(English) DM-0001A-004 Dealer’s Manual 6770 Series
INDEX 6770 Series IMPORTANT NOTICE....................................................................................................................................................... 4 TO ENSURE SAFETY........................................................................................................................................................ 5 ELECTRONIC GEAR SHIFTING SYSTEM........................................................................................................................
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.
TO ENSURE SAFETY DANGER Be sure to observe the following in order to avoid burns or other injury from fluid leakages, overheating, fire or explosions. Be sure to also inform users of the following: Do not use anything other than the special charger to If any non-specified items are used, fire, overheating or charge the battery. leakages may occur. Do not heat the battery or throw it into fire. If this is not observed, fire or bursting may occur.
WARNING •• When installing components, be sure to follow the instructions that are given in the instruction manuals. It is recommended that you use only genuine Shimano parts. 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.
If you do not hold the power cable by the power plug, Be sure to hold the power cable by the power plug when fire or electric shocks may occur. * If heat or acrid-smelling smoke is coming out from the power plug. * There may be a bad connection inside the power plug. connecting and disconnecting the power plug from the electrical outlet.
•• Maintenance interval depends on the usage and riding circumstances. Clean regularly the chain with an appropriate chaincleaner. Never use alkali based or acid based solvents such as rust cleaners. If those solvent be used chain might break and cause serious injury. •• In order to obtain good gear shifting performance, applicable chains have a forward side and a reverse side, and the sides are marked so that the chains will face the correct way when installed.
CAUTION Be sure to also inform users of the following: •• Disconnect the power plug from the electrical outlet before cleaning. •• Do not disassemble or break the battery. If this is not observed, there is the danger that fire or burns may result. •• Do not heat the battery to temperatures which exceed 60°C (140°F). In addition, do not put the battery into fire.
•• The battery is uncharged at the time of purchase. Before riding, be sure to charge the battery until it is fully charged. •• When storing the battery away, remove the battery from the bicycle and install the terminal cover first. •• If the battery is stored away while the battery charge is 50% or higher (the indicator is illuminated green), the battery will last longer. It is recommended that you check the condition of the battery about once every half a year.
For Installation to the Bicycle, and Maintenance: •• This is a small waterproof connector. Do not repeat connecting and disconnecting it. It may impair the function. •• Be sure to attach dummy plugs to any unused terminals. •• The units are designed to be fully waterproof to withstand wet weather riding conditions. However, do not deliberately place them into water. •• Always be sure to use the TL-EW02 special tool to remove the electric wires.
•• As illustrated in Fig. A, we strongly recommend to set the connecting pin in the hole of the outer link on the front side in the direction of travel. The chain’s level of strength is enhanced compared to the method in Fig. B. A Inner link Outer link Chain’s direction of travel Connecting pin B Inner link Outer link Connecting pin •• Place the chain into the chain cutting tool as shown in the illustration.
Be sure to also inform users of the following: When the system fails to operate, the system may be recovered by resetting the system power. After the battery is removed, about one minute is usually required for the system power to reset. In the case of using SM-BTR1 Remove the battery from the battery mount. After about one minute, install the battery. In the case of using SM-BTR2 Disconnect the plug from SM-BTR2. After about one minute, insert the plug.
ELECTRONIC GEAR SHIFTING SYSTEM In order to obtain the optimum performance, it is recommended that you use the following combination of components.
Built-in type (SM-JC41) SM-EW67-A-E FD-6770 ST-6770 SM-BTR1 RD-6770 EW-SD50-I SM-JC41 SM-BMR1/SM-BMR2 External type (SM-JC40) SM-EW67-A-E FD-6770 ST-6770 SM-BTR1 RD-6770 EW-SD50 SM-JC40 15 SM-BMR1/SM-BMR2
SYSTEM CONFIGURATION DETAILS Dual control lever (ST-6770) / Electric wire tool (TL-EW02) Front junction: Junction (A) (SM-EW67-A-E) Electric wires (EW-SD50 / EW-SD50-I) (ST-6770) (TL-EW02) Front derailleur (FD-6770) (EW-SD50) (EW-SD50-I) Band adapter (SM-AD67) Electric wire cover (SM-EWC2) (SM-AD67L) (SM-AD67M) Rear derailleur (RD-6770) Frame grommets (SM-GM01 / SM-GM02) 16
Lithium ion battery (SM-BTR1) Bottle cage adapter (SM-BA01) Rear junction: Junction (B) Built-in type (SM-JC41) / External type (SM-JC40) Accessories •• Terminal cover Battery charger (SM-BCR1) (SM-JC41) (SM-JC40) E-tube Project: System checker (SM-PCE1) Battery charger cord (SM-BCC1) Accessories •• PC-link cable (×2) 2m •• USB cable (×1) 50cm Battery mount (SM-BMR1/SM-BMR2) (SM-BMR1-I / SM-BMR2-I) (SM-BMR1-L / SM-BMR2-L) Accessories •• Cable tie (×1) •• Low head M4 bolt (×1) Acces
SPECIFICATIONS Front derailleur Type Model number Band adapter (installation band diameter) Brazed-on type Band type FD-6770-F FD-6770-L FD-6770-M FD-6770-S – SM-AD67L (34.9 mm) SM-AD67M (31.8 mm) SM-AD67MS (28.6 mm) Number of larger chainring teeth 50 - 56 T Difference in number of larger and smaller chainring teeth 16T or less Chainstay angle (ɑ) 61° - 66° Chain line 43.5 mm Rear derailleur Type SS Total capacity 33 T Maximum no. of largest sprocket teeth 28 T Minimum no.
Battery charger Input 100 - 240 V AC, 50/60 Hz Output Dimensions 8.4 V DC, 0.55 A Approx. 100 mm (W) x 30 mm (H) x 72 mm (D) Weight Approx.
INSTALLATION Installation of the dual control lever Open up the bracket cover from the front, and then use a 5 mm Allen key to tighten the mounting nut in order to secure the lever unit. Bracket cover 5mm Allen key Tightening torque: 6 - 8 N·m {52 - 69 in. lbs.
The lever stroke can be smoothly adjusted using the bolt on the top of the bracket unit. Check the lever operation while adjusting. Installation of the front derailleur 1. Install the front derailleur to the frame. When installing a brazed-on type If installing the front derailleur to a brazed-on type frame, a protector must be attached to the seat tube. Always be sure to install the protector in order to prevent damage to the frame from the pressure applied by the support bolt of the front derailleur.
When installing a band type * If using the band adapter (SM-AD67), a support bolt will be necessary. A protector and a mounting washer will not be needed. Use the SM-AD67 in combination with the FD-6770. The SM-AD11/15 cannot be installed. Band adapter Tightening torque: 5 - 7 N·m {43 - 60 in. lbs.
4. Use a 2 mm Allen key to turn the support bolt in order to adjust the position of the front derailleur so that the flat part of the chain guide outer plate is directly above and parallel to the large chainring. Installation of the rear derailleur When installing the rear derailleur, make sure that the B-tension adjustment bolt does not touch the dropout tab and cause it to bend. B-tension adjustment bolt Dropout tab 5mm Allen key Bracket tightening torque: 8 - 10 N·m {70 - 86 in. lbs.
CONNECTION OF THE ELECTRIC WIRES Names and example locations of each part Built-in type (SM-JC41) SM-EW67-A-E SM-JC41 EW-SD50-I External type (SM-JC40) SM-EW67-A-E SM-JC40 EW-SD50 24
Front junction: Connection of junction (A) When routing the SM-EW67-A-E, allow enough looseness in the cable so that the ST-6770 installation position can be adjusted and so that the handlebars can be turned fully to the left and right. When routing the electric wires, they can be wrapped around the handlebars when wrapping the handlebar tape. (Sample connection diagram for ST-6770 and SM-EW67-A-E) Connection to the Dual control lever 1. Use the TL-EW02 special tool to connect to the ST-6770.
3. Use the accessory cable ties to secure junction (A) to the outer casing of the brake cable. Installation of the battery mount 1. Set the battery mount into position. Use the bottle cage fixing bolt to provisionally install the battery mount to the bottom of the bottle cage. Use the bolts which are included with the bottle cage to secure the SM-BMR1-L/ SM-BMR2-L (long type). Refer to the Service Instructions for the bottle cage for details on the tightening torques. Tightening torque: 1.2 - 1.
3. Tighten the bolt of the bottle cage to secure the battery mount. For the SM-BMR1-L/SM-BMR2-L (long type), use the accessory cable tie to secure the battery mount to the frame. * If there is a mounting boss on the frame, the battery mount can be secured to the frame with a bolt. Cable tie 2mm Allen key Battery mount fixing bolt (M4 x 15mm) Tightening torque: 1.2 - 1.5 N·m {10.4 - 13 in. lbs.} Rear junction: Connection of junction (B) External type External type (SM-JC40) 1.
2. Connect the electric wires to the front derailleur, the rear derailleur and the battery mount. At front derailleur At rear derailleur At battery mount 3. Provisionally secure the electric wire along the frame with tape, and then connect it to junction (B). * When routing the electric wire to the rear derailleur, be sure to install it to the bottom of the chainstay to avoid any interference between the cable and the chain.
4. Once the electric wires have been routed, secure junction (B) underneath the bottom bracket shell. Junction (B) fixing bolt (10.5mm or 15mm) (3mm Allen key) Tightening torque: 1.5 - 2 N·m {13 - 18 in. lbs.} 5. Next, install the electric wire cover to the frame. In order to make sure that the electric wire cover is securely installed, clean the frame with alcohol or some other cleaning agent to remove any grease or other substances before installing the cover.
Disconnection of the electric wires This is a small waterproof connector. Do not repeat connecting and disconnecting it. The waterproof section or the connecting section may become worn or deformed, and the function may be affected. Use the wide end of the TL-EW02 special tool to disconnect the electric wires. If you pull too firmly on the connectors, problems with operation may occur.
Rear junction: Connection of junction (B) Built-in type Built-in type (SM-JC41) 1. First pass the electric wires for junction (A), the battery mount, the front derailleur and the rear derailleur through the holes in the frame into the bottom bracket shell. * The electric wires have a correct way of being inserted. Make sure that you insert them from the direction shown in the illustration.
3. Connect the electric wires to junction (A), the front derailleur, the rear derailleur and the battery mount.
Routing junction (B) and the electric wires inside the frame 1. Pass the electric wires for the front derailleur and the rear derailleur through the seat tube and chainstay respectively. 2. Pass the electric wires for junction (A) and the battery mount and junction (B) through the down tube. Check that the screws of 3. the bottom bracket shell do not damage any of the components at this time.
Installation of the battery mount 1. Set the electric wire for the battery mount into the groove in the electric wire cover for the battery mount. 2. Place the accessory spacers in between the battery mount and the frame and then secure them by tightening the bolts. 3. * If installing the bottle cage, it is easier to install it at this stage. * Refer to the Service Instructions for the bottle cage for details on the tightening torques. Use the accessory cable tie to secure the battery mount to the frame.
Installation of the grommets Install grommets in appropriate positions for the electric wires by inserting the bottoms into the holes in the frame and then pushing the tops to fit them into place. At junction (A) Closed Open At rear derailleur At front derailleur Installation of the bottle cage adapter 3mm Allen key If the bottle cage which is installed to the seat tube interferes with the battery, move the position of the bottle cage upward.
ADJUSTMENT Adjustment of the rear derailleur Junction (A) Illuminates (red) Rear derailleur adjustment button 1. 2. 3. 4. Install the battery. Shift the rear derailleur to the 5th sprocket position. Press the button at the junction (A) of the SM-EW67-A-E until the red LED illuminates in order to switch to rear derailleur adjustment mode. Note that if you keep pressing the button after the red LED has illuminated, protection recovery operation will begin.
5. Next, operate shifting switch (Y) 4 times to move the guide pulley toward the outside by 4 steps to the target position. 4 times 4 steps 6. Press the button at junction (A) until the red LED turns off in order to switch from rear derailleur adjustment mode to gear shifting mode. Shift to each gear and check that no noise is generated at any gear position. If fine adjustment is needed, switch back to adjustment mode and readjust the rear derailleur. Turned off Rear derailleur adjustment button 7.
By shifting from a large sprocket to a smaller sprocket, the rear derailleur will move toward the outside by the over-stroke allowance and then move back. Largest sprocket 8. Adjust the B-tension adjustment bolt. Set the chain onto the smaller chainring and the largest sprocket, and then turn the crank arms backward. Turn the B-tension adjustment bolt to adjust so that the guide pulley moves close to the sprocket without obstructing the chain.
Set the chain onto the smaller chainring and the largest sprocket. Use a 2 mm Allen key to turn the low adjustment bolt to adjust so that there is a clearance of 0 - 0.5 mm between the chain and the chain guide inner plate. 0 - 0.5 mm Next, set the chain onto the larger chainring and the smallest sprocket. Use a 2 mm Allen key to turn the top adjustment bolt to adjust so that there is a clearance of 0.5 - 1.0 mm between the chain and the chain guide outer plate.
OTHER FUNCTIONS Battery charge display function Press and hold either shifting switch for 0.5 seconds or more. You can check the amount of battery charge remaining using the battery indicator on junction (A). Battery indicator Illuminates green (for 2 seconds) 100 % 50 % Flashes green (5 times) 25 % Illuminates red (for 2 seconds) 0% Flashes red (5 times) * When the battery charge is low, first the front derailleur will stop operating, and then the rear derailleur will stop operating.
MAINTENANCE * The illustrations show the right-side lever. Disassembly of the bracket unit and lever unit 1. Use the special tool which is sold separately to remove the E-ring. Align part B of the special tool with the removal direction of the E-ring. Next, set part A onto the E-ring and remove the E-ring. (A) Special E-ring removal tool Y6RT68000 (B) Note: * The E-ring may fly off suddenly during removal, so check that there are no people or objects nearby while removing the E-ring. 2.
4. Remove the two switch unit fixing screws, and then remove the switches and the switch springs. The bracket unit and the lever unit can then be disassembled. Switch unit fixing screws (#T5 TORX®) TORX is a registered trademark of Camcar LLC. Assembly of the switch unit 1. Check that the buttons are attached to the springs, and then place the switch springs into the holes in the switch unit setting plate. Switch springs 2.
3. Press the switch unit by hand so that the switch springs go into the grooves in the buttons, and then push the shifting switches (X and Y) in as far as they will go. Switch unit Shifting switches (X/Y) 4. Make a gap between the switch unit and the switch unit setting plate and check that the end of the rubber on the switch unit is on the button. 5.
2. Align with the hole in the stud, and then press-fit the lever stud. * The correct direction for the lever stud is when the E-ring groove is at the top. * Check that the surface of the bracket unit and the top end of the lever stud are flush with each other so that the E-ring will fit into the groove. 3. Use part A of the special tool to install the E-ring. * Operate the shifting switches (X and Y) and check that they turn on, and check that the lever operates smoothly.
HANDLING THE BATTERY The battery is a lithium ion battery. Use the special battery charger (SM-BCR1) to recharge the battery. Never use any other battery charger to recharge the battery. If this is not observed, explosions or fire may result. Electrical contacts Do not modify or damage these, otherwise problems with operation will result. Take proper care when handling the battery. Storing the battery When storing the battery away, remove the battery from the system and install the terminal cover first.
Proper use of the battery If the battery feels difficult to insert or remove, apply some specified grease (DURA-ACE grease). Apply the specified grease to the sides where the O-rings touch. Apply grease DURA-ACE Grease (Y-04110000) Note: * For the DURA-ACE (7970), the bicycle can be ridden for approximately 1000 km on a full charge. For the ULTEGRA (6770), the riding distance will be shorter. (Approximately 30% less according to tests carried out by Shimano.
Charging the battery 1. 2. 3. 4. Insert the plug of the battery charger into an electrical outlet. Place the battery securely into the battery charger as far as it will go. * The charging time is approximately 1.5 hours. (Note that the actual time will vary depending on the amount of charge remaining in the battery.) When the CHARGE indicator (orange) turns off, charging is complete. * If the ERROR indicator flashes, it means that there may be a problem with the battery.
INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS. DANGER - TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, CAREFULLY FOLLOW THESE INSTRUCTIONS. For connection to a supply not in the U.S.A., use an attachment plug adapter of the proper configuration for the power outlet, if needed. This power unit is intended to be correctly orientated in a vertical or floor mount position. Battery to be recharged for this product is follows Brand Name : SHIMANO Battery Type : SM-BTR1 Rating : DC7.
Please note: specifications are subject to change for improvement without notice. (English) © Sep. 2012 by Shimano Inc.
