Shimano AI-3S10 Service Instructions

Page 1
WARNING
Obtain and read the service instructions carefully prior to installing the parts. Loose, worn, or damaged parts may cause serious injury to the rider. We strongly recommend only using genuine Shimano replacement parts.
CAUTION
The Automatic Inter-3 is an automatic gear shifting system in which the shifting points are determined by the speed of the bicycle (the rotating speed of the wheels). Because of this, gear shifting can occur independently of the rider's intentions, and so shocks may be felt during shifting. Make sure that you understand and become accustomed to these shifting characteristics before using the system extensively.
Make sure that the bicycle has been secured in a stable position before replacing the batteries or adjusting the bell crank or the magnet. If the bicycle is not stable, it may cause injury, or the main unit may not operate correctly.
SERVICE INSTRUCTIONS
Before use‚ read these instructions carefully‚ and follow them for correct use.
Automatic Inter-3
SI-AI3UD
NOTE
The Automatic Inter-3 returns to 1st gear when the bicycle stops. When riding the bicycle, a beep will be heard before a gear shift
occurs to notify the rider that a gear shift is about to take place. When the battery is nearly spent, a long beep (about three seconds),
and the gear mechanism will return to 1st gear. If you continue to use the unit with spent batteries still inserted, the unit will not operate correctly, and the batteries may leak. Replace spent batteries with new alkali batteries as soon as possible.
Some types of batteries may become spent more quickly than usual when used in cold temperature conditions.
Replacement of the battery
Note:
When replacing the batteries, secure the bicycle wheels so that they cannot rotate. In addition, do not rotate the wheels until at least four seconds have passed after inserting the batteries. If the wheels are rotated within this time the motor unit will switch to sleep mode, which will prevent the unit from operating for two minutes.
Do not mix old and new batteries or batteries of different types.
Use a Phillips screwdriver to loosen the two cover fixing screws,
1.
and then remove the main unit cover.
Cover fixing screw
Cover fixing screw
Main unit cover
Remove
Use a Phillips screwdriver to loosen the battery box cover fixing
2.
screw, and then remove the battery box cover.
Battery box cover
Remove
Battery box cover fixing screw
Insert the new batteries (four alkali AA batteries), making sure that
3.
the polarities are correct.
Alkali AA batteries (4 pcs.)
Insert the tab on the battery box cover into the battery box, and then
4.
tighten the battery box cover fixing screw.
Battery box cover
Install
Battery box cover fixing screw
Tab
Tightening torque:
0.5 – 1 Nm {5 – 10 kgfcm}
Install the main unit cover, and then securely tighten the two cover
5.
fixing screws.
Cover fixing screw
Main unit cover
Install
Tightening torque: 1 – 1.5 Nm {10 – 15 kgfcm}
Cover fixing screw
Bell crank (N position) adjustment
Rotate the wheel so that the magnet which has been attached to the
1.
spoke is aligned with the speed sensor ( mark position). Make a note of which side of the mark on the speed sensor the magnet is aligned at this time.
Magnet
Main unit
Speed sensor
Magnet
Set Magnet Position for shifting mode
Loosen the magnet fixing bolt, and remove the magnet from the
2.
magnet holder. Next, push the magnet against the mark (N position) of the speed sensor, and then remove the magnet from the mark. A beeping sound will be heard and the motor unit will shift to the 2nd gear position.
Set Magnet Position
Magnet fixing bolt
Set Magnet Position for shifting mode
Magnet
for shifting mode
Insert the magnet into the magnet holder. Move the magnet so that
4.
its center is aligned with the original position ( mark) on the speed sensor and so that there is a space of 1 – 5 mm between the magnet and the speed sensor, and then use a coin to tighten the magnet fixing bolt.
Tightening torque: 2 – 3 Nm {20 – 30 kgfcm}
Magnet
Magnet holder
Turn the cable adjustment bolt of the bell crank counterclockwise so
3.
that the end of the hub axle and the red line on the push rod are aligned.
Magnet fixing bolt
"D" and "Ds" modes
Move the magnet to the "D" or "Ds" position for automatic gear shifting in accordance with the bicycle speed.
In "D" mode, slow automatic shifting is carried out. In "Ds" mode, quick automatic shifting is carried out.
Turn the front chainwheel to rotate the wheels, and check that the
5.
gears change from 1st to 2nd to 3rd. If the gear does not change from 2nd to 3rd, stop rotating the wheel and turn the cable adjustment bolt of the bell crank half a turn clockwise. Turn the front chainwheel again to rotate the wheels, and check that the gears shift to all stages.
After adjusting the bell crank, secure the cable adjustment bolt by
6.
tightening the cable adjustment nut.
Red line on push rod
Yellow line
Yellow line
End of hub axle
SET
Yellow section of link
SET
SET
Cable adjustment bolt
Align the red line with the end of the hub axle
SET
If the red line on the push rod is not visible, adjust so that the yellow section of the link is between the two yellow lines on the window.
Note:
Look at the two yellow lines from directly above during adjustment.
Troubleshooting
For any questions regarding installation or adjustments, please contact the place of purchase.
Symptom
Gear shifting is not possible.
Buzzer does not sound.
Gear shifting timing is not correct.
A long beep (about three seconds) sounds and no gear shifting occurs.
These service instructions explain how to use and maintain the Shimano bicycle parts which have been used on your new bicycle. For any questions regarding your bicycle or other matters which are not related to Shimano parts‚ please contact the place of purchase or the bicycle manufacturer.
These service instructions are printed on recycled paper. Please note: Specifications are subject to change for improvement without notice. (English)
Are the batteries installed correctly ? Are the batteries spent ? Are the correct type of batteries being used ? Is the magnet installed in the correct position ? Is the gear shifting cable installed correctly ?
Is the magnet installed in the correct position ? Is the gear shifting cable installed correctly ?
Are the batteries spent ? Is the gear shifting cable installed correctly ? Are the bell crank, motor unit or cable blocked
with mud ?
Check
Insert the batteries so that the polarities are correct. Replace with new batteries. Use alkali AA batteries. Install the magnet in the correct position. Adjust the N position. Align the magnet with the mark on the speed sensor
which matches the number of teeth on the rear sprockets. Adjust the N position. Replace with new batteries. Adjust the N position.
Remove the cause of the problem.
Align the center of the magnet with the mark on the speed sensor.
Set Magnet Position for shifting mode
Magnet
1 --- 5 mm
Cable adjustment nut
SET
SET
Magnet holder
Tightening torque:
1.5 – 2.5 Nm {15 – 25 kgfcm}
Remedy
One Holland Irvine CA 92618 U.S.A. Phone 949-951-5003
Industrieweg 24 NL-8071 CT Nunspeet‚ Holland Phone 31-341-272222
3-77 Oimatsucho‚ Sakai‚ Osaka‚ Japan Phone 072- 223-3243
C
Sep. 2002 by Shimano Inc. PIT. SZK. Printed in Singapore
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