Page 1
(English)
DM-MDFD001-02
Dealer's Manual
ROAD MTB Trekking
City Touring/
Comfort Bike
ALIVIO
FD-M4000
FD-M4020
Non-Series
FD-MT400
URBAN SPORT E-BIKE
Front derailleur
Page 2
CONTENTS
IMPORTANT NOTICE .............................................................................................. 3
TO ENSURE SAFETY ............................................................................................... 4
LIST OF TOOLS TO BE USED .................................................................................. 7
INSTALLATION ....................................................................................................... 9
Installation of the front derailleur (Front triple) .......................................................................................9
Installation of the front derailleur (Front double) ................................................................................... 13
ADJUSTMENT ...................................................................................................... 18
Installing the cable and adjusting shifting operation (Front triple) .......................................................18
Installing the cable and adjusting shifting operation (Front double) ....................................................26
MAINTENANCE .................................................................................................... 35
Replacing the chain catcher ......................................................................................................................35
Replacing rubber pad B .............................................................................................................................36
2
Page 3
IMPORTANT NOTICE
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.
DANGER
Failure to follow the instructions will result in death or serious injury.
WARNING
Failure to follow the instructions could result in death or serious injury.
CAUTION
Failure to follow the instructions could cause personal injury or physical damage to equipment and surroundings.
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 local
bicycle dealer for their assistance.
•
Make sure to read all instruction 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 dealer’s manuals and instruction manuals can be viewed on-line on our website (http://si.shimano.com).
•
Please observe the appropriate rules and regulations of the country, state or region in which you conduct your business as a dealer.
For safety, be sure to read this dealer’s manual thoroughly before use, and follow it for correct use.
3
Page 4
TO ENSURE SAFETY
TO ENSURE SAFETY
WARNING
•
Be sure to follow the instructions provided in the manuals when installing the product.
It is recommended to use genuine Shimano parts only. If parts such as bolts and nuts become loose or damaged, the bicycle may suddenly fall over,
which may cause serious injury.
In addition, if adjustments are not carried out correctly, problems may occur, and the bicycle may suddenly fall over, which may cause serious injury.
•
Be sure to wear safety glasses or goggles to protect your eyes while performing maintenance tasks such as replacing parts.
•
After reading the dealer’s manual thoroughly, keep it in a safe place for later reference.
Be sure to also inform users of the following:
•
Be careful not to let the hemming of your clothes get caught in the chain while riding. Otherwise you may fall off the bicycle.
NOTE
Be sure to also inform users of the following:
•
If gear shifting operations do not feel smooth, wash the derailleur and lubricate all moving parts.
•
When the chain is in any of the positions shown in the illustration, the chain may come into contact with the front chainring or front derailleur and
generate noise. If noise is a problem, shift the chain onto the next largest rear sprocket or the one after if the chain is in the position shown in Figure
1. Shift the chain onto the next smallest sprocket or the one after if it is in the position shown in Figure 2.
Figure 1 Figure 2
Double Triple
Front chainring
Rear sprocket
4
Page 5
TO ENSURE SAFETY
For Installation to the Bicycle, and Maintenance:
•
A triple front derailleur cannot be used with a double crankset because the shifting points do not match. Similarly, a double front derailleur cannot be
used with a triple crankset.
•
For frames with suspension, the chainstay angle will vary depending on whether the bicycle is being ridden or not being ridden.
•
When the bicycle is not being ridden and the chain is positioned on the largest chainring and on the smallest sprocket, the chain guide outer plate of
the front derailleur may touch the chain.
•
Use an outer casing [OT-SP40] and a cable guide (SM-SP17/SP18) for smooth operation.
•
If the amount of looseness in the links is so great that adjustment is not possible, you should replace the derailleur.
•
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.
The actual product may differ from the illustration because this manual is intended mainly to explain the procedures for using
the product.
5
Page 6
LIST OF TOOLS TO BE USED
Page 7
LIST OF TOOLS TO BE USED
LIST OF TOOLS TO BE USED
The following tools are needed for installation, adjustment, and maintenance purposes.
Tool Tool
2 mm hexagon wrench Hexalobular[#10]
5 mm hexagon wrench Screwdriver[#2]
7
Page 8
INSTALLATION
Page 9
INSTALLATION
Installation of the front derailleur (Front triple)
INSTALLATION
NOTE
When installing components to a carbon frame/handlebar, check the tightening torque recommended by the carbon frame or component
manufacturer to avoid carbon material damage due to excessive tightening or insufficient component holding force resulting from insufficient
tightening torque.
TECH TIPS
Bicycles with rear suspensions may be positioned differently when a rider is off the bicycle and on the bicycle. Perform installation and SIS
adjustment while seated on the bicycle.
Installation of the front derailleur (Front triple)
Band type
Side swing
Temporarily attach the clamp bolt.
(z)
5 mm hexagon wrench
(z)
(A)
1
(A)
Clamp bolt
To be continued on next page
9
Page 10
INSTALLATION
Installation of the front derailleur (Front triple)
2
[A-B]
(A)
(B)
Align the flat portion of the chain guide
outer plate in parallel with the flat
surface of the largest chainring.
Make sure that distance [A-B] from the
chain guide to the tip of the teeth of the
largest chainring is 1 to 3 mm.
[A-B]
1 – 3 mm
(A)
Chain guide outer plate
(B)
Largest chainring
TECH TIPS
•
Check by holding a hexagon wrench
against the flat surface of the largest
chainring as shown in the illustration.
•
When performing a readjustment etc.,
without a pro-set alignment block, align
the flat surface of the largest chainring
using the low adjustment bolt.
Low adjustment bolt
When adjustment is complete, tighten the clamp bolt.
3
Screwdriver[#2]
Tightening torque
5 - 7 N·m
10
Page 11
INSTALLATION
Installation of the front derailleur (Front triple)
Top swing/Down swing
1
(z)
(A)
Temporarily attach the clamp bolt.
(z)
5 mm hexagon wrench
(A)
Clamp bolt
To be continued on next page
11
Page 12
INSTALLATION
Installation of the front derailleur (Front triple)
Adjust the low adjustment bolt and align the flat portion of the chain guide outer plate
parallel to the flat surface of the largest chainring.
Make sure that distance [B-C] from the chain guide to the tip of the teeth of the largest
chainring is 1 to 3 mm.
(x)
(z)
(A)
(y)
(z)
(A)
(B)
[B-C]
2
(C)
[B-C]
1 – 3 mm
(x)
Top swing
(y)
Down swing
(z)
Screwdriver[#2]
(A)
Low adjustment bolt
(B)
Chain guide outer plate
(C)
Largest chainring
NOTE
When confirming the installation position,
make sure not to position the chain guide as
shown in the illustration.
When adjustment is complete, tighten the clamp bolt.
3
TECH TIPS
Check by holding a hexagon wrench against
the flat surface of the largest chainring as
shown in the illustration.
Tightening torque
5 - 7 N·m
12
Page 13
INSTALLATION
Installation of the front derailleur (Front double)
Installation of the front derailleur (Front double)
Band type
1
(z)
(A)
(z)
(A)
Temporarily attach the clamp bolt.
(z)
5 mm hexagon wrench
Adjust the low adjustment bolt and align
the flat portion of the chain guide outer
plate parallel to the flat surface of the
largest chainring.
Make sure that distance [B-C] from the
chain guide to the tip of the teeth of the
largest chainring is 1 to 3 mm.
[B-C]
1 – 3 mm
(z)
Screwdriver[#2]
(A)
Clamp bolt
(A)
Low adjustment bolt
(B)
Chain guide outer plate
(C)
Largest chainring
NOTE
When confirming the installation position,
make sure not to position the chain guide as
shown in the illustration.
2
(B)
[B-C]
(C)
When adjustment is complete, tighten the clamp bolt.
3
Tightening torque
5 - 7 N·m
13
Page 14
INSTALLATION
Installation of the front derailleur (Front double)
Direct mount type
Temporarily attach the front derailleur
to the frame.
1
H L
(z)
(z)
(z)
5 mm hexagon wrench
Adjust the low adjustment bolt and align
the flat portion of the chain guide outer
plate parallel to the flat surface of the
largest chainring.
Make sure that distance [A-B] from the
chain guide to the tip of the teeth of the
largest chainring is 1 to 3 mm.
[A-B]
1 – 3 mm
(z)
2 mm hexagon wrench/
Screwdriver[#2]
(A)
Chain guide outer plate
(B)
Largest chainring
NOTE
When confirming the installation position,
make sure not to position the chain guide as
shown in the illustration.
2
(A)
[A-B]
(B)
When adjustment is complete, secure the front derailleur to the frame.
3
Tightening torque
5 - 7 N·m
14
Page 15
INSTALLATION
Installation of the front derailleur (Front double)
Type E
1
Fixing position
(A)(B) (C)
Secure with bottom bracket mount
fixing bolts.
Fixing position varies depending on the
number of gear teeth used.
Refer to the illustration for fixing
position.
(A)
Bottom bracket mount fixing bolt
(B)
Bottom bracket mount
(C)
Bracket
NOTE
Shimano does not provide the bottom bracket
mount fixing bolts.
To be continued on next page
15
Page 16
INSTALLATION
Installation of the front derailleur (Front double)
2
H L
(z)
(A)
[A-B]
Adjust the low adjustment bolt and align
the flat portion of the chain guide outer
plate parallel to the flat surface of the
largest chainring.
Make sure that distance [A-B] from the
chain guide to the tip of the teeth of the
largest chainring is 1 to 3 mm after
installing the front chainwheel.
If the clearance does not fall within the
range, adjust the fixing position with the
elongated hole and fix the fixing bolt
again.
[A-B]
1 – 3 mm
(z)
2 mm hexagon wrench/
Screwdriver[#2]
(A)
Chain guide outer plate
(B)
Largest chainring
NOTE
When confirming the installation position,
make sure not to position the chain guide as
shown in the illustration.
(B)
16
Page 17
ADJUSTMENT
Page 18
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front triple)
ADJUSTMENT
Adjustment procedures differ depending on whether the bicycle features front triples or front doubles.
Before making adjustments, check the specifications of the bicycle.
Installing the cable and adjusting shifting operation
(Front triple)
Position adjustment of the low side
(A)
Remove the Pro-Set alignment block.
1
Adjust the chain position to the smallest chainring and the largest sprocket as shown in the
illustration.
(A)
(A)
Pro-Set alignment block
(w)
Low
(x)
Middle
(y)
Top
(z)
Cable index point
2
(z)
(A)
Smallest chainring
(B)
Largest sprocket
(y)(x)(w)
(B)
To be continued on next page
18
Page 19
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front triple)
3
(B)
(C)
(w)
(x)
(y)
Adjust the position of the chain guide
with the low adjustment bolt.
Adjust the clearance [B-C] between the
chain guide inner plate and the chain to
be 0 to 0.5 mm.
A
B
(z)
[B-C]
0 – 0.5 mm
(A)
Low adjustment bolt
(B)
Chain guide inner plate
(C)
Chain
(A)
(w)
Top swing
(x)
(z)
(A)
A
B
Down swing
(y)
Side swing
(z)
Screwdriver[#2]
(z)
(A)
A
B
B
[B-C]
A
19
Page 20
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front triple)
Securing the cable
Side swing
1
(A) (C) (D)(B)
(A)
Adjust the shifting lever to the low
position.
Run the cable through the front
derailleur.
Run the inner cable along the cable
guide.
Pass the inner cable through along the
cable guide on the top of the fixing bolt.
(A)
Inner cable
(B)
Cable guide
(C)
Sealed outer cap
(D)
Outer casing
NOTE
•
Fuzz may be generated when the inner
cable is installed or when the coating is
damaged during use, but this will not
affect its functions.
•
If the outer casing moves to a large degree,
such as in bicycles with suspension, it is
recommended that you use an aluminum
type sealed outer cap.
Sealed outer cap Sealed outer cap
(A)
Cable guide
(aluminum type)
NOTE
2
Be sure to run the inner cable along the cable
guide as shown in the illustration.
To be continued on next page
20
Page 21
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front triple)
3
Fix the inner cable with a cable-fixing
bolt.
Tightening torque
6 - 7 N·m
21
Page 22
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front triple)
Top Swing
Down pull
Top pull
(A)
Fix the inner cable with a cable-fixing
bolt.
(A)
5 mm hexagon wrench
Tightening torque
5 - 7 N·m
NOTE
Run the cable through as shown in the
illustration.
Wire mounting bolt
(A)
22
Page 23
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front triple)
Down swing
Down pull Use a hexagon wrench to tighten the
wire mounting bolt.
Top pull Use a hexagon wrench to tighten the
wire mounting bolt.
Tightening torque
5 - 7 N·m
NOTE
Run the cable through as shown in the
illustration.
Wire mounting bolt
Tightening torque
5 - 7 N·m
23
Page 24
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front triple)
Adjustment of the cable tension
Adjust the chain position to the middle chainring and the largest sprocket as shown in the
illustration.
(A)
1
(w) (x) (y)
(z)
(B)
(A)
B
A
Adjust the position with the cable
adjuster.
Adjust the clearance [B-C] between the
chain guide inner plate and the chain to
be 0 to 0.5 mm.
[B-C]
0 – 0.5 mm
(w)
Low
(x)
Middle
(y)
Top
(z)
Cable index point
(A)
Middle chainring
(B)
Largest sprocket
NOTE
Adjust the lever after operating it from top to
middle, not low to middle.
(A)
Cable adjuster
(B)
Chain guide inner plate
(C)
Chain
TECH TIPS
2
(B)
(C)
[B-C]
B
After adjusting the position with the cable
adjuster, operate the lever once and check the
clearance again.
A
24
Page 25
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front triple)
Top adjustment
Adjust the chain position to the largest chainring and the smallest sprocket as shown in the
illustration.
(A)
1
(w) (x)
(w)
B
(x)
(z)
(A)
A
(y)
(z)
(B)
Adjust the position of the chain guide
with the top adjustment bolt.
Adjust the clearance [B-C] between the
chain guide outer plate and the chain to
be 0 to 0.5 mm.
[B-C]
0 – 0.5 mm
(w)
Top swing
(x)
Down swing
(y)
Side swing
(z)
Screwdriver[#2]
(w)
Low
(x)
Middle
(y)
Top
(z)
Cable index point
(A)
Largest chainring
(B)
Smallest sprocket
(A)
Top adjustment bolt
(B)
Chain
(C)
Chain guide outer plate
2
(B)
(C)
(y)
A
B
(z)
(A)
(z)
(A)
A
B
[B-C]
A
B
25
Page 26
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front double)
Checking gear shifting and minor adjustments
After the cable is installed and adjusted, check the gear-shift by operating the shifting lever.
(This also applies if shifting becomes diffi cult during use.)
Use the table as a reference when adjusting the bolts. Turn the bolt by 1/8th turn for each adjustment.
If the chain falls to the crank side. Turn the top adjustment bolt clockwise.
If shifting is diffi cult from the middle chainring to the largest
chainring.
If shifting is diffi cult from the largest chainring to the middle
chainring.
If the chain falls to the bottom bracket side. Turn the low adjustment bolt clockwise.
If the middle chainring is skipped when shifting from the largest
chainring.
If shifting is diffi cult from the middle chainring to the smallest
chainring.
Tighten the cable. If this does not improve the situation, turn the
top adjustment bolt counterclockwise.
Loosen the cable.
Tighten the cable.
Turn the low adjustment bolt counterclockwise.
Installing the cable and adjusting shifting operation (Front double)
Note: Number of front chainring positions and lever position
For front triple-compatible shifting levers, the procedure for shifting lever operation is as follows.
(A) (B)
Use the low and middle positions of the
shifter. The top position is not used.
(A)
Smallest chainring
(B)
Largest chainring
(v)
(w)
(x) (y)
(z)
(v)
Front chainring position
(w)
Shifting lever position
(x)
Low
(y)
Middle
(z)
Top
26
Page 27
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front double)
Position adjustment of the low side
Adjust the chain position to the smallest chainring and the largest sprocket as shown in the
illustration.
(A)
1
(x)
(z)
H L
B
(z)
(A)
A
(y)
(B)
Adjust the position of the chain guide
with the low adjustment bolt.
Adjust the clearance [B-C] between the
chain guide inner plate and the chain to
be 0 to 0.5 mm.
[B-C]
0 – 0.5 mm
(z)
2 mm hexagon wrench /
Screwdriver[#2]
2
(x)
Low
(y)
Top
(z)
Cable index point
(A)
Smallest chainring
(B)
Largest sprocket
(A)
Low adjustment bolt
(B)
Chain guide inner plate
(C)
Chain
(B)
(C)
B
[B-C]
A
27
Page 28
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front double)
Securing the cable
1
(A) (C) (D)(B)
(A)
Adjust the shifting lever to the low
position.
Run the cable through the front
derailleur.
Run the inner cable along the cable
guide.
Pass the inner cable through along the
cable guide on the top of the fixing
bolt.
(A)
Inner cable
(B)
Cable guide
(C)
Sealed outer cap
(D)
Outer casing
NOTE
•
Fuzz may be generated when the inner
cable is installed or when the coating is
damaged during use, but this will not
affect its functions.
•
If the outer casing moves to a large degree,
such as in bicycles with suspension, it is
recommended that you use an aluminum
type sealed outer cap.
Sealed outer cap Sealed outer cap
(A)
Cable guide
(aluminum type)
NOTE
2
Be sure to run the inner cable along the cable
guide as shown in the illustration.
To be continued on next page
28
Page 29
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front double)
3
Fix the inner cable with a cable-fixing
bolt.
Tightening torque
6 - 7 N·m
29
Page 30
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front double)
Adjustment of the cable tension
Adjust the chain position to the largest chainring and the largest sprocket as shown in the
illustration.
(A)
1
(x) (y)
(z)
(B)
(A)
B
A
Adjust the position with the cable
adjuster.
Adjust the clearance [B-C] between the
chain guide inner plate and the chain to
be 0 to 0.5 mm.
[B-C]
0 – 0.5 mm
(x)
Low
(y)
Top
(z)
Cable index point
(A)
Largest chainring
(B)
Largest sprocket
(A)
Cable adjuster
(B)
Chain guide inner plate
(C)
Chain
TECH TIPS
2
(B)
(C)
[B-C]
B
After adjusting the position with the cable
adjuster, operate the lever once and check the
clearance again.
A
30
Page 31
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front double)
Top adjustment
Adjust the chain position to the largest chainring and the smallest sprocket as shown in the
illustration.
(A)
1
(x) (y)
(z)
(B)
Adjust the position of the chain guide
with the top adjustment bolt.
Adjust the clearance [B-C] between the
chain guide outer plate and the chain to
be 0 to 0.5 mm.
[B-C]
0 – 0.5 mm
(z)
2 mm hexagon wrench /
Screwdriver[#2]
B
H L
A
(z)
(A)
(x)
Low
(y)
Top
(z)
Cable index point
(A)
Largest chainring
(B)
Smallest sprocket
(A)
Top adjustment bolt
(B)
Chain
(C)
Chain guide outer plate
2
(B)
(C)
[B-C]
A
B
31
Page 32
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front double)
Checking gear shifting and minor adjustments
After the cable is installed and adjusted, check the gear-shift by operating the shifting lever.
(This also applies if shifting becomes difficult during use.)
Use the table as a reference when adjusting the bolts. Turn the bolt by 1/8th turn for each adjustment.
If the chain falls to the crank side. Turn the top adjustment bolt clockwise.
If shifting is difficult from the smallest chainring to the largest
chainring.
If shifting is difficult from the largest chainring to the smallest
chainring.
If the chain falls to the bottom bracket side.
Tighten the cable. If this does not improve the situation, turn the
top adjustment bolt counterclockwise.
Loosen the cable.
Tighten the cable. If this does not improve the situation, turn the
low adjustment bolt clockwise.
32
Page 33
ADJUSTMENT
Installing the cable and adjusting shifting operation (Front double)
Fine adjustment of contact between chain and chain guide inner plate
After installing and adjusting the cable, adjust the chain to the smallest chainring and the
largest sprocket as shown in the illustration, and then check whether or not contact is made.
(A)
1
(x)
(z)
(A)
B
A
(y)
(B)
If contact is made, adjust the position
with the cable adjuster so that the [B-C]
gap is 0 mm.
(x)
Low
(y)
Top
(z)
Cable index point
(A)
Smallest chainring
(B)
Largest sprocket
(A)
Cable adjuster
(B)
Chain guide inner plate
(C)
Chain
TECH TIPS
2
(B)
(C)
[B-C]
B
After adjusting the position with the cable
adjuster, operate the lever once and check the
clearance again.
A
33
Page 34
MAINTENANCE
Page 35
MAINTENANCE
(B)
(C)
Replacing the chain catcher
MAINTENANCE
Replacing the chain catcher
Depending on the specifications, there are also models where the chain catcher cannot be replaced.
Removal
Installation
(A)
1
(A)
(B)
(B)
(C)
Remove the fixing bolt.
Temporarily attach the chain catcher to
the chain guide.
(A)
Hexalobular[#10]
(B)
Fixing bolt
(A)
Chain guide
(B)
Chain catcher
(C)
Arm of the chain catcher
2
3
(A)
(A)
Securely attach the arm of the chain
catcher as shown in the illustration.
Fix the chain catcher to the chain guide
inner plate.
(A)
Arm of the chain catcher
(A)
Hexalobular[#10]
(B)
Fixing bolt
(C)
Chain guide inner plate
Tightening torque
1 - 2 N·m
35
Page 36
MAINTENANCE
Replacing rubber pad B
Replacing rubber pad B
Removal
Installation
(A)
Peel back rubber pad B from the reverse
side of the chain guide and remove it.
(A)
Rubber pad B
(A)
Align the rubber pad B mounting hole of
the chain guide with the protrusion of
rubber pad B.
Push in the protrusion from the reverse
side of rubber pad B.
Make sure that the protrusion of rubber
pad B is securely fitted on the chain
guide.
(A)
Rubber pad B mounting hole
36
Page 37
Please note: specifications are subject to change for improvement without notice. (English)
©
Mar. 2018 by Shimano Inc. ITP
Loading...