Shimano Alivio FD-M3100 Front Derailleur Dealer's Manual PDF

(English)

Dealer's Manual ROAD MTB Trekking

City Touring/ Comfort Bike

URBAN SPORT E-BIKE

FRONT DERAILLEUR

ALIVIO FD-M3100 FD-M3120

DM-MDFD002-00

2

CONTENTS CONTENTS .................................................................................2

IMPORTANT NOTICE ..................................................................3

TO ENSURE SAFETY ...................................................................4

LIST OF TOOLS TO BE USED ......................................................6

INSTALLATION/REMOVAL .........................................................7

Installing the front derailleur (front triple) ..........................................8 Band type .................................................................................................................................. 8

Installing the front derailleur (front double) .....................................11 Band type ................................................................................................................................ 11

Direct mount type .................................................................................................................. 14

E Type ...................................................................................................................................... 16

ADJUSTMENT ..........................................................................19

Installing the cable and adjusting gear shifting (front triple) ..........19 Adjusting the position of the low side ................................................................................. 19

Connection and securing of the inner cable ........................................................................ 21

Adjusting the cable tension ................................................................................................... 23

Adjusting the top side ............................................................................................................ 25

Checking gear shifting and fine tuning ................................................................................ 27

Installing the cable and adjusting gear shifting (front double) .......28 Adjusting the position of the low side ................................................................................. 28

Connection and securing of the inner cable ........................................................................ 30

Adjusting the cable tension ................................................................................................... 32

Adjusting the top side ............................................................................................................ 34

Checking gear shifting and fine tuning ................................................................................ 36

Fine tuning the contact of the chain and inner plate .......................................................... 36

MAINTENANCE ........................................................................38

Replacing rubber pad B .......................................................................38 Removal .................................................................................................................................. 38

Installation .............................................................................................................................. 39

3

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.

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.

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.

4

TO ENSURE SAFETY

TO ENSURE SAFETY WARNING

Be sure to follow the instructions provided in the manuals when installing the product.

Use SHIMANO genuine parts only. Inappropriate assembly or adjustment of products and replacement parts may bring about product malfunctions which may cause the bicycle to fall over and lead to serious injury.

Wear approved eye protection while performing maintenance tasks such as replacing components.

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.

NOTICE

Be sure to also inform users of the following:

If gear shifting operations do not feel smooth, wash the shifting unit and lubricate all moving parts.

When the chain is in any of the positions shown in the figures, 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

Front chainring

Double Triple

Rear sprocket

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 OT-SP40 cable and a cable guide (SM-SP17/SP18) for smooth operation.

If the amount of excess play in the links is so great that gear shifting adjustment is not possible, you should replace the shifting unit.

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.

6

LIST OF TOOLS TO BE USED

LIST OF TOOLS TO BE USED The following tools are needed for installation, adjustment, and maintenance purposes.

Tool

5 mm hexagon wrench

Cross head screwdriver [#2]

7

INSTALLATION/REMOVAL

INSTALLATION/REMOVAL NOTICE

When installing parts on a carbon frame/handlebars, confirm the recommended tightening torque with the carbon frame or part manufacturer in order to prevent damage to the carbon material due to overtightening or inadequate securing of the parts due to insufficient tightening torque.

TECH TIPS

The position of bicycles with rear suspension may differ depending on whether a rider is on or off the bicycle. For the installation and SIS adjustment procedures, refer to the figure and secure the bicycle in the state it is in when a rider is on the bicycle.

8

INSTALLATION/REMOVAL

Installing the front derailleur (front triple)

Installing the front derailleur (front triple)

Band type

1. Temporarily attach the clamp bolt.

Clamp bolt

2. Adjust the position of the chain guide.

Use the low adjustment bolt to align the chain guide outer plate with the flat surface of the largest chainring.

Low adjustment bolt

Chain guide outer plate

Largest chainring

9

INSTALLATION/REMOVAL

Installing the front derailleur (front triple)

NOTICE

Make sure not to position the chain guide as shown in the figure.

3. Adjust the height.

Adjust the installation height so that the distance from the tips of the teeth on the largest chainring is 1 - 3 mm.

1 - 3 mm

Chain guide outer plate

Largest chainring

10

INSTALLATION/REMOVAL

Installing the front derailleur (front triple)

4. Adjust the installation position.

As shown in the figure, hold a tool such as a hexagon wrench against the flat surface of the largest chainring and make sure that the front derailleur is installed so that it is parallel with the front chainring.

5. Secure the clamp bolt.

Clamp bolt

5 - 7 Nm

11

INSTALLATION/REMOVAL

Installing the front derailleur (front double)

Installing the front derailleur (front double)

Band type

1. Temporarily attach the clamp bolt.

Clamp bolt

2. Adjust the position of the chain guide.

Use the low adjustment bolt to align the chain guide outer plate with the flat surface of the largest chainring.

Low adjustment bolt

Chain guide outer plate

Largest chainring

12

INSTALLATION/REMOVAL

Installing the front derailleur (front double)

NOTICE

Make sure not to position the chain guide as shown in the figure.

3. Adjust the height.

Adjust the installation height so that the distance from the tips of the teeth on the largest chainring is 1 - 3 mm.

1 - 3 mm

Largest chainring

Chain guide outer plate

13

INSTALLATION/REMOVAL

Installing the front derailleur (front double)

4. Adjust the installation position.

As shown in the figure, hold a tool such as a hexagon wrench against the flat surface of the largest chainring and make sure that the front derailleur is installed so that it is parallel with the front chainring.

5. Secure the clamp bolt.

Clamp bolt

5 - 7 Nm

14

INSTALLATION/REMOVAL

Installing the front derailleur (front double)

Direct mount type

1. Temporarily install the front derailleur to the frame.

Fixing bolt

Installation height

2. Adjust the position of the chain guide.

Use the low adjustment bolt to align the chain guide outer plate with the flat surface of the largest chainring.

Low adjustment bolt

Chain guide outer plate

Largest chainring

15

INSTALLATION/REMOVAL

Installing the front derailleur (front double)

NOTICE

Make sure not to position the chain guide as shown in the figure.

3. Adjust the height.

Adjust the installation height so that the distance from the tips of the teeth on the largest chainring is 1 - 3 mm.

1 - 3 mm

Chain guide outer plate

Largest chainring

16

INSTALLATION/REMOVAL

Installing the front derailleur (front double)

4. Secure the front derailleur to the frame.

Fixing bolt

5 - 7 Nm

E Type

1. Temporarily install the front derailleur to the frame.

Secure with the bottom bracket mount fixing bolts.

Bracket

Bottom bracket mount xing bolts

Bottom bracket mount

NOTICE

The bottom bracket mount fixing bolts are not included with SHIMANO components.

17

INSTALLATION/REMOVAL

Installing the front derailleur (front double)

2. Adjust the position of the chain guide.

Use the low adjustment bolt to align the chain guide outer plate with the flat surface of the largest chainring.

Low adjustment bolt

Chain guide outer plate

Largest chainring

NOTICE

Make sure not to position the chain guide as shown in the figure.

18

INSTALLATION/REMOVAL

Installing the front derailleur (front double)

3. Adjust the height.

Adjust the installation height so that the distance from the tips of the teeth on the largest chainring is 1 - 3 mm.

1 - 3 mm

Chain guide outer plate

Largest chainring

4. Secure the front derailleur to the frame.

19

ADJUSTMENT

Installing the cable and adjusting gear shifting (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 gear shifting (front triple)

Adjusting the position of the low side

1. Remove the Pro-Set alignment block.

Pro-Set alignment block

20

ADJUSTMENT

Installing the cable and adjusting gear shifting (front triple)

2. Adjust the chain to the smallest chainring and the largest sprocket.

Smallest chainring

Largest sprocket

3. Adjust the low position of the inner plate.

Adjust the gap between the inner plate and chain to 0 - 0.5 mm.

Inner plate

Chain

Low adjustment bolt

0 - 0.5 mm

21

ADJUSTMENT

Installing the cable and adjusting gear shifting (front triple)

Connection and securing of the inner cable

1. Operate the release lever of the shifting lever and set it to the initial position (smallest chainring side).

2. Pass the inner cable through the front derailleur.

Pass the cable through the cable guide and along the cable fixing groove.

The cable fixing groove is located on the top side of the inner cable fixing bolt.

Sealed outer cap

Outer casing

Inner cable

Cable guide

Cable xing groove

NOTICE

Fuzz may be generated when the inner cable is assembled or when the coating is damaged during use; however, this will not affect performance.

If the outer casing moves to a large degree, such as in bicycles with suspension frames, it is recommended that you use an aluminum type sealed outer cap.

Sealed outer cap Sealed outer cap (aluminum type)

22

ADJUSTMENT

Installing the cable and adjusting gear shifting (front triple)

3. Secure the inner cable.

5 - 7 Nm Cable xing bolt

NOTICE

Be sure to pass the inner cable along the cable fixing groove as shown in the figure. If the cable is not distributed along the groove, the gear shifting performance may become obstructed due to a reduction in the holding force, etc.

23

ADJUSTMENT

Installing the cable and adjusting gear shifting (front triple)

Adjusting the cable tension

1. Adjust the chain to the middle chainring and the largest sprocket.

Middle chainring

Largest sprocket

24

ADJUSTMENT

Installing the cable and adjusting gear shifting (front triple)

2. Adjust the position of the inner plate.

Adjust the gap between the inner plate and the chain to 0 - 0.5 mm with the cable adjuster.

Inner plate

Chain

0 - 0.5 mm

TECH TIPS

Operate the lever once after adjusting with the cable adjuster and re-check the gap.

25

ADJUSTMENT

Installing the cable and adjusting gear shifting (front triple)

Adjusting the top side

1. Adjust the chain to the largest chainring and the smallest sprocket.

Largest chainring

Smallest sprocket

26

ADJUSTMENT

Installing the cable and adjusting gear shifting (front triple)

2. Adjust the position of the outer plate.

Adjust the gap between the outer plate and chain to 0 - 0.5 mm.

Outer plate

Chain

Top adjustment bolt

0 - 0.5 mm

27

ADJUSTMENT

Installing the cable and adjusting gear shifting (front triple)

Checking gear shifting and fine tuning

After the cable is installed and adjusted, operate the shifting lever to check the gear shifting performance. (This also applies if shifting becomes difficult during use.)

Refer to the table when fine tuning. Turn 1/8 of a turn for each adjustment.

If the chain falls to the crank side Turn the top adjustment bolt clockwise.

If shifting is difficult from the middle chainring to the largest chainring

Tighten the cable. If this does not improve the

situation, turn the top adjustment bolt

counterclockwise.

If shifting is difficult from the largest chainring to the middle chainring

Loosen the cable.

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

Tighten the cable.

If shifting is difficult from the middle chainring to the smallest chainring

Turn the low adjustment bolt counterclockwise.

28

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

Installing the cable and adjusting gear shifting (front double)

NOTICE

When using a shifting lever that supports front triple, the shifter uses the lowest position and middle position. The top position is not used.

Largest chainring

Low

Middle

Top

Smallest chainring

Front chainring position

Shifting lever position

Adjusting the position of the low side

1. Adjust the chain to the smallest chainring and the largest sprocket.

Smallest chainring

Largest sprocket

29

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

2. Adjust the low position of the inner plate.

Adjust the gap between the inner plate and chain to 0 - 0.5 mm.

Inner plate

Chain

0 - 0.5 mm

Low adjustment bolt

30

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

Connection and securing of the inner cable

1. Operate the release lever of the shifting lever and set it to the initial position (smallest chainring side).

2. Pass the inner cable through the front derailleur.

Pass the cable through the cable guide and along the cable fixing groove.

The cable fixing groove is located on the top side of the inner cable fixing bolt.

Sealed outer cap

Outer casing

Inner cable

Cable guide

Cable xing groove

NOTICE

Fuzz may be generated when the inner cable is assembled or when the coating is damaged during use; however, this will not affect performance.

If the outer casing moves to a large degree, such as in bicycles with suspension frames, it is recommended that you use an aluminum type sealed outer cap.

Sealed outer cap Sealed outer cap (aluminum type)

31

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

3. Secure the inner cable.

5 - 7 Nm Cable xing bolt

NOTICE

Be sure to pass the inner cable along the cable fixing groove as shown in the figure. If the cable is not distributed along the groove, the gear shifting performance may become obstructed due to a reduction in the holding force, etc.

32

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

Adjusting the cable tension

1. Adjust the chain to the largest chainring and the largest sprocket.

Largest chainring

Largest sprocket

33

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

2. Adjust the position of the inner plate.

Adjust the gap between the inner plate and the chain to 0 - 0.5 mm with the cable adjuster.

0 - 0.5 mm

Inner plate

Chain

TECH TIPS

Operate the lever once after adjusting with the cable adjuster and re-check the gap.

34

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

Adjusting the top side

1. Adjust the chain to the largest chainring and the smallest sprocket.

Largest chainring

Smallest sprocket

35

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

2. Adjust the position of the outer plate.

Adjust the gap between the outer plate and chain to 0 - 0.5 mm.

H LAB

A B

Top adjustment bolt

0 - 0.5 mm

Outer plate

Chain

36

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

Checking gear shifting and fine tuning

After the cable is installed and adjusted, operate the shifting lever to check the gear shifting performance. (This also applies if shifting becomes difficult during use.)

Refer to the table when fine tuning. Turn 1/8 of a 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

Tighten the cable. If this does not improve the

situation, turn the top adjustment bolt

counterclockwise.

If shifting is difficult from the largest chainring to the smallest chainring

Turn the low adjustment bolt counterclockwise.

If this does not improve the situation, loosen the

cable.

If the chain falls to the bottom bracket side Turn the low adjustment bolt clockwise.

Fine tuning the contact of the chain and inner plate

After the cable is installed and adjusted, check whether the chain and inner plate are in contact.

1. Adjust the chain to the smallest chainring and the largest sprocket and check whether there is contact.

Smallest chainring

Largest sprocket

37

ADJUSTMENT

Installing the cable and adjusting gear shifting (front double)

2. If there is contact, adjust the position so that there is a gap of 0 mm between the chain and the inner plate.

0 mm

Chain

Inner plate

TECH TIPS

Operate the lever once after adjusting with the cable adjuster and re-check the gap.

38

MAINTENANCE

Replacing rubber pad B

MAINTENANCE Replacing rubber pad B

Removal

1. Peel back and remove rubber pad B from the inner side of the chain guide.

Rubber pad B

39

MAINTENANCE

Replacing rubber pad B

Installation

1. Align in the installation position as shown in the figure, and then push in rubber pad B to install it.

Make sure that the protrusion of rubber pad B fits securely into the chain guide.

Rubber pad B mounting hole

Please note: specifications are subject to change for improvement without notice.