Green Power IET FORMULA GOBLIN G2 User manual

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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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INTRODUCTION TO YOUR GOBLIN G2 KIT CAR
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• 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
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• 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
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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.