Shimano Non Series Dealer's Manual
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Shimano Non Series Dealer's Manual

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(English)
DM-BTE001-00
Dealer's Manual
ROAD
MTB
Trekking
City Touring/
URBAN SPORT
E-BIKE
Comfort Bike
Special Battery and Parts (Gen.2)
Non Series
BT-EN404
BT-EN405
BT-EN604
BT-EN605
BT-EN606
BT-EN805
BT-EN805-L
BT-EN806
BM-EN400-A
BM-EN400-B
BM-EN600
BM-EN800-A
BM-EN800-B
BM-EN801-A
BM-EN801-B
EW-SW310
SHIMANO (E-BIKE)
EW-CP100

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Summary of Contents for Shimano Non Series

  • Page 1 (English) DM-BTE001-00 Dealer's Manual ROAD Trekking City Touring/ URBAN SPORT E-BIKE Comfort Bike Special Battery and Parts (Gen.2) Non Series BT-EN404 BT-EN405 BT-EN604 BT-EN605 BT-EN606 BT-EN805 BT-EN805-L BT-EN806 BM-EN400-A BM-EN400-B BM-EN600 BM-EN800-A BM-EN800-B BM-EN801-A BM-EN801-B EW-SW310 SHIMANO (E-BIKE) EW-CP100...

  • Page 2: Table Of Contents

    TO ENSURE SAFETY..................4 Booklet structure ..................12 List of tools to be used ................. 14 Installation/removal ..................15 SHIMANO STEPS battery management systems and compatibility ....15 Wiring example....................16 Electric wires.......................17 Installing the battery mount ................23 Installing the satellite charging port ..............39 Installing the satellite system ON/OFF switch...........40...

  • Page 3: Important Notice

    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.

  • Page 4: To Ensure Safety

    TO ENSURE SAFETY TO ENSURE SAFETY...
  • Page 5 Doing otherwise may cause overheating, bursting, or ignition. Refer to the user's manual of the battery charger or the “ SHIMANO STEPS Special Battery and Parts User's Manual (Gen.2) ” for information on the designated charging time of the battery.
  • Page 6 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.
  • Page 7 TO ENSURE SAFETY lightning storm. If lightning strikes, electric shocks may occur. Do not overload the electrical outlet with appliances beyond its rated capacity, and use only a 100 - 240 V AC electrical outlet. If the electrical outlet is overloaded by connecting too many appliances using adapters, overheating resulting in fire may occur.
  • Page 8 TO ENSURE SAFETY Be sure to also inform users of the following: Handling the 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.
  • Page 9 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. 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.
  • Page 10 TO ENSURE SAFETY Charge the battery indoors to avoid exposure to rain or wind. (EC-E6002) Do not place the battery charger on dusty floors when using it. Place the battery charger on a stable surface such as a table when using it. Do not place any objects on top of the battery charger or its cable.
  • Page 11 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. The actual product may differ from the illustration because this manual is...

  • Page 12: Booklet Structure

    Booklet structure 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...
  • Page 13 Booklet structure Name Details SHIMANO STEPS Dealer's Manual 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...

  • Page 14: List Of Tools To Be Used

    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 type Tool Electric wire Plug TL-EW300 (EW-SD300) Key unit Cross head screwdriver [#2] Slotted screwdriver (6.5 mm) Battery mount (BM-EN400)

  • Page 15: Installation/Removal

    This manual only describes products compatible with Gen.2. With some exceptions, first-generation and Gen.2 products of SHIMANO STEPS components are not compatible with each other. For details, refer to the compatibility information on the SHIMANO product website ( https://productinfo.shimano.com/#/com The Gen.2 battery and compatible battery mount are marked “Gen.2” as indicated below.

  • Page 16: Wiring Example

    *1 For the satellite system ON/OFF switch, pay attention to the compatibility with the cycle computer and switch unit. For details, refer to the compatibility information ( https://productinfo.shimano.com/#/com *2 Take care to ensure that the satellite charging port is compatible with the battery mount. For details, refer to the compatibility information ( https://productinfo.shimano.com/#/com...

  • Page 17: Electric Wires

    Electric wires 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.
  • Page 18 Installation/removal Electric wires 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.
  • Page 19 Installation/removal Electric wires 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...
  • Page 20 Installation/removal Electric wires Insert the plug on the electric wire into the E-TUBE port. Push it straight in until you feel a click. Plug E-TUBE port When connecting the EW-SD300, the method below can also be used.
  • Page 21 Installation/removal Electric wires Removing the electric wire (EW-SD300) Remove the electric wire. Insert the TL-EW300 into the groove on the plug part of the electric wire. 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.
  • Page 22 Electric wires 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 Insert the plug on the electric wire into the E-TUBE port.

  • Page 23: Installing The Battery Mount

    Installation/removal Installing the battery mount Removing the electric wire (EW-SD50) Remove the electric wire. Insert the TL-EW02 into the groove on the plug of the electric wire. 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.
  • Page 24 Installation/removal Installing the battery mount Set the plug unit to the lower case, and install it to the battery rail. Set the plug unit to the lower case. Set the battery rail to the lower case. Be careful not to pinch the power cord between the lower case and battery rail.
  • Page 25 Installation/removal Installing the battery mount Install the upper case. Upper case 1.1 - 1.3 N·m Upper case mounting screw...
  • Page 26 External type Depending on the frame, it may be installed at a location different from the position specified in this section. BM-EN600 The SHIMANO original tool TL-BME02 can be used to easily determine the installation location for the key unit.
  • Page 27 Installation/removal Installing the battery mount The lower case is composed of two parts: a metal part secured to the frame with a screw, and a plastic cover. The metal part and plastic cover may separate before the procedure in step .
  • Page 28 Installation/removal Installing the battery mount Install the lower case. Set the lower case on the lower side of the down tube, then temporarily install the lower case mounting screws. * Temporarily install the two types of screws as shown in the figure. Tighten lower case mounting screw A.
  • Page 29 Installation/removal Installing the battery mount Temporarily install the key unit. Key units are not included with SHIMANO products. (Temporary) Key unit mounting screw Spacer Spacer...
  • Page 30 Installation/removal Installing the battery mount Use TL-BME02 to determine the location for the key unit. Align the two protrusions on the key unit with the holes in TL-BME02. Adjust the location of the key unit so that the contact surface of TL-BME02 will be pushed against the lower case as shown in the figure.
  • Page 31 Installation/removal Installing the battery mount Install the key unit cover. Temporarily install the key unit cover. Try attaching and removing the battery, and check the following: The battery can be smoothly attached and removed There is no rattling in the key unit cover or battery that could result in abnormal noise when riding Secure the key unit cover.
  • Page 32 Depending on the frame, it may be installed at a location different from the position specified in this section. BM-EN800 / BM-EN801 The SHIMANO original tool can be used to easily determine the installation location for the key unit. Use the appropriate SHIMANO original tool according to the battery that is used.
  • Page 33 Installation/removal Installing the battery mount TL-BME04 is composed of TL-BME04-L and TL-BME04-S. TL-BME05 is composed of TL-BME05-L and TL-BME04-S. The BM-EN801 has an unlock pin unit installed, which enables the battery to be unlocked with a hexagon wrench instead of a key. For information on the method for externally accessing the unlock pin unit, refer to the manual for the frame in advance.
  • Page 34 Installation/removal Installing the battery mount Temporarily install the upper bracket with the installation position determined. BM-EN800 Install the TL-BME04-S to the upper bracket, and temporarily install the upper bracket so that the dummy key cylinder can be seen in the center position from the frame key hole. Proceed to the next procedure with the TL-BME04-S installed.
  • Page 35 Install the SHIMANO original tools as shown in the figure. Check that the SHIMANO original tool is making firm and even contact with the contact surfaces of the upper bracket and lower bracket, then secure the upper bracket.
  • Page 36 Installation/removal Installing the battery mount Install the latch base to the upper bracket. BM-EN800 First install the key cylinder to the latch base. Key cylinders are not included with SHIMANO products. 1 N·m 2 N·m Fixing screw Latch base mounting screw B...
  • Page 37 Installation/removal Installing the battery mount Install the spring unit if necessary. For a frame where the battery is removed downwards Hold the spring unit stable when installing it so that it does not turn when tightening the spring unit mounting screw. 0.5 N·m Spring unit mounting screw...
  • Page 38 Secure the lower bracket. Set the SHIMANO original tools as shown in the figure. Check that the SHIMANO original tool is making firm and even contact with the contact surfaces of the upper bracket and the lower bracket, then secure the lower bracket.

  • Page 39: Installing The Satellite Charging Port

    Installation/removal Installing the satellite charging port Installing the satellite charging port EW-CP100 The work procedure and tightening torque may vary depending on the design of the frame. Contact a distributor for details. Install the connection cable. The connection cable may need to be connected after installing the satellite charging port, depending on the design of the frame.

  • Page 40: Installing The Satellite System On/Off Switch

    Installation/removal Installing the satellite system ON/OFF switch Install the satellite charging port. Open the charging port cap, and insert the satellite charging port into the frame after ensuring that section A is not exposed. Close the charging port cap, and secure the satellite charging port. 0.6 N·m Charging port cap Fixing screw...
  • Page 41 Installation/removal Installing the satellite system ON/OFF switch Connect the electric wires to the satellite system ON/OFF switch. The electric wires to the drive unit are required. Connect the electric wires to the cycle computer, depending on the specifications of the bicycle. Attach dummy plugs to any unused E-TUBE ports.

  • Page 42: Maintenance

    Maintenance Replacing the double latch plate Maintenance Replacing the double latch plate For models: BM-EN800 / BM-EN801 Remove the double latch plate. Install a new double latch plate. 0.6 N·m Double latch plate mounting screw Replacing the spring unit For models: BM-EN800 / BM-EN801 Refer to “...
  • Page 43 Maintenance Replacing the charging port cap Remove the charging port cap. Replace with a new charging port cap. As shown in the figure, push it in with your fingers.

  • Page 44: Troubleshooting

    When an error occurs, the following components notify you via LED indicators. Refer to the user's manual for each component. Battery charger (EC-E6002) Battery charger (EC-E8004) Satellite system ON/OFF switch Battery The FAQ for SHIMANO STEPS can also be accessed with the following: https://si.shimano.com/iFAQ/STP0A...
  • Page 45 Please note: specifications are subject to change for improvement without notice. (English) © Dec. 2021 by SHIMANO INC. ITP...

This manual is also suitable for:

Non bt-en404Non bt-en405Non bt-en604Non bt-en605Non bt-en606Non bt-en805 ... Show all

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