Vélo Electrique Cargo E250 User manual

Date: 1 July 2013 CD 1001
Issue: 1.0 Vélo Cargo Owner’s Manual Page 1 of 34
Vélo Cargo E250
Owner’s Manual
Operation
Maintenance
Vélo Electrique Ltd
Poole
Dorset, UK
Web: www.veloelectrique.co.uk
E: [e-mail]
Velo Electrique®and Velo Cargo®are registered trademark ofVelo Electrique Ltd.
© Vélo Electrique, 2013

Date: 1 July 2013 CD 1001
Issue: 1.0 Vélo Cargo Owner’s Manual Page 2 of 34
Table of amendments
Issue number Amendment summary Date
1.0 Initial issue 1 July 2013

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1Introduction..................................................................................................................................... 5
2Important safety instructions.......................................................................................................... 5
2.1 Disclaimer............................................................................................................................... 5
2.2 Symbols used in this manual ................................................................................................. 5
2.3 General safety instructions..................................................................................................... 6
2.3.1 UK Standards Compliance............................................................................................. 6
2.3.2 European Standards Compliance.................................................................................. 6
2.3.3 Electrical Modifications................................................................................................... 7
2.3.4 Mechanical Modifications............................................................................................... 7
3General description........................................................................................................................ 7
4Specifications................................................................................................................................. 8
4.1 Performance (Speed and Range)........................................................................................ 10
4.2 Performance (Battery Lifespan)........................................................................................... 10
5Operation...................................................................................................................................... 11
5.1 Pre ride safety checks.......................................................................................................... 11
5.1.1 Check the brakes ......................................................................................................... 11
5.1.2 Check the tyres are inflated to the correct pressure.................................................... 11
5.1.3 Adjusting the handlebars.............................................................................................. 11
Removing the battery....................................................................................................................... 12
5.2 Removing and charging the battery..................................................................................... 12
5.2.1 The battery charger...................................................................................................... 12
5.2.2 Turning the battery on and off and removing from the cycle ....................................... 13
5.2.3 Refitting the battery...................................................................................................... 14
5.3 Adjusting the saddle............................................................................................................. 14
5.4 Check all nuts and bolts are secure..................................................................................... 15
5.4.1 Wheelnuts .................................................................................................................... 15
5.4.2 Cargo box pivot bearing nut......................................................................................... 15
6Packing List.................................................................................................................................. 15
6.1 Recommended tools ............................................................................................................ 15
7Riding the Vélo Cargo for the first time........................................................................................ 17
7.1 Pulling off on level ground.................................................................................................... 17
7.2 Pulling off on a hill................................................................................................................ 18
7.2.1 Is the hill too steep???? ............................................................................................... 19
7.3 Cornering.............................................................................................................................. 19
7.3.1 Entering a turn.............................................................................................................. 19
7.3.2 Whilst in a turn.............................................................................................................. 19
7.3.3 Cornering whilst going down hills................................................................................. 19
7.4 Braking ................................................................................................................................. 20

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Issue: 1.0 Vélo Cargo Owner’s Manual Page 4 of 34
7.5 Parking the Vélo Cargo........................................................................................................ 20
7.6 Locking the Vélo................................................................................................................... 20
7.7 Using the seatbelts............................................................................................................... 20
7.8 Using the rain cover ............................................................................................................. 21
7.9 Removing the seats ............................................................................................................. 21
7.10 General tricycle riding rules.................................................................................................. 22
8Maintenance and inspection ........................................................................................................ 22
8.1 Adjusting and replacing the brakes...................................................................................... 22
8.1.1 To adjust and rebalance the front brakes .................................................................... 23
8.1.2 To adjust the rear brake............................................................................................... 24
8.1.3 Replacing the brake blocks.......................................................................................... 24
8.2 Removing a wheel / replacing the tyres............................................................................... 25
8.2.1 Standard tyre inflation pressures ................................................................................. 26
8.2.2 Removing a front wheel and its tyre............................................................................. 26
8.2.3 Removing the rear wheel and its tyre........................................................................... 26
8.3 Troubleshooting failure in the motor and electronic control system..................................... 28
8.4 Actions in the event of damage to the battery bank............................................................. 28
9Warranty and repair ..................................................................................................................... 28
10 Electrical drawings ................................................................................................................... 29
11 Vélo Cargo logbook.................................................................................................................. 31
12 End user warranty registration card......................................................................................... 32

Date: 1 July 2013 CD 1001
Issue: 1.0 Vélo Cargo Owner’s Manual Page 5 of 34
1 Introduction
Thank you for purchasing a VeloCargo E250 electric power assisted cargo tricycle.
Vélo Électrique cargo bikes are sold as an affordable alternative to the second car or delivery vehicle.
They provide low cost family or cargo transport and come with electric power assistance as standard
to make the navigation of our roads comfortable and safe for the rider and its occupants. The electric
assistance is predominately designed for the safe exit/ pull off from junctions into traffic streams and
for the accent of hills, however it can be used as a gentle assistance to the riders pedal power input
at any time.
Our cycles are assembled in the UK and are manufactured using imported and UK produced
components.
The VeloCargo E250 is essentially a cycle like any other; it shares the same components such as
brakes, gears, chain, seats, wheels and tyres. Like a conventional bicycle its effective and safe
operation will depend on the manner in which it is used and also the necessity for frequent inspection
and maintenance. Furthermore there are safety hazards associated with all cycles and this is why we
ask that you read this entire manual carefully.
2 Important safety instructions
Please read these instructions in their entirety before operating the cycle and save these instructions
for future reference.
WARNING:
Read and save all of these instructions.
2.1 Disclaimer
The information in this manual is believed to be correct and reliable. However Vélo Électrique
assumes no responsibility for inaccuracies and omissions. The user of this information and product
assumes full responsibility and risk.
All specifications are subject to change without notice.
Tricycles, electrical power and battery systems are all capable of causing death or serious injury or
fire if damaged, incorrectly operated, or maintained. If in doubt, ensure that all activities are carried
out by trained and competent personnel.
2.2 Symbols used in this manual
WARNING:
Warning: risk of injury or death – proceed with extreme caution
PROFESSIONAL:
Professional person:highly recommended

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IMPORTANT:
Important: please take note
TIP:
Tip: helpful information
2.3 General safety instructions
The Vélo Electrique cargo tricycle is inherently much safer and easier to ride that a bicycle due to the
fact that it has three wheels – if one wheel hits an obstacle such as a stone or pinecone, the tricycle
cannot then easily flip over as a bicycle can. Whilst on the whole the tricycle is a more stable platform
to ride and transport your children or cargo, there are some very important differences to a bicycle
which must be understood.
2.3.1 UK Standards Compliance
The Vélo Cargo is defined as an ‘electric pedal cycle’ by law rather than a ‘vehicle’ (a vehicle requires
tax, MOT, insurance and a licence). The Vélo Electrique Cargo Tricycle conforms to the UK Standard
instrument for Electrically Assisted Pedal Cycle Regulations 1983 (SI 1983/1168), these laws whilst
theoretically superseded by a more recent EU requirement have not been rescinded and still apply.
These require that;
•the motor has an average power output limited to 200 W (250 W for tricycles and tandems
•unladen weight limited to 40 kg (60 kg for tricycles and tandems)
•maximum speed when power-assisted of 15 mph.
•manufacturers serial identification plate must be fitted showing motor wattage, battery
voltage and weight.
•The operation of the brakes must override and disable the electric propulsion system
•The throttle control must be of a type that defaults to zero power assist when released
For electric cycles meeting these requirements, the vehicle does not require registration or periodic
road worthiness assessment, and operators do not require a licence or insurance.
However operators must be at least 14 years of age.
IMPORTANT:
Important: You must be 14 years of age or older in order to ride an electric cycle
2.3.2 European Standards Compliance
If you are going to ride your Vélo Electrique in EU countries there is one difference between the UK
Standards and the EU standards that must be noted. The UK allows the use of a ‘twist and go’ type
throttle whilst the EU favours the use of what is called a ‘Pedelec’ power administration system. This
senses when the rider is pedalling and only allows power to be applied when the rider is pedalling.
This requires the fitment of a ‘hall effect sensor’ to the crank, this is a fairly straight forward

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modification and the existing Vélo Electrique speed controller has a connector where this can be
plugged in. The sensor itself fits over the crank Vélo Electrique can supply these items on request
and at extra charge, fitment instructions are provided so that the job can be completed by a the owner
or a cycle mechanic.
2.3.3 Electrical Modifications
Do not make any modifications to the electrical system including its mounting system, if you do so
your warranty will be voided and you may risk harm to yourself and others through electric shock and
electrical fires. If you still wish to modify or ‘hack’ your electrical system and have the appropriate
knowledge to do so you must do so at your own risk and you must ensure that your modifications
continue to meet the UK or EU standards, notably speed limitation and motor wattage limitation. Vélo
Electrique cannot be held responsible in any way if your modifications contravene these laws.
WARNING:
Electrical Modifications: Risk of burning, fire or electrical shock if the 36V
electrical propulsion system is tampered with. Similarly
the battery charger
should not be tampered with. Do not attempt to charge the battery with any other
charger than the one provided.
PROFESSIONAL:
Professional person:All modifications or repairs to the electrical system must
be made by a skilled person who fully understands the risks of working with DC
and AC electrical systems.
2.3.4 Mechanical Modifications
The only modification that is permitted under warranty is that the body of the cargo box may be
repainted in another colour and minor modifications to the layout of the front cargo box. Vélo
Electrique welcomes your creativity in making the front cargo box suit your needs, however you must
remember that you do so at your and your passengers own risk and it is your responsibility to make
sure that the cycle continues to adhere to the UK or EU standards, particularly in terms of unladen
weight being below 60kg.
WARNING:
Do not modify the cycle frame by welding/screwing into it, this may weaken it and
cause it to fail.
Do not overload the cycle; remember that its maximum permitted unladen weight
must not exceed 60kg by law.
Do not make any modifications that impede the movement of any parts of the
steering or make the cycle unbalanced
3 General description
The Vélo Electrique Vélo Cargo is a three wheeled electric cargo tricycle of a design which has been
around for over 100 years. The cycle comprises of a standard rear section of a bicycle with an
elongated and re-enforced front section of frame that attaches to the cargo box.
The cargo box is made of 10mm marine plywood with a steel frame; this box pivots on a central shaft
which utilises two heavy duty taper roller bearings around a shaft. The handlebars are connected to
the rear uprights of the cargo box.

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The cargo box has two bench seats with four sets of seatbelts for four children; the seats can be
removed to carry loads, an animal or an adult as long as the total load capacity is not exceeded.
The electric system comprises of a 36V 10 Ah battery powering a 250W DC brushless motor
controlled by a twist and go throttle and a remote control unit on fitted to the handlebars. Three
different power levels can be selected on the remote control along with a power on/off switch.
The electric power being 250W only is not designed to power the cycle on its own, it requires human
input.
The braking system is comprised of 3 x V-brakes which are operated by two standard brake levers on
the handlebars, both of the front brakes being linked together in order to be applied by one cable.
Each brake lever has an electric power override switch which cuts power to the motor should either
the brake be applied.
The rear brake is fitted with a catch-type handbrake system which allows the brake lever to be locked
in the on position.
The gears are of the derailleur type with a six speed index shift controller, these gears are used in
conjunction with the electric power system to maximise the rider’s power input and extend the battery
range.
4 Specifications
Vélo Cargo E250
Weight (unladen with rain cover and seats fitted) 57kg
Max load (cargo box) 100kg
Max load (rider) 120kg
Max gross weight (rider + cargo + trike weight) 277kg
Width 850 mm
Height 110 mm
Length 225 mm
Front cargo box construction 10mm marine plywood
Front cargo box frame Mild steel
Rear (cycle) frame Aluminium
Battery Voltage 36V
Battery Amp hours 10Ah
Battery Watt Hours 360Wh

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Motor Wattage 250W peak continuous
Speed control system 3 speed power limitation coupled
to variable twist and go throttle
on right hand of handlebars
Gears (mechanical)
Shimano brand 6 speed
derailleur
Wheels Front 20 inch x 1 inch
Wheels Rear 26 inch x 1.5 inch
Tyres Front (factory spec to maximum size) 20 x 1” to 20 x 2.5”
Tyres Rear (factory spec to maximum size) 26 x 1.5” to 26 x 2”

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4.1 Performance (Speed and Range)
Your Vélo Electrique cargo cycle is designed to be ridden like a normal cycle, the electric power being
used only to assist your human effort. Whilst the cycle can be propelled solely by the electric power, it
will dramatically reduce the range and also the amount of ‘cycles’ or lifespan of the battery. You also
risk burning out the motor if it is allowed to grind to a halt without your pedalling assistance.
For optimum range and battery lifespan the Vélo Electrique power should be used to ascend hills, pull
out of junctions and to lightly assist the rider to maintain a satisfactory speed.
If this is the case, distances of 20-50 miles are easily achievable between recharges on terrain with
continual light to moderate hills with a fit adult riding the bike and using the correct gear to optimise
human power input.
We recommend that you use the ‘low’ power setting on level to light hills and use the ‘medium’ power
setting to pull out of junctions and to ascent lengthy or steep hills. ‘Medium’ power setting can be
used all the time if higher road speeds are required.
Every owner's pedalling power, local terrain and traffic conditions are different and hence we cannot
offer more specific figures for range and performance.
4.2 Performance (Battery Lifespan)
Before you use the battery for the first time it is best to give it a full deep charge for 12 hours. To fully
condition your new battery give it complete deep charge, discharge cycles for the first three charges.
This is achieved by charging your battery for 12 hours and then using the bike until the battery is
completely drained. After this “conditioning” process, you can leave the battery charging as and when
you require.
If you are going to leave your battery uncharged for more than eight weeks it is best left half charged.
You should then re charge it every four weeks for two hours to keep it in top condition.
Always remember that you use up to three times more power when pulling off from standstill when
compared to continuous speed. To preserve the life of each charge always set off using your
pedalling power as much as possible.
Check the indicators on the actual battery to see how much power you have left. Please note that the
indicators on the handlebar dashboard (if purchased) lights do not necessarily show the amount of
power you have left, but the amount of load the battery is experiencing at any one point. If the lights
go down to “Empty”, then this is a strong indication that you ought to be pedalling more to take some
of the load off the battery. This will improve the battery life cycle.
Do not expose the bicycle or battery pack to fire, heat sources, acid or alkaline substances.
For best results, always charge the battery at room temperature, batteries behave very strangely if
cold, for example a battery being charged at zero Celsius is only able to receive half the charge that it
would when charged at room temperature.
Always make sure the battery is turned off before detaching/connecting it.
9- If your battery is damaged or appears to be overheating for any reason immediately return it to
your retailer for advice and a safety check.