Instruction Manual Hub Dynamo - dbap GmbH
Instruction Manual Hub Dynamo - dbap GmbH
Instruction Manual Hub Dynamo - dbap GmbH
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<strong>Instruction</strong> <strong>Manual</strong><br />
<strong>Hub</strong> <strong>Dynamo</strong><br />
DH-CT624-32H<br />
DH-CT624-36H<br />
DH-CT630-32H<br />
DH-CT630-36H<br />
Status: May 2006
<strong>Instruction</strong> <strong>Manual</strong><br />
SR Suntour <strong>Hub</strong> <strong>Dynamo</strong> DH-CT600 Series<br />
Congratulations for having chosen a hub dynamo from the SR SUNTOUR DH-CT600 series.<br />
Please ensure that you thoroughly familiarise yourself with this instruction manual as it contains<br />
important information for reliable operation and instructions on maintenance and care of the<br />
hub dynamo. The manual also explains the risks and hazards that may occur as a result of<br />
improper handling of the SR SUNTOUR DH-CT600 hub dynamo.<br />
The hub dynamo in the SR SUNTOUR DH-CT600 series is available in various specifi cations<br />
which comply with national legislation and bicycle specifi cations:<br />
• SR SUNTOUR DH-CT624-32H (6 V, 2.4 W, 32 spoke holes)<br />
• SR SUNTOUR DH-CT624-36H (6 V, 2.4 W, 36 spoke holes)<br />
• SR SUNTOUR DH-CT630-32H (6 V, 3.0 W, 32 spoke holes)<br />
• SR SUNTOUR DH-CT630-36H (6 V, 3.0 W, 36 spoke holes)<br />
Our new DH-CT600 series of hub dynamos offer compact dimensions, a high degree of<br />
effi ciency and reliability which comply with the latest requirements of Section 22a of the<br />
German Road Traffi c Regulations. These new features include, among other things, integrated<br />
surge protection so that if one of the light sources breaks down, the others are not invariably<br />
affected. A plug connection that disconnects the supply leads makes it very easy to attach the<br />
hub dynamo to and remove it from the front wheel. The hub dynamo is designed so that it does<br />
not require an on/off switch and is connected via the lighting system instead.<br />
Before setting off<br />
Before you use a hub dynamo from the SR SUNTOUR DH-CT600 series or a bicycle that is<br />
fi tted with one, we would like to stress the importance of reading this manual carefully. You<br />
should not use the bicycle until you have read and understood this instruction manual.<br />
Spare Parts and Repairs<br />
Only carry out the maintenance work that is described in this instruction manual. For your own<br />
safety, we recommend that any additional maintenance work and repairs are carried out by a<br />
SR SUNTOUR dealer.<br />
Only use original spare parts.<br />
Components<br />
Fork (#1)<br />
Washer (#2)<br />
DIN125A-M10<br />
Nut (#3)<br />
FG9.5<br />
Cable connection<br />
terminal (#5)<br />
Washer (#2)<br />
DIN125A-M10<br />
Nut (#3)<br />
FG9.5<br />
<strong>Dynamo</strong> hub (#4)<br />
SR Suntour DH-CT600<br />
<strong>Instruction</strong> <strong>Manual</strong> <strong>Hub</strong> <strong>Dynamo</strong> DH-CT600, Page 2
Important <strong>Instruction</strong>s<br />
Safety Tips<br />
The hub dynamo in the SR SUNTOUR DH-CT600 series is designed for use with bicycles<br />
intended for public road transport. SR SUNTOUR does not accept any liability for any accidents<br />
and damage whatsoever if caused by failure to comply with the intended use of this product.<br />
WARNING!<br />
The following points should be observed in the interests of safety:<br />
• <strong>Hub</strong> dynamos in the SR SUNTOUR DH-CT600 series are designed for use<br />
with city and trekking bicycles intended for public road transport on surfaced<br />
bicycle paths.<br />
• Do not make any technical alterations to the hub dynamo in the SR SUNTOUR<br />
DH-CT600 series that could impair the operational safety of the bicycle.<br />
• The hub dynamo in the SR SUNTOUR DH-CT600 series limits the total<br />
admissible weight of the bicycle to 120 kg. If the bicycle manufacturer states<br />
that the total admissible weight is lower or if another component on the bicycle<br />
reduces the total admissible weight, the lower admissible total weight is<br />
relevant.<br />
• Follow the instructions provided by the fork and bicycle manufacturers in<br />
addition to the instruction manual.<br />
Safety check to be performed when switching on the hub dynamo and<br />
before every journey<br />
Before every journey check:<br />
• the front wheel to ensure that the tightening torque of the hub axle nuts is correct.<br />
• the front wheel for excessive clearance in the hub mounting.<br />
• that the cabling is intact and positioned correctly and that the headlight and rear light are<br />
working.<br />
Fitting<br />
To fi t the hub dynamo from the SR SUNTOUR DH-CT600 series on the front wheel, follow the<br />
steps below:<br />
1. Remove the nuts (2 items FG9.5; #3) and washers (2 items DIN125A-M10; #2) on the left<br />
and right-hand sides of the front axle.<br />
Note: Depending on the type of fork, instead of the 2 washers (DIN125A-M10; #2)<br />
2 special collar disks must be used to ensure the system is fail-safe.<br />
2. Insert the front wheel in the fork of your bicycle so that both sides of the axle engage with the<br />
front ends of the fork. The front wheel must be adjusted so that the cable connection terminal<br />
(#5) is on the right-hand side of the bicycle.<br />
Ensure that the connection terminal is aligned parallel to the fork blades.<br />
<strong>Instruction</strong> <strong>Manual</strong> <strong>Hub</strong> <strong>Dynamo</strong> DH-CT600, Page 3
Fork (#1)<br />
Note: If the cable connection terminal is not aligned parallel, the connection<br />
cable will bend and may cut off the power supply to the headlight.<br />
3. Ensure that the washers (2 items DIN125A-M10; #2) are correctly positioned on the front<br />
ends of the fork or that the collar disks fi t fi rmly into the recesses provided for this purpose<br />
on the front ends of the fork.<br />
4. Tighten the nuts (#3) fi rmly on both sides.<br />
5. Check once more that the hub axle is fully inserted into the front ends of the fork.<br />
Note: If the axle is not fully inserted into the front ends of the fork, the “uneven”<br />
load may lead to problems with the brakes and tyres, which under certain circumstances<br />
may also result in loss of control of the bicycle and in accidents.<br />
6. Tighten the nuts alternately (#3) in stages up to a torque of 20 Nm.<br />
Fork (#1)<br />
Front fork end (#6)<br />
Washer (#2)<br />
DIN125A-M10<br />
Nut (#3)<br />
FG9.5<br />
Right-hand front fork end<br />
(#6)<br />
Cable connection<br />
terminal (#5)<br />
<strong>Dynamo</strong> hub (#4)<br />
Cable connection<br />
terminal (#5)<br />
Washer (#2)<br />
DIN125A-M10<br />
<strong>Dynamo</strong> hub (#4)<br />
SR Suntour DH-CT600<br />
Nut (#3)<br />
FG9.5<br />
Left-hand front fork end<br />
(#7)<br />
<strong>Instruction</strong> <strong>Manual</strong> <strong>Hub</strong> <strong>Dynamo</strong> DH-CT600, Page 4
Connection of the two-wire cable<br />
1. The lower ends (= hub side) of the two-wire cable must be<br />
stripped by approx.18 mm.<br />
2. Insert both cable ends in the connector (#11), using the righthand<br />
side of the connector for the earthed cable.<br />
3. Bend the protruding ends over so that they pass into<br />
the slots provided for this purpose and do not under any<br />
circumstances let them come<br />
into contact with each other.<br />
4. Connect the other end of the<br />
two-wire cable in accordance<br />
with the specifi cation of the<br />
headlight used or the external<br />
light switch.<br />
Warning: To prevent short<br />
circuiting, both ends of the earthed<br />
cable must be “grounded” or<br />
connected to the designated<br />
contacts. Mixing up the contacts<br />
will cause short circuiting,<br />
malfunctioning of the lighting<br />
system and damage to the<br />
hub dynamo if operated over a<br />
prolonged period.<br />
Bend the cable<br />
ends over<br />
5. Attach the cable to the fork so that it is protected<br />
throughout its length from the hub to the headlight.<br />
6. Test whether the lighting system functions by lifting the<br />
front wheel off the ground and setting it in motion in the<br />
direction indicated on the hub.<br />
Front<br />
headlight<br />
(#8)<br />
Wire<br />
(#9)<br />
insert<br />
Earthed<br />
cable<br />
(#10)<br />
Connector<br />
(#11)<br />
<strong>Dynamo</strong><br />
hub<br />
(#4)<br />
Note: If the lighting system does not function, check whether the wiring has short<br />
circuited and whether the contacts are loose, or have the installation checked by your<br />
SR SUNTOUR dealer.<br />
Maintenance and Servicing<br />
The hub dynamos in the SR SUNTOUR DH-CT-600 series require minimal maintenance and<br />
their positioning need only be checked for excessive clearance every 1,000 km. In the event of<br />
excessive clearance, please seek advice from your SR SUNTOUR dealer.<br />
Note: The hub should be cleaned at regular intervals and if it becomes extremely dirty.<br />
Use a sponge with lukewarm water and some soap. Do not under any circumstances<br />
use a high-pressure or steam jet device on the hub as this may destroy the washers and<br />
result in an infl ux of water and cause the lubricants that were added at the factory to be<br />
washed out.<br />
<strong>Instruction</strong> <strong>Manual</strong> <strong>Hub</strong> <strong>Dynamo</strong> DH-CT600, Page 5
SR SUNTOUR DH-CT-600 <strong>Hub</strong> <strong>Dynamo</strong> Guarantee Card<br />
Model SR SUNTOUR DH-CT624-32H (6 V, 2.4 W, 32 spoke holes)<br />
SR SUNTOUR DH-CT624-36H (6 V, 2.4 W, 36 spoke holes)<br />
SR SUNTOUR DH-CT630-32H (6 V, 3.0 W, 32 spoke holes)<br />
SR SUNTOUR DH-CT630-36H (6 V, 3.0 W, 3 6 spoke holes)<br />
Date of purchase _______________________________________________<br />
Dealer _______________________________________________<br />
Dealer’s address. _______________________________________________<br />
Dealer’s tel.-# _______________________________________________<br />
Dealer’s e-mail _______________________________________________<br />
Purchaser _______________________________________________<br />
Purchaser’s address _______________________________________________<br />
Purchaser’s tel.-# _______________________________________________<br />
Purchaser’s e-mail _______________________________________________<br />
Inspection<br />
1. Inspection Date ______________, Stamp __________________<br />
Dealer________________________________________<br />
2. Inspection Date ______________, Stamp __________________<br />
Dealer________________________________________<br />
1) This Guarantee Card is only valid on presentation with the receipt<br />
2) A form provided by the dealer may also be used to document the after-sales service commitment, if desired.<br />
<strong>Instruction</strong> <strong>Manual</strong> <strong>Hub</strong> <strong>Dynamo</strong> DH-CT600, Page 6
Limited Liability<br />
SR SUNTOUR provides a 2-year guarantee from the date of purchase for hub dynamos in the<br />
SR SUNTOUR DH-CT600 series, for material and manufacturing defects in accordance with<br />
the intended use.<br />
This guarantee does not under any circumstances cover any damage or malfunctioning of<br />
the hub dynamo caused by the following circumstances: improper mounting, dismantling,<br />
assembly, wilful damage, alterations by the user or by third parties, any unreasonable use,<br />
misuse or use of the product that breaches its intended use. This guarantee is limited to<br />
the repair or exchange of the hub dynamo or one of its components that shows evidence of<br />
material or manufacturing defects within 2 years from the date of purchase.<br />
The purchaser will only be able to claim under this guarantee if the guarantee card is sent<br />
to SR SUNTOUR within 30 days following the purchase of the hub dynamo. Any attempt to<br />
commit fraud with this guarantee, alterations to or manipulation of this card will automatically<br />
terminate the validity of the guarantee.<br />
SR SUNTOUR does not guarantee any express or implicit suitability or marketability<br />
whatsoever, with the exception of the foregoing notice. Liability on the part of SR SUNTOUR<br />
is expressly limited to repair or exchange of the product. SR SUNTOUR cannot under any<br />
circumstances accept liability for unforeseen damage or consequential loss. Some national<br />
laws and regulations do not permit exclusion of unforeseen damage or consequential loss,<br />
which means that this exclusion may not be valid. This guarantee gives you certain rights; you<br />
may also have other rights – notwithstanding the respective legislation in force.<br />
The purchaser is in any event strongly advised to contact his dealer to remedy problems under<br />
the guarantee.<br />
Distribution partners and after-sales service<br />
Visit our website http://www.srsuntour-cycling.com – where you will fi nd a list of our national<br />
distribution and after-sales service partners.<br />
SR SUNTOUR INC.<br />
No.7 Hsing Yeh Road,<br />
Fu Hsing Ind. Zone.<br />
Changhua.50606<br />
Taiwan, R.O.C.<br />
Telephone: +886 (4) 7695115<br />
Fax: +886 (4) 769 4028<br />
E-mail: orders@srsuntour.com.tw<br />
SR SUNTOUR USA<br />
P.O. Box 61988<br />
Vancouver WA 98666<br />
U.S.A<br />
Telephone: +1 (360) 737 6450<br />
Fax: +1 (360) 737 6452<br />
E-mail: service@usulcorp.com<br />
SR SUNTOUR EUROPE GMBH<br />
Am Marschallfeld 6a<br />
83626 Valley<br />
Germany<br />
Telephone: +49 / (0)8024 / 3 03 81 52<br />
Fax: +49 / (0)8024 / 4 73 09 84<br />
E-mail: service@srsuntoureurope.com<br />
<strong>Instruction</strong> <strong>Manual</strong> <strong>Hub</strong> <strong>Dynamo</strong> DH-CT600, Page 7
www.srsuntour-cycling.com