Instruction Manual Hub Dynamo - dbap GmbH

Instruction Manual
Hub Dynamo
DH-CT624-32H
DH-CT624-36H
DH-CT630-32H
DH-CT630-36H
Status: May 2006

Instruction Manual
SR Suntour Hub Dynamo DH-CT600 Series
Congratulations for having chosen a hub dynamo from the SR SUNTOUR DH-CT600 series.
Please ensure that you thoroughly familiarise yourself with this instruction manual as it contains
important information for reliable operation and instructions on maintenance and care of the
hub dynamo. The manual also explains the risks and hazards that may occur as a result of
improper handling of the SR SUNTOUR DH-CT600 hub dynamo.
The hub dynamo in the SR SUNTOUR DH-CT600 series is available in various specifi cations
which comply with national legislation and bicycle specifi cations:
• SR SUNTOUR DH-CT624-32H (6 V, 2.4 W, 32 spoke holes)
• SR SUNTOUR DH-CT624-36H (6 V, 2.4 W, 36 spoke holes)
• SR SUNTOUR DH-CT630-32H (6 V, 3.0 W, 32 spoke holes)
• SR SUNTOUR DH-CT630-36H (6 V, 3.0 W, 36 spoke holes)
Our new DH-CT600 series of hub dynamos offer compact dimensions, a high degree of
effi ciency and reliability which comply with the latest requirements of Section 22a of the
German Road Traffi c Regulations. These new features include, among other things, integrated
surge protection so that if one of the light sources breaks down, the others are not invariably
affected. A plug connection that disconnects the supply leads makes it very easy to attach the
hub dynamo to and remove it from the front wheel. The hub dynamo is designed so that it does
not require an on/off switch and is connected via the lighting system instead.
Before setting off
Before you use a hub dynamo from the SR SUNTOUR DH-CT600 series or a bicycle that is
fi tted with one, we would like to stress the importance of reading this manual carefully. You
should not use the bicycle until you have read and understood this instruction manual.
Spare Parts and Repairs
Only carry out the maintenance work that is described in this instruction manual. For your own
safety, we recommend that any additional maintenance work and repairs are carried out by a
SR SUNTOUR dealer.
Only use original spare parts.
Components
Fork (#1)
Washer (#2)
DIN125A-M10
Nut (#3)
FG9.5
Cable connection
terminal (#5)
Washer (#2)
DIN125A-M10
Nut (#3)
FG9.5
Dynamo hub (#4)
SR Suntour DH-CT600
Instruction Manual Hub Dynamo DH-CT600, Page 2

Important Instructions
Safety Tips
The hub dynamo in the SR SUNTOUR DH-CT600 series is designed for use with bicycles
intended for public road transport. SR SUNTOUR does not accept any liability for any accidents
and damage whatsoever if caused by failure to comply with the intended use of this product.
WARNING!
The following points should be observed in the interests of safety:
• Hub dynamos in the SR SUNTOUR DH-CT600 series are designed for use
with city and trekking bicycles intended for public road transport on surfaced
bicycle paths.
• Do not make any technical alterations to the hub dynamo in the SR SUNTOUR
DH-CT600 series that could impair the operational safety of the bicycle.
• The hub dynamo in the SR SUNTOUR DH-CT600 series limits the total
admissible weight of the bicycle to 120 kg. If the bicycle manufacturer states
that the total admissible weight is lower or if another component on the bicycle
reduces the total admissible weight, the lower admissible total weight is
relevant.
• Follow the instructions provided by the fork and bicycle manufacturers in
addition to the instruction manual.
Safety check to be performed when switching on the hub dynamo and
before every journey
Before every journey check:
• the front wheel to ensure that the tightening torque of the hub axle nuts is correct.
• the front wheel for excessive clearance in the hub mounting.
• that the cabling is intact and positioned correctly and that the headlight and rear light are
working.
Fitting
To fi t the hub dynamo from the SR SUNTOUR DH-CT600 series on the front wheel, follow the
steps below:
1. Remove the nuts (2 items FG9.5; #3) and washers (2 items DIN125A-M10; #2) on the left
and right-hand sides of the front axle.
Note: Depending on the type of fork, instead of the 2 washers (DIN125A-M10; #2)
2 special collar disks must be used to ensure the system is fail-safe.
2. Insert the front wheel in the fork of your bicycle so that both sides of the axle engage with the
front ends of the fork. The front wheel must be adjusted so that the cable connection terminal
(#5) is on the right-hand side of the bicycle.
Ensure that the connection terminal is aligned parallel to the fork blades.
Instruction Manual Hub Dynamo DH-CT600, Page 3

Fork (#1)
Note: If the cable connection terminal is not aligned parallel, the connection
cable will bend and may cut off the power supply to the headlight.
3. Ensure that the washers (2 items DIN125A-M10; #2) are correctly positioned on the front
ends of the fork or that the collar disks fi t fi rmly into the recesses provided for this purpose
on the front ends of the fork.
4. Tighten the nuts (#3) fi rmly on both sides.
5. Check once more that the hub axle is fully inserted into the front ends of the fork.
Note: If the axle is not fully inserted into the front ends of the fork, the “uneven”
load may lead to problems with the brakes and tyres, which under certain circumstances
may also result in loss of control of the bicycle and in accidents.
6. Tighten the nuts alternately (#3) in stages up to a torque of 20 Nm.
Fork (#1)
Front fork end (#6)
Washer (#2)
DIN125A-M10
Nut (#3)
FG9.5
Right-hand front fork end
(#6)
Cable connection
terminal (#5)
Dynamo hub (#4)
Cable connection
terminal (#5)
Washer (#2)
DIN125A-M10
Dynamo hub (#4)
SR Suntour DH-CT600
Nut (#3)
FG9.5
Left-hand front fork end
(#7)
Instruction Manual Hub Dynamo DH-CT600, Page 4

Connection of the two-wire cable
1. The lower ends (= hub side) of the two-wire cable must be
stripped by approx.18 mm.
2. Insert both cable ends in the connector (#11), using the righthand
side of the connector for the earthed cable.
3. Bend the protruding ends over so that they pass into
the slots provided for this purpose and do not under any
circumstances let them come
into contact with each other.
4. Connect the other end of the
two-wire cable in accordance
with the specifi cation of the
headlight used or the external
light switch.
Warning: To prevent short
circuiting, both ends of the earthed
cable must be “grounded” or
connected to the designated
contacts. Mixing up the contacts
will cause short circuiting,
malfunctioning of the lighting
system and damage to the
hub dynamo if operated over a
prolonged period.
Bend the cable
ends over
5. Attach the cable to the fork so that it is protected
throughout its length from the hub to the headlight.
6. Test whether the lighting system functions by lifting the
front wheel off the ground and setting it in motion in the
direction indicated on the hub.
Front
headlight
(#8)
Wire
(#9)
insert
Earthed
cable
(#10)
Connector
(#11)
Dynamo
hub
(#4)
Note: If the lighting system does not function, check whether the wiring has short
circuited and whether the contacts are loose, or have the installation checked by your
SR SUNTOUR dealer.
Maintenance and Servicing
The hub dynamos in the SR SUNTOUR DH-CT-600 series require minimal maintenance and
their positioning need only be checked for excessive clearance every 1,000 km. In the event of
excessive clearance, please seek advice from your SR SUNTOUR dealer.
Note: The hub should be cleaned at regular intervals and if it becomes extremely dirty.
Use a sponge with lukewarm water and some soap. Do not under any circumstances
use a high-pressure or steam jet device on the hub as this may destroy the washers and
result in an infl ux of water and cause the lubricants that were added at the factory to be
washed out.
Instruction Manual Hub Dynamo DH-CT600, Page 5

SR SUNTOUR DH-CT-600 Hub Dynamo Guarantee Card
Model SR SUNTOUR DH-CT624-32H (6 V, 2.4 W, 32 spoke holes)
SR SUNTOUR DH-CT624-36H (6 V, 2.4 W, 36 spoke holes)
SR SUNTOUR DH-CT630-32H (6 V, 3.0 W, 32 spoke holes)
SR SUNTOUR DH-CT630-36H (6 V, 3.0 W, 3 6 spoke holes)
Date of purchase _______________________________________________
Dealer _______________________________________________
Dealer’s address. _______________________________________________
Dealer’s tel.-# _______________________________________________
Dealer’s e-mail _______________________________________________
Purchaser _______________________________________________
Purchaser’s address _______________________________________________
Purchaser’s tel.-# _______________________________________________
Purchaser’s e-mail _______________________________________________
Inspection
1. Inspection Date ______________, Stamp __________________
Dealer________________________________________
2. Inspection Date ______________, Stamp __________________
Dealer________________________________________
1) This Guarantee Card is only valid on presentation with the receipt
2) A form provided by the dealer may also be used to document the after-sales service commitment, if desired.
Instruction Manual Hub Dynamo DH-CT600, Page 6

Limited Liability
SR SUNTOUR provides a 2-year guarantee from the date of purchase for hub dynamos in the
SR SUNTOUR DH-CT600 series, for material and manufacturing defects in accordance with
the intended use.
This guarantee does not under any circumstances cover any damage or malfunctioning of
the hub dynamo caused by the following circumstances: improper mounting, dismantling,
assembly, wilful damage, alterations by the user or by third parties, any unreasonable use,
misuse or use of the product that breaches its intended use. This guarantee is limited to
the repair or exchange of the hub dynamo or one of its components that shows evidence of
material or manufacturing defects within 2 years from the date of purchase.
The purchaser will only be able to claim under this guarantee if the guarantee card is sent
to SR SUNTOUR within 30 days following the purchase of the hub dynamo. Any attempt to
commit fraud with this guarantee, alterations to or manipulation of this card will automatically
terminate the validity of the guarantee.
SR SUNTOUR does not guarantee any express or implicit suitability or marketability
whatsoever, with the exception of the foregoing notice. Liability on the part of SR SUNTOUR
is expressly limited to repair or exchange of the product. SR SUNTOUR cannot under any
circumstances accept liability for unforeseen damage or consequential loss. Some national
laws and regulations do not permit exclusion of unforeseen damage or consequential loss,
which means that this exclusion may not be valid. This guarantee gives you certain rights; you
may also have other rights – notwithstanding the respective legislation in force.
The purchaser is in any event strongly advised to contact his dealer to remedy problems under
the guarantee.
Distribution partners and after-sales service
Visit our website http://www.srsuntour-cycling.com – where you will fi nd a list of our national
distribution and after-sales service partners.
SR SUNTOUR INC.
No.7 Hsing Yeh Road,
Fu Hsing Ind. Zone.
Changhua.50606
Taiwan, R.O.C.
Telephone: +886 (4) 7695115
Fax: +886 (4) 769 4028
E-mail: orders@srsuntour.com.tw
SR SUNTOUR USA
P.O. Box 61988
Vancouver WA 98666
U.S.A
Telephone: +1 (360) 737 6450
Fax: +1 (360) 737 6452
E-mail: service@usulcorp.com
SR SUNTOUR EUROPE GMBH
Am Marschallfeld 6a
83626 Valley
Germany
Telephone: +49 / (0)8024 / 3 03 81 52
Fax: +49 / (0)8024 / 4 73 09 84
E-mail: service@srsuntoureurope.com
Instruction Manual Hub Dynamo DH-CT600, Page 7

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