Johnny Loco type 4 User manual

Assembly mAnuAl
CArgo bike type 4
ASSEMBLING A JOHNNY LOCO
TYPE 4 CARGO BIKE

2
supplied:
› Cargo bike rear frame
› Cargo bike triangle
› Cargo bike box assembled with bench
› Cargo bike fenders and parts
› Front connection part triangle
› Front wheels (left and right)
› Front brakes (left and right)
› Connection parts
tools:
ConsumAbles:
› Wrench
› Allen keys
› Socket wrench
› zip-ties (medium)
› mounting grease
› cable caps (supplied)

3
suspending the reAr frAme
› To minimize the risk of damaging the
bike during installation we recommend
a soft work oor. The cargo bike
packaging is a good alternative. Make
sure al metal clamps are removed from
the box before placing parts on it.
› For easy instalation we recommend
to hang the rear frame in a workshop
hoist. When frame is suspended
the connection of parts is easy and
the installation will be as smooth as
possible.
› Make sure the frame is suspended in
balans. To make sure the frame will
not fall during assembly, put the hoist
cable true the rear fork.
hoisting the frame

4
unpACking the box
instAlling the seAt
› Put the cargo box at on the
protected oor.
› Take the bolts out of the support
bars of the seat and put mounting
grease in threaded holes.
› Hold seat in place and insert bolts
from outside of the box through the
holes.
› Make sure turbo cover and seat
belts are properly positioned around
bottom and top support bar, as
shown in picture.
› Thighten the bolts.
› Check if seat is stabile and secure. connection points
all parts of seat installed correctly
connection point of the seat

5
ConneCting the
triAngle
Bolt
Large washer
Medium Washer
Small washer
Installation fixation bolt
Head axle
Triangle
Front connection
› Keep the headset of the frame elevated just
above ground for easy instalation.
› Take the top and bottom bolt with washer
out of the headset en install triangle as
shown in diagram. Leave the bottom bolt
untightend (6 mm) to instal front connection
to the triangle later.
connecting the triangle
triangle
front connection

6
ConneCting the box
› Put the cargobox nose down on a clean
and protective surface. The packing
plastic supplied with box , or a soft
blanket are a good option.
› Hoist the rearframe with triangle to
match the height of connection place to
the box and align the holes on the side.
› Connect the triangle to the side of
the box with supplied nuts (M6x 20)
as shown in pictures. Use a 10mm
spanner to hold nuts in place when
thightning the bolts.
› Instal the front connection and thighten
the bottom bolt of the headset. Use 3x
bolt (M6 x 55)
› Thighten al connections to the box
› Remove instalation xation screw from
headset (see previous page)
3x M6x 55 Bolt en Nut
Bottom bolt headset
holding nut when thightning connection bolts

7
inserting the hAndlebAr
› Put mounting grease on the ends of the handlebar.
› Check if the tube clamps on the box are loose.
› Insert the handlebar end evenly in the rear of the box.
› Check if cables are positioned nicely.
› press the handle bar down evenly and set to desired height, keep in mind
that the handle bar needs te be inserted with a minimal length of 80mm.
› Thighten the clamps.
thightning handlebar clamps
insert handlebar evenly

8
instAlling the wheels
› The two front wheels are different,
there is a ‘left’ and ‘right’ version.
Make sure the ‘right’ wheel is inserted
on the right side and ‘left’ wheel on
the left side of the box. If this is done
incorrect, the thread on the axle can
be damaged and the axle or triangle
wil need replacement.
› Loosen the safety nut from the axle.
› Put grease on the axle.
› Hold axle in place and screw in
without force. When axle is fully
inserted thighten the axle with
a proper tool.
› The direction of the used threads is
different for left and right, check direction of thread before inserting!
› Put the safety nut on the end of the axle,
use a socket wrench to thighten safety
nut properly.
› Check if the wheels spin freely.
careful insertion of the wheels
hight side indication sticker on wheel

9
mounting the brAkes
› Loosen bolts as shown in picture.
› Mount the brakes as shown above.
› Mount with supplied bolts on the frame check position.
loosen 1 turn before installing
(on both brake claws)
take out before installing
installed brake

10
ConneCting And Adjusting
the front brAkes
› Thighten outside pad of the
brake 1/4 turn.
› Squeeze the brake tight.
› Thighten the cable in the
brake.
› Secure the brake to the
bracket.
› Losen the outside pad 1/4
turn.
› Check functioning of both
brakes.

11
hArnessing the CAbles
rear cargobox
› Pull one side of the strap of the button on the cargo box.
› Put cables under the strap.
› Put the strap back in place and make sure the cables are positioned
properly, as shown in picture above.

12
mounting the fenders
› front fender (2x)
› front fender stay(4x)
› front fender rod (2x)
› washer m6 (6x)
› bolt M6x16 (4x) (preinstalled in triangle)
› Install fender stays on fender with M5x12 bolt, nut and 2 washers per stay.
› Install fender rod on the fender with M5x12 on the fender.
› Make sure to assemble a ‘left’ and ‘right’ version of the fender.
› Use sufcient amounts of grease during installation to ensure smooth
installlation and a durable connection.
› bolt M6x20 (2x)
› washer M5 (12x)
› bolt M5x16 (4x)
› bolt M5x12 (2x)
pArts

13
fender rod connection
fender on cargo bike
› Position the fender on
the cargo box. Make sure
the ducktail side is on the
lower back of the cargo
box.
› Connect fender tube to
the fender.
› Hold fender in place and
connect the fender rod on
the inside of the box.
› Connect fender stays to
wheel mounting plate
threaded holes.
› Check alignment of the
fender with the wheel.
fender stay
ducktail
fender rod

14
instAlling steering dAmper
bottom Cargo box
instAlling sAfety brACket
› Position the safety
bracket as shown in
drawing.
› Put zip-ties through
the end hooks, around
the frame and over the
bracket.
› Thighten the zip-ties
and cut off long ends.
› Check if the bracket
and damper do not
interfere when steering
left or right.
› Connect the steering damper
to frame and triangle as
shown in picture. Check
if the ‘extending rod’
side is mounted to the
triangle.
safety bracket instalation