Shimano DH-2R30-E, DH-2R35-E-H, DH-2R30-ES, DH-2R35-E Service Instructions

SI-20M0E-003-00

General Safety Information

WARNING – To avoid serious injuries:

●Compatible bicycles are those with 26-28 inch wheels (for the DH-2R35/DH-2R30-E hub dynamos) or 16-20 inch wheels (for the DH-2R30-ES hub dynamo).

If the hub dynamo is used with wheels which are smaller than 26 inches (for the DH-2R35/DH-2R30-E) or 16 inches (for the DH-2R30-ES), the braking force may be too great, which could cause the wheels to lock and the bicycle to lose its balance and fall over.

●The hub of the DH-2R35/DH-2R30 has a built-in power modulator which controls the braking force to prevent it from being too great. When the braking force reaches a certain level, the power modulator operates to prevent the braking force from going past that level.

The recommended operating range for the power modulator is for bicycles with a gross weight (bicycle + rider + luggage) of 80 – 140 kg (176 – 308 lb.) for the DH-2R35-E-H and 65 – 120 kg (144 – 265 lb.) for DH-2R35-E/DH-2R30.

If the gross weight of the bicycle is heavier than the recommended weight range, the braking force may be insufficient, and if it is lighter than the recommended weight range, the braking force may become too great and the wheels may lock and bicycle may fall over.

It is essential that you fully understand and test the performance of the power modulator before use. The power modulator is not equipped with a function to prevent the wheel from locking up.

●Obtain and read the service instructions carefully prior to installing the parts. Loose, worn, or damaged parts may cause serious injury to the rider.

We strongly recommend only using genuine Shimano replacement parts.

●Check that the wheels are fastened securely before riding the bicycle. If the wheels are loose in any way, they may come off the bicycle and serious injury may result.

●Check that the lamp illuminates normally when riding at nighttime.

●Read these Technical Service Instructions carefully, and keep them in a safe place for later reference.

CAUTION – To avoid serious injuries:

The hub dynamo generates an extremely high voltage. Never touch the connection terminal of the hub dynamo directly while riding the bicycle or while the wheel is spinning. Touching the dynamo terminal may cause an electric shock.

NOTE:

●This hub dynamo is rated for 6 V/ 2.4 W specifications. It cannot be used for 6 V/3 W specifications.

●Carefully read the Front Inter-M Brake System Service Instructions for roller brakes in conjunction with these Service Instructions.

●Check the degree of parallel of the front fork end. If the front fork end is severely out of parallel, deformation of the hub axle may cause noise from an obstruction inside the hub dynamo to be generated.

●Install the hub dynamo to the front fork so that the side with the connection terminal is on the right when facing toward the front of the bicycle. If the side with the connection terminal is facing toward the left, the hub dynamo may not turn properly while riding.

●Check that the hub dynamo connection terminal is securely connected before using the hub dynamo.

●Use a 6 V/ 2.4 W bulb for the front lamp.

●If the lamp is frequently turned on when riding at high speed ranges, it will shorten the operating life of the bulbs.

●Do not disassemble the internal hub mechanism.

●Do not apply any lubricant to the inside of the hub, otherwise the grease will come out and it may cause problems with conductivity.

●The hub dynamo will cause the turning of the wheel to become slightly heavier because of the magnet inside the hub.

●Parts are not guaranteed against natural wear or deterioration resulting from normal use.

DH-2R35-E

DH-2R35-E-H

DH-2R30-E

DH-2R30-ES

Technical Service Instructions

Installation of the front wheel

SI-20M0E-003

Hub Dynamo

Install the wheel so that the side with the hub dynamo connection terminal is on the right side when looking toward the front of the bicycle, and so that the hub connection terminal is aligned with the front fork or with the basket stay. Then install by following the procedure shown in the illustration below so that the connection terminal is facing upward. Do not force the connection terminal to turn after the cap nut has been secured.

	Basket stay	Connection terminal
		Connection
	Front fork	terminal
		Front fork
		Mudguard stay

Mudguard stay

	Tightening torque:
	20 – 25 N·m	Basket stay
	{174 – 218 in. lbs.}
		Washer

Cap nut (M9)

Note:

When tightening the cap nuts, tighten the nuts alternately on both sides and do not concentrate all of the effort for tightening and loosening the cap nut on one side of the wheel only, otherwise the hub axle may turn, which could excessively tighten or loosen the lock nuts.

Connection of the cables

Connect the cables as shown in the illustration below.

Note:

Scrape away the paint from the lamp’s frame connection terminal and the lamp connection terminal when connecting the cables.

Frame connection terminal

Lamp connection terminal

Note:

●Do not switch over the frame cable and the lamp cable by mistake. If the cables are connected incorrectly, the lamp will not illuminate.

●Twist the cable wires before connecting them so that they stay together.

●Recommended wire specifications

Wire Insulation

	Type	Stranded
	Wire	Size (AWG) 22
		Diameter approx. 0.8 mm
	Insulation	Diameter 1.8 – 2 mm

Frame cable

Lamp cable	Note:

Approx. 16 mm

Connector cap (gray)

Connector cover (black)

Note:

● Set so that it faces the right way.

●Press in until you hear a click.

Approx. 16 mm

●Bend the cable wires and run them along the grooves.

Insert

Groove Bend

●Do not allow the cable wires to touch each other.

Hub dynamo connection terminal

Frame connection terminal

Lamp connection terminal

Note:

● Secure the cable to the front fork or the basket stay so that it will not

get caught in the spokes or any other parts while riding. If the	Connector
position of the hub dynamo may change with respect to the lamp	cover
while riding, for example when using a suspension fork, make sure
that the cable is connected so that it will not be too loose or too tight	Remove
at any point within the range of movement.
● Connect so that the current from the hub dynamo flows through the
cable from the lamp connection terminal of the hub dynamo to the
frame connection terminal.

●To disconnect the lamp from the hub dynamo, remove the connector cover.

●Do not ride the bicycle while the connector cover is removed, otherwise the cable might get caught in the bicycle wheel.

●When removing the bicycle wheel, first remove the

connector cover. If the cables are pulled strongly,

it may break the cable wires or cause poor contacts. Furthermore, when installing the wheel, first secure the wheel to the front forks and then connect the connector cover.

Connector	Cable
cover
Connect	Front fork

Checking the lamp illumination

Rotate the front wheel and check that the lamp illuminates.

These service instructions explain how to use and maintain the Shimano bicycle parts which have been used on your new bicycle. For any questions regarding your bicycle or other matters which are not related to Shimano parts please contact the place of purchase or the bicycle manufacturer.

* Service Instructions in further languages are available at : http://techdocs.shimano.com

Please note: Specifications are subject to change for improvement without notice. (English)

One Holland, Irvine, California 92618, U.S.A. Phone: [phone]

Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: [phone]

3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Japan

© Apr. 2010 by Shimano Inc. AWS. SZK. Printed in Singapore