Shimano DH-3R30-N, DH-3R35-N, DH-3R35-H, DH-3R30-H Service Instructions

SI-2ZL0A-002-00

General Safety Information

Connection of the cables

WARNING

The tire outer diameter for wheels which are compatible with the DH-3R35/DH-3R30 hub dynamos is 646-716 mm. ●
If the hub dynamo is used on a bicycle with a tire outer diameter which is smaller than 646 mm, 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 DH-3R35/DH-3R30 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 {177 – 310 lb.} (for the DH-3R35-H/DH-3R30-H) or 65 – 120 kg {144 – 265 lb.} (for the
DH-3R35-N/DH-3R30-N). If the gross weight of the bicycle is heavier than the recommended weight range, the
braking force may be insuffi cient, 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

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.

– To avoid serious injuries:

– To avoid serious injuries:

NOTE:

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

According to German regulations (StVZO), a hub dynamo in Germany requires overvoltage protection. This hub ●
dynamo does not have overvoltage protection inside the hub itself. Use an external overvoltage protector with a
symbol to show that it complies with the German regulations (Shimano SM-DH10 overvoltage protector or similar
product).

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 and a 6 V/ 0.6 W bulb for the taillamp. ●
If the bulb of either the front lamp or taillamp blows, excessive voltage will be applied to the remaining lamp and ●

shorten the operating life of the bulb, so any blown bulbs should be replaced as soon as possible.
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. ●

SI-2ZL0A-002

DH-3R35-H
DH-3R35-N

Hub Dynamo

DH-3R30-H
DH-3R30-N

Technical Service Instructions

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

Connector cap (gray)

Connector cover (black)

Note:

Set so that it faces ●
the right way.

Press in until you hear ●
a click.

Lamp
connection
terminal

Lamp cable

Approx. 16 mm

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.

Recomm ended wire speci fi cations ●

Wire

Type Stranded

Wire

Insulation Diameter 1.8 – 2 mm

Frame cable

Size (AWG) 22
Diameter approx. 0.8 mm

Insulation

Note:

Approx.
16 mm

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

Groove

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

Insert

Bend

Hub dynamo connection terminal

Frame 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
position of the hub dynamo may change with respect to the lamp
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
at any point within the range of movement.

Connect so that the current from the hub dynamo fl ows 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, fi rst 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, fi rst secure the wheel to the front forks and then connect the connector cover.

Connector
cover

Remove

Installation of the front wheel

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 quick release nut or the cap nut has been secured.

For quick release type

Front fork

Connection
terminal

Mudguard stay

Quick release nut

For nut type

Basket stay

Front fork

Mudguard stay

Connection
terminal

Tightening torque:
20 N·m {174 in. lbs.}

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.

Note:

Cap nut (M9)

Mudguard stay

Volute spring

Quick release nut

Do not use the toothed axle washer with a quick release type. ●
Connect the two wires to ensure that the current fl ows smoothly. ●

Basket stay

Washer

Front fork

Mudguard stay

Connection terminal

Connection terminal

Front fork

Connector
cover

Connect

Cable

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: specifi cations 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 Shiman o Inc. AWS. SZK. Print ed in Singapore