Freeplay Energy Weza User Manual
ENGLISH
www.freeplayenergy.com
USER INSTRUCTIONS & SERVICE MANUAL
1. INTRODUCTION
2. IMPORTANT SAFETY INFORMATION
3. FEATURES
4. OPERATION
4.1 display and controls
4.2
first time use
4.3 recharging the Freecharge Weza
4.4 operating DC appliances
4.5 jump-starting
5. FREECHARGE MAINTENANCE AND STORAGE
5.1 battery care
5.2 battery removal and disposal
6. PRODUCT SPECIFICATIONS
7. CUSTOMER SUPPORT AND WARRANTY
8. FAQ & TROUBLE SHOOTING
9. SERVICE MANUAL
1. INTRODUCTION
Congratulations FreeCharge Weza Portable Energy Source.
FreeCharge Weza Portable Energy Source
The is the only booster pack you will ever need. It
incorporates failsafe Freeplay technology, in the form of a step charge input, with both AC and DC recharge
capability.
The FreeCharge provides a truly in one compact, rugged unit, for emergency or
recreational use, anytime, anywhere.
2. IMPORTANT SAFETY INFORMATION
Read these instructions completely before using the FreeCharge and save them for future reference. Read
them in conjunction with the user manuals of the particular devices being powered by Freecharge.
The FreeCharge contains a sealed LEAD-ACID battery that must be disposed of properly at the end of its
useful life.
! Warning:
it is well ventilated. Always follow the specific instructions in this manual each time you jump-start using the
FreeCharge.
General Precautions:
#
When storing the FreeCharge ensure that it is out of reach of children.
#
When connected to the FreeCharge, the jumper cable clamps may cause sparks if touched together.
This could cause damage to the unit.
#
Never charge or boost a frozen battery.
#
Do not submerge the FreeCharge in water.
#
Do not operate in the vicinity of flammables
#
Do not expose the FreeCharge to temperatures over 104F (40C)
#
The lead-acid battery in the FreeCharge is a sealed unit with no free liquid acid. Batteries being jumpstarted with the FreeCharge will likely contain liquid acids, which are hazardous if spilled.
Precautions when working with batteries:
#
Follow manufacturer’s instructions and safety procedures.
#
Ensure that the area around the battery is well ventilated.
#
Never smoke or allow a spark or flame in the vicinity of an engine or batteries.
#
Take care not to allow any metal objects to make contact with the positive and negative terminals
simultaneously. This will short circuit the battery causing sparks and possible damage to the battery or
electrical equipment, or even cause an explosion.
#
If you need to remove a battery, always remove the negative terminal from the battery first.
#
Wear appropriate protective clothing and avoid touching your eyes after working with batteries.
#
If battery acid comes into contact with skin or clothing, wash immediately with soap and water. If acid
enters your eyes, immediately flood them with cold running water and seek immediate medical
attention.
3. FEATURES
#
Step Charge input to provide power anytime, anywhere.
#
Step input effort indication.
#
Runs 12-volt DC products via a cigarette lighter socket
#
Sealed, non-spill 7 amp-hour lead acid battery
#
Jump-starting cables designed for safe and efficient use
#
Internal battery level indicator
#
Rechargeable at home, from a boat, motor vehicle or on the move
#
Service tool kit
#
AC/DC Charging adapter
#
DC charging cable
#
The FreeCharge Weza, with its accessories and tools, is stored neatly in a rugged carry bag.
Pedal
Figure 1
on purchasing the
Portable Energy Source
During jump-starting, the receiving lead-acid battery may release explosive gases - ensure that
Control Panel
Battery
Disconnect
Switch
Input Lever
Stabilizer Arm
Figure 2 - control panel
Display Bar
Battery Level
Display Switch
12V DC Output
Cigarette Lighter Socket
Negative Jumper Terminal
DC Input Socket
Positive Jumper Terminal
4. OPERATION
4.1 Display and Controls
Battery Level Indication
In the default state the FreeCharge battery level indication is in sleep mode to conserve battery power.
Press the battery level display button to display the state of charge of the FreeCharge's internal
battery. This will be indicated by the number of lights that are illuminated on the display bar. Six lights
indicate a fully charged FreeCharge battery. After 5 seconds the display bar will return to sleep mode.
Battery level cannot be displayed while the FreeCharge is being charged.
Note:
Input Effort Indication
The amount of human energy transferred into the FreeCharge via step input is indicated on the display bar
(Figure 2).
will be illuminated. When step input stops, the display bar will show the battery level for 5 seconds before
powering down.
Charge Indication
When receiving an input charge, the display bar illuminates in a linear pattern. Once the charging source is
disconnected, the display bar will display the battery level for 5 seconds before powering down.
The more vigorous the step input, the more energy generated, and consequently the more lights
(figure 2)
4.2 First Time Use
The FreeCharge contains a sealed, non-spill, lead-acid battery that should be kept fully charged for efficient
and effective use. The FreeCharge should be recharged when first received, after each use and every 3
months during storage. It is recommended that the FreeCharge be fully charged before planning a trip.
4.3 Recharging the FreeCharge
Step Input
To operate, fold out the stabilizing arms and place the FreeCharge on a level surface. Ensure that you have
a firm footing before placing a foot on the input pedal At a rate of 60-70 steps per minute, the
FreeCharge will generate approximately 25 - 40 watts of energy, which is stored in the internal battery.
If the input pedal is used, the FreeCharge will immediately display the step input effort indication. Once the
step input stops, the display bar will show the battery level for 5 seconds before powering down.
(Figure 3).
Figure 3
AC Source
The FreeCharge is supplied with a 18V 1.5A AC/DC adapter.
To charge from the AC/DC adapter, plug it into a standard AC wall outlet. Insert the DC output jack of the
adapter into the DC input socket of the FreeCharge . The display bar lights will illuminate to
indicate that the FreeCharge is accepting a charge. After approximately 8 hours (if the battery is totally
discharged) the FreeCharge will be fully charged.
FreeCharge within 24 hours to prevent over-charging.
bar will show battery level for 5 seconds before powering down.
! Warning:
DC Source
Vehicles and boats:
The FreeCharge is supplied with a DC charging cable that enables charging from the cigarette lighter socket
of a vehicle or a boat with a 12 V DC system.
A meaningful charge level will only be obtained if the vehicle’s engine is running while connected to the
FreeCharge. Plug the one end of the DC charging cable into the FreeCharge's DC input socket
and the opposite end into the vehicle's cigarette lighter socket. The display bar will illuminate to indicate that
the FreeCharge is accepting a charge. Disconnect the DC charging cable to terminate the charging
process. The display bar will then show the battery level for 5 seconds before powering down.
Solar panels and Wind generators:
The FreeCharge can be charged from a solar panel or wind generator through the DC input socket
4).
The FreeCharge has been designed to accept a DC input voltage of between 13V and 21V.
Ensure that the input jack from the solar panel or wind generator is the correct size and polarity (2.1mm
center pin positive).
! Warning:
Only use the supplied Freeplay AC/DC Adapter.
The Solar panel or Wind generator output must be intended for battery charging and have
(figure 4)
Ensure that the adapter is disconnected from the
When the adapter is disconnected, the display
(figure 4)
(Figure
an output of between 13V and 21V DC. Refer to the User Manual of the Solar Panel or Wind
Generator for detailed instructions on how to recharge batteries.
Figure 4
4.4 Operating DC Appliances
The FreeCharge can power many 12 V DC accessories via the cigarette lighter output socket .
(Figure 5)
Figure 5
A switchable voltage DC output cable (not supplied) is available as an accessory, enabling the FreeCharge
to power a range of DC appliances of up to 12V with a power consumption of up to 0.4 Amperes.
The FreeCharge is able to deliver a charge or operate an appliance whilst at the same time receive a
charge via the DC input charge socket or step input.
4.5 Jump-starting
! Warning
terminal) and negative to negative (black clamp to battery negative terminal). Never connect in reverse
polarity (positive to negative) as this may cause damage to both the FreeCharge and the battery being jump
started.
! Warning:
duration in excess of 5 seconds may cause damage to the FreeCharge battery. Ideally the FreeCharge
battery should be allowed to recover for at least 2 minutes between jump-start cycles.
! Warning:
not in use. If a metal object is placed across the terminal posts it may cause a spark or damage the battery.
! Warning:
: Always connect the jumper cable clamps positive to positive (red clamp to battery positive
The FreeCharge's jump-start feature should only be used in 5-second bursts. A cranking
Always ensure the insulated clamping nuts are secured on the jump-start terminal posts when
Refer to the "Precautions When Working With Batteries" in the front of this manual.
Figure 6
Jump-starting with a fully charged FreeCharge battery:
The FreeCharge should ideally be fully charged before attempting to jump-start a boat or vehicle engine check the battery level by pressing battery level display button . If there is insufficient energy,
recharge the FreeCharge from an AC or DC source.
#
Turn the ignition off
#
Ensure that any other power consuming systems e.g. lights, radio etc are also turned off.
#
Ensure that the ‘Battery Disconnect Switch” under the rubber cover on the outer casing of the
FreeCharge is in the closed position with the bolts firmly tightened.
#
Connect the jumper cables to the FreeCharge. The red cable must be attached to the red positive
terminal (+) and the black cable to the black negative terminal (-) of the FreeCharge . Ensure
that the clamping nuts are securely fastened to prevent the jumper cables from working loose.
#
Connect the FreeCharge's red positive clamp to the positive (+) battery terminal (it usually has a red wire
connected to it). Then attach the black negative clamp to the negative (-) battery terminal.
#
For best results the FreeCharge and the receiving battery should remain connected for several minutes
before attempting to crank the engine. This allows the FreeCharge to transfer energy to the receiving
battery, improving cranking performance
(figure 2)
(Figure 6)
#
Crank the engine in 5 second cycles with rests in between as specified above.
Jump-starting with a discharged FreeCharge Battery:
In the event that the FreeCharge battery is in a state of discharge the step input system may be used to
charge the vehicle battery directly. To do this, follow the procedure below:
#
disconnect the FreeCharge internal battery using the battery disconnect switch located behind
the rubber cover on the outer casing. Loosen both bolts and slide the metal switch completely to the left.
Re-tighten the bolts to retain the metal switch in the “open” position.
#
Switch off the ignition and other power consuming systems and connect the jumper cables as detailed
above.
#
Operate the step input pedal at a rate of 60 - 70 treads per minute for several minutes. Larger engines
may require in excess of 5 minutes of input effort in order to provide the vehicle battery with enough
energy to crank the engine. Because you have disconnected the FreeCharge internal battery, all the
energy you are generating is used to charge the vehicle battery directly.
#
After the engine has started, disconnect the black negative clamp and then the red positive clamp from
the battery terminals.
#
Finally, remove the jumper cables from the FreeCharge, ensure the insulated clamping nuts are secured
on the terminal posts and restore the “battery disconnect switch” to the closed position (completely to the
right) with its 2 bolts securely fastened.
Note: It is strongly recommended that you recharge you FreeCharge after use.
(figure 1)
5. MAINTENANCE AND STORAGE
5.1 Battery Care
The FreeCharge contains a sealed Lead Acid battery that should not be stored in a fully discharged state.
Prolonged storage of a totally discharged Lead Acid battery may damage it.
Fully recharge the Freecharge before storage.
The battery self-discharge rate is per month when the unit is stored at a temperature of 68 F. The selfdischarge rate increases with an increase in ambient temperature.
In order to prolong battery life when not in regular use, recharge the FreeCharge every 3 months.
5%
°
5.2 Battery removal and disposal
The battery inside the FreeCharge is a sealed lead-acid battery. It needs to be removed at the end of its
useful life and either recycled or disposed of in accordance with local regulations.
When the battery needs replacing, remove it according to the instructions provided in the FreeCharge
Service Manual. If you have any questions or problems concerning your unit, please contact the Freeplay
Customer Support center.
6. PRODUCT SPECIFICATIONS
Electrical Specifications
Battery 12V 7 Amp-hours sealed lead acid
Cigarette Lighter Output Socket 12V 10 Amps (fused, self resettable)
Max DC output power 120 Watts
jump-start cable length 5ft (1.6m)
Cable rating
AC/DC Charging Adapter 18V 1.5 Amps
Full charge time 8 hrs
Maximum recommended on charge time 24hrs
DC input socket 13V - 21V (2.1mm center pin positive)
Step Input power range 25W - 40W
Step Input Peak input power 48W
General Specifications
Dimensions (HxWXL) 10.4" x 8.6" x 16.3" (264 x 218 x 414mm)
Weight 18.7 lbs (8.5 kg)
Warranty 2 years
200 Amps
7. CUSTOMER SUPPORT AND WARRANTY
Freeplay Customer Support Center:
United States and Canada: Dixie Sales, Tel: 1866 6977 529, e-mail: freeplay@dixiesales.com
United Kingdom: Tango Group, Tel: 0870 6091541, e-mail: info@tangogroup.net
Rest of the world: e-mail: info@freeplayenergy.com
The Freeplay Customer Support Center provides support to
owners. The FreeCharge Weza has been designed for easy maintenance and servicing and is supplied with
a service manual and basic tool kit.
For more information about the and other Freeplay products
please visit our web site at: www.freeplayenergy.com
Warranty Issues
Contact the relevant Freeplay Customer Support Center.
2 YEAR WARRANTY
The manufacturer undertakes that, if within 2 (two) years of purchase, this appliance or any part thereof is
proved to be defective by reason of faulty workmanship or materials, we will, at our option repair or replace
the same free of charge for labor or materials on condition that:
#
The original invoice or sales receipt (indicating the date of purchase, product type and dealer's name) is
presented together with the defective unit.
#
The complete unit is returned to the manufacturer or representative, postage paid.
#
All service work is undertaken by the manufacturer or appointed agents.
#
Any defective unit or part shall become the property of the manufacturer.
#
This warranty is in addition to your statutory rights.
This warranty excludes:
#
Normal wear and tear
#
Damage through misuse, neglect or damage as a result of alteration either internally or externally, or
damaged from improper use or used in an unsuitable environment.
#
The battery, which has a warranty period of 1 year.
To register your warranty online visit www.freeplayenergy.com or alternatively, fill out and post the supplied
warranty card (US & UK only).
6. FAQ & TROUBLESHOOTING
Please read this section before calling the Freeplay Customer Support Center. Both the Troubleshooting
and FAQ are designed to help you solve the most common problems and answer any questions you may
have regarding your FreeCharge Weza.
FAQ
Q: Can the FreeCharge's internal battery be replaced?
A: Yes, please consult your service manual or contact the Freeplay Customer Support Center for advice.
Q: I have a regular 5 Amp battery charger with crocodile connector clips, can I use it to charge the
FreeCharge through the terminal posts?
A: Yes
Q: How do I know when the FreeCharge is fully charged?
A: Read all recharging instructions in the user manual. The lights on the display bar indicate charge level.
Q: How can I test the battery in the FreeCharge to see if it needs to be replaced?
A: The Manufacturer recommends that you use a 100 Amp battery load tester. Load the FreeCharge with a
100 Amp load (on terminal posts) and it should maintain at least9VDC.
Q: What products can my FreeCharge power or recharge?
A: most products compatible with a 12V DC power source.
FreeCharge Weza Portable Energy Source
FreeCharge Weza Portable Energy Source
Q: Is using the Step Input the only means to charge my FreeCharge?
A: No. The FreeCharge can also be charged from either a DC or AC power source.
Q: How long will it take to charge my FreeCharge from the wall socket with the AC/DC charging
adapter?
A: It will take approximately 8 hours to fully charge the FreeCharge.
Q: Can I charge my 12V DC device while the FreeCharge is being charged either through the DC
input or via the Crank?
A: Yes.
Q: What materials are used in the FreeCharge and are they recyclable?
A: The casings are made of polypropylene and glass-filled nylon. The transmission is made of a
combination of acetyl, glass-filled nylon and aluminum, while the input levers, pedal and stabilizer arms
consist of a glass-filled nylon. All plastic materials used are thermoplastics and can be recycled. The
FreeCharge contains a non-spill rechargeable Lead Acid battery, which needs to be recycled according to
regulations stipulated by your local authority. Please consult your user manual or contact the Freeplay
Customer Support Center for more advice.
Q. How long will a fully charged battery retain its charge?
A: The battery will self-discharge at 5% per month when the unit is stored at a temperature of 68 F. The selfdischarge rate increases with an increase in ambient temperature.
Q. Will I damage the FreeCharge if I crank the pedal too fast?
A. No, the faster you crank the more energy you store in the internal battery.
Q: Can I over-crank the unit - does it ever stop you from cranking?
A. No, you cannot over-crank the internal mechanism. It consists of simple gearbox, which drives an
alternator, providing power to the internal battery.
Q: What type of rechargeable battery is used in the FreeCharge?
A. The FreeCharge incorporates a non-spill rechargeable 12 V 7 Amp hour Lead Acid battery.
Q: How long does the warranty last?
A. The FreeCharge has a 2 year warranty
Q: Can I leave my FreeCharge charging from an AC wall charger all the time and unplug it when I
need to use it?
A: The FreeCharge should not be left on charge for longer than 24 hours.
Q: Should I discharge the FreeCharge's internal battery before recharging?
A: No. The FreeCharge contains a non-spill Lead Acid battery, which does not require total discharge before
recharging. Leaving a Lead Acid battery in a fully discharged state for an extended period of time will cause
damage to the battery and limit its life.
TROUBLESHOOTING
#
The FreeCharge will not accept a Charge from a DC source.
°
9. SERVICE MANUAL
DISASSEMBLING THE FREECHARGE WEZA
Sequence of disassembly
NOTE:
#
The FreeCharge is supplied with a tool kit to enable disassembly.
#
Left and right components
#
The input levers and stabilizer arms must first be removed before the outer, and then the inner casings
can be opened.
are not intending to split the 2 inner casings, as the internal spring is attached to this shaft .
#
The input levers and splined drive shaft have an indexing tooth (which has a rounded tip) and should only
be assembled in their correct indexed orientation .
#
The gearbox and alternator are located under the outer left casing.
#
The battery and bolts to release the control panel assembly are located under the right outer casing.
#
The 5 bolts to split the inner casings are located in the inner right casing (battery
compartment) and are accessed by removing the right outer casing.
#
The drive shaft assembly, drive belt and return spring are located within the inner casings.
PART REPLACEMENT
1. Replacing an Input Lever and Pedal
Remove the input lever by unscrewing 2 bolts, one located at the pivot end of the input lever and the other
at the pedal end. Work the input lever off the drive shaft and the pedal shaft. The pedal consists of 2 halves
which can be removed once one of the input levers has been removed. The input levers and splined drive
shaft have an indexing tooth and should only be re-assembled in their correct indexed orientation .
The pedal halves should be assembled with the diamond pattern facing upward.
2. Replacing a Stabilizer Arm
DO NOT
(Figure 11)
- these are defined when viewing the FreeCharge from its pedal end.
remove the stabilizer arm pivot shaft from the main assembly if you
(Figure 7)
(Figure 8, E)
(Figure 8, D)
(Figure 10, A)
(Figure 7)
Figure 7
Figure 9
considerable resistance due to the alternator magnets).
Loosen the 4 bolts and remove the alternator, drawing its 3 wires from the conduit to the battery
compartment.
Pull the rotor cup off the base plate of the replacement alternator. Bolt the base plate to its mountings on the
left inner casing. Feed the 3 wires through to the battery compartment and reconnect at the connector block
in the battery compartment The order of connection does not matter. Replace the rotor cup
(figure 9, C)
7. Replacing the Drive Shaft Assembly or the Drive Belt and Spring
Remove the right input lever and right stabiliser arm. Remove the right side outer casing by removing its 5
. Replace the other components by reversing the disassembly procedure.
(Figure 8, A).
Figure 10
bolts. Remove the battery and control panel, as described previously.
Remove the 5 bolts which lock the inner casings and the circlip and washer on the input shaft
(figure 8, C). (figure 8, A)
casing feeding the alternator wires through their conduit and leaving the internal parts assembled in the left
inner casing. Unhook the spring from the stabilizer arm pivot shaft and pull the drive shaft
assembly together with the attached belt and spring free Remove 2 bolts to
detach the belt together with the spring from the drive shaft assembly. Reverse this procedure to reassemble making sure that the belt is tracked correctly under the belt retaining bush and over
the toothed input pulley before re-hooking the spring end to the stabilizer pivot shaft
A)
. Make sure that the input lever arms are indexed correctly to the drive shaft assembly when re-
assembling .
Disconnect the 3 alternator wires at the connector block . Pull away the right inner
(figure 10, E) (figure 10,
(figure 7)
(figure 8, E)
(figure 10, A)
(Figure 10, B). (figure 10, C)
(figure 10, D)
Symptom
The display bar does not illuminate to show that the FreeCharge is receiving a charge.
Possible Cause Solution
The DC source has insufficient power to charge
the FreeCharge or is faulty. The FreeCharge will
not accept a charge from a DC source that has a
voltage lower than 13 volts.
The voltage of the DC source is too high for the
FreeCharge (over 25 Volts) and has burnt out the
charge electronic circuitry.
A faulty charging cable Replace charging cable
Incorrect polarity Check polarity
#
The FreeCharge will not accept a charge from the AC/DC adapter.
Symptom
The display bar does not illuminate after plugging in and switching on the AC/DC adapter
Possible Cause Solution
A faulty AC adapter Check or Replace the AC adapter
#
The FreeCharge cannot operate or charge an appliance from is cigarette lighter DC output socket.
Symptom
The appliance does not operate.
Possible Cause Solution
The FreeCharge's internal battery is discharged. Recharge the FreeCharge using, either an AC
The FreeCharge's internal battery is damaged Replace the internal battery
#
The FreeCharge cannot jump start a boat or vehicle's engine.
Symptom
The engine is not turning over
Possible Cause Solution
The FreeCharge's battery is not sufficiently
charged
The engine receiving is in poor condition. Replace the receiving battery.
The engine's cranking amps requirements
exceeds the FreeCharge's jump start capability **
Disconnect the FreeCharge from the DC source.
Charge the FreeCharge by using either the Step
Input or the AC charging adapter.
Replace the control panel unit.
source, DC source or the step input. After charging
confirm the charge status by pressing the “Display
Battery Level” button.
Recharge the FreeCharge using an AC or DC
source. After charging confirm the charge status
by pressing the “Display Battery Level” button.
Alternatively, disconnect the FreeCharge’s internal
battery with the ‘battery disconnect switch’ and use
the step charge input to recharge the receiving
battery directly.
It is not possible to jump start this particular engine
using FreeCharge.
Remove a stabilizer arm by removing 2 bolts. Work the stabilizer arm off the stabilizer pivot shaft and the
stabilizer locking shaft. DO NOT remove the stabilizer arm pivot shaft from the main assembly if
you are not intending to split the 2 inner casings, as the internal spring is attached to this shaft.
Reverse this procedure to re-assemble.
3. Replacing the Battery
Remove the right input lever and right stabilizer arm as described above.
Remove the right side outer casing by removing its 5 bolts.
The casing will come away partly, as the battery is attached to it. The battery should now be visible and its 2
terminals should be accessible. Disconnect the wires from the battery by undoing the bolts and remove the
battery.
To insert a new battery, reverse the procedure above. Ensure that the wires are connected to the correct
terminals. The red wire to the positive terminal and the black wire to the negative terminal.
4. Replacing the Control Panel
Remove the battery as described previously. Remove the leads to the battery disconnect switch terminals
located in the right outer casing. Disconnect the 3 alternator wires at the connector block and
release the wires from their cleats. Remove the 2 bolts that hold the control panel in place . The
control panel unit can now be pulled free, feeding the cables and the 3 alternator wires through the aperture
in the right inner casing.
The control panel is replaced by reversing this procedure.
(figure 8, D)
(figure 8, A)
(figure 8, B)
Figure 8
Figure 11
002
202
302
204
006
206
208
206
210
206
206
208
208
102
104
304
106
004
108
008
104
040
214
110
112
212
042
110
306
114
010
122
014
116
118
124
012
120
038
020
216
036
318
310
308
022
218
210
016
206
024
018
316
208
204
206
218
202
314
208
034
026
312
206
028
030
032
206
208
**Cranking Amps are a measure of how much power a battery can supply to start an engine at 32º F.
#
The Step Input does not work
Symptom
The Input arm is either stuck or has no resistance.
Possible Cause Solution
Internal gears and mechanism are damaged. Consult the Service manual or contact the
#
The display bar does not work
Symptom
The display bar does not illuminate.
Possible Cause Solution
The FreeCharge is totally discharged. Recharge the FreeCharge.
The FreeCharge internal battery is damaged. Replace the internal battery.
The electronic circuitry is damaged. Contact the Freeplay Customer Service Center.
Freeplay Customer Service Center.
5. Replacing Gear Components
Remove the left input lever and left stabilizer arm as described previously. DO NOT remove the stabilizer
arm pivot shaft from the main assembly if you are not intending to split the 2 inner casings, as the internal
spring is attached to this shaft.
Remove the left outer casing by removing 5 bolts.
Remove the gear plate by removing 3 bolts . The secondary gear can now be removed or
replaced. Remove the circlip from the input shaft o remove or replace the input gear.
6. Replacing the Alternator
Remove the right and left input lever and the right and left stabilizer arms as described above. DO NOT
remove the stabilizer arm pivot shaft from the main assembly if you are not intending to split the 2 inner
casings, as the internal spring is attached to this shaft.
Remove the right outer casing by removing 5 bolts.
Disconnect the battery as described above.
Disconnect the 3 alternator wires at the connector block .
Remove the left outer casing by removing 5 bolts.
Remove the gear plate by removing 3 bolts . Remove the secondary gear. To gain access to
the 4 bolts that fasten the alternator to the left inner casing, pull the rotor cup off its base plate .
Do not lever the rotor cup off, but pull in a straight line so as not to cause damage. (There will be
(Figure 9, A)
(figure 9, B) t
(Figure 8, A)
(Figure 9, A)
(figure 9, C)
PART NAME
KEY
Left Input Lever
002
Left Stabilizer Arm
004
Left Outer Casing
006
Left Rear Foot
008
Left Front Foot
010
Left Inner Casing
012
Control Panel Gasket
014
Right Inner Casing
016
Right Front Foot
018
Right Rear Foot
020
Right Outer Casing
022
Right Input Lever
024
Battery Switch Cover
026
Pedal Top
028
Pedal Shaft
030
Pedal Bottom
032
Right Stabilizer Arm
034
PART No.
114-ILL-GOL
012-SL-GOL-A
002-COL-GOL
010-FBL-GOL
008-FFL-GOL
001-CIL-GOL-A
032-PG-GOL
003-CIR-GOL-A
009-FFR-GOL
011-FBR-GOL
004-COR-GOL
115-ILR-GOL
043-BSG-GOL
120-PT-GOL
118-LB-GOL
121-PB-GOL
013-SR-GOL-A
PART NAME
KEY
Stabilizer Locking Shaft
036
Stabilizer Pivot Shaft
038
Positive Clamping Nut
040
Negative Clamping Nut
042
Gear Plate
102
Secondary Gear Bearing
104
Secondary Gear
106
Input Gear
108
Alternator
110
Input Shaft
112
Clutch Bearing
114
Toothed Pulley
116
Drive Belt
118
Input Shaft Washer
120
Drive Shaft Assembly
122
Return Spring
124
Bolt
202
PART No.
016-SS-GOL
016-SS-GOL
038-PNG-GOL-RED
038-PNG-GOL-BLK
005-GP-GOL
144-SGB-GOL
142-SGP-GOL-A
140-IGH-GOL-A
100-ALT-GOL
103-IS-GOL
112-CB-GOL
111-TP-GOL
107-TB-GOL
125-ISW-GOL
102-DS-GOL-A
104-TS-GOL
200-CS-BH-M10x25
PART NAME
KEY
Serrated Washer
204
Bolt
206
Serrated Washer
208
Washer
210
Countersunk Bolt
212
Circlip
214
Circlip
216
Bolt
218
Positive Jumper Cable
302
Negative Jumper Cable
304
Control Panel Unit
306
Battery
308
Battery Switch Lead
310
Battery Switch
312
AC/DC Charging Adapter
314
DC Charging Cable
316
Selectable DC Output Adapter (not supplied)
318
PART No.
200-W-S-M10
200-CS-M6x20
200-W-S-M6
200-W-M6
200-CS-C-M4x12
200-CC-EX-36
200-CC-EX-23
200-CS-M6x10
017-JC-GOL-A-RED
017-JC-GOL-A-BLK
030-IP-GOL-A
300-BAT-GOL
300-BLS-GOL
044-BS-GOL
600-ACDC-GOL
601-DCCC-GOL
602-SVDCO-GOL
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