sturmey archer - aw 3 speed

Technical Informationand Parts List

Three Speed Hub Gear

Type AW

Technical Information-AW Three Speed Hub

1.1 Scope of this leafletThis leaflet refers to the Sturmey-Archer AWT h ree Speed Hub Gear, and associatedcontrols, cables and fittings.The hub model can be identified from themarkings on the hub shell.

Part 1 GENERAL INFORMATION

Part 2 ROUTINE MAINTENANCE

Part 3 ASSEMBLY/DISASSEMBLYINSTRUCTIONS

1.5 SprocketsThe overall drive ratio can be altered bychanging the size of the sprocket. A range ofsprockets from 14 to 22 teeth is available,suitable for 1/2" x 1/8" chain.

When service problems arise they usuallyoccur outside the hub, and the following checksmust be made before removing the wheel fro mthe bicycle:

1.4 Gear RatiosThe AW hub has three gears:

1st gear _ Decrease of 25%2nd gear _ Direct drive3rd gear _ Increase of 331/3%

1.2 LubricationNo routine lubrication is required. However,during assembly/disassembly the hubgreases should be replenished (See Section3). Grease types meeting the followingSturmey-Archer Technical Standards shouldbe used:

For Bearings - SA103BFor all other internal parts - SA103A

Please contact Sturm e y - A rcher fori n f o rmation on the availability of thesegreases.

2.1 Gear Adjustment1. Check that the fulcrum clip is secured

tightly to the frame tube, and that theindicator rod is screwed correctly into theaxle.

2. Select 3rd gear position on the gearcontrol. Screw the cable adjuster (1) ontothe indicator coupling.

3. Change down to 2nd gear and turn thecable adjuster until the end of theindicator rod is exactly level with the end

GearAdjustment

of the axle. This can be seen through theround window in the right hand axle nut(3).

4. Tighten the locknut (2) against thea d j u s t e r. Check that all 3 gears areselected correctly. If correct adjustmentcannot be achieved, the fulcrum clipmust be moved in the appro p r i a t ed i rection along the frame tube. Re-tighten the clip and adjust as describedabove.

WARNING: The hub must not be ridden outof adjustment as this may damage thei n t e rnal parts and cause the hub tomalfunction.2.2 Hub Bearing AdjustmentIf for any reason the bearing adjustment isaltered, the cones must be reset correctlybefore using the hub. The right-hand cone ispre-set at the factory and should only bedisturbed at major service intervals. The left-hand cone is used to adjust the bearings inthe hub.Left Hand Cone:1. Loosen the cone locknut.2. Adjust the left hand cone until very slight

side play can be felt at the wheel rim, andnone at the hub.

3. Tighten the cone locknut.Right Hand Cone:1. Loosen the left hand cone locknut and

cone.2. Loosen the right hand cone locknut.

Disengage the cone lockwasher.3. Screw down the right hand cone figure

tight.4. Unscrew the right hand cone by half a

turn.5. Fit the cone lockwasher. If the washer will

not engage with the cone, unscrew thecone slightly.NB Under no circumstances must theright hand cone be unscrewed more than5/8 of a turn.

6. Tighten the right hand cone locknut.7. Tighten the left hand cone locknut and

adjust as above.

When service problems occur which cannotbe corrected by attention to extern a lmaintenance, a close inspection of theworking parts inside the hub will benecessary.

Fig. 21. Loosen the right hand ball ring with a C-

spanner or hammer and punch, andu n s c rew the ball ring to release theinternal assembly from the hub shell.

2. Remove the left hand low gear pawls,pins and springs.

Fig. 31. Clamp the left hand end of the axle in a

vice.2. Remove the right hand cone locknut,

spacers, lockwasher, cone, spring, capand clutch spring.

Fig. 41. Lift off the driver, ball cage, ball ring and

gear ring.2. Remove the gear ring pawls, pawl pins

and springs.Fig. 5Lift off the thrust ring, axle key, clutch andclutch sleeve.Fig. 61. Remove the planet pinion pins and

pinions.2. Lift the planet cage off the axle.

1.3 Gear ChangingGear changing is simple and smooth with thep roven Sturm e y - A rcher indexed contro lsystem. Continue pedalling, but easepressure on the pedals, and select the gearre q u i red. If stationary, simply select gearrequired.

3.1 DisassemblyFig. 11. Remove the indicator rod, axle nuts and

spacing washers from both ends of theaxle.

2. Use a screwdriver to release the sprocketcirclip from the driver, then remove thespacing washers, sprocket and outerdustcap ( note the order of these parts).

3. Unscrew the left hand cone locknut andcone.

Fig. 1

Fig. 2

Fig. 3

Technical Information-AW Three Speed Hub

3.2 Inspection of the Internal PartsThoroughly clean all the internal parts, andreplace any which are damaged or worn. Inparticular, check the following:1. The clutch must slide easily in the driver.

Its corners must not be rounded, and thesplines in the driver should be free fromdamage.

2. Check the axle for straightness and theaxle slot and threads for damage.

3. Examine all gear teeth for signs of wearand chipping.

4. Check all bearing surfaces for wear andpitting.

5. Check the ends of the planet pinion pinsand the edges of the gear ring splines forroundness and chipping.

3.3 AssemblyNB The hub greases must be replenishedduring assembly using lubricants to thefollowing Sturm e y - A rcher Te c h n i c a lStandards.

For Bearings - SA103BFor all other internal parts - SA103A

If a replacement gear internal assemblycomplete is to be fitted, assemblycommences at Fig. 2, point 3.Fig. 61. Clamp the left hand end of the axle in a

vice with its axle slot uppermost.2. Locate the planet cage over the axle,

and fit the planet pinions and pins withtheir small diameter upwards.

6. Check the pawls and ratchets for signs ofwear. Always fit new pawl springs on re-assembly.

7. Check the condition of the indicatorthreads, chain and axle key.

Fig. 41. Take the gear ring and fit the pawls, pawl

pins and springs as indicated in DiagramA.

2. Fit the gear ring onto the planet cage.3. See Diagram B. Fit the ball ring and ball

cage assembly - ensuring that the ballsface downwards.

4. Fit the driver with ball cage and outerdust cap. Ensure that the driver splinesengage with the clutch.

Fig. 11. Fit the left hand cone, spacing washer(s)

and locknut, and adjust the bearings asinstructed in Section 2.2.

2. Assemble the sprocket with its dust capand spacers as indicated in Diagram D.NB Fit the spacing washers in their origi-nal position if different from the diagram.

3. Assemble the wheel into the bicycle andfit washers and axle nuts. Tighten axlenuts to 24-26 Nm torque. Check correctindicator is fitted and adjust gears asinstructed in Section 2.1.

Use this chart only if a fault persists after attention to gear adjustment, bearingadjustment and lubrication. (See Parts 1 and 2).

SYMPTOM FAULT REMEDYSlipping in 1st gear 1. Worn clutch 1. Replace

2. Worn low gear pawls 2. Replace3. Weak low gear pawl springs 3. Replace4. I n c o rrect right hand cone adjustment 4 . Re-adjust5. Kinks in control wire 5. Replace6. Twisted indicator chain 6. Replace

Self changing between 1st and 2nd Gear 1. Worn gear ring pawls 1. ReplaceSlipping in 2nd gear 1. Gear ring dogs and/or clutch worn 1. ReplaceSlipping in 3rd gear 1. Pinion pins and/or clutch wor n 1. Replace

2. Weak or distorted clutch spring 2. Replace3. I n c o rrect right hand cone adjustment 3. Re-adjust

Hub runs stiffly 1. Chainstay ends not parallel 1 Re-alignDrag on pedals 2. Corrosion 2. Clean and lubricate

3. Distorted dust caps 3. ReplaceSluggish gear change 1. Distorted Clutch spring 1. Replace

2. Bent axle 2. Replace3. Damaged indicator chain 3. Replace4. Frayed gear cable wire 4. Replace

P a rt 4 FA U LT DIAGNOSIS CHART

Fig. 31. Slide the clutch spring and clutch

spring cap (with its flat face uppermost)over the axle.

2. Screw down the right hand cone fingertight. Slacken the cone off by half a turnand lock it in this position with thelockwasher and locknut.NB Under no circumstances must thecone be unscrewed by more than 5/8 of aturn as this could adversely affect thegear alignment.

Fig. 4

Fig. 5

Fig. 6

Diagram DDiagram A Diagram B Diagram C

Fig. 5Fit the clutch sleeve, clutch, axle key (withflats uppermost) and thrust ring.

Fig. 21. Insert the assembly in the vice, and fit the

low gear pawls, pins and springs into theplanet cage as indicated in Diagram C.

2. Remove the assembly from the vice andliberally grease the working parts partic-ularly the planet pinions, pinion pins, sunpinion and gear ring.

3. Insert the unit into the hub shell, andtighten the ball ring.

Parts List - AW Three Speed Hub

Item SalesNo. No.

1 HSA 1022 HSA 2843 *HSA 239

*HSA 105*HSA 104

4 HSA 1125 HSA 1116 HSA 1207 HSA 1138 HSA 2929 HSA 114

10 HSA 11811 HSA12012 HSA 11913 HSA 11214 HSA 12115 HSA 43816 HSA 39417 HSA 28418 HSA 10219 HSL 70120 HMW 12721 *HSL 714

*HSL 715*HSL 716*HSL 717

REPRESENTED THROUGHOUT THE WORLD

Item SalesNo. No.21 *HSL 718

*HSL 719*HSL 720*HSL 747*HSL 722

22 HMW 12723 HSL 72124 HMN 12825 *HMW 155

*HMW 49426 HMN 13227 *HMW 146

*HMW 129*HMW 483*HMW 484

28 HSA10129 *HSA 107

*HSA 37030 HSA 11731 HSA 12432 HSA 11633 HSA 28334 HSA 12835 HSA 12936 *HSA 12536 *HSA 12637 HSA 10138 HMW 147

Item SalesNo. No.39 *HMW146

*HMW 129*HMW 483*HMW 484

40 HMN 13241 *HMW 155

*HMW 49442 HMN 12943 HSL 711 44 *HSJ 88045 *HSJ 86546 *HSJ 82347 *HSJ 762

*HSJ 76548 *HSJ 101

*HSJ 10249 *HSJ 88450 *HSJ 88251 *HSJ 88352 *HSJ 607

*HSJ 553*HSJ 548*HSJ 753

53 *HSL 75954 *HSX 105

*HSX 106

DescriptionOuter Dust CapBall Cage Assembly L.H. 6.4 mm BallHub Shell Assembly 28 holes

(chrome)Hub Shell Assembly 36 holes

(chrome)Hub Shell Assembly 40 holes

(chrome)N.B. - Hub Shell Assembliesinclude 1 off items 1and 2

Pawl PinL.H. Low Gear PawlPawl SpringPlanet CagePlanet PinionPinion PinGear RingPawl SpringR.H. Pawl for Gear RingPawl PinBall Ring Ball Cage AssemblyDriver Assembly Complete (includes

1 off Items 17 and 18)Ball Cage Assembly R.H. 6.4 mmBallOuter Dust CapSprocket Dust CapSprocket Spacing Washer 1.6 mm Sprocket 14 TeethSprocket 15 TeethSprocket 16 TeethSprocket 17 Teeth

DescriptionSprocket 18 TeethSprocket 19 TeethSprocket 20 TeethSprocket 21 TeethSprocket 22 TeethSprocket Spacing Washer 1.6 mmSprocket CirclipAxle Nut L.H.Serrated Lockwasher 7.9 mm SlotSerrated Lockwasher 9.5 mm SlotCone LocknutSpacing Washer 1.6 mm Spacing Washer 3.2 mm Spacing Washer 4.8mm Spacing Washer 6.4 mm Cone L.H. with Dust CapAxle - 146 mm (5 3/4") with

Sun PinionAxle - 163 mm (6 13/32") with

Sun PinionClutchAxle KeyClutch SleeveThrust RingClutch SpringCap for Clutch SpringGear Indicator R.H. for 146 mm

(53/4') Axle (1 Mark)Gear Indicator R.H. for 163 mm

(613/32"') Axle (11 Mark)Cone R.H. with Dust CapCone Lockwasher

DescriptionSpacing Washer 1.6 mm Spacing Washer 3.2 mm Spacing Washer 4.8mm Spacing Washer 6.4 mm Cone LocknutSerrated Lockwasher 7.9 mm SlotSerrated Lockwasher 9.5 mm SlotAxle Nut R.H.Indicator GuardTwistgrip Control c/w inner wireOrion ControlNIMBUS Control 22.2mm ClipTrigger Control 22.2mm ClipTrigger Control 23.8mm ClipTrigger Cable with Anchorage

530mm x 1520mm BlackTrigger Cable with Anchorage

1420mm x 1570mm BlackNIMBUSCable with Anchorage

1420mm x 1570mm BlackTwistgrip Cable with Anchorage

1420mm x 1570mm BlackOrionCable with Anchorage

1420mm x 1570mm BlackChainstay Fulcrum Clip 12.7 mm øChainstay Fulcrum Clip 15.9 mm øChainstay Fulcrum Clip 17.9 mm øChainstay Fulcrum Clip 19.1 mm øCable AnchorageAW Internal Replacement Unit

146 mm (53/4") AxleAW Internal Replacement Unit

163 mm (613/32") Axle

* Optional Fitment

LTE 100/4

Sturmey-Archer Ltd.,Triumph Road, Nottingham NG7 2GL, England, U.K.Tel: (0115) 942 0800 Fax: (0115) 942 0801Email: sales@sturmey-archer.com

S t u rm e y - A rcher hubs and components have been designed for normal bicycle use. They have not been designed for tandems, stunt riding and off - road racing, and their use for such purposes is at the purchaser's own risk.The policy of Sturm e y - A rcher is one of continued development and improvement. Consequently, we re s e rve the right to change or amend or discontinue specifications in this publication without prior notice.

Persons Majestic Mfg. Co.,21 Hamilton Street, MONROEVILLE, OHIO 44847, U.S.ATel: 419-465-2504 Fax: 419-465-4070

1 2 3 4 5 6 7 8 9 1 0 1 11 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2 2 3

2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 13 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 4 0 4 1 4 2 4 3

4 4

4 5

4 6 4 7 4 84 95 05 1

5 2 5 35 4