ASSEMBLY MANUAL SE-4S35

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1 Automatic drive ASSEBLY ANUAL SE-4S35 AI-4S35 SG-4R35 Battery box otor unit Inter-4 hub

2 CONTENTS WARNING 1 INSTALLATION CONITIONS Battery box Speed sensor Cable lengths and diameters otor unit Recommended gear ratios Hub shell dimensions INSTALLATION ETHO 1. Installing the battery box 4 2. Installing the right-side brake lever 4 3. Installing the operating panel 4 4. Installing the speed sensor 5 5. Installing the motor unit to the hub (rear wheel) 6 6. Installing the hub (rear wheel) to the frame 6 7. Installing the batteries 8 CHANGING THE INITIAL SETTINGS (FOR BICYCLE RETAILER) Selecting the setting to be changed 9 Changing the wheel size setting Selecting mph or km/h Recalibrating the motor unit 10

3 Be sure to observe the following when using the Auto-. If this is not done, incorrect operations such as unwanted gear shifting may occur while riding, and this might lead to your feet coming off the pedals and the bicycle falling over. 1) WARNING Check that the motor unit and the connector are securely installed with the connector fixing bolts so that there is no gap between them. If there is a gap between the motor unit and the connector, vibration may occur or water may get inside, and this may cause incorrect signals to be output. AUTOATIC-RIVE otor unit Connector 2) Check that the motor unit cable does not come into contact with parts such as the chain or the wheel, and that there are no other places where the cable may become damaged. otor unit cable AUTOATIC-RIVE There should be no gap The connector fixing bolts should be securely tightened Nm {1 2 kgfcm} The cable should be routed so that it is not loose and does not come into contact with parts such as the chain and wheel. 1

4 38.1 mm INSTALLATION CONITIONS Speed sensor Necessary length for straight section of handlebar: Grip length + 65 mm Install the speed sensor to the left-side chainstay. Install the magnet to one of the rear spokes mm Battery box Install the battery box to the chainstay. 30 mm radius (mudguard cross-section shape) Spoke diameter should be 2.3 mm or less 23 mm or more 28 mm or more (inside width of chainstay) 3mm 19.3mm inimum distance should be within mm iameter of chainstay should be mm (pad assembly dimensions) A Lug B C Bridge Find a place which meets these conditions. Size A B C mm or less 77 mm or more 92 mm or more 52 mm or less 80 mm or more 95 mm or more 47 mm or less 75 mm or more 90 mm or more If the mudguard cross-section has a radius of more than 30 mm, it will be necessary to increase the dimensions for C. The bridge/lug should be less than 3.0 mm, including the weld. 2

5 Km-ile/h Cable lengths and diameters connector cable cover s Lead tubes imension A: Cable cover: length 1,040 mm, diameter 5.4 mm Cable: length 1,200 mm, diameter 3.7 mm imension B: Cable: length 400 mm, diameter 5.2 mm imension C: Cable: length 250 mm, diameter 3 mm (Any excess cable running from the speed sensor should be tucked inside the battery box.) The cable lengths are the lengths from the exit points for each connector to the exit/entry points at the battery box. Battery box B: otor unit cable (attached to right-side chainstay) Lead tubes otor unit The shapes of the lead tubes should be hooking types rather than pass-through types. Ideally there should be three lead tubes attached to the down tube and two attached to the right-side chainstay. otor unit A: cable Speed sensor otor unit connector C: Speed sensor cable (attached to left-side chainstay) When designing the frame, make sure that there are no obstructions between the frame, motor unit and hub. C A B Leave a gap otor unit Frame B AUTOATIC-RIVE Section A Section B Section C Section A C Gap 1.1 mm 2.6 mm 1.6 mm 2.0 mm otor unit The dimensions are when no items such as chain pullers are clamping the inside of the fork end. E F 53.2 mm imension E: 31.8 mm imension F: 29.0 mm 76.7 mm Recommended gear ratios For 26/27 inches Front chainwheel: 31T/ 32T/ 33T Rear sprockets: 20T/ 21T/ 22T/ 23T Frame center Hub shell dimensions Width between cones: 130 mm No. of spoke holes: 36H/28H Spoke hole P.C..: 83.5 mm imension G: 54.8 mm imension H: 3.7 mm 3 G H

6 INSTALLATION ETHO 1. Installing the battery box 3. Installing the operating panel Place the battery box on the chainstay between the seat tube and the rear wheel. Next, place the fixing plate against the bottom of the chainstay, and then use a 4 mm Allen key to tighten the battery box fixing screws to secure the battery box to the chainstay. To seat tube The upper cover fixing screws are tapping screws, so be careful not to over-tighten them. Attach the connector at the operating panel end of 1. the cable to the operating panel, and then use a Phillips screwdriver to tighten it into place. The connector fixing screws are tapping screws, so be careful not to over-tighten them. Battery box To rear wheel cable Connector fixing screw 0.1 Nm {1 kgfcm} Chainstay Check that there is sufficient length of cable, and 2. then use a Phillips screwdriver to install the operating panel to the brake lever bracket, while being careful of the cable.. Fixing plate Spring washer Nm {10 15 kgfcm} fixing screw Battery box fixing screw Brake lever bracket 4 mm Allen key 4 5 Nm {40 50 kgfcm} 2. Installing the right-side brake lever Km-ile/h s Use a 5 mm Allen key to install the brake lever installation band to the handlebars. Installation band fixing screw 22.2 mm Installation bolt SE-4S mm Allen key 6 8 Nm {60 80 kgfcm} 4

7 SENSOR 4. Installing the speed sensor Installation position Install the speed sensor to the left-side chainstay of the rear wheel, in a position as close to the hub as possible. Install the speed sensor close to the hub. Installing the magnet Install the magnet to one of the wheel spokes so that the magnet is aligned with one or other of the two lines on the speed sensor. Install the magnet so that there is a clearance of 2 6 mm between the magnet and the speed sensor at this time. Speed sensor 2 lines Installing the speed sensor Gently wrap the speed sensor cable twice around the stay so that the cable then points toward the front of the bicycle. Next, place the pad in between the speed sensor and the chainstay, and then tighten the speed sensor fixing bolt so that the speed sensor will not turn. agnet 1 Nm {10 kgfcm} agnet fixing bolt Spacer Spoke 1 Nm {10 kgfcm} Speed sensor fixing bolt Cable Spoke side o not forget to install the spacer, otherwise the magnet fixing bolt will loosen and the magnet will fall off the spoke. agnet Speed sensor Speed sensor Chainstay agnet Pad SENSOR Leave a clearance of 2 6 mm between the speed sensor and the magnet. 5

8 5. Installing the motor unit to the hub (rear wheel) Check that the rubber seal is attached. If the rubber 1. seal is not attached, attach as shown in the illustration. Reverse side of motor unit otor unit Rubber seal 6. Installing the hub (rear wheel) to the frame ount the chain on the sprocket, and then set the 1. hub axle into the fork ends. For reversed fork end When mounting the chain on the sprocket, remove the chain from the chainring in order to protect the motor unit. After mounting the chain on the sprocket and setting the hub axle into the fork ends, place the chain back onto the chainring. Hub axle Fork end otor unit 2. Install the motor unit to the hub so that the mark (yellow) on the motor unit is aligned with the mark (yellow) on the hub lock spacer. After this, gently push the motor unit while turning it slowly to set it correctly until it stops turning on the hub axle. Next, secure the motor unit by tightening right-hand lock nut B. When tightening right-hand lock nut B, hold the two bevelled surfaces of the hub axle (8-mm wide) with a spanner to stop the hub axle from turning. Check that the guide of right-hand lock nut A is seated securely in the guide hole on the front of the motor unit. otor unit guide hole Right-hand lock nut A guide otor unit Front For standard fork end The motor unit may be obstructed by the frame in this case, which can cause difficulties in setting the hub into the fork ends. Turn the motor unit slightly as shown in the illustration before setting the hub into the fork ends. At this time, do not tighten the brake unit fixing nut of the Inter- brake so that the Inter- brake can rotate on the hub axle during installation. AUTOATIC-RIVE Hub axle Fork end otor unit Right-hand lock nut A mark (yellow) on lock spacer Right-hand lock nut B Nm { kgfcm} AUTOATIC-RIVE Turn the motor unit slightly AUTOATIC-RIVE mark (yellow) on motor unit Right-hand lock nut B 6

9 6R 6R Install the non-turn washers onto the right side and 2. the left side of the hub axle. At this time, turn the motor unit until it is almost parallel to the chainstay so that the projecting parts of the non-turn washers fit into the grooves of the fork end. Non-turn washer (for left side) This surface should be almost parallel to the chainstay Chainstay If the brake arm is in the incorrect position as shown in the illustration so that it cannot be provisionally installed to the chainstay, loosen the brake unit fixing nut and turn the brake arm. Then, after provisionally securing the brake arm to the chainstay, tighten the brake unit fixing nut. Brake arm clip otor unit Non-turn washer (for right side) Brake unit fixing nut Chainstay AUTOATIC-RIVE Brake arm Nm { kgfcm} ifferent types of left and right non-turn washers are provided for use with standard and reversed fork ends. Use whichever nonturn washers are suitable. Fork end Reversed Standard 7R Non-turn washer ark/ Color Right Left 6R/ Silver 7R/ Black ark Groove of fork end 6L/ White 7L/ Gray Size = Take up the slack in the chain and secure the wheel 4. to the frame with the hub nuts. Non-turn washer AUTOATIC-RIVE Hub nut Hub nut Nm { kgfcm} Section A Section B The projecting parts should be on the fork end side. Install the non-turn washers so that the projecting parts are securely in section A or section B of the fork end grooves. If inserting the projecting parts into section B, insert the hub axle as far as possible into the fork ends so that the projecting parts are not too close to the groove openings. When installing a part such as a mudguard stay to the hub axle, install in the order shown in the illustration below. Right side AUTOATIC-RIVE Non-turn washer (for right side) Washer Hub nut Install the brake arm of the Inter- brake to the 3. chainstay with the brake arm clip, provisionally tighten the clip bolt and clip nut, and then tighten the brake unit fixing nut. udguard stay Carrier stay 7

10 Left side Attach the connector at the motor unit end of the 6. cable to the motor unit, and then tighten the bolts to secure it in place Nm {1 2 kgfcm} otor unit Non-turn washer (for left side) Washer 6L Securely tighten the connector fixing bolts Connector Hub nut Carrier stay Stand udguard stay Because a non-turn washer is used, the chain tension may become too loose if the slot in the stand is too short in length. A stand with a slot length of 31 mm or more and a height of 10 mm should be used. Slot in stand 10 mm otor unit cable ake sufficiently sure that the cable is not loose and does not come into contact with parts such as the chain and wheel. AUTOATIC-RIVE There should be no gap between the contact surfaces of the motor unit and mm or more Fix the brake arm of the Inter- brake securely to the chainstay with the brake arm clip. 7. Installing the battery Use a Phillips screwdriver to remove the four battery 1. cover fixing screws, and then open the battery cover. Brake arm clip Chainstay Brake arm Loosen If excessive force is applied to the brake arm, the wheel will become difficult to turn. ake sure that you don't apply excessive force when installing. Battery cover Battery cover fixing screw Insert the new lithium battery (CR-P2), making sure 2. that its polarity is correct. When installing the brake arm clip, securely tighten the clip bolt while holding the clip nut with a 10 mm spanner. 2 3 Nm {20 30 kgfcm} After installing the brake arm clip, check that the clip bolt protrudes about 2 3 mm from the surface of the clip nut. Clip nut About 2 3 mm Brake arm Brake arm clip Clip bolt (6 x 16 mm) Nm {5 10 kgfcm} LITHIU Lithium battery (CR-P2) After inserting the battery, close the battery cover 3. and tighten the battery cover fixing screws. CR-P2 8

11 AUTOATIC RIVE The Auto- system is ready to run as soon as the CR-P2 battery is installed. The initial settings are as follows: Speed units: km/h Wheel size: 27" If necessary, modify the initial settings to properly suit the bicycle dimensions or rider preferences. FOR BICYCLE RETAILER CHANGING THE INITIAL SETTINGS Check that the battery has been inserted. If the battery has not been inserted, refer to "Installing the battery" on page 8. If the battery has been inserted correctly, a beep will sound, the LE will illuminate red and will illuminate in the digital display (for about 1 second). After this, will illuminate in the digital display. Km-ile/h s Beep ove the mode select switch to the "" or "s" position. Changing the settings is not possible in "" mode. Press the and keys simultaneously for 3 seconds or more. will illuminate in the digital display. Km-ile/h Km-ile/h s s Km-ile/h s 3. Press the (left) key to scroll the digital display until the setting to be changed appears. Km-ile/h s If the above does not appear even after the battery has been replaced, remove and reinsert the battery. Scroll using the... Ready for (left) key Change the wheel size setting... Select mph or km/h... Recalibrate the motor unit Press the (right) key to select the setting to be changed. If you lose your place at any time during the above procedure, or if you make a mistake in operation, wait 10 seconds or more without pressing any of the operating keys. The digital display will return to, and you can then start the procedure again from step 2. 9

12 1. 2. Changing the wheel size setting Follow steps 1 to 4 on page 15 to select. If you lose your place at any time during the procedure for changing the wheel size, or if you make a mistake in operation, wait 10 seconds or more without pressing any of the operating keys. The digital display will return to, and you can then start the procedure again from step 2 on page 9. Check that is flashing in the digital display. Km-ile/h s Press the (left) key to select either km/h or mph. The digital display switches between and each time the (left) key is pressed. km/h mph Press the (right) key. The speed unit setting will then be accepted. Example: The speed unit is km/h. Km-ile/h Km-ile/h s s Press the (left) key to scroll the digital display in order to select the desired wheel size setting. The digital display switches each time the (left) key is pressed. Scroll using the Press the (right) key. The wheel size setting will then be accepted. Example: Setting the wheel size to 27". (left) key Km-ile/h Km-ile/h s (27 ) (26 ) (28 ) (700C) (650B) A (24 ) (22 ) (20 ) (18 ) (16 ) s If the rear wheel, internal hub mechanism or the motor unit has been replaced, then the motor unit should be recalibrated as follows to ensure optimal shifting performance Recalibrating the motor unit Follow steps 1 to 3 on page 15 to select. Press the (right) key. At the same time that the key is pressed, the motor unit will start moving and recalibrate automatically. If you carry out the recalibration operation by mistake, it will not cause any problems Selecting mph or km/h Follow steps 1 to 4 on page 15 to select. If you lose your place at any time during the procedure for changing the speed units, or if you make a mistake in operation, wait 10 seconds or more without pressing any of the operating keys. The digital display will return to, and you can then start the procedure again from step 2 on page 9. Check the current speed unit setting by checking whether or is flashing in the digital display. Km-ile/h s or Km-ile/h s 10

13 R Automatic drive Please note: Specifications are subject to change for improvement without notice. (English) C Sep by Shimano Inc. PIT. Printed in Japan

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