Green Power IET FORMULA GOBLIN G2 User manual

1
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TOOLS REQUIRED FOR THE BUILD
• Metric Spanners (selecon including 8,10,13, 17 and 19mm)
• Metric Allen Keys (selecon)
• Hammer
• Safety Equipment
• Tyre Pump with Pressure Gauge
• Electrical Screwdriver
• Wiring Crimp Tool
• Further tools may be required
CONTENTS
Introducon To Your Goblin G2 Kit Car
Important Health & Safety Notes
Chassis Assembly
Chassis Assembly
Steering Column Assembly
Front Axle Assembly
Rear Axle Assembly
Rear Axle Assembly
Brake and Throle
Motor Cage and Electrics
Motor Assembly
Baery Tray Assembly
Fing Motor Cage to Chassis
Fing Baeries
Seat Assembly
Fing Seat
Fing Roll Bar
Harness Assembly
Wiring Installaon
G2 Wiring Diagram
Baery Charging
Rebuilds & Spare Parts
Test Driving & Driver Training
Final Pre-Race Checks
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3
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5
6
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INTRODUCTION TO YOUR GOBLIN G2 KIT CAR
3
• Welcome to your Goblin G2. We hope you enjoy the Greenpower experience!
• ThekeyobjecveofbuildingaGoblinistoencourageanappreciaonandunderstandingof  
 engineeringandtechnologybythepupilsinvolved.Werecommendyouinvolvealocalengineer 
 duringthebuildtoadviseontechnicalmaersandtoactasateammentor.
• Ifyouhavealargenumberofpupilsinvolved,wesuggestyoudividethemintoanumberofteams 
 toworkondierentareasofthebuildsuchasChassisTeam,FrontAxleTeam,SteeringTeam,Rear 
 AxleTeam,WiringTeamandBodyworkTeam.Eachteamcanthenoperateseparatelyfromthe 
 otherscomingtogetherforthenalassembly.
• Themethodofassemblyisbasicallycleanandhencetheprojectcansafelytakeplaceina  
 classroom.Beawarethatsomepartsmaybecoveredinalightlmofoiltopreventcorrosion.Itis 
 advisabletousegloveswhenhandlingtheseparts.
• Rememberthatthecompletedcarwillneedtobestoredsomewheredryandbaeries,aeruse, 
 shouldberechargedandstoredfullychargedtomaintainperformance.
• Pleaseensurethatpupilsarecarefullyintroducedtothetoolsusedandthattheyusethecorrect 
 toolsforthevariousjobs.
• BeforeanydrivingtakesplacepleasereadtheTestDrivingandDriverTrainingpageofthismanual.
 Ifyourequireanyhelpwhatsoever,pleasedocontactGreenpower–Weareheretohelp.
E: [e-mail] T: 01243 552305

IMPORTANT HEALTH & SAFETY NOTES
4
• Although Goblin kits are designed to be built by 9-11 year olds there are sll some potenal risks
when working with tools and electricity.
Baeries
• Thebaeriesareabsorbedglassmat(AGM)typebaeries,socannotleakorspillmakingthemsafer 
 thanotherleadacidtypebaeries.
• Cauonmustbetakenwhenthebaeriesareoutoftheirpackingboxesastheterminalsare  
 exposed.Werecommendthatbaeriesarestoredintheirpackingboxeswhennotinuseinthecar. 
 Anyshorngbetweenbaeryterminalscanbedangerousanddamagethebaery.
• Beforerstchargingbaeriescheckyourchargervoltage.A12vchargerwillchargeasingle  
 baeryatame.A24vchargermustonlybeusedtochargeapairofbaerieslinkedinseries.  
 Incorrectchargingmaydamagebaeriesandbedangerous.
• Baeriesshouldbestoredfullychargedandneverbeledischargedasthismayresultindamage. 
 Oncechargingiscompleteremovefromchargeandstorethebaeriessafelytopreventanychance 
 ofashortcircuit.
Tyres
• Thereisariskoftyresbursngifoverinated.Pleasenotethemaximumpressuremarkedonthe 
 tyresanddonotexceedthis.
• Donotstoretyresindirectsunlightasoverheangcanresultinincreasedpressureandtheriskof 
 thembursng.

FRONT
FRONT
GP1334
GP1334
GP1233
GP1230
GP1227
GP1332
GP1335
GP1333
CHASSIS ASSEMBLY
5
Tools Tip: Ordinaryspanners
aregoodbut,youcansave
mebyusingaspanner
ononeendofanutand
boltandasocket&ratchet
handleontheother.See
FingerTightnote.
Finger Tight:Whenyourst
xnuts&bolts,don’tfully
ghtenthem.Dothemupjust
withngersto“ngerght”.
Onceasetofpartshavebeen
assembledandalignedthen
goroundandfullyghten
them.
Nyloc Nuts:ManynutssuchasGP1227usedontheGoblin
areNylocnuts.Thesehaveaplascringinsertedinoneend
whichpreventsthenvibrangundone.Theymustbeed
withtheplascinsertfacingawayfromtheheadofthebolt.

FRONT
FRONT
GP1233
GP1230
GP1233
GP1230
GP1230
GP1227
GP1391
GP1362
GP1338
GP1336R
GP1436
GP1230
GP1233
GP1336L
GP1436
GP1230
GP1233
GP1363
GP1216
GP1337
GP1339
GP1362
GP1212
GP1233
GP1230
CHASSIS ASSEMBLY
6
Small Parts: Whenyouhaveasetof
smallpartssuchasnuts&boltsto
workwithplacetheminaplasctray
beforeuse.Thiswayyoushouldavoid
losingthem.Makesureyouknow
whichpartiswhichthough.

FRONT
FRONT
GP1392
GP1216
GP1158
GP1354
GP1236
GP1269
GP1230
GP1216
GP1158
GP1356
GP1215
GP1231
GP1393
GP1230
GP1236
GP1231
GP1227
GP1230
GP1269
GP1157
GP1157
GP1237
STEERING COLUMN ASSEMBLY
7
Safety Note: Aminimumof10mmofGP1237shouldbescrewedintoGP1354.GP1231
shouldbeghteneduptoGP1354tolockGP1237inplace.
Smooth Steering:Oncecompletethesteeringshouldturnfreelywithnofreeplayinit.
Tighteningorlooseningtheboltsonthesupportblocksandattheboomcanalterthe
resistance.Asmalldropofoilorlubricantbetweenthecolumnandsupportblockscan
help.
Steering Column:Looselyassemble
thesteeringcolumn&support
blocks(GP1158)tothechassis.
Thenconnecttheboomsecon
tothechassisusingGP1237,2x
GP1236,GP1231andGP1230.
GP1237shouldbedoneupunlit
stopsthesteeringfromturningand
thenbackedojustenoughtoallow
freemovement.GP1231shouldthen
beghteneduptotheboomofthe
columntolocktheboltinplace.
Steering Alignment: Oncethewheelsare
edmakesurethatwhenthesteering
iscenteredbothwheelsareparalleland
poinngstraightahead.Adjustmentisdone
bywindingthesteeringarms(GP1157)in
oroutoftherodends(GP1269).However,
forsafetyensureatleast10mmofthearms
areinsideeachrodend.

GP1190
GP1001
GP1127
GP1312 - Right
GP1311 - Left
GP1157
GP1204
GP1202
GP1230
GP1227
GP1269
GP1231
GP1230
GP1216
GP1201
GP1204
GP1207
GP1360
GP1216
GP1358
GP1142
GP1215
GP1237
FRONT AXLE ASSEMBLY
8
Steering Arms: Fitthe
steeringarmGP1157aer
thestubaxleandensure
aminimumof10mmis
threadedintoGP1269
thenlockedinplacewith
GP1231.
Safe Steering: Tightenthe
largenut&bolts(GP1202/
GP1207)unlthereisno
movementup/downbutit
cansllturnfromsideto
sideeasily,Somelubricaon
isusefulhere.
Cauon: Thebearingsinside
thewheelswillbegreasy.This
lubricaonreducesfriconhelping
speedupyourGoblin.Besureto
usethecorrectwheel.Theone
withoutbearingsshouldbeedto
thelerear.
Linch Pins: Becareful
whenngthelinchpins
(GP1190)astheywillspring
shut.Mindngers!
Go Faster: To
reducefricon
applyalilegrease
toeachsideof
washersGP1001
andinatetyres
tothemaximum
pressureindicated
onthesidewalls.
Thishelpsreduce
friconandrolling
resistanceand
makesyourGoblin
gofaster!Donot
over-inatetyres
astheymayburst.

✘✔ ✘✔
✔
✔
GP1341
GP1365
GP1128GP1138
2 x GP1005
GP1161
GP1139
GP1150
GP1205
GP1203
GP1206
GP1002
GP1128
GP1128
GP1291
GP1364
GP1192
GP1004
GP1004
GP1364
REAR AXLE ASSEMBLY LEFT
9
Note: Grubscrews,
GP1005,packagedinside
GP1161,mustbefully
ghtenedtoclampbush
toaxle.ThirdholeisNOT
used.Seediagram,le.
Keep it Tight: Where
Nylocnutsarenotused,
forexampleGP1002and
GP1005alilemedium
strengthliquidthreadlock
canbeused.Thisstops
thingsvibrangloose.
SearchYouTubefortutorials.
Drive Wheel: YourGoblin
usesjustonedrivewheel
onthelerearofthecar.
Powerfromthemotoris
transferredtothewheelvia
therollpin,GP1004.Sois
brakingforce-toomuch
hardbrakingriskswearing
out the tyre.
Roll Pin: Hammertherollpin,GP1004,through
theaxlebeforengthewheel.Itneedstobe
insertedunlequalamountsshowoneachside
oftheaxle.ADULTS: Thiscantakesignicant
forceandcareneedstobetakennottodamage
theaxleorcauseinjury.Theaxleshouldbewell
supported.

GP1365
GP1364
GP1342
GP1001
GP1294
GP1150
GP1381
GP1128
GP1128
GP1004
GP1128
GP1364
GP1192
GP1004
GP1006
GP1127
GP1206
GP1205
GP1203
REAR AXLE ASSEMBLY RIGHT
10
1, 2, 3... Followthenotesin
numberedorder.Rollpins
shouldbeinsertedunl
equallengthsshoweach
sideoftheaxle.
1. Fitthedischub,GP1381,
overtheaxleandsecurein
placewitharollpinthrough
theholenearestthecentre
oftheaxle.
2. Fitthebrakedisc,nongthe
correctrotaonarrow,tothe
hubusing6xGP1006with
alilethreadlock(seeKeep
itTightnoteon“REARAXLE
ASSEMBLY-LEFT”page.
3. Slidethecentrepartof
thebearing,GP1128,onto
theaxle.Donotghtenthe
grubscrewsunltheaxleis
alignedonthecar-butdon’t
forgettodoso.
4. Insertthenalrollpin
oncethehub,discand
bearinghavebeened.
Remembertosupportthe
axleandtakegreatcare
whenhammeringthisin.

GP1131
GP1040
GP1295
GP1040
GP1217
GP1216
GP1261
GP1355
BRAKE AND THROTTLE ASSEMBLY
11
Fricon: Ifyourbrakepadsanddiscarerubbingwithoutthebrakelever
beingpulledthiswillslowyoudown.
Brake Disc: Thebrakecaliperstraddlesthedisc.Havingletheaxlebearing
grubscrewslooseoncethecaliperhasbeenedandalignedthesecanbe
ghtened.Furthercaliperalignmentcanbeachievedbyslightlyloosening
theblackcaliperbracketbolts,thenwhilstapplyingthebrake,re-
ghteningthem.Aimtobeabletospinthewheelswithout
thediscrubbingonthebrakepadsinthecaliper.

FF
N
GP1215
GP1343
GP1034 GP1034
GP1216
GP1212
GP1054
GP1219
GP1264
GP1216
GP1215
GP1214
GP1123
GP1383
GP1140
GP1264
GP1215
GP1219
GP1216
GP1216
GP1219GP1216
GP1216
MOTOR CAGE AND ELECTRICS
12
Note:FitGP1034and
associatedcablesbefore
ngGP1343tochassis.
Ensurecorrectorientaon
sotheredkeyalignswith
theo/onmarkings.
Safety Note:Theredisolatorswitchkeyshouldbeoutof
theswitchexceptwhenabouttodrive.Thisimmobilises
theGoblinbyturningoallpower.Itshouldonlybe
insertedandswitchtotheonposionimmediatelybefore
drivingwiththedriverinthecar.

FF
N
GP1230
GP1291
GP1211
GP1137
GP1230
GP1237
GP1230
GP1344
GP1227
GP1227
GP1248
MOTOR ASSEMBLY
13
Motor Pulley:Thepulley,GP1137,shouldbeslid
ontothemotorsha.Movingitinoroutalongwith
adjustmentoftheaxlepulley,GP1139(see“REAR
AXLEASSEMBLYLEFT”page),allowsthetwopulleysto
bealigned.Ifthemotorpulleyisaghttuseasoer
materialsuchasapieceofwoodorrubbermallettotap
it on.
Tightening:Oncethemotorandaxlepulleyshavebeen
alignedonthecarthegrubscrew,GP1211,canbe
ghtened.Alilethreadlockonthisscrewwillprevent
itcomingundone.
Belt Tension:Correctdrivebelttensionisimportantto
aidaquickstartandpreventexcessbeltwear.Loosen
the4boltsGP1237andnutsGP1227,slidethemotor
mounngplate,GP1344,towardsthebackofthecar
totensionthebeltthenre-ghtenthenuts&bolts.
Ifwhenstarngtodrivethecaragraunchingsounds
occursthenthebeltistooloose.Asageneralguidea
correctlytensionedbeltwhentwistedbyhandshould
rotatebetween45°and90°.

FF
N
GP1233
GP1230
GP1345
GP1233
GP1230
BATTERY TRAY ASSEMBLY
14

FRONT
FRONT
FF
N
GP1363
GP1343
GP1230
GP1227
GP1363
GP1216
GP1230
GP1216
GP1219 GP1227
GP1216
GP1233
GP1230
FITTING MOTOR CAGE TO CHASSIS
15
Note: RemembertotGP1343
MotorCagefrontxings,not
shown.Usethesamexingsas
attherear.

FRONT
FRONT
FF
N
GP1363
GP1216
GP1363
GP1216
GP1346
FITTING BATTERIES
Safety Note:Onlytand
connectbaeriesonceall
wiringisinstalledandhas
beendoublechecked.
16
Baery Connecons:Takecare
nottoover-ghtenthebaery
terminalbolts.

GP1391
GP1362
GP1212
GP1347
GP1349
GP1350
GP1348
GP1351
SEAT ASSEMBLY
17

FRONT
FRONT
GP1360
GP1215
GP1442
GP1360
FITTING SEAT
18

FRONT
FRONT
FF
N
GP1352
GP1230
GP1397
GP1436
GP1227
GP1436
GP1233
GP1230
GP1233
GP1230
GP1233
GP1230
GP1233
GP1230
FITTING ROLL BAR
19

FRONT
FRONT
FRONT
FRONT
FF
N
GP1365
GP1364
GP1364
GP1192
GP1365
GP1364
GP1364
GP1192
GP1120
HARNESS ASSEMBLY
20
Note:Thesafetyharnessmustbe
adjustedtosecurelyrestrainthe
driver.Alooseharnesswillmean
driverswillnotbepermiedtostart
anevent.Itistheresponsibilityof
teamstoensuresuitableadjustments
aremade.
Safety Harness: Wheninstallingthesafety
harnesskeepthebuckledoneuptohelpprevent
twisngduringng.