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Amcargobikes Classic Operation instructions

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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