Page 1
(English)
DM-E6100-06
Dealer's Manual
ROAD MTB Trekking
City Touring/
Comfort Bike
DU-E6100
DU-E6100-CRG
DU-E6110
DU-E6180
FC-E6100
FC-E8000
FC-E8050
FC-M8050
SM-CRE61
SM-DUE10
SM-DUE11
SM-DUE61-T
SM-DUE61-TC
SM-DUE61-TCRG
SM-DUE61-C
SM-DUE61-CC
SM-DUE61-CCRG
URBAN SPORT E-BIKE
E6100 / E6180 Series
Page 2
Contents
Contents ...................................................................................2
IMPORTANT NOTICE ..................................................................4
TO ENSURE SAFETY ................................................................... 5
List of tools to be used .......................................................... 12
Installing electrical parts ......................................................13
Names of parts .....................................................................................13
• Rear carrier mount type ......................................................................................................... 13
• Down tube mount type ......................................................................................................... 14
• Integrated mount type .......................................................................................................... 15
Overall wiring diagram ........................................................................16
Specifications ........................................................................................17
Electric wires .........................................................................................17
• Supported products ................................................................................................................ 17
• Conversion adapter ................................................................................................................ 19
• Connecting / disconnecting the electric wire ....................................................................... 19
Installing cockpit peripheral components .......................................... 23
Installing the battery mount and parts .............................................. 23
Installing the speed sensor ..................................................................23
• Generic type ............................................................................................................................ 23
• Type designed exclusively for use with a disc brake rotor with magnet unit .................... 25
Installing the drive unit and peripheral parts ..................... 27
Installing the drive unit .......................................................................27
Connecting the power cable ...............................................................29
• Connection method ............................................................................................................... 29
• Removal method .................................................................................................................... 30
Connecting cockpit peripheral parts and electronic gear shifting
components .......................................................................................... 30
Connecting the speed sensor .............................................................. 31
2
Page 3
Connecting the light cables ................................................................. 32
Installing the drive unit cover ............................................................. 33
• When only using a SHIMANO drive unit cover ..................................................................... 33
• When also using a drive unit cover from another company ............................................... 34
• Affixing the thermal hazard label ......................................................................................... 36
Installing the chainring and crank arms ............................................. 36
Installing the arm covers .....................................................................42
Measuring and adjusting the chain tension ......................................44
• Manual adjustment ................................................................................................................ 45
• Measuring and adjusting with TL-DUE60 ............................................................................. 45
Connection and communication with devices ....................48
Maintenance ........................................................................... 49
Replacing the chainring ....................................................................... 49
Replacing the chain guard ................................................................... 50
Replacing the arm cover ...................................................................... 51
3
Page 4
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 the 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.
4
Page 5
TO ENSURE SAFETY
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 to 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. You may fall and
be seriously injured.
• 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.
5
Page 6
TO ENSURE SAFETY
• 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, that can result in an explosion of the built-in battery or the leakage of
flammable liquid or gas from it.
• Do not expose the cycle computer to excessively low pressures. If a battery is
incorporated, that can result in an explosion of the built-in battery or the leakage of
flammable liquid or gas from it. 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 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 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 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.
6
Page 7
TO ENSURE SAFETY
• Clean the chain with an appropriate chain cleaner regularly. Intervals between
maintenance depend on the use and riding circumstances.
• Never use alkali based 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.
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.
7
Page 8
TO ENSURE SAFETY
• 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 with a high-pressure washer. If water gets into any of the
components, operating problems or corrosion 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.
• 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 resin 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.
8
Page 9
TO ENSURE SAFETY
• 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 to perform a range of tasks, such as customizing individual
components or the entire system, or updating firmware.
• PC linkage device: SM-PCE1 / SM-PCE02
• E-TUBE PROJECT: PC application
• Firmware: Software inside each component
Connection and communication with smartphone or tablet
Connecting your bicycle (system or component) over Bluetooth® LE to a smartphone or
tablet allows you to use the smartphone/tablet version of E-TUBE PROJECT to perform a
range of tasks, such as customizing individual components or the system, or updating
firmware.
• E-TUBE PROJECT: Application for smartphones/tablets
• 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.
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).
9
Page 10
TO ENSURE SAFETY
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 shifting 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).
Name Details
This is the basic manual for the SHIMANO STEPS series:
• Overall wiring diagram
SHIMANO STEPS Dealer's Manual (this
document)
• 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
10
Page 11
TO ENSURE SAFETY
Name Details
SHIMANO STEPS Dealer's Manual for
Drop Handlebar Bicycles (separate
booklet)
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 the PC version of E-TUBE PROJECT
This manual describes the installation and maintenance of
the SHIMANO STEPS special chain device.
11
Page 12
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
4 mm hexagon wrench /
hexalobular [#25]
Cross head screwdriver [#2]
Hexalobular [#10]
Cross head screwdriver [#2]
Cross head screwdriver [#2]
Speed sensor
(SM-DUE10)
Speed sensor
(SM-DUE11)
Drive unit
Light cable
Speed sensor mounting
screw
Magnet unit mounting
screw
Speed sensor mounting
screw
Drive unit mounting screw - Contact the bicycle manufacturer.
Drive unit cover
Light cable mounting
screw
Crank arm
Chain case stay
Chainring
Chain
Cap
Clamp screw
Mounting screw (SM-
DUE61-FB)
Lock ring
Chain guard
Arm cover
Tension adjustment for
internal geared hub
models
TL-FC16 / TL-FC18
5 mm hexagon wrench
2 mm hexagon wrench
TL-FC39 + TL-FC33
TL-FC39 + TL-FC36
Cross head screwdriver [#2]
TL-DUE60
12
Page 13
Installing electrical parts
Names of parts
Installing electrical parts
Names of parts
Rear carrier mount type
(A)
(C)
(O)
(I)
Battery
Drive unit
(G)
(A) (B)
(H)
(G)
(F)
(E)
(C)
(B)
(D)
(D)
(J)
(M)
Battery mount
Drive unit cover
(K)
(L)
(N)
(E)
(G)
(I)
(K)
(M)
(O)
*1 Attach it to one of the two locations specified in the figure.
*2 Electronic gear shifting: DI2 rear derailleur or motor unit + DI2 internal geared hub
Mechanical gear shifting: rear derailleur or internal geared hub
*3 Use either one.
Crank arm
Speed sensor*1
Disc brake rotor
Switch unit (shifting switch) or shifting
lever
Cycle computer*3
Battery charger
(F)
(H)
(J)
(L)
(N)
Chainring
Shifting unit*2
Switch unit (assist switch)
Electric wire
Junction [A] (wireless unit)*3
13
Page 14
Installing electrical parts
Names of parts
Down tube mount type
(A)
(C)
(O)
(I)
Battery*1
Drive unit
(G)
(H)
(G)
(F)
(C)
(D)
(A)
(E) (B)
(B)
(D)
(J)
(M)
Battery mount
Drive unit cover
(K)
(L)
(N)
(E)
(G)
(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
*4 Use either one.
Crank arm
Speed sensor*2
Disc brake rotor
Switch unit (shifting switch) or shifting
lever
Cycle computer*4
Battery charger
(F)
(H)
(J)
(L)
(N)
Chainring
Shifting unit*3
Switch unit (assist switch)
Electric wire
Junction [A] (wireless unit)*4
14
Page 15
Installing electrical parts
Names of parts
Integrated mount type
(A)
(C)
(E)
(O)
(I)
Battery*1
Drive unit
Crank arm
(G)
(H)
(G)
(F)
(E)
(C)
(D)
(B)
(D)
(F)
(J)
(M)
Battery mount*2
Drive unit cover
Chainring
(K)
(L)
(N)
(A)
(G)
(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 The built-in type battery mount is attached inside the frame.
*3 Attach it to one of the two locations specified in the figure.
*4 Electronic gear shifting: DI2 rear derailleur or motor unit + DI2 internal geared hub
Mechanical gear shifting: rear derailleur or internal geared hub
*5 Use either one.
Speed sensor*3
Disc brake rotor
Switch unit (shifting switch) or shifting
lever
Cycle computer*5
Battery charger
(H)
(J)
(L)
(N)
Shifting unit*4
Switch unit (assist switch)
Electric wire
Junction [A] (wireless unit)*5
15
Page 16
Installing electrical parts
Overall wiring diagram
Overall wiring diagram
EW-EN100
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.
16
Page 17
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 according to the 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 wire
TL-EW300 TL-EW02
17
Page 18
Installing electrical parts
Electric wires
Product name Intended purpose EW-SD300 type EW-SD50 type
EW-CL300-S
Cord clip
Cord cover
Grommets
Binding the wiring and the
brake 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.
Branching / gathering the
wiring inside and outside
the frame
Refer to “Conversion
adapter.”
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.
18
Differentiation
groove
EW-CL300-M EW-CL300-S
Page 19
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 wire
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
19
Page 20
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.
20
Page 21
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.
21
Page 22
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.
22
Page 23
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 models: SM-DUE10 (SD50 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.
23
Page 24
Installing electrical parts
Speed sensor
Magnet unit
Clearance between speed sensor and
Installing the speed sensor
(2) Temporarily install the mounting screw.
(Temporary)
Spoke
Mounting screw
2. Install the speed sensor.
Check that the clearance between the speed sensor and magnet unit is from 3 - 17 mm.
magnet unit
3 - 17 mm
24
Page 25
Installing electrical parts
Clearance between speed sensor
Clearance between speed sensor
Speed sensorMagnet unit
Installing the speed sensor
and magnet unit is 3 to 17 mm
Toothed washer
Speed sensor mounting screw
(length 16 mm)
and magnet unit exceeds 17 mm
Spacer
1.5 - 2 N·m
1.5 - 2 N·m
Speed sensor mounting screw
(length 22 mm)
3. Secure the magnet unit.
1.5 - 2 N·m
Spoke
Mounting screw
4. Route the electric wire for the speed sensor to the frame along the
chainstay and wire it to the drive unit.
Type designed exclusively for use with a disc brake rotor with magnet unit
For models: SM-DUE11 (SD50 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.
25
Page 26
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 mounting 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.
26
Page 27
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 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 right cover (front side) 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 mounting screws on the right side so that the drive unit makes firm
contact with the inner surface on the right side of the frame.
27
Page 28
Installing the drive unit and peripheral parts
Right side
Installation hole
Installing the drive unit
(3) Tighten the mounting screws on the left side of the frame.
(1)
(2)
Front
10 - 12.5 N·m
Drive unit mounting screw (M8)
(3) Left side
Drive unit
10 - 12.5 N·m
Drive unit mounting screw (M8)
Rear
NOTICE
• Drive unit mounting screws (M8) are not included with SHIMANO products. Use
the screws supplied by the bicycle manufacturer.
28
Page 29
Installing the drive unit and peripheral parts
Connecting the power cable
Connecting the power cable
Connection method
1. Connect the power cable.
Align the Δ marking on the drive unit's power port with the arrow marking on the tip of
the power cable, then insert the power cable until it clicks.
* Check that it is securely connected.
29
Page 30
Installing the drive unit and peripheral parts
Connecting cockpit peripheral parts and electronic gear shifting components
Removal method
1. Remove the power cable.
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 cable (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 cockpit peripheral parts (such as the cycle computer and junction [A])
and wires from electronic gear shifting components to the drive unit's E-TUBE port.
30
Page 31
Installing the drive unit and peripheral parts
Connecting the speed sensor
1. Connect the electric wire to the drive unit's E-TUBE port.
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.
1. Connect the electric wire to the drive unit's speed sensor port.
Speed sensor electric wire
Speed sensor port
31
Page 32
Installing the drive unit and peripheral parts
Connecting the light cables
Connecting the light cables
Connect the wires connected to the front and rear lights to the drive unit.
1. Loosen the mounting screws.
Mounting screw
2. Connect the light cables to the light connection terminals, then tighten
the mounting screws.
0.6 N·m
Light connection terminal
Mounting screw
32
Page 33
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.
When only using a SHIMANO drive unit cover
For models: SM-DUE61-T, SM-DUE61-TCRG, SM-DUE61-C, SM-DUE61-CCRG
TECH TIPS
• The SM-DUE61-TCRG and SM-DUE61-CCRG have the “CARGO” logo. Use them as the
drive unit cover for the DU-E6100-CRG.
1. Install the left cover.
0.6 N·m
Cover mounting screw
33
Page 34
Installing the drive unit and peripheral parts
Installing the drive unit cover
2. Install the right cover (rear side).
0.6 N·m
Cover mounting screw
Right cover (rear side)
3. Install the right cover (front side).
Terminal block
Right cover (front side)
0.6 N·m
Cover mounting screw
When also using a drive unit cover from another company
For models: SM-DUE61-TC, SM-DUE61-CC
Always install a drive unit cover from another company after installing the SHIMANO drive unit
cover.
34
Page 35
Installing the drive unit and peripheral parts
Installing the drive unit cover
1. Install the left cover.
0.6 N·m
Cover mounting screw
Left cover
2. Affix the right cover.
(1) Peel the release liner on the back of the right cover.
(2) Align the positions of the convex section on the rear of the right cover and the
concave section on the drive unit, then affix it.
Right cover
Concave section
Convex section
35
Page 36
Installing the drive unit and peripheral parts
Drive unit cover from another company
Installing the chainring and crank arms
NOTICE
• Check that there is no oil or other foreign matter on the adhesive surface of the
adhesive tape on the right cover or on the adhesion surface on the drive unit.
Remove any oil or other foreign matter before affixing.
Affixing the thermal hazard label
If you use SM-DUE61-CC or SM-DUE61-TC as your drive unit cover and add a custom cover from
another company, affix the thermal hazard label at the position below.
Right cover
(SM-DUE61-CC / SM-DUE61-TC)
Thermal hazard label
Installing the chainring 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.
36
Page 37
Installing the drive unit and peripheral parts
Installing the chainring and crank arms
(3) Tighten the cap.
(1)
L
Left crank arm
(2)
Cross-section
Stopper plate
(4)
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.
(3)
Wide part Wide part
37
Page 38
Installing the drive unit and peripheral parts
Installing the chainring and crank arms
(2) Tighten both clamp screws alternately and equally to the specified tightening torque.
Cross-section
(1)
Plate pin
Stopper plate
(2)
12 - 14 N·m
Clamp screw (x 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
38
Page 39
Installing the drive unit and peripheral parts
Installing the chainring and crank arms
3. When installing a chain case, install the chain case stay before
installing the chainring.
Chain cases and chain case stays are not included with SHIMANO products.
Installation hole
Chain case stay (example)
1.2 N·m
Mounting screw SM-DUE61-FB
(sold separately)
4. Set the chainring.
Set with the spline on the chainring aligned with the chainring installation spline on the
axle.
Axle
Chainring
39
Chainring installation
spline
Page 40
Installing the drive unit and peripheral parts
Installing the chainring and crank arms
TECH TIPS
• There are three types of chainrings: those with a chain guard on both the front
and rear sides, those with a chain guard only on the outside, and those with no
chain guard. The explanation in this section uses one without a chain guard.
5. Install the chain.
Refer to the dealer's manual for the chain to use.
6. Secure the chainring.
(1) Install the lock ring (left-hand thread) by hand.
(2) Tighten the lock ring while holding the left crank arm stable.
35 - 45 N·m
Lock ring
NOTICE
• Do not use an impact wrench.
40
Page 41
Installing the drive unit and peripheral parts
Installing the chainring and crank arms
7. Set the right crank arm and tighten the cap.
R
0.7 - 1.5 N·m
Right crank arm
8. Secure the right crank arm.
(1) Press the stopper plate in.
* Check that the plate pin is firmly set.
(2) Tighten the clamp screw.
Cap
41
Page 42
Installing the drive unit and peripheral parts
Installing the arm covers
* For a chainring without a chain guard, proceed to the next section “Installing the
arm covers.”
* For internal geared hub models, proceed to “Measuring and adjusting the chain
tension.”
12 - 14 N·m
(2)
Clamp screw (x 2)
(1)
Cross-section
Stopper plate
Plate pin
NOTICE
• 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.
42
Page 43
Installing the drive unit and peripheral parts
Installing the arm covers
1. Set 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
43
Page 44
Installing the drive unit and peripheral parts
Measuring and adjusting the chain tension
2. Tighten the two mounting screws from the left and right.
For internal geared hub models, proceed to the next section “Measuring and adjusting
the chain tension.”
0.8 N·m
Mounting
screw
0.8 N·m
Mounting
screw
Measuring and adjusting the chain tension
The chain tension must be adjusted for internal geared hub models.
NOTICE
• The proper assistance may not be achieved if the chain tension is too high.
44
Page 45
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.
45
Page 46
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.
46
Page 47
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
47
Page 48
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.
48
Page 49
Maintenance
Replacing the chainring
Maintenance
Replacing the chainring
When replacing the chainring, make sure that the chain is attached.
Refer to “Installing the chainring and crank arms” and “Installing the arm covers” 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
Installation
TL-FC36
Lock ring
hole
49
Page 50
Maintenance
Installation hole
Replacing the chain guard
TECH TIPS
• The TL-FC39 can be secured to the TL-FC36 with a zip tie as indicated in the
figure below.
Zip tie
3. Replace the chainring.
Remove the chainring, then install a new chainring.
Replacing the chain guard
To replace the chain guard, first remove the chainring from the bicycle.
Refer to “Replacing the chainring” for information on how to remove the chainring.
1. Remove the chainring.
50
Page 51
Maintenance
Replacing the arm cover
2. Remove the chain guard then replace it with a new chain guard.
Chain guard (inward)
0.7 N·m
Mounting bolt
*Only for double chain guard
Chain guard (outward)
Chainring
Replacing the arm cover
The arm cover can be replaced with the chainring attached to the drive unit. Refer to “Installing
the arm covers.”
51
Page 52
Please note: specifications are subject to change for improvement without notice. (English)
© Nov. 2020 by SHIMANO INC. ITP
Loading...