................................... 5
Booklet structure ..................................................................................10
List of tools to be used .......................................................... 12
Installing electrical parts ......................................................13
Names of parts .....................................................................................13
• External type ........................................................................................................................... 13
• Internal type ........................................................................................................................... 14
Overall wiring diagram ........................................................................15
Specifications ........................................................................................16
Electric wires .........................................................................................16
• Supported products ................................................................................................................ 16
• Conversion adapter ................................................................................................................ 18
• Connecting/disconnecting the electric wires ........................................................................ 18
Installing cockpit peripheral components .......................................... 22
Installing the battery mount and parts .............................................. 22
Installing the speed sensor ..................................................................22
• Generic type ............................................................................................................................ 22
• Type designed exclusively for use with a disc brake rotor with magnet unit .................... 24
• Type designed exclusively for use with a lock ring with magnet ........................................ 25
Installing the drive unit and peripheral parts ..................... 27
Installing the drive unit .......................................................................27
Connecting the power cord .................................................................29
• Connection method ............................................................................................................... 29
• Removal method .................................................................................................................... 30
Connecting cockpit peripheral parts and electronic gear shifting
components .......................................................................................... 30
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Connecting the speed sensor .............................................................. 31
Connecting the light cables ................................................................. 32
Installing the drive unit cover ............................................................. 34
• Affixing the thermal hazard label ......................................................................................... 35
Installing the chainring unit and crank arms .....................................35
Installing the arm covers .....................................................................40
Measuring and adjusting the chain tension ......................................42
• Manual adjustment ................................................................................................................ 43
• Measuring and adjusting with TL-DUE60 ............................................................................. 43
Connection and communication with devices ....................46
Maintenance ........................................................................... 47
Replacing the chainring unit ...............................................................47
Replacing the chainring ....................................................................... 48
Replacing the chain guard ................................................................... 49
Replacing the arm cover ...................................................................... 50
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IMPORTANT NOTICE
IMPORTANT NOTICE
• This dealer's manual is intended primarily for use by professional bicycle mechanics.
Users who are not professionally trained for bicycle assembly should not attempt to
install the components themselves using the dealer's manuals.
If any part of the information on the manual is unclear to you, do not proceed with the
installation. Instead, contact your place of purchase or a distributor for assistance.
• Make sure to read all manuals included with each product.
• Do not disassemble or modify the product other than as stated in the information
contained in this dealer's manual.
• All manuals and technical documents are accessible online at https://si.shimano.com.
• For consumers who do not have easy access to the internet, please contact a SHIMANO
distributor or any of the SHIMANO offices to obtain a hardcopy of the user's manual.
• Please observe the appropriate rules and regulations of the country, state or region in
which you conduct your business as a dealer.
®
• The Bluetooth
SIG, Inc. and any use of such marks by SHIMANO INC. is under license.
Other trademarks and trade names are those of their respective owners.
word mark and logos are registered trademarks owned by the Bluetooth
For safety, be sure to read this dealer's manual thoroughly before use, and
follow it for correct use.
The following instructions must be observed at all times in order to prevent personal injury
and physical damage to equipment and surroundings.
The instructions are classified according to the degree of danger or damage which may occur
if the product is used incorrectly.
Failure to follow the instructions will result in death or serious
DANGER
injury.
WARNING
CAUTION
Failure to follow the instructions could result in death or
serious injury.
Failure to follow the instructions could cause personal injury or
physical damage to equipment and surroundings.
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TO ENSURE SAFETY
DANGER
Be sure to also inform users of the following:
Handling the battery
• Do not deform, modify, disassemble, or apply solder directly to the battery. Doing so may
cause leakage, overheating, bursting, or ignition.
• Do not leave the battery near sources of heat such as heaters, and do not heat the
battery or throw it into a fire. Doing so may cause bursting or ignition.
• Do not throw or subject the battery to strong shock. Doing otherwise may cause it to
overheat, burst, or ignite.
• Do not place the battery into fresh water or sea water, and do not allow the battery
terminals to get wet. Doing otherwise may cause it to overheat, burst, or ignite.
• When charging the specified battery, use the specified battery charger for charging and
observe the specified charging conditions. Doing otherwise may cause overheating,
bursting, or ignition.
WARNING
• Be sure to follow the instructions provided in the manuals when installing the product.
Only use SHIMANO genuine parts. If a component or replacement part is incorrectly
assembled or adjusted, it can lead to component failure and cause the rider to lose
control and crash.
•
• For information on products not explained in this manual, refer to the manuals for each
Wear approved eye protection while performing maintenance tasks such as
replacing components.
product.
Be sure to also inform users of the following:
• Do not pay excessive attention to the cycle computer display while riding. Doing so may
result in an accident.
• Check that the wheels are fastened securely before riding the bicycle. Using the axle
release lever incorrectly may cause the wheel to fall off, etc. and lead to serious injury
due to a fall.
• Be sufficiently familiar with how to start the power assisted bicycle before riding on busy
streets. You may start the bicycle unexpectedly, which may result in an accident.
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• Ensure that head and tail lights can turn on before riding the bicycle.
• Do not disassemble the product. Disassembling may cause injury.
• Do not leave the cycle computer in an extremely high temperature surrounding
environment such as in a closed vehicle on a hot day, or near a heater. If a battery is
incorporated, it could result in an explosion of the built-in battery or the leakage of
flammable liquid or gas.
• Do not expose the cycle computer to excessively low pressures. If a battery is
incorporated, it could result in an explosion of the built-in battery or the leakage of
flammable liquid or gas. Transporting this product by air is not a problem.
• When charging the battery while it is installed on the bicycle, do not move the bicycle.
The battery charger's power plug may come loose and not be fully inserted into the
electrical outlet, resulting in a risk of fire.
• Do not touch the drive unit when it has been continuously used for a long period of
time. The surface of the drive unit becomes hot and could cause burns.
Lithium-ion battery
• If any liquid leaking from the battery gets into your eyes, immediately wash the affected
area thoroughly with clean water such as tap water without rubbing your eyes, and seek
medical attention immediately. If this is not done, the battery liquid may damage your
eyes.
• Do not recharge the battery in very humid places or the outdoors. Doing so may result in
electric shock.
• Do not insert or remove the plug while it is wet. Doing so may result in electric shock. If
the inside of the plug is wet, dry it thoroughly before inserting it.
• If the battery does not become fully charged even 2 hours after the designated charging
time, immediately unplug the battery from the electrical outlet and contact the place of
purchase. Doing otherwise may cause it to overheat, burst, or ignite.
• Do not use the battery if it has any noticeable scratches or other external damage. If this
is not observed, bursting, overheating or problems with operation may occur.
• Do not use it outside of the operating temperature range of the battery. If it is used or
stored in temperatures which are outside these ranges, fire, injury or problems with
operation may occur.
1. During discharge: -10°C - 50°C
2. During charging: 0°C - 40°C
For installation to the bicycle and maintenance
• Be sure to remove the battery and charging cable before wiring or attaching parts to the
bicycle. Failure to do so may cause an electric shock.
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• The two left crank screws should be tightened alternately in stages rather than each fully
tightened at once. Use a torque wrench to check that the tightening torques are within
the range of 12 - 14 N·m. Also, after riding approximately 100 km (60 miles), use a torque
wrench to re-check the tightening torques. Thereafter, continue to check the tightening
torques periodically. If the tightening torques are too weak or if the fixing screws are not
tightened alternately in stages, the left crank may come off and the bicycle may fall over,
and serious injury may occur as a result.
• Clean the chain with an appropriate chain cleaner regularly. Intervals between
maintenance depend on the use and riding circumstances.
• Never use alkali- or acid-based solvents such as rust cleaners. If those solvents are used
the chain might break and cause serious injury.
Disposal precautions
• Observe all federal, state and local environmental regulations when disposing of a cycle
computer that incorporates a battery. Disposal of this product into fire or a hot oven, or
mechanically crushing or cutting of it, can result in an explosion of the built-in battery.
CAUTION
Be sure to also inform users of the following:
• Observe the instructions in the manual for the bicycle in order to ride safely.
• Periodically check the battery charger and adapter, particularly the cord, plug, and case,
for any damage. If the battery charger or adapter is damaged, consult the place of
purchase.
• Use the product under the supervision of someone responsible for safety, and only as
instructed. Do not allow anyone (including children) with reduced physical, sensual, or
mental capacity, or those without experience or knowledge, to use the product.
• Do not allow children to play near the product.
• Never modify the system. Doing so may cause a system error.
Lithium-ion battery
• Do not leave the battery in a place exposed to direct sunlight, inside a vehicle on a hot
day, or other hot places. This may result in battery leakage.
• If any leaked fluid gets on your skin or clothes, wash it off immediately with clean water.
The leaked fluid may damage your skin.
• Store the battery in a safe place out of the reach of children.
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NOTICE
Be sure to also inform users of the following:
• If any malfunction or trouble occurs, consult the place of purchase.
• Be sure to attach dummy plugs to any unused E-TUBE ports.
• For installation and adjustment of the product, consult the place of purchase.
• The components are designed to be fully waterproofed to withstand wet weather riding
conditions. However, do not deliberately place them into water.
• Do not clean the bicycle in a high-pressure wash. If water gets into any of the
components, operating problems or rusting may result.
• Handle the components carefully, and avoid subjecting them to strong shock.
• Do not turn the bicycle upside down. There is a risk of damage to the cycle computer and
switch unit.
• Although the bicycle still functions as a normal bicycle even when the battery is removed,
the light will not turn on if it is connected to the electric power system. Be aware that
using the bicycle under these conditions will be considered non-observance of the road
traffic laws in Germany.
• When carrying the assist bicycle in a car, remove the battery from the bicycle and place it
on a stable surface in the car.
• Before connecting the battery, make sure that there is no water collecting in the area
where the battery will be connected (connector), and that it is not dirty.
• When charging the battery while it is mounted on the bicycle, be careful of the
following:
– Before charging, check that there is no water on the charging port or the plug of the
battery charger.
– Check that the battery mount is locked before charging.
– Do not remove the battery from the battery mount while charging.
– Do not ride with the battery charger mounted.
– Close the cap on the charging port when not charging.
– Fix the bicycle in place when charging, so that it does not tip over.
• It is recommended to use a SHIMANO genuine battery. If using a battery from another
company, be sure to read the owner's manual thoroughly prior to use.
• Some of the important information in this dealer's manual can also be found on the
device labels.
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• The number written on the key of the battery mount is necessary when purchasing a
spare key. Store it carefully.
• Use a damp, well wrung out cloth, when cleaning the battery and plastic cover.
• For any questions regarding methods of installation and maintenance, please contact
your place of purchase.
• Contact the place of purchase for updates of the component software. The most up-to-
date information is available on the SHIMANO website.
• Products are not guaranteed against natural wear and deterioration from normal use
and aging.
• For maximum performance we highly recommend SHIMANO lubricants and maintenance
products.
Connection and communication with PC
Using a PC linkage device to connect a PC to your bicycle (system or component) allows
you to use E-TUBE PROJECT Professional to perform a range of tasks, such as
customizing individual components or the entire system, or updating firmware.
• PC linkage device: SM-PCE02
• E-TUBE PROJECT Professional: PC application
• Firmware: Software inside each component
Connection and communication with smartphone
Cycle computers compatible with Bluetooth® LE can connect to E-TUBE PROJECT Cyclist
installed on a smartphone. E-TUBE PROJECT Cyclist enables you to use a range of
functions, such as customizing the system, or updating firmware.
• E-TUBE PROJECT Cyclist: Application for smartphones
• Firmware: Software inside each component
Disposal information for countries outside the European Union
This symbol is only valid within the European Union.
Follow local regulations when disposing of used batteries. If you are not
sure, consult the place of purchase or distributor.
The actual product may differ from the illustration because this manual is
intended mainly to explain the procedures for using the product.
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Booklet structure
User's manual
SHIMANO STEPS series user's manuals are split among several booklets, as described
below.
The latest manuals are available on our website (https://si.shimano.com).
Name Details
SHIMANO STEPS User's Manual
This is the basic manual for the SHIMANO STEPS series. It
contains the following content:
• SHIMANO STEPS quick guide
• Basic operations when riding
• How to operate assist bicycles that use flat handlebars,
such as city, trekking, or MTB type bicycles
• General troubleshooting
SHIMANO STEPS User's Manual for
Drop Handlebar Bicycles(separate
booklet)
SHIMANO STEPS Special Battery and
Parts User's Manual (separate
booklet)
SHIMANO STEPS Cycle Computer
User's Manual
This booklet describes how to operate assist bicycles that
use a drop handlebar and are controlled using dual control
levers. This should be read along with the SHIMANO STEPS
User's Manual.
It contains the following content:
• How to charge and handle the SHIMANO STEPS special
battery
• How to attach and remove the SHIMANO STEPS special
battery to the bicycle
• How to use the satellite system ON/OFF switch and
satellite charging port
• How to read the battery LEDs when charging or during an
error, and how to handle errors
It contains the following content:
• Method for configuring settings via the main body
buttons and switch unit
• Wireless communication method
• Problems and errors / warnings and remedies
Switch Unit User's Manual
This is the assist switch and shift switch user's manual. It
describes switch unit handling and operations only.
Dealer's manual
SHIMANO STEPS series dealer's manuals are split among several booklets, as described
below.
The latest manuals are available on our website (https://si.shimano.com).
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Name Details
SHIMANO STEPS Dealer's Manual (this
document)
SHIMANO STEPS Dealer's Manual for
Drop Handlebar Bicycles (separate
booklet)
This is the basic manual for the SHIMANO STEPS series.
• Overall wiring diagram
• Overall flow of operations for installing the SHIMANO
STEPS components to an assist bicycle
• Installation / removal and maintenance of the drive unit
area
• Installation / removal of the speed sensor
It specializes in the following information regarding assist
bicycles that use a drop handlebar and are controlled using
dual control levers. This should be read along with the
SHIMANO STEPS Dealer's Manual:
• Overall wiring diagram
• Cautions to follow when installing the drive unit
SHIMANO STEPS Special Battery and
Parts Dealer's Manual (separate
booklet)
SHIMANO STEPS Cycle Computer and
Switch Unit Parts Dealer's Manual
SHIMANO STEPS Chain Device
Dealer's Manual
It contains the following content:
• How to install the battery mount
• How to install the satellite system ON/OFF switch and
satellite charging port
It contains the following content:
• Installation and maintenance of the SHIMANO STEPS
special cycle computer, special junction [A] and switch
unit
• How to connect to E-TUBE PROJECT Professional
This manual describes the installation and maintenance of
the SHIMANO STEPS special chain device.
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List of tools to be used
List of tools to be used
The following tools are needed for installation/removal, adjustment, and maintenance
purposes.
Component Location used/screw
Tool
type
Electric wire Plug TL-EW02 / TL-EW300
Speed sensor fixing
Speed sensor
(EW-SS300)
Speed sensor
(EW-SS301 / EW-
SS302)
Drive unit
Light cable Light cable fixing screw
Magnet unit fixing
Speed sensor fixing
Drive unit fixing screw -
screw
screw
screw
Drive unit cover
4 mm hexagon wrench /
hexalobular [#25]
Cross head screwdriver [#2]
Hexalobular [#10]
Contact the bicycle
manufacturer.
Cross head screwdriver [#2]
Cross head screwdriver [#2]
Crank arm
Chainring unit
Chain
Cap
Clamp screw
Lock ring
Chain guard
Arm cover
Chainring
Tension adjustment for
internal geared hub
models
TL-FC16 / TL-FC18
5 mm hexagon wrench
TL-FC39 + TL-FC33
TL-FC39 + TL-FC36
Cross head screwdriver [#2]
TL-FC22 + 5 mm hexagon
wrench / hexalobular [#30]
TL-DUE60
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Installing electrical parts
(F)
(E) (B)
(H)
(G)
(C)
Names of parts
Installing electrical parts
Names of parts
External type
(O)
(L)
(K)(J)
(A)
(C)
(E)
(G)
(N)
(I)
External type battery*1
Drive unit
Crank arm
Speed sensor*2
(G)
(D)
(A)
(B)
(D)
(F)
(H)
(M)
Battery mount
Drive unit cover (left side and bottom
side)
Chainring unit
Shifting unit*3
(I)
(K)
(M)
(O)
*1 Depending on the frame, the battery may be installed at a location different from the position specified in the
figure.
*2 Attach it to one of the two locations specified in the figure.
*3 Electronic gear shifting: Di2 rear derailleur or motor unit + Di2 internal geared hub
Mechanical gear shifting: rear derailleur or internal geared hub
Disc brake rotor
Switch unit (shift switch) or shift lever
Electric wire
Battery charger
(J)
(L)
(N)
Switch unit (assist switch)
Cycle computer or junction [A]
Chain device
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Installing electrical parts
(F)
(E)
(H)
(G)
Names of parts
Internal type
(A)
(C)
(O)
(N)
(I)
Internal type battery*1
Drive unit
(G)
(C)
(D)
(B)
(D)
(K)(J)
(L)
(M)
(A)
Battery mount*1
Drive unit cover (left side and bottom
side)
(E)
(G)
(I)
(K)
(M)
(O)
*1 Attach the battery mount and battery inside the frame. Depending on the assist bicycle, the battery may be
installed at a location different from the position specified in the figure.
*2 Attach it to one of the two locations specified in the figure.
*3 Electronic gear shifting: Di2 rear derailleur or motor unit + Di2 internal geared hub
Mechanical gear shifting: rear derailleur or internal geared hub
Crank arm
Speed sensor*2
Disc brake rotor
Switch unit (shift switch) or shift lever
Electric wire
Battery charger
(F)
(H)
(J)
(L)
(N)
Chainring unit
Shifting unit*3
Switch unit (assist switch)
Cycle computer or junction [A]
Chain device
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Installing electrical parts
Overall wiring diagram
Overall wiring diagram
NOTICE
• The maximum electric wire length between components is 1,600 mm. Ensure that the
total length is 1,600 mm or less when connecting via a junction [B] or conversion
adapter.
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Installing electrical parts
Specifications
Specifications
Operating
temperature range:
Discharging
-10 - 50°C
Battery type
Lithium-ion battery
Operating
temperature range:
Charging
Storage temperature
Storage temperature
(battery)
Charging voltage
Charging time
0 - 40°C
-20 - 70°C
-20 - 60°C
100 - 240 V AC
Refer to the “SHIMANO
STEPS Special Battery
and Parts User's
Manual.”
Nominal capacity
Rated voltage
Drive unit type
Motor type
Rated drive unit
power
Refer to the “SHIMANO
STEPS Special Battery
and Parts User's
Manual.”
36 V DC
Midship
Brushless DC
250 W
TECH TIPS
• The maximum speed provided by assist is set by the manufacturer, but may vary
depending on the conditions under which the bicycle is used.
• The latest manual information can be accessed on our website (https://si.shimano.com).
Electric wires
There are two types of electric wire: the EW-SD300 and the EW-SD50. The supported electric
wire differs based on the component model. Check the component specifications on the
SHIMANO product website in advance (https://productinfo.shimano.com/).
Supported products
The following products support each type of electric wire.
Product name Intended purpose EW-SD300 type EW-SD50 type
SHIMANO original
tool
Dummy plug Blocking empty ports Y7HE30000 Y6VE15000
Connecting / disconnecting
the electric wires
TL-EW300 TL-EW02
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Installing electrical parts
Electric wires
Product name Intended purpose EW-SD300 type EW-SD50 type
EW-CL300-S
Cord clip
Cord cover
Grommet
Binding the wiring and the
outer casing / brake hose
together
Supporting / protecting
the electric wire (external
wiring)
Installing to the wire
insertion hole of a frame
that supports internal
wiring
(for shift outer casing)
EW-CL300-M
(for brake outer casing
and brake hose)
EW-CC300 SM-EWC2
EW-GM300-S
EW-GM300-M
Y70H98040
SM-GM01
SM-GM02
Cord band
Junction [A]
(for Di2)
Junction [B]
Conversion adapter
Supporting the electric
wire (flat handlebar
external wiring)
Gathering the wiring
around the cockpit. Also
has functions for changing
the shift mode, etc.
Conjoining the wiring
inside and outside the
frame
Refer to the “Conversion
adapter” section.
EW-CB300-S
EW-CB300-M
EW-CB300-L
-
EW-JC304
EW-JC302
EW-AD305 EW-AD305
SM-EWE1
EW-RS910
SM-EW90-A
SM-EW90-B
SM-JC41
SM-JC40
EW-JC200
EW-JC130
NOTICE
• The SHIMANO original tool used for installation/removal and the accessories used for
wiring differ for the EW-SD300 and EW-SD50. Be sure to use a compatible product.
• EW-CL300-S is marked with a groove in order to
differentiate it from EW-CL300-M.
17
Differentiation
groove
EW-CL300-M EW-CL300-S
Page 18
Installing electrical parts
Electric wires
Conversion adapter
A conversion adapter (EW-AD305) is required to connect the EW-SD50 to a component with an
E-TUBE port for the EW-SD300.
Conversion adapter (EW-AD305)
Electric wire (EW-SD300) Electric wire (EW-SD50)
Connecting/disconnecting the electric wires
Be sure to use the SHIMANO original tool to remove and insert electric wires.
NOTICE
• When connecting and disconnecting electric wires, do not forcibly bend the plug part.
It may result in a poor connection.
` Connecting the electric wire (EW-SD300)
Connect the electric wire to the E-TUBE port.
1. Set the plug of the electric wire to the TL-EW300.
If there is an alignment tab on the plug of the electric wire, check the shape of the
E-TUBE port you are trying to connect to, and set it aligned with the alignment tab.
Without alignment tab on plug
Groove
Guide
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Installing electrical parts
Alignment tab
With alignment tab on plug
Electric wires
Groove
Guide
2. Insert the plug on the electric wire into the E-TUBE port.
Push it straight in until you feel it click into place.
` Removing the electric wire (EW-SD300)
1. Remove the electric wire.
Plug
E-TUBE port
(1) Insert the TL-EW300 into the groove on the plug part of the electric wire.
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Installing electrical parts
(1) (2)
Electric wires
(2) Disconnect the electric wire from the E-TUBE port.
* As shown in the figure, use part (A) of the TL-EW300 as a fulcrum, move the tool like a
lever, then disconnect the plug part.
(A)
TECH TIPS
• If there is limited space to insert the tool, you can use the TL-EW300 as indicated
in the figure to disconnect the electric wire.
` Connecting the electric wire (EW-SD50)
Connect the electric wire to the E-TUBE port.
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Installing electrical parts
Plug
Electric wires
1. Set the plug of the electric wire to the TL-EW02.
If there is an alignment tab on the plug of the electric wire, set it aligned with the groove
on the SHIMANO original tool.
Without alignment tab on plug With alignment tab on plug
2. Insert the plug on the electric wire into the E-TUBE port.
Push it straight in until you feel it click into place.
E-TUBE port
` Removing the electric wire (EW-SD50)
1. Remove the electric wire.
(1) Insert the TL-EW02 into the groove on the plug of the electric wire.
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Installing electrical parts
(1) (2)
Installing cockpit peripheral components
(2) Disconnect the electric wire from the E-TUBE port.
* As shown in the figure, use part (A) of the TL-EW02 as a fulcrum, move the tool like a
lever, then disconnect the plug part. If there is limited space to insert the tool, lift the
TL-EW02 straight up and disconnect the electric wire.
(A)
Installing cockpit peripheral components
Refer to the “SHIMANO STEPS Cycle Computer and Switch Unit Parts Dealer's Manual.”
Installing the battery mount and parts
Refer to the “SHIMANO STEPS Special Battery and Battery Charger Parts Dealer's Manual.”
Installing the speed sensor
NOTICE
• For details on the compatibility of the speed sensor and drive unit, refer to the
compatibility information (https://productinfo.shimano.com/#/com).
Generic type
For model: EW-SS300 (SD300 type)
The generic type speed sensor can be installed regardless of the type of brake, such as rim
brake, roller brake, or coaster brake. Install the magnet unit on a spoke on the rear wheel.
1. Temporarily install the magnet unit to the spoke.
(1) Hold the speed sensor in its installation position on the frame and determine the
installation location of the magnet unit. The center of the magnet unit should be
aligned with the tip of the Δ marking on the speed sensor.
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Installing electrical parts
Speed sensor
Magnet unit
Spoke
Clearance between speed sensor and magnet
Installing the speed sensor
(2) Temporarily install the fixing screw.
Fixing screw
(Temporary)
2. Install the speed sensor.
Check that the clearance between the speed sensor and magnet unit is from 3 - 17 mm.
unit
3 - 17 mm
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Installing electrical parts
Clearance between speed sensor
and magnet unit is 3 to 17 mm
Clearance between speed sensor
Speed sensorMagnet unit
Installing the speed sensor
washer
and magnet unit exceeds 17 mm
Spacer
Speed sensor fixing screw (length 16 mm)Toothed
1.5 - 2 N·m
Speed sensor fixing screw (length 22 mm)
3. Secure the magnet unit.
Spoke
4. Route the electric wire for the speed sensor to the frame along the
chainstay and wire it to the drive unit.
1.5 - 2 N·m
1.5 - 2 N·m
Fixing screw
Type designed exclusively for use with a disc brake rotor with magnet unit
For model: EW-SS301 (SD300 type)
Use in combination with a disc brake rotor with magnet unit (rear wheel only).
1. Install the disc brake rotor to the wheel.
• Refer to the “Disc Brake” chapter of General Operations for the installation method.
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Installing electrical parts
Installing the speed sensor
• The disc brake rotor with magnet unit is the internal spline type. Install it using the
TL-LR15 SHIMANO original tool.
2. Install the speed sensor to the frame.
0.6 N·m
Speed sensor fixing screw
3. Affix the wire for the speed sensor to the chainstay and wire it to the
drive unit.
4. Install the rear wheel in the frame.
Type designed exclusively for use with a lock ring with magnet
For model: EW-SS302
Use in combination with a disc brake rotor (rear wheel only) secured with a lock ring with
magnet.
TECH TIPS
• For details on disc brake rotors that have a lock ring with magnet, check the SHIMANO
product website (https://productinfo.shimano.com/).
1. Install the disc brake rotor to the wheel using the lock ring with
magnet.
• Refer to the “Disc Brake” section of General Operations for the installation method.
• The lock ring with magnet is the internal spline type. Install it using the TL-LR15
SHIMANO original tool.
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Installing electrical parts
Installing the speed sensor
2. Install the speed sensor to the frame.
Insert the protrusion of the speed sensor into the frame, and secure the speed sensor.
Protrusion part
0.8 - 1.3 N·m
Speed sensor fixing screw
3. Affix the wire for the speed sensor to the chainstay and wire it to the
drive unit.
4. Install the rear wheel in the frame.
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Installing the drive unit and peripheral parts
Installing the drive unit
Installing the drive unit and
peripheral parts
Use the following procedure to install the drive unit and peripheral parts:
(1) Installing the drive unit
(2) Wiring to the drive unit
(3) Installing the drive unit cover
(4) Installing the chainring unit and crank arms
TECH TIPS
• To check the wiring of the drive unit on a completed bicycle, you will need to first
remove the drive unit cover. Remove the left cover to access the power cord and
terminal block.
Installing the drive unit
Before installing the drive unit to the frame, first check that all the wires that connect to the
drive unit have been routed to the drive unit installation area.
1. Secure the drive unit.
(1) Set the drive unit to the installation area of the frame.
(2) Tighten the fixing screws on the right side so that the drive unit makes firm contact
with the inner surface on the right side of the frame.
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Installing the drive unit and peripheral parts
(2)(1)
Installation hole
Installing the drive unit
(3) Tighten the fixing screws on the left side of the frame.
Right side
10 - 12.5 N·m
Front
Drive unit
(3)
Left side
Drive unit fixing screw (M8)
10 - 12.5 N·m
Drive unit fixing screw (M8)
Rear
NOTICE
• Drive unit fixing screws (M8) are not included with SHIMANO products. Use the
screws supplied by the bicycle manufacturer.
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Installing the drive unit and peripheral parts
Connecting the power cord
Connecting the power cord
Connection method
1. Connect the power cord.
Align the Δ marking on the drive unit's power port with the arrow marking on the tip of
the power cord, then insert the power cord until you feel a click.
* Check that it is securely connected.
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Installing the drive unit and peripheral parts
Connecting cockpit peripheral parts and electronic gear shifting components
Removal method
1. Remove the power cord.
Hold the groove on the plug and slide the tip of the plug to pull it out, as shown in the
figure.
Plug part of power cord
(when connected with the DU)
Plug part Plug part
When disconnecting the
plug
Connecting cockpit peripheral parts and
electronic gear shifting components
Connect wires from the cycle computer and electronic gear shifting components to the drive
unit's terminal block.
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Installing the drive unit and peripheral parts
Connecting the speed sensor
1. Connect the electric wires to the drive unit's E-TUBE ports.
E-TUBE port
Electric wire
NOTICE
• Be sure to attach dummy plugs to any unused E-TUBE ports.
Connecting the speed sensor
Connect the speed sensor's electric wire to the drive unit's terminal block.
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Installing the drive unit and peripheral parts
Connecting the light cables
1. Connect the electric wire to the drive unit's speed sensor port.
Speed sensor port
Speed sensor electric wire
Connecting the light cables
Connect the wires connected to the front and rear lights to the drive unit.
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Installing the drive unit and peripheral parts
Connecting the light cables
1. Loosen the fixing screws.
Fixing screw
2. Connect the light cables to the light connection terminals, then tighten
the fixing screws.
Light connection
terminal
33
0.6 N·m
Fixing screw
Page 34
Installing the drive unit and peripheral parts
Installing the drive unit cover
Installing the drive unit cover
• The appearance of the drive unit cover differs depending on the model, but the installation
method is the same.
• When also using a drive unit cover from another company, refer to the manual for the frame.
1. Install the left cover.
2. Install the guard.
0.6 N·m
Cover fixing screw
0.6 N·m
Cover fixing screw
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Installing the drive unit and peripheral parts
Installing the chainring unit and crank arms
Affixing the thermal hazard label
A thermal hazard label is affixed to the position shown in the figure on the guard (DC-EP800-G:
SHIMANO drive unit cover).
For bicycles that use custom covers from another company, refer to the position shown in the
figure to affix the thermal hazard label included with the DU-EP800 to a visible location around
the motor fins.
Motor fin
Thermal hazard label
Installing the chainring unit and crank arms
Install the rear wheel in the frame prior to performing the following procedures.
1. Set the left crank arm.
(1) Check that the stopper plate on the left crank arm is sticking out.
(2) Install the left crank arm so the wide part of its spline is aligned with the wide part of
the spline on the crank axle.
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Installing the drive unit and peripheral parts
Installing the chainring unit and crank arms
(3) Tighten the cap.
L
Left crank arm
(1)
Cross-section
Stopper plate
(3)
Cap
0.7 - 1.5 N·m
2. Secure the left crank arm.
(1) Press the stopper plate in.
* Check that the plate pin is firmly engaged.
(2)
Wide section Wide section
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Installing the drive unit and peripheral parts
Installing the chainring unit and crank arms
(2) Tighten both clamp screws alternately and equally to the specified tightening torque.
(1)
Cross-section
Plate pin
Stopper plate
12 - 14 N·m
Clamp screw (x 2)
(2)
NOTICE
• Set the stopper plate in the correct direction as shown in figure. For the left
crank arm, the figure depicts the part as looking from the back of the bicycle.
Cross-section
Bicycle sideOutward
• When installing the chain device, refer to the “SHIMANO STEPS Chain Device
Dealer's Manual” before installing the chainring using the following procedures.
• When installing the chain device, special fixing screws for magnesium products
are required. Make sure to use the fixing screws included with the drive unit.
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Installing the drive unit and peripheral parts
Chainring unit
Installing the chainring unit and crank arms
3. Install the chainring unit.
Axle
4. Install the chain.
Refer to the dealer's manual for the chain to use.
5. Secure the chainring unit.
(1) Install the lock ring (left-hand thread) by hand.
Chainring unit installation
spline
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Installing the drive unit and peripheral parts
Installing the chainring unit and crank arms
(2) Tighten the lock ring while holding the left crank stable.
Lock ring
NOTICE
35 - 45 N·m
• Do not use an impact wrench.
6. Set the right crank arm and tighten the cap.
R
Cap
0.7 - 1.5 N·m
Right crank arm
7. Secure the right crank arm.
(1) Press the stopper plate in.
* Check that the plate pin is firmly engaged.
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Installing the drive unit and peripheral parts
Installing the arm covers
(2) Tighten both clamp screws alternately and equally to the specified tightening torque.
12 - 14 N·m
(2)
Clamp screw (x 2)
(1)
Cross-section
Stopper plate
Plate pin
NOTICE
• The two screws should be tightened alternately in stages rather than each screw
being fully tightened at once.
• Set the stopper plate in the correct direction as shown in figure.
Cross-section
Bicycle side Outward
Installing the arm covers
If arm covers are included with the chainring, install the arm covers after installing the
chainring to the drive unit.
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Installing the drive unit and peripheral parts
Installing the arm covers
1. Install the arm covers to the left and right sides of the chainring.
Install so that the hooks catch the spider arm on the chainring.
Hook
Arm cover
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Page 42
Installing the drive unit and peripheral parts
Measuring and adjusting the chain tension
2. Tighten the two fixing screws from the left and right.
For internal geared hub models, proceed to “Measuring and adjusting the chain tension.”
0.8 N·m
Fixing
screw
0.8 N·m
Fixing screw
Measuring and adjusting the chain tension
The chain tension must be adjusted for internal geared hub models.
NOTICE
• The proper level of assistance may not be achieved if the chain tension is too high.
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Installing the drive unit and peripheral parts
Measuring and adjusting the chain tension
Manual adjustment
1. Check and adjust the chain tension.
Pull the upper side of the chain up and down with a force of approximately 10 N (1 kgf),
roughly in the middle between the drive unit axle and rear wheel axle. Adjust the chain
tension so that the chain has a slack of 15 mm or more.
Measuring and adjusting with TL-DUE60
When using chain tension measurement tool TL-DUE60, you can measure and adjust the chain
tension from either the top or bottom of the chain.
` Measuring and adjusting from the upper side of the
chain
1. Set TL-DUE60.
(1) Set TL-DUE60 to the upper side of the chain.
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Installing the drive unit and peripheral parts
Measuring and adjusting the chain tension
(2) Push TL-DUE60 down, and make it touch the chainring and rear sprocket.
Plunger
2. Adjust the chain tension so the plunger depresses slightly.
Make sure the top of the plunger does not stick out of the top of the frame.
` Measuring and adjusting from the lower side of the
chain
1. Set TL-DUE60.
(1) Set TL-DUE60 to the lower side of the chain.
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Installing the drive unit and peripheral parts
Measuring and adjusting the chain tension
(2) Push TL-DUE60 up, and make it touch the chainring and rear sprocket.
Plunger
2. Adjust the chain tension so the plunger depresses slightly.
Make sure that the flange of the plunger does not sink into the hollow of the frame.
Flange
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Connection and communication with devices
Connection and communication
with devices
Connecting the bicycle to a device allows you to configure the system, update firmware, and
more. Refer to the “SHIMANO STEPS Cycle Computer User's Manual” and the “SHIMANO STEPS
Special Cycle Computer and Switch Unit Parts Dealer's Manual” as well.
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Page 47
Maintenance
Replacing the chainring unit
Maintenance
Replacing the chainring unit
When replacing the chainring unit, make sure that the chain is attached.
Refer to “Installing the chainring unit and crank arms” for detailed instructions.
1. Remove the right crank arm.
2. Remove the lock ring (left-hand thread).
Hold the rear wheel firmly while removing the lock ring to keep the chainring from
turning.
TL-FC39
Lock ring
TL-FC36
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Maintenance
Installation hole
Replacing the chainring
TECH TIPS
• The TL-FC39 can be secured to the TL-FC36 with zip ties as indicated in the figure.
Zip tie
3. Replace the chainring unit.
Remove the chainring unit, then install a new chainring unit.
Refer to “Replacing the chainring” when replacing the chainring.
Replacing the chainring
Refer to “Replacing the chainring unit” for information on how to remove the chainring unit.
1. Remove the chainring unit.
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Maintenance
Replacing the chain guard
2. Remove the chainring, then replace it with a new chainring.
Tighten 4 chainring fixing bolts alternately and equally to the specified tightening torque.
“INSIDE” or model name mark
X
X
-
X
X
X
X
X
12 - 14 N·m
Chainring fixing bolt
Chainring fixing nut
4-arm adapter
Chainring
Replacing the chain guard
To replace the chain guard, first remove the chainring unit from the bicycle.
Refer to “Replacing the chainring unit” for information on how to remove the chainring unit.
1. Remove the chainring unit.
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Maintenance
Replacing the arm cover
2. Remove the chain guard then replace it with a new chain guard.
Chain guard (outward)
Chainring unit
Chain guard (inward)
*Only for double chain guard
Fixing screw
0.7 N·m
Replacing the arm cover
The arm cover can be replaced with the chainring unit attached to the drive unit. Refer to
“Installing the arm covers.”
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Please note: specifications are subject to change for improvement without notice. (English)
© Feb. 2022 by SHIMANO INC. ITP
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