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CARQON D2, User Manual

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CARQON D2 User Manual Download Page 42

42

7  Belt drive 

Depending on your chosen model, Carqon is equipped with a belt drive or chain drive. The following 
sections give more information about these two drive systems. 

 

●

Carqon with a belt drive is combined with an Enviolo gear hub.

 

●

Carqon with a chain drive is combined with a Shimano Deore XT derailleur gear system (see page 
44).

7.1  Principles of a belt drive 

A Carqon with beltdrive, combined with an Enviolo gear hub (continuous variable transmission) is an 
advanced alternative to the traditional chain drive. The belt drive is a carbon reinforced belt that offers 
advantages over the traditional, metal chain. It is a solution for everyone who loves to cycle, but not the 
maintanance activity. Besides, the belt makes hardly any noise while driving.

1. 

Enviolo gear hub 

2. 

The Gates belt drive 

3. 

The Gates sprocket

7.2  Correct adjustment of the belt drive

When the Carqon has been delivered to you, Carqon or your dealer have adjusted the belt to the 
correct tension. During servicing, your dealer will check the tension of your belt with professional tools. 

7.2.1  Handling the belt 

Do not crimp, twist, backbend, invert, bundle or zip tie the belt. Do not use the belt as a strap wrench or 
chain whip. Do not roll on or pry the belt. 

7.2.2  Care for your belt drive 

Wash the belt with water to remove debris. Acceptable temperature range for belt is  from -53 °C 
(-65°F) to +85 °C (+185°F). 

Note: 

a correct tension is very important for a comfortable driving experience. 

Besides, this will extent the lifetime of your belt.

Summary of Contents for D2

Page 1: ...1 User manual Carqon Cargo Bikes Carqon D2 E2 ...

Page 2: ...your Carqon go to register carqon com Ga naar support carqon com voor de Nederlandstalige handleiding Besuchen Sie support carqon com für das deutsche Handbuch Visitez support carqon com pour le manuel en français ...

Page 3: ...ional 500Wh dual battery option Display Bosch Purion Display with derailleur or Bosch Intuvia Display unit with Enviolo Brakes Tektro Dorado HD E730 4 Piston Hydraulic Disc brakes Saddle Velo Saddle with handle Lights Front Spanninga Axendo 40 Rear Spanninga O guard XE box design lightning Spokes GIX 13 Sapim strong single butted inox spoke Wheel sizes Front 20 and Rear 27 5 Front Tire Schwalbe Su...

Page 4: ...e or KMC Chain Drive 5 Velo Saddle with Handle 6 Bosch Performance CX Gen 4 Cargo line motor 7 Double Cable Steering System 8 Bosch Dual Battery Option 9 Child Door with Security Lock 10 High Strong Box 11 Suspension Cargo Front Fork 12 Hydraulic Tektro Disk Brakes Highlights of Carqon More information go to support carqon com ...

Page 5: ...Safety 14 2 1 Instructions for safe use 14 2 2 General safety instructions 14 2 3 Safety in road traffic 16 2 4 Transporting children in the box 16 2 5 Replacing bike components 18 2 6 Misuse of cargo bikes 18 2 7 Fastening and opening the three point belt 19 3 Basic settings 20 3 1 Before making your first journey 20 3 2 To be checked before every journey 20 3 3 Adjusting the seating position 21 ...

Page 6: ... Electrical drive system 28 5 3 Bosch Intuvia Display 28 5 4 Bosch Purion Display 32 5 5 Instructions for using the battery 35 5 6 Protective features 37 5 7 Instructions on the additional components of the cargo bike 37 5 8 Information on road traffic 37 5 9 Error code display 38 6 Brakes 39 6 1 Checking the brakes 39 6 2 Brake lever assignment 40 6 3 Disc brakes 40 6 4 Adjusting the disc brakes ...

Page 7: ... headlight 47 10 Wheels tires and suspension 48 10 1 Rims and Spokes 48 10 2 Tires 48 10 3 Valves 49 10 4 Tire pressure 49 10 5 Suspension fork 51 11 Individual components 52 11 1 Double Cable Steering System 52 11 2 Optional luggage carrier 52 11 3 Luggage 52 11 4 Bell 53 11 5 Prop stand 53 12 Storage cleaning and disposal 54 12 1 Storing the cargo bike 54 12 2 Cleaning the cargo bike 54 12 3 Sto...

Page 8: ...12 4 Disposal 55 13 First inspection and maintenance 56 13 1 First inspection 56 13 2 Annual maintenance 56 14 Carqon Bike passport 58 14 1 Handover record 59 14 2 Inspection record 60 15 Legal notice 63 ...

Page 9: ...g errors in this manual Pictures and parts may differ from your purchased Carqon 1 1 Identification of the warning instructions The point of warning instructions is to draw your attention to possible dangers The warning instructions require your full attention and understanding for statements By not following a warning instruction this can lead to injuring yourself or others Warning instructions a...

Page 10: ...e should not be disposed of via the household rubbish Dispose of the charging device at a suitable collection point for it to be disposed of in an environmentally friendly manner This symbol indicates that the battery should not be disposed of via the household rubbish Remove the battery via a suitable collection point for environmentally friendly recycling WARNING This product can expose you to P...

Page 11: ...se Only use the cargo bike as described in this user manual Any other use is deemed to be improper and can lead to accidents serious injury and damage to the cargo bike The cargo bike is only intended for use on roads and paths with a smooth surface Any use on unfinished paths which have not been covered in asphalt cement or plaster may lead to damage to the cargo bike The first inspection is part...

Page 12: ...n into account when tightening the screw connections For this reason a torque key with a corresponding settings zone is required If you are not experienced in using torque keys or if you do not own a suitable torque key have the screw connections checked by a Carqon dealer The correct torque of a screw connection depends on the material and the diameter of the screw as well as the material and the...

Page 13: ...go bike regularly for wear Do not use the cargo bike if cracks deformities or color changes due to material fatigue or heavy rust are present Do not use the cargo bike if excessive wear or loose screw connections are present Have the cargo bike checked immediately by a Carqon dealer if excessive wear loose screw connections cracks deformities or color changes due to material fatigue or heavy rust ...

Page 14: ... tools to make adjustment and repairs have them carried out by a Carqon dealer 2 2 General safety instructions In the interest of your safety note the following safety instructions Wet slippery or dirty riding tracks may extend the braking distance Adapt your riding style and speed to the weather and the surface conditions Moving parts of the cargo bike may trap clothing and body parts Do not allo...

Page 15: ...device only on fire resistant material when charging Only charge the original battery with the original charging device After charging always pull the main plug out of the socket Note the additional safety information on the charging device Safety instructions on the battery Damage to the battery may lead to overheating and to the emission of gases and liquids Always keep the battery away from the...

Page 16: ...e relevant regulations governing road traffic for the state or the region e g from the Ministry for Transport Always continue to look for information about amended content of the valid regulations Ride carefully and with consideration for other road users Ride in such a way that no one is injured endangered disabled or annoyed Always use cycle paths intended for bikes Cargo bikes must be equipped ...

Page 17: ...transport box is as balanced as possible Transporting newborns and toddlers in the transport box You can find information on the Carqon website or from your Carqon dealer about the availability of seats for babies small children and children in your country Age Accessory from 3 to 10 months Carqon Maxi Cosi carrier from 8 to 18 months Carqon toddler seat From 18 months Carqon seat cushion The Maxi...

Page 18: ...the brakes Have the cargo bike checked for dammage by a Carqon dealer after a fall or an accident 2 6 Misuse of cargo bikes In order to use your Carqon do not misuse it in the following ways Using the cargo bike for competitions jumps stunts or tricks Improper repairs and maintenance Improper use of the battery Structural modifications to the original condition of the cargo bike particularly the t...

Page 19: ...lts are installed inside the box of your Carqon Fasten the belts over the child s shoulder Place the shoulder pads at the level of the child s collarbone Bring the ends of the belt together and snap it into the belt holder Pull the belt tight by using the straps of the belts Warning A maximum of one adult s hand may fit between the belt and the child s collarbone ...

Page 20: ...at you can operate the gear shift in such a way that your attention to road traffic is not distracted Check whether you can also assume a comfortable seating position for longer journeys and that you can safely operate all of the components on the handlebar 3 2 To be checked before every journey Check the cargo bike for damage and excessive wear prior to every journey Do not use the cargo bike if ...

Page 21: ...he optimal seating position depends on the rider s body size the frame size and frame geometry of the cargo bike and the settings of the handlebar and the seat An incorrect seating position may mean that you can only reach the control elements on the handlebar to a limited extent The seating position can be adjusted correctly by a Carqon dealer Significant features of a suitable seating position a...

Page 22: ...usual sounds are emitted when opening or locking the quick release Remove any soiling from the quick release with the help of a clean cloth If the quick release is not properly locked to the seat tube the seat may become loose or be released during your ride Before riding away ensure that the quick release lever is locked with sufficient pre tension by tightening of the clamp bolt and is connected...

Page 23: ...nation on your cargo bike and the distance to the handlebar 1 Turn the screw 1 or the screws 2 or 3 below the saddle one to two rotations in a clockwise direction 2 Position the saddle in such a way that you assume a suitable seating position and so that you are able to operate all of the components on the handlebar safely during the journey 3 Tilt the saddle in such a way that you can adopt a sui...

Page 24: ...e seating position you can have components with different measurements or you might look for alternative components with different specifications installed by a Carqon dealer 3 8 Noting the rotational direction of the screws Turn in an anti clockwise direction to loose the cotter pin nuts screws and shafts If there are deviations from this rule the relevant rotational difference will be indicated ...

Page 25: ...x Ensure that children wear a suitable bike helmet when riding which corresponds to the country specific and regional regulations or which has been tested according to the standard DIN EN 1078 and which bears the CE test mark Ensure that children do not allow any body parts to protrude from the box Ensure that children remain strapped in during their journey in the box Ensure that the maximum perm...

Page 26: ... industrial areas airports are advised to clean the box twice a month The cleanser must meet the following criteria No abrasive effect low alkaline or acidic a pH value between 6 and 8 Free from strong solvents or alcohol these substances can damage the film The water must not be warmer than 80 C 176 F If you want to use cleaning with the help of high pressure consider the following Maximum water ...

Page 27: ...se of the cargo bike s weight and the extra load This may mean that the level of wear is greater than with conventional bikes All of the above elements will change the riding behaviour Familiarize yourself with the riding and braking behaviour of the cargo bike away from road traffic Note that other road users will be required to adapt to the higher speed of the cargo bike 5 1 Tuning or manipulati...

Page 28: ...ed on as the Carqon cargo bike can suddenly accelerate if you accidentally bump into the pedals Ifyou still want to switch on the pedal assistance while walking use the walk assist function Stop pedalling while braking and try to brake simultaneously and evenly with both brake levers Switch off the support in case of a poor or slippery road surface 5 3 Bosch Intuvia Display For a detailed explanat...

Page 29: ...cal drive will automatically switch off If the speed falls below 25 km h or 15 5 mph the electrical drive will once again automatically switch on If the on board computer is not inserted in the holder it automatically switches off after 1 minute to save energy if no button is pressed If you are not going to use your Carqon for several weeks remove the on board computer from its holder Store the on...

Page 30: ...ctivated 5 3 4 Switching the push walk assistance on off The push walk assistance helps you to push your Carqon while walking with the bike in your hands The speed in this function depends on the selected gear and can reach a maximum of 6 km h The lower the selected gear the lower the speed of the push walking assistance function at full power The push walking assistance function must only be used...

Page 31: ... does not account for other consumers e g automatic gearbox charging external devices at the USB port If the on board computer is removed from the holder 4 the last displayed state of charge of the battery is saved If your Carqon is powered by two batteries the battery charge indicator displays the state of charge of both batteries 5 3 6 Placing and removing the on board computer To place the on b...

Page 32: ...ator i Assistance level indicator value indicator j Trip distance indicator TRIP 5 4 1 Switching the Carqon system on and off Only switch on the drive system if you are sitting on the cargo bike The following options are available for switching on the system Press the on off button 1 of the on board computer with the battery inserted Press the on off button of the cargo bike battery see battery op...

Page 33: ...an 25 km h or 15 5 mph the electrical drive will automatically switch off If the speed falls below 25 km h or 15 5 mph the electrical drive will once again automatically switch on To increase the assistance level press the button 6 on the operating unit repeatedly until the required assistance level appears on indicator i To decrease the assistance level press the button 5 The requested motor outp...

Page 34: ...completely 5 4 5 Battery charge indicator The battery charge indicator g displays the state of charge of the bike s battery not that of the onboard computer s internal battery The state of charge of the battery can also be checked on the LEDs of the battery itself Each bar of the battery symbol on the indicator g represents approximately 20 of the capacity The battery pack is fully charged The bat...

Page 35: ...outside this charging range three of the LEDs on the battery charge indicator will flash Disconnect the battery from the charger and let it acclimatise Do not reconnect the battery to the charger until it has reached the correct charging temperature The five green LEDs on the battery charge indicator indicate the battery s state of charge of when the battery is switched on Each LED represents appr...

Page 36: ...reduce its range Look after your cargo bike and take note of all of the instructions concerning the battery in the Bosch original instructions Check the tire pressure regularly to improve your range see section Tire pressure on page 50 Adhere to the servicing intervals see section Inspection record on page 60 Temperatures below 10 C 50 F may reduce the battery range If you are not using your cargo...

Page 37: ...qon dealer If you are transporting the cargo bike remove the battery and transport it separately and secure it against knocks and impact 5 6 Protective features The battery of your cargo bike is equipped with protective features Protection against overheating Protection against exhaustive discharge Note the accompanying Bosch original instructions when using your cargo bike s battery 5 7 Instructi...

Page 38: ...t assistance from the drive Check the full Bosch manual or bosch ebike com for all the possible error codes Code Reason Corrective measures 410 One or more buttons of the on board computer are disabled Check whether any buttons are stuck e g as a result of dirt finding its way in Clean the buttons if need be 414 Operating unit connection problem Have the connections checked 430 Internal battery of...

Page 39: ...ly with both brakes Warning If you notice that the effect of the brake is low have the brake system checked by a Carqon dealer 6 1 Checking the brakes Carry out the following instructions for the front wheel brake and the rear wheel brake 1 Check that all the screws in the braking system are firmly screwed 2 Check whether the brake lever is torque proof against the handlebar 3 Check whether there ...

Page 40: ... brakes and the brake disc immediately with a lightly moistened towel Clean the brake discs regularly with brake cleaning fluid or warm water Using the disc brakes causes wear to the brake pads and brake discs With hydraulic disc brakes the brake liquid in the hydraulic lines 1 is also subject to wear Ask a Carqon dealer for an inspection to check the wear of the brake pads Carry out the following...

Page 41: ...ith your fingers in the direction of the handlebar Regulate the braking effect by using different force levels on the brake lever In order to loosen the disc brake release the brake lever Over a short braking distance brake evenly with both brakes 6 4 Adjusting the disc brakes If brakes are not installed professionally the brake performance may reduce or the brakes may fail Let the brakes only be ...

Page 42: ... loves to cycle but not the maintanance activity Besides the belt makes hardly any noise while driving 1 Enviolo gear hub 2 The Gates belt drive 3 The Gates sprocket 7 2 Correct adjustment of the belt drive When the Carqon has been delivered to you Carqon or your dealer have adjusted the belt to the correct tension During servicing your dealer will check the tension of your belt with professional ...

Page 43: ...g the pedal frequency propelling the bike becomes heavier To the front in the direction of travel to switch down to increase the pedal frequency pro pelling the bike becomes easier 7 2 5 Adjusting the continuously variable transmission If the gear shift is incorrectly adjusted it may damage during use Only adjust the settings of the continuously variable transmission yourself if you have practiced...

Page 44: ... wires for damage or cracks Check the function of the derailleur gears in the following way Lift the cargo bike by the frame in such a way that the rear wheel can move freely Set the rear wheel in motion with the help of the pedals Shift through all of the gears Check whether you are able to shift through all of the gears properly Ensure that there are no unusual noises when shifting gears 8 2 Che...

Page 45: ...his may distract you from the road traffic Before entering road traffic familiarize yourself with the functions of the derailleur gears If you operate the derailleur gears improperly this may cause damage Do not press hard on the pedals when shifting gears Do not pedal backwards when shifting gears 8 4 Using the gear shift lever Release the gear shift lever after switching gears in such a way that...

Page 46: ...is exclusively used in daylight in light conditions LEDs cannot be replaced in headlights and rear lights When the LEDs have reached the end of their service life the corresponding lighting components must be exchanged Have any defective lighting replaced by a Carqon dealer 9 1 Operating the lighting You can switch on the lighting of your Carqon by using the Bosch remote control on your handlebar ...

Page 47: ... the headlight range The headlights must be set up in such a way that the light beam emitted is at half the height of the headlight at a distance of 5 m 16 4 ft Switch the headlights on in order to check the direction of the light beam being emitted Loosen the screw 1 by several turns in an anti clockwise direction Set up the headlights correctly as described above by tipping them forwards and bac...

Page 48: ...and rear wheel aligned by a Carqon dealer if they are not aligned or if they wobble If the spokes are not correctly or evenly tensioned this may compromise how well the front or rear wheels turn By riding over obstacles quickly such as a curb or if a spoke nipple comes loose this may compromise the tension of individual spokes If individual spokes are not correctly tensioned or if they are damaged...

Page 49: ...lve Express valve Dunlop secured with union nuts rim holes 8 5 mm 0 3 Turn the upper knurled nut 1 in an anti clockwise direction towards the top to let air out of the tires Completely unscrew the lower knurled nut 2 in order to change the valve insert Turn the lower knurled nut 3 clockwise as far as it goes in order to close the valve Depending on the type of valve you will require a pump to pump...

Page 50: ...o check the tire pressure when pumping up the tires 10 4 1 Basic settings The tire pressure has an influence on the roll resistance and the suspension of the cargo bike 1 Ensure that your air pump has the appropriate connector or adapter for your valve 2 Check the tire pressure with the help of a pressure gauge or an air pump with pressure display 3 Increase or reduce the pressure as desired by pu...

Page 51: ...ring preload It is not the coil spring hardness that is set but the spring preload This reduces the Sag of the fork when the rider sits down Sag is the amount of travel your suspension moves through just by adding your own weight body clothes pack etc to the bike A semi hard spring is used by default 10 5 1 Changing the sag of your front fork Turn the preload adjust button clockwise to increase th...

Page 52: ...double cable system or if one of the cable breaks 11 2 Optional luggage carrier If the optional luggage carrier is improperly assembled this can cause damage to bike components The luggage carrier is intended for transporting children up to 25kg and lighter luggage whilst travelling Do not modify the luggage carrier otherwise the stability or functionality of the cargo bike may be compromised Cont...

Page 53: ... signal Position the bell on the handlebar in such a way that you can reach it comfortably without removing your hand from the handlebar grip 11 5 Prop stand Your Carqon is equipped with a prop stand With the help of the prop stand you can park the cargo bike upright when it is not in use 11 5 1 Using the prop stand Hold the cargo bike securely with both hands and push the cargo bike forward so th...

Page 54: ...rts if possible Do not use any aggressive cleaning products Using incorrect cleaning products may lead to damage of the bike Do not use any sharp pointed or metallic cleaning utensils If necessary have your Carqon dealer advise you on suitable cleaning and maintenance products For cleaning purposes you require Clean cleaning cloths Mild lukewarm soapy water A sponge or a soft brush Cleaning and ma...

Page 55: ...the capacity of the battery once a month 12 4 Disposal Familiarize yourself with the disposal symbols which are shown on the packaging the battery and the charging device see section Symbols and signs on page 10 Your Carqon exists of an HDPE box aluminium frame stainless steel mounts and electric components 12 4 1 Disposing the packaging Dispose the packaging of the Carqon according to your local ...

Page 56: ...ding whichever comes first The first inspection may be carried out by your local Carqon dealer Retain the documentation for the first inspection with care so that you can produce this documentation in case of warranty claims see section Inspection record on page 60 13 2 Annual maintenance Have your cargo bike maintained at least once a year by a Carqon dealer a second maintenance is strongly advis...

Page 57: ...57 ...

Page 58: ...58 14 Carqon Bike passport Brand model Model year Art no Frame number where appropriate key number Other Vehicle condition New Used mileage Your notes ...

Page 59: ...nt guides for cargo bikes where appropriate Bosch quick start guide for the drive system all functions of the cargo bike have been explained the cargo bike has been handed over ready to ride the cargo bike has been handed over pre assembled instructions on making it ready to ride have been provided Purchase and or delivery date Purchase price Purchaser First and last name Address Email Tel Stamp C...

Page 60: ... Inspection After approx 100 km 62 miles or 2 months which ever comes first Works carried out Replaced components 2 Inspection After approx 1000 km 620 miles or 1 year which ever comes first Works carried out Replaced components ...

Page 61: ...fter approx 2000 km 1240 miles or 2 years which ever comes first Works carried out Replaced components 4 Inspection After approx 3000 km 1860 miles or 3 year which ever comes first Works carried out Replaced components ...

Page 62: ...fter approx 4000 km 2480 miles or 4 years which ever comes first Works carried out Replaced components 6 Inspection After approx 5000 km 3100 miles or 5 years which ever comes first Works carried out Replaced components ...

Page 63: ... damage which has arisen through improper use Only use the cargo bike as described in this user manual Any other use is deemed to be improper and can lead to accidents serious injury and damage to the cargo bike Improper use of the cargo bike voids the warranty see full user manual The cargo bike is intended for use by one person as a rider and the seating position of the cargo bike should be set ...

Page 64: ...Designed to help you conquer the world together with your children ...

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