Shimano SG-7R46 User manual

SERVICE MANUAL
vol.1
SG-7R46
SHIMANO NEXUS 7-SPEED HUB
t

Disassembly of the Inter-7 hub
1.
Hold the two bevelled surfaces
of the hub axle on the sprocket
side in a vice.
2.
Remove the lock nut for left
hand cone and the left hand
cone with dust cap from
the hub axle.
Note:
Be careful not to
damage the sections
A of the lock nut for
left hand cone when
using the spanner.
Left hand cone
with dust cap
2
SG-7R46
Sections A
Tools
Note:
Do not damage the threads of
the hub axle.
Vice
Hub spanners
Part no. Y-230 90010
13 mm x 14 mm(2 pcs.)
TL-HS10 ScrewdriverPlier

3
3.
Remove the ball retainer I from
the hub shell.
4.
Remove the right hand dust cap
with a screwdriver.
5.
Remove the hub shell.
Internal assembly
For 182 mm axle length : Part no. Y-35D 9801
For 201 mm axle length : Part no. Y-35D 9802
Hub shell
Ball retainer I
Right hand dust cap
Screwdriver
Internal assembly
Hub shell

Carrier guide 2
Carrier unit 2
Ring gear unit 2
6.
Use pliers or similar to remove
the stop spring for carrier
guide 2.
Stop spring for
carrier guide 2
Plier
Note:
If undue force is applied during
removal, the pawls inside will
become damaged, which will
cause operation problems.
Note:
Cover the internal assembly
with a cloth to prevent the
stop spring for carrier guide 2
from flying off during removal.
After removing
them at the same
time, remove carrier
unit 2 and carrier
guide 2 from ring
gear unit 2.
7.
Remove ring gear unit 2, carrier
unit 2 and carrier guide 2 at the
same time while turning ring
gear unit 2 slightly to the left
and right.
8.
Remove sun gear unit 2 & 3
while turning them slightly to
the left and right.
4
9.
Remove carrier unit 1.
Carrier unit 1
Plier
Stop spring
Carrier guide 2
Carrier unit 2
Ring gear unit 2
Sun gear unit 2 & 3

5
10.
Remove ball retainer M from
the driver unit.
Be careful not to bend ball
retainer M.
This completes the disassembly of the Inter-7 hub.
Ball retainer M
Driver unit

6
Assembly of the Inter-7 hub
2.
Place ball retainer M onto the
driver unit.
3.
Engage the teeth of the planet
pinion in carrier unit 1 with the
teeth of the driver unit, and
then press in the driver unit
while turning it slightly to the
left and right.
1.
Hold the two bevelled surfaces
of the hub axle on the sprocket
side in a vice.
Note:
Apply a liberal coating of internal
hub grease to the planet pinions
(3 places) in carrier unit 1.
Note:
Do not damage the threads of
the hub axle.
Note:
Be careful of the setting
direction.
Apply a liberal coating of internal
hub grease.
Be careful not to bend ball
retainer M.
Vice
Ball retainer M
Driver unit
Teeth of planet pinion in carrier unit 1 Teeth of driver unit
(Y-041 20800)
GREASE

7
6.
Engage the teeth of the planet
pinion in carrier unit 2,carrier
guides 2 and the teeth of ring
gear unit 2 while turning carrier
unit 2 slightly to the left and
right, and then press in ring
gear unit 2.
Note:
Apply a liberal coating of
internal hub grease to the teeth
of the planet pinion (3 places) in
carrier unit 2.
If undue force is applied, the
pawls inside will become
damaged, which will cause
operation problems.
Check:
Check that the groove in the stop
spring for carrier guide 2 is visible
from the edge of carrier unit 2
while carrier unit 2 is pushed
down.
Groove in stop ring for carrier
guide 2 should be visible
Note:
Apply a liberal coating of internal
hub grease to the teeth of sun
gear unit 2 & 3.
Be careful of the setting
direction. If the setting is
reversed, installation will not be
possible.
If undue force is applied, the
pawls inside will become
damaged, which will cause
operation problems.
The gear with the smooth ring
section is at the top
Note:
Apply a liberal coating of internal
hub grease to the teeth of ring
gear unit 2.
Set so that the part with the
teeth is at the top.
4.
Engage the teeth of sun gear
unit 2 & 3 with the teeth of the
planet pinion in carrier unit 1
while turning sun gear unit 2 &
3 slightly to the left and right,
and then press in carrier unit 1.
5.
Place ring gear unit 2 onto
carrier unit 1.
Carrier unit 1
Teeth of sun gear unit 2 & 3
Ring gear unit 2
Teeth of planet pinion in carrier unit 1
Teeth of planet pinion
in carrier unit 2
Teeth of ring gear
unit 2
(Y-041 20800)
GREASE
(Y-041 20800)
GREASE

10.
Screw the left hand cone with
dust cap to adjust so that the
hub shell can be turned
smoothly without any play.
After adjusting, secure the left
hand cone with dust cap with
the lock nut for left hand
cone.
8
8.
Install the internal assembly
while turning the hub shell
slightly to the right and left so
that seal spring R of the hub
shell is sitting in the right hand
dust cap of the internal
assembly.
9.
Place ball retainer I onto the hub
shell.
7.
While pushing down carrier
guide 2, insert the stop spring
into the hub axle groove at the
surface of carrier guide 2.
1
While
pushing
down
Note:
Be careful of the setting
direction.
Insert securely as far as
it will go.
Note:
Apply a liberal coating of internal
hub grease to the grease groove
of the hub shell.
If seal spring R hooks into the
wrong part of the right hand dust
cap, push seal spring R with a
screwdriver.
Note:
Be careful of the setting direction.
Apply a liberal coating of internal
hub grease.
Check:
After installing the hub shell, turn
the hub shell counterclockwise
and check that it turns smoothly.
Note:
Be careful not to
damage the sections
A of the lock nut for
left hand cone when
using the spanner.
Left hand cone
with dust cap
Sections A
2 Insert
Hub shell
(Y-041 20800)
GREASE
(Y-041 20800)
GREASE
Not OKOK
Internal assembly
Hub shell
Ball retainer I
Stop spring
Hub axle groove
Carrier guide 2

11.
Hold the two bevelled surfaces
of the hub axle
in a vice.
12.
Install the right hand dust cap.
This completes the assembly of the Inter-7 hub.
9
Note:
Do not damage the threads of
the hub axle.
Check:
After installing right hand dust cap to the hub shell, turn the hub shell clockwise and check that it
turns smoothly. If the hub shell does not turn smoothly, re-install right hand dust cap.
(Y-041 20800)
GREASE
Vice

10
Spare parts list
For Axle Length
201 mm
26
27
GREASE
MIN.2Nm
JAPAN
04
PE-LD
CJ-7S40
TL-7S40-B
Grease
Internal Assembly
1
234 5 6 7
8
8
9
9
10
10
10
11
11
11
12 13 14 15
16
17 18
19
20
21
2222 23 24 25
26 46
23
7L
For Axle Length
201 mm
27
28
29 30
31
32
33
34
35 36 37
38
39
40
41 42 43
44
1
45
47
SG-7R46
SHIMANO NEXUS 7-SPEED HUB w/Hi-Power Roller Brake
Inter-7 Hub BR-IM41-R Inter-M Brake

11
DESCRIPTIONQ'TY SHIMANO
CODE NO.
ITEM
NO.
Internal Assembly (Axle Length 182 mm)
Internal Assembly (Axle Length 201 mm)
Stop Ring for Carrier Guide 2
Carrier Guide 2
Carrier Unit 2
Ring Gear Unit 2
Sun Gear Unit 2 & 3
Carrier Unit 1
Carrier guide 2 / Axle & Driver Unit
(Axle Length 182 mm)
Carrier guide 2 / Axle & Driver Unit
(Axle Length 201 mm)
Ball Retainer M (3/16" x 26)
Right Hand Dust Cap B
Right Hand Dust Cap C
Axle Unit (Axle Length 182 mm)
Axle Unit (Axle Length 201 mm)
Return Spring A
Gear Shifting Cam
Feed Cam
Driver Unit w/Right Hand Dust Cap B & C
Driver Unit
Ball Retainer F (3/16" x 12)
Right Hand Cone w/Seal
Right Hand Cone Seal
Driver Plate w/Seal
Driver Plate Seal
Lock Washer
Stop Washer
Right Hand Lock Nut (6 mm)
Cap Nut (3/8")
Washer (3.2 mm) for Axle Length 201 mm
Non-turn Washer 5R (Yellow)
Non-turn Washer 6R (Silver)
Non-turn Washer 7R (Black)
Non-turn Washer 5L (Brown)
Non-turn Washer 6L (White)
Non-turn Washer 7L (Gray)
Brake Unit Fixing Nut (8.2 mm)
Grease Hole Cap
Brake Arm Clip Unit (5/8")
Brake Arm Clip Unit (3/4")
Brake Cable Adjusting Bolt Unit
Inner Cable Fixing Bolt Unit
Lock Nut for Left Hand Cone
Left Hand Cone w/Dust Cap
Ball Retainer I (3/16" x 11)
Sprocket Wheel 16T (Silver)
Sprocket Wheel 18T (Silver)
Sprocket Wheel 19T (Silver)
Sprocket Wheel 20T (Silver)
Sprocket Wheel 21T (Silver)
Sprocket Wheel 22T (Silver)
Snap Ring C
CJ-7S40 Cassette Joint Unit
Cassette Joint Pulley
Cassette Joint Bracket
Cassette Joint Fixing Ring
Inner Cable Fixing Bolt Unit for CJ-7S40
TL-7S40-B Right Hand Cone Tool
Internal Hub Grease (Net. 100g)
Roller Brake Grease (Net. 100g)
Roller Brake Grease (Net. 10g)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Y-35D
Y-35D
Y-308
Y-33E
Y-33E
Y-308
Y-33F
Y-330
Y-35D
Y-35D
Y-330
Y-35C
Y-33Z
Y-34L
Y-34L
Y-330
Y-33Z
Y-33Z
Y-35D
Y-35D
Y-330
Y-33Z
Y-33Z
Y-33F
Y-330
Y-33E
Y-33Z
Y-308
Y-314
Y-220
Y-33Z
Y-33M
Y-33M
Y-33M
Y-33M
Y-33M
Y-75V
Y-75V
Y-33F
Y-33F
Y-75P
Y-75M
Y-31Z
Y-308
Y-308
Y-322
Y-322
Y-322
Y-322
Y-330
Y-330
Y-321
Y-74Y
Y-74Y
Y-74Y
Y-33Z
Y-74Y
Y-308
Y-041
Y-041
Y-041
98010
98020
07000
03000
98070
98040
98060
98060
98030
98040
91800
07000
26000
98050
98060
24000
10000
11000
98050
98060
91600
98030
28000
98040
12000
98120
08000
03020
14010
06040
20500
39600
39700
39510
39610
39710
13000
16010
98090
98100
98030
98070
06020
98070
98080
03220
03420
03520
03620
60000
60100
20010
98010
02000
98020
98020
98030
89000
20800
20400
40020
IL/SG Printed in Japan 0202-2128

SHIMANO AMERICAN CORPORATION
One Holland, Irvine, California 92618, U.S.A. Phone: [phone] Fax: [phone]
This publication is printed on recycled paper.
MA35DA © Jan. 2004 Shimano Inc.
UCI official neutral
technical support
Specifications are subject to change for improvement without notice.
SG-7R46
t