SERVICE MANUAL SHIMANO NEXUS 3
Contents
1. ITEM NO DESCRIPTION Internal Assembly Axle Length 170 3 mm 1 Internal Assembly Axle Length 176 8 mm Internal Assembly Axle Length 189 4 mm 2 Stop Ring 9 6 mm 3 Carrier Unit 4 Ring Gear Unit 5 Ball Retainer K 7 32 x 10 Axle Unit Axle Length 170 3 mm 6 Axle Unit Axle Length 176 8 mm Axle Unit Axle Length 189 4 mm 7 Driver Unit 8 Ball Retainer J 7 32 x 8 9 Right Hand Cone w Dust Seal 10 Right Hand Lock Nut 5 mm for Axle Length 170 3 mm 189 4 mm Right Hand Lock Nut 9 9 mm for Axle Length 176 8 mm 11 Flange Nut for Axle Length 170 3 mm 176 8 mm 42 Hub Nut 7 mm for Axle Length 189 4 mm Hub Nut 9 mm for Axle Length 189 4 mm 13 Washer 2 mm for Axle Length 189 4 mm Washer 3 2 mm for Axle Length 189 4 mm 14 Non turn Washer 2 Yellow 15 Brake Unit Fixing Nut 8 2 mm for Axle Length 170 3 mm 189 4 mm Brake Unit Fixing Nut 9 7 mm for Axle Length 176 8 mm 16 Grease Hole Cap Brake Arm Clip Unit 15 mm 17 Brake Arm Clip Unit 5 8 Brake Arm Clip Unit 11 16 Brake Arm Clip Unit 3 4 18 Brake Cable Adjusting Bolt amp Nut 19 Inner Cable Fixing Bolt amp Nut 20 Lock Nut for Left Hand Cone 21 Left Hand Cone 22 Left Hand Dust Cap 23 Ball Retainer A 1 4 x 7 24 Right Hand Dust Cap A 25 Right Hand Dust Cap B Sprocket Wheel 16T Black Sprocket Wheel 18T Black Sprocket Wheel 19T Black 26 Sprocket Wheel 20T Black Sprocket Wheel 21T Black Sprocket Wheel 22T Black Sprocket Whee2. Incorrect installation of right hand dust cap A Install right hand dust cap correctly to the hub shell Right hand dust cap A Malfunction of the bell crank I unit Replace the bell crank II unit with a new one Bell crank M unit Damaged or malfunctioning cable Replace the cable with a new one of a type recommended by Shimano Damaged or malfunctioning push rod CEID i Comm Replace the push rod with a new one 11 SHIMANO www shimano com SHIMANO AMERICAN CORPORATION One Holland Irvine California 92618 U S A Phone 1 949 951 5003 Fax 1 949 768 0920 Specifications are subject to change for improvement without notice This publication is printed on recycled paper MA33SA Jan 2004 Shimano Inc UCI official neutral technical support
3. SHIMANO NEXUS 3 SPEED HUB SEIRA 7 a a i a ites a j head om a4 l SHIMANO CCIC m E me SG 3R40 Tools TL HS20 TL HS10 Screwdriver Hub spanners Hub spanners Part no Y 320 90010 Part no Y 230 90010 15 mm 17 mm 2 pcs 13 mm x 14 mm 2 pcs 1 Hold the two bevelled surfaces of the hub axle in a vice Note Do not damage the threads of the hub axle 2 Remove the right hand dust cap A with a screwdriver Right hand dust cap A 3 Hold the two bevelled surfaces of the hub axle on the driver side in a vice Driver Note Do not damage the threads of the hub axle Vice 4 Hold the left hand cone and TL HS10 then remove the lock nut for 14 mm left hand cone Next remove the left hand cone TL HS10 14 mm Left hand cone 5 Remove the hub shell Hub shell Now it can be replaced with Internal assembly for quick the new internal assembly replacement Part no Axle length Y 33S 90700 170 3 mm Y 33S 98270 176 8 mm Y 33S 90710 189 4 mm 6 Remove the stop ring with a i ees Screwdriver screwdriver i Stop ring 9 6 mm dia At this time the stop ring come off with great force Be careful of the safety using cloth and so on J Remove the carrier unit and the ring gear unit at the same time F i while turning the ring gear unit fy slightly to the left and right Carri
4. dents inside the driver unit with the two smaller projections at the top of the clutch when installing the driver unit 3 Place ball retainer J onto the driver unit Ball retainer J Driver unit Note e Be careful of the setting direction e Apply a liberal coating of internal hub grease GREASE Y 041 20800 4 Screw the right hand cone with dust seal onto the hub axle as far as it will go Then turn the right hand cone counterclockwise by 120 degree and then secure it by tightening the right hand lock nut TL HS20 17 mm TL HS20 15 mm Tightening torque 12 20 N m 104 174 in lbs 5 Turn the axle unit with driver upside down and hold the two bevelled surfaces of the axle on the driver side in a vice Axle unit with driver Note Do not damage the threads of the hub axle Vice Note e Be careful of the setting direction 6 Install ball retainer K while pressing in pawl A 1 and pawl A 2 on the driver unit with your fingers e Apply a liberal coating of internal hub grease Pawl A 1 GREASE Ball retainer K Y 041 20800 Pawl A 2 Ring gear unit J While pushing the two pawls B on the ring gear unit with your fingers push the two pawls A 1 and the two pawls A 2 on the Pawl B driver unit one by one with a screwdriver and install the ring gear unit to the driver unit gt O Internal ratchet i K mechanism Pawl A 1 Pawl A 2 Driv
5. er unit Ring gear unit Carrier unit Ring gear unit After removing them at the same time remove the carrier unit from the ring gear unit Remove ball retainer K while pressing in pawl A 1 and pawl A 2 on the driver unit with your fingers Pawl A 1 Pawl A 2 Ball retainer K 9 Turn the axle unit with driver upside down and hold the two bevelled surfaces of the axle in a vice Axle unit with driver a Note the hub axle Vice Do not damage the threads of 10 Remove the right hand lock nut and the right hand cone with dust seal from the hub axle Right hand lock nut TL HS20 ey TL HS20 15 mm Right hand cone with dust seal 11 Remove ball retainer J from the driver unit Ball retainer J Driver unit 12 Turn the driver unit clockwise to remove it from the axle unit Driver unit Note Do not disassemble the axle unit otherwise it may cause problems with gear shifting This completes the disassembly of the Inter 3 hub o 1 Hold the two bevelled surfaces of the axle unit on the gear side in a vice Axle unit Gear nn Note Do not damage the threads of the hub axle Vie gt 2 Install the driver unit onto the axle unit Driver unit Clutch ee cae Axle unit Smaller indents inside the driver unit Smaller projections at top of clutch Note Align the two smaller in
6. er unit Screwdriver Note e Be careful of the directions of the two pawls B e Apply a liberal coating of internal hub grease e Check that pawls B are not hooked onto the clutch e Check that pawls A 1 and A 2 are engaged with the ratchet mechanism in the ring gear unit e Apply a liberal coating of internal hub grease to the gear inside the ring gear unit 8 Engage the teeth of the planetary gear of the carrier unit with the teeth of the ring gear unit while turning the carrier unit slightly to the left and right and pushing it onto Teeth of carrier unit planetary gear the ring gear unit Check Teeth of ring Check that the stop ring Jarun groove of the hub axle Note Apply a liberal coating of internal hub grease to the planetary gear in 4 places inside the carrier unit is visible from the edge of the carrier unit after the carrier unit has been installed Note After inserting the stop ring check that there is a small amount of play in the carrier unit in the vertical direction If there is no vertical play and the carrier unit turns stiffly turn the internal assembly upside down and hold the hub axle in a vice Then loosen the right hand lock nut and the right hand cone with dust seal to adjust until there is sufficient play 9 Insert the stop ring into the groove of the hub axle Stop ring 9 6 mm dia Groove of hub axle Carrier unit 10 While turning the
7. hub shell counterclockwise slightly place it onto the internal assembly Hub shell Internal assembly 11 Screw on the left hand cone TL HS10 to adjust so that the hub shell 14 mm can be turned smoothly a without any play After a adjusting secure the left hand sack mae tar ER cone with the lock nut for left hand cone TL HS10 14 mm Tightening torque 12 20 N m 104 174 in lbs li 12 Turn the hub upside down and hold the two bevelled surfaces of the axle in a vice Driver Note Do not damage the threads of the hub axle 13 Install right hand dust cap A to the hub shell Right hand dust cap A Check After installing right hand dust cap A to the hub shell turn the Note e Apply a coating of internal hub grease to the inside of right hub shell clockwise and check that it turns smoothly If the hub shell does not turn smoothly re install right hand dust cap A This completes the assembly of the Inter 3 hub hand dust cap A to waterproof it e Push right hand dust cap A firmly onto the hub shell until it clicks Exploded view and parts list SHIMANO NEXUS 3 SPEED HUB W Hi Power Roller Brake SG 3R40 mezne BR IM3 1 2 inter m Brake am For Axle Length 189 4 mm Grease For Axle Length FA 170 3 mm 176 8 mm _ J j Bell Crank I For Axle Length 189 4 mm For Axle Length 170 3 mm 176 8 mm
8. l 23T Black 27 Snap Ring C Push Rod 81 85 mm for Axle Length 170 3 mm 28 Push Rod 86 85 mm for Axle Length 176 8 mm Push Rod 90 75 mm for Axle Length 189 4 mm 29 Bell Crank II Unit 30 Cable Adjusting Bolt amp Nut 31 Bell Crank Body Fixing Bolt 32 Bell Crank Cover amp Fixing Screw 33 Inner Cable Fixing Bolt Unit 34 Internal Hub Grease Net 100g Roller Brake Grease Net 100g Inter 3 hub troubleshooting Cause and remedy Mechanism spins freely or slips when in top 3 gear Mechanism spins freely or slips when in normal 2 gear Mechanism spins freely or slips when in low 1 gear Turning Is difficult and noise is heard Gear shifting is not possible Push rod does not move Malfunction of the internal assembly Replace with a new one Malfunction of the axle unit and driver unit Replace with new ones a Malfunction of pawls B Replace the ring gear unit with a new one Ring gear unit Malfunction of pawls A Replace the driver unit with a new one Driver unit Malfunction of pawl D or the planetary gear S Replace the carrier unit with a new one p Carrier unit Na MA E oT P Damaged ball retainer K 7 32 x 10 J 7 32 x 8 or A 1 4 x 7 Replace the damaged part with a new one Apply grease to the new part when replacing Ball retainer Internal hub grease 2 a St K 7 32 x 10 J 7 32 x 8 A 1 4 x 7 Part no Y 041 20800
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