Shimano AI-3S30 Service Instructions

General Safety Information

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.

Read these Technical Service Instructions carefully, and keep
them in a safe place for later reference.

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.

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.

The riding lamps may periodically become darker than usual,
but this is not a sign of a problem. It happens when the power
required to run the system is being recharged, such as when
the gear shifting motor has operated.

Use a dry cloth or a cloth that is lightly moistened with neutral
detergent to clean the unit. Solvents such as thinner will
damage the unit's surface.

Parts are not guaranteed against natural wear or deterioration
resulting from normal use.

AI-3S30

Technical Service Instructions

Operation of the 8-mode switch

The gear shifting timing can be adjusted to one of eight settings.

– To avoid serious injuries:

– To avoid serious injuries:

Automatic Inter-3

If you prefer slower, firmer
pedaling

Gear shifting timing is advanced

If you prefer faster pedaling

Gear shifting timing is delayed

SI-7B70B

N position adjustment

Use a Phillips screwdriver to loosen the two cover fixing screws, and

1.

then remove the main unit cover.

Main unit cover

Remove

Cover fixing screw

Cover fixing screw

Insert a 5 mm Allen key into the hexagonal recess in the winder unit

2.

as shown in the illustration, and use it to turn the winder unit in the
direction of the arrow until it is against the stopper.

5 mm Allen key

Next, turn the winder unit back in the direction of the arrow until it

3.

stops (N position).

In this position, turn the cable adjustment bolt of the bell crank

4.

counterclockwise so that the end of the hub axle and the red line on
the push rod are aligned.

Red line on
push rod

Yellow line

Yellow line

N position

End of hub axle

SET

Yellow section of link

ET

S

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.

Turn the front wheel to charge the power.

5.

When the power is fully charged, the gear
will shift automatically from the N position
to the L position.

Rotate the front wheel rapidly and check that the gears change from

6.

1st to 2nd to 3rd. If the gear does not change from 2nd to 3rd, stop
rotating the front wheel and turn the cable adjustment bolt of the bell
crank half a turn clockwise. After this, check the shifting of the gears
once more.

After adjusting the bell crank, secure the cable adjustment bolt by

7.

tightening the cable adjustment nut.

Cable adjustment nut

SET

SET

Tightening torque:

Install the main unit cover while making sure that the cable is routed

8.

correctly, and then securely tighten the two cover fixing screws.

Main unit cover

Tightening torque:
1 – 1.5 Nm {10 – 15 kgfcm}

Checking lamp illumination

While covering the illumination sensor receiving
window at the rear of the main unit with your
hand, turn the front wheel and check that
the lamp lights.

1.5 – 2.5 Nm {15 – 25 kgfcm}

Troubleshooting

For any questions regarding installation or adjustments, please contact the place of purchase.

Symptom

No gear shifting
occurs.

Gears do not shift
above 2nd.

A long beep sounds
and no gear shifting
occurs.

The lamp does not
illuminate.

The lamp stays illu­minated while riding.

Are the cables connected correctly?

Is the gear shifting cable connected correctly?

Is the gear shifting cable broken?

Is the frame grounded electrically?

Are the proper lamp bulbs being used? (If the electrical
load is too great, the power required for shifting may not
be supplied.)

Is the 8-mode switch at the "
not have reached the speed required for shifting to 3rd.)

Does the bell crank move smoothly?

Does the push rod move smoothly?

Is the proper push rod being used?

Does the gear shifting cable work smoothly?

Is the shifting cable winder on the main unit blocked with
mud or small stones?

Has the N position been adjusted correctly?

Are the cables connected correctly?

Is the frame grounded electrically?

Are the surroundings dark? (The sensor detects light and
has a circuit that automatically turns the lamp on and off.)

Are the proper lamp bulbs being used?

Are the lamp bulbs blown?

Is the illumination sensor receiving window covered with
mud?

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.

Please note: Specifications are subject to change for improvement without notice. (English)

Check

" position? (The speed may

–

Connect the cables correctly between the main unit and the hub
dynamo, and between the main unit and the lamp stay.

Connect the cable correctly at the main unit and bell crank.

Replace the cable with a new one.

Check if the main unit installation is too loose.

Install the toothed washer in the correct position.

Use the proper lamp bulbs (Front lamp: 6 V/ 2.4 W; Taillamp: 6 V/

0.6 W).

Set the 8-mode switch to the "

Replace with a new part, or eliminate the cause of the problem.

Replace with a new part, or eliminate the cause of the problem.

Use the proper push rod.

Replace with a new part, or eliminate the cause of the problem.

Remove the cause of the problem.

Refer to "N position adjustment".

Connect the cables correctly between the main unit and the hub
dynamo, between the main unit and the lamp stay, and between the
main unit and the lamp.

Check if the main unit installation is too loose.

Install the toothed washer in the correct position.

Refer to "Checking lamp illumination".

Use the proper lamp bulbs (Front lamp: 6 V/ 2.4 W; Taillamp: 6 V/0.6 W).

Replace the lamp bulb with a new one.

Clean away the mud.

Install

Cover fixing screw

Cover fixing screw

Illumination sensor
receiving window

Remedy

+" position.

®

One Holland, Irvine, California 92618, U.S.A. Phone: [phone]

Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: [phone]

3-77 Oimatsu-cho, Sakai, Osaka 590-8577, Japan

C

Aug. 2003 by Shimano Inc. PIT. SZK. Printed in China