Amcargobikes Classic Operation instructions

SAMLEMANUAL
CLASSIC CARGO BIKE
with mechanical disc breaks
ASSEMBLE INSTRUCTIONS
Read and understand these instructions before you begin the assembly. The bike
comes partly assembled, and it is important to read the manual carefully before
starting assembly, so the bicycle will be assembled in the correct order. It is
recommended to be two people to assemble the cargo bike. Be aware that the
bike must be re-tightened after some weeks of use. Make sure to check all parts
of the bike and re-tighten all screws and bolts.
Page 1

Step 1: Assembly of the back and front frame
•When the parts have been taken out of the boxes and wrapping, place the front frame upside
down on a table or two chairs.
•Place the back frame upside down "on top” of the front frame. Avoid taking the plastic on the
luggage carrier off to avoid scratches in the paint.
•The main bolt is mounted from below as shown in picture 1A, 1B, and 1C by using a hammer or
something similar. It should fit tightly. The bearings should be lubricated with grease. Do not
tighten the nut yet.
•With the 7 large bolts, washers and nuts mount the bow-shaped and the two straight metal rods
as shown on picture 1C, 1D and 1E. The metal rods must be placed below the trazezodial plate
as shown in picture 1F. In order to avoid that the stainless steel locknuts get stuck halfway
down on the bolt, use some grease at the end of the bolts, before the nut is tightened.
•Only when these are tightened, tighten the large nut on the main bolt as hard as possible and
insert the split (see picture 1F).
Picture 1B
Picture 1A
Page 2

Picture 1C
•7 pc. 13 mm bolts
(length: 25 mm)
•7 pc. washers
•7 pc. 13 mm nuts
Picture 1D
Picture 1E
Page 3

Step 2: Fenders, front wheels and brake pads
•If the bike is assembled using two chairs, one of the chairs is now moved to the end of the front
frame and the second chair is removed.
•The front fenders are mounted with 8 small bolts, washers and nuts + the four brackets (see
picture 2A and 2B). To make sure that the fenders are just above the wheels, the nuts are
tightened after the wheels are mounted.
Picture 1F
Page 4
• 8 pcs. 8 mm bolts
(length: 12 mm)
• 8 pcs. washers
• 8 pcs. 8 mm nuts

Picture 2A Picture 2B
•The break discs are mounted on the front wheels with the 2 x 6 small black torx bolts –see
picture 2C
•Mount the front wheels as in picture 2D
Page 5
• 2 pc. brake discs
• 2 x 6 small black torx bolts

•The two brake calibers are mounted with the 2x2 black allen key bolts. Notice: use 2-3 extra
washers per allen key bolt to ensure a good distance from the end of the bolt to the break disc.
See picture 2E.
•The position of the brake calibers versus the brake discs are adjusted via the blank allen key-
disc on the outside og the caliber and the side-by-side adjustment bolts on the brake caliber –
see picture 2F and 2G
•The brake discs should in this way run freely without touching the brake pads when the wheel
is turned. It is however OK if there is a small ”whisling” sound from the brake when the wheel is
turned –this will disappear after a few days of use
•Then the bike is turned (see picture 2H).
Picture 2C Picture 2D
Page 6
• 2 brake calibers
• 2x2 black allen key bolts
with 2-3 ekstra washers

Page 7
Picture 2E Picture 2F
Picture 2G Picture 2H

Step 3: Assemble the box
•The corner brackets for the box are mounted as shown in picture 3A.
•The correct position of the four different corner fittings is shown on picture 3B.
Picture 3A
•8 pc. 10 mm bolts (length 30 mm)
•8 pc. washers
•8 pc. 10 mm lock nuts
Picture 3B
Page 8
•The side panels are mounted (see picture 3C). The four canopy holders are mounted with the
long bolts in the holes in the middle (see picture 3D)
•The front and back panels are mounted (see picture 3E).
•The base panel is mounted using the long bolts and the nuts on the underside. The two small
bolts are used in the front and back end of the base panel (see picture 3F)
…and then all nuts are tightened.

•16 pc. 10 mm bolts (length 18 mm)
•16 pc. washers
•16 pc. 10 mm round nuts
•4 pc. 10 mm bolts (length 30 mm)
•4 plastic canopy holders
•4 pc. washers
•4 pc. 10 mm round nuts
Page 9
Picture 3C Picture 3D

•The front-, back- and side-reflectors are mounted (see picture 4G and 4H)
•2 pc. white front reflectors
•2 pc. red back reflectors
•3 pc. yellow reflectors for the wheels
Page 10
Picture 3E
Picture 3F
•2 pc. 10 mm bolts (length 70 mm)
•2 pc washers
•2 pc.. 10 mm lock nuts
•2 pc. small bolts
•2 pc. washers

Picture 3G
Picture 3H
•The headlights are mounted on the sides of the box (see picture 4A).
•The pedals are mounted (see picture 4B) –please notice that they have markings for left and
right side.
Step 4: The rest of the equipment
Picture 4A
Page 11

Picture 4B
Page 12
•4 pc. 10 mm bolts
(length 18 mm)
•4 pc. washers
•4 pc. 10 mm lock nuts
Picture 4C Picture 4D
•The two mouldings, which keep the child seats in place are secured with the two long bolts. (see
picture 4C).
•The child seat is mounted with two screws (see picture 4D). The seat belts are mounted on the
outside of the box (on the back panel) and below the child seat (see picture 4E)
Picture 4E
•2 pc. 10 mm bolts
(length 35 mm)
•2 pc. washers
•2 pc. 10 mm lock nuts

•The plastic fittings for the handle bar and the canopy holders are mounted using a small hammer
(see picture 4F and 4G.
•The plastic fittings for the wheel nuts are mounted using a small hammer (see picture 4H)
Picture 4F
Picture 4G
Picture 4H
Page 13
Picture 4I
•The saddle is mounted on the saddle post and this is mounted
on the bike (see picture 4I).

•The handlebar is mounted and the break handles, gear shifter and bell are mounted on the
handlebar (see picture 4J, 4K, 4L and 4M).
Picture 4J
Picture 4K
Picture 4L Picture 4M
Page 14
•The rear-brake is mounted (see picture 5A and 5B):
•The allen key bolt on the brake arm is loosened
•Make sure that the brake pads are in the right position versus the rim on both sides
•The screws on each side of the brake arms are adjusted so that the two arms are equally
tight when pushed against the rim
•Give a couple of mm space to the rim on each side before the allen key bolt is tightened.
Step 5: Brake cables and adjustment of brakes and gear

•The front cables are mounted in the brake handle (see picture 5C). They are pulled through the
hole in the handlebar (see picture 5D) and through the cable holders (see picture 5E). The cables
are mounted on the brake calibers so that the brake discs can move freely. It is however OK if
there is a small ”whisling” sound from the break when the wheel is turned – this will disappear
after a few days of use.
•Final adjustment is done partly at the brake calibers (see picture 2F) and partly via the two small
blank screws at the brake handle (see picture 5C) –until the bike brakes even and effectively.
•Finally the cable-holder is mounted on the back plate (see picture 5G).
Picture 5A Picture 5B
Page 15
Picture 5C
Picture 5D
Picture 5E

ENJOY YOUR NEW CARGO BIKE…!
IMPORTANT:
•The frame number is stamped into the frame on the left side of the bike –just in front of the left
pedal.
•Remember to adjust and re-tighten all moving parts on the bike after some weeks of use. If re-
tightening of the spokes are needed, please use a spoke tightener.
•The gear is tested. If the gear “clicks” or it feels difficult to change gear for some of the six levels, please
use the plastic hand-screw located where the gear cable meet the gear to adjust it (see picture 5H).
Page 16
Picture 5F Picture 5G
1. Adjust the whole
cassette
2. Left adjustment
screw
3. Right adjustment
screw
4. Gear position
adjustment Billede 5H