4OPERATION41DisplayandControls42FirstTimeUse43RechargingtheFreeChargeBatteryLevelIndicationInputEffortIndicationChargeIndicationInthedefaultstatetheFreeChargebatterylevelindicationisinsleepmodetoc ID: 832578
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USERINSTRUCTIONS&SERVICEMANUAL1.INTRODUC
USERINSTRUCTIONS&SERVICEMANUAL1.INTRODUCTIONfirsttimeuse6.PRODUCTSPECIFICATIONS7.CUSTOMERSUPPORTANDWARRANTY!Warning:2.IMPORTANTSAFETYINFORMATION3.FEATURES4.OPERATION4.1displayandcontrols4.3rechargingtheFreechargeWeza4.4operatingDCappliances4.5jump-starting5.FREECHARGEMAINTENANCEANDSTORAGE5.1batterycare5.2batteryremovalanddisposal8.FAQ&TROUBLESHOOTING9.SERVICEMANUALReadtheseinstructionscompletelybeforeusingtheFreeChargeandsavethemforfuturereference.ReadtheminconjunctionwiththeusermanualsoftheparticulardevicesbeingpoweredbyFreecharge.TheFreeChargecontainsasealedLEAD-ACIDbatterythatmustbedisposedofproperlyattheendofitsusefullife.Duringjump-starting,thereceivinglead-acidbatterymayreleaseexplosivegases-ensurethatitiswellventilated.Alwaysfollowthespecificinstructionsinthismanualeachtimeyoujump-startusingthe1.INTRODUCTION2.IMPORTANTSAFETYINFORMATION3.FEATURESCongratulationsFreeChargeWezaPortableEnergySource.FreeChargeWezaPortableEnergySourceGeneralPrecautions:Precautionswhenworkingwithbatteries:onpurchasingtheTheistheonlyboosterpackyouwilleverneed.ItincorporatesfailsafeFreeplaytechnology,intheformofastepchargeinput,withbothACandDCrechargecapability.TheFreeChargeprovidesatrulyinonecompact,ruggedunit,foremergencyorrecreationaluse,anytime,anywhere.WhenstoringtheFreeChargeensurethatitisoutofreachofchildren.WhenconnectedtotheFreeCharge,thejumpercableclampsmaycausesparksiftouchedtogether.Thiscouldcausedamagetotheunit.Neverchargeorboostafrozenbattery.DonotsubmergetheFreeChargeinwater.DonotoperateinthevicinityofflammablesDonotexposetheFreeChargetotemperaturesover104F(40C)Thelead-acidbatteryintheFreeChargeisasealedunitwithnofreeliquidacid.Batteriesbeingjump-startedwiththeFreeChargewilllikelycontainliquidacids,whicharehazardousifspilled.Followmanufacturer’sinstructionsandsafetyprocedures.Ensurethattheareaaroundthebatteryiswellventilated.Neversmokeorallowasparkorflameinthevicinityofanengineorbatteries.Takecarenottoallowanymetalobjectstomakecontactwiththepositiveandnegativeterminalssimultaneously.Thiswillshortcircuitthebatterycausingsparksandpossibledamagetothebatteryorelectricalequipment,orevencauseanexplosion.Ifyouneedtoremoveabattery,alwaysremovethenegativeterminalfromthebatteryfirst.Wearappropriateprotectiveclothingandavoidtouchingyoureyesafterworkingwithbatteries.Ifbatteryacidcomesintocontactwithskinorclothing,washimmediatelywithsoapandwater.Ifacidentersyoureyes,immediatelyfloodthemwithcoldrunningwaterandseekimmediatemedicalStepChargeinputtoprovidepoweranytime,anywhere.Stepinputeffortindication.Runs12-voltDCproductsviaacigarettelightersocketSealed,non-spill7amp-hourleadacidbatteryJump-startingcablesdesignedforsafeandefficientuseInternalbatterylevelindicatorRechargeableathome,fromaboat,motorvehicleoronthemoveServicetoolkitAC/DCChargingadapterDCchargingcableTheFreeChargeWeza,withitsaccessoriesandtools,isstoredneatlyinaruggedcarrybag.PortableEnergySource4.OPERATION4.1DisplayandControls4.2FirstTimeUse4.3RechargingtheFreeChargeBatteryLevelIndicationInputEffortIndicationChargeIndicationInthedefaultstatetheFreeChargebatterylevelindicationisinsleepmodetoconservebatterypower.PressthebatteryleveldisplaybuttontodisplaythestateofchargeoftheFreeCharge'sinternalbattery.Thiswillbeindicatedbythenumberoflightsthatareilluminatedonthedisplaybar.SixlightsindicateafullychargedFreeChargebattery.After5secondsthedisplaybarwillreturntosleepmode.BatterylevelcannotbedisplayedwhiletheFreeChargeisbeingcharged.TheamountofhumanenergytransferredintotheFreeChargeviastepinputisindicatedonthedisplaybarThemorevigorousthestepinput,themoreenergygenerated,andconsequentlythemorelightswillbeilluminated.Whenstepinputstops,thedisplaybarwillshowthebatterylevelfor5secondsbeforepoweringdown.Whenreceivinganinputcharge,thedisplaybarilluminatesinalinearpattern.Oncethechargingsourceisdisconnected,thedisplaybarwilldisplaythebatterylevelfor5secondsbeforepoweringdown.TheFreeChargecontainsasealed,non-spill,lead-acidbatterythatshouldbekeptfullychargedforefficientandeffectiveuse.TheFreeChargeshouldberechargedwhenfirstreceived,aftereachuseandevery3monthsduringstorage.ItisrecommendedthattheFreeChargebefullychargedbeforeplanningatrip.(figure2)(Figure2).StepInputACSourceEnsurethattheadapterisdisconnectedfromtheFreeChargewithin24hourstopreventover-charging.OnlyusethesuppliedFreeplayAC/DCAdapter.DCSourceTheSolarpanelorWindgeneratoroutputmustbeintendedforbatterychargingandhaveTooperate,foldoutthestabilizingarmsandplacetheFreeChargeonalevelsurface.EnsurethatyouhaveafirmfootingbeforeplacingafootontheinputpedalAtarateof60-70stepsperminute,theFreeChargewillgenerateapproximately25-40wattsofenergy,whichisstoredintheinternalbattery.Iftheinputpedalisused,theFreeChargewillimmediatelydisplaythestepinputeffortindication.Oncethestepinputstops,thedisplaybarwillshowthebatterylevelfor5secondsbeforepoweringdown.TheFreeChargeissuppliedwitha18V1.5AAC/DCadapter.TochargefromtheAC/DCadapter,plugitintoastandardACwalloutlet.InserttheDCoutputjackoftheadapterintotheDCinputsocketoftheFreeCharge.ThedisplaybarlightswillilluminatetoindicatethattheFreeChargeisacceptingacharge.Afterapproximately8hours(ifthebatteryistotallydischarged)theFreeChargewillbefullycharged.Whentheadapterisdisconnected,thedisplaybarwillshowbatterylevelfor5secondsbeforepoweringdown.TheFreeChargeissuppliedwithaDCchargingcablethatenableschargingfromthecigarettelightersocketofavehicleoraboatwitha12VDCsystem.Ameaningfulchargelevelwillonlybeobtainedifthevehicle’sengineisrunningwhileconnectedtotheFreeCharge.PlugtheoneendoftheDCchargingcableintotheFreeCharge'sDCinputsocketandtheoppositeendintothevehicle'scigarettelightersocket.ThedisplaybarwillilluminatetoindicatethattheFreeChargeisacceptingacharge.DisconnecttheDCchargingcabletoterminatethechargingprocess.Thedisplaybarwillthenshowthebatterylevelfor5secondsbeforepoweringdown.TheFreeChargecanbechargedfromasolarpanelorwindgeneratorthroughtheDCinputsocketTheFreeChargehasbeendesignedtoacceptaDCinputvoltageofbetween13Vand21V.Ensurethattheinputjackfromthesolarpanelorwindgeneratoristhecorrectsizeandpolarity(2.1mmcenterpinpositive).(Figure3).(figure4)Vehiclesandboats:(figure4)SolarpanelsandWindgenerators:!Warning:!Warning:anoutputofbetween13Vand21VDC.RefertotheUserManualoftheSolarPanelorWindGeneratorfordetailedinstructionsonhowtorechargebatteries.!Warning!Warning:!Warning:!Warning:4.4OperatingDCAppliances4.5Jump-startingTheFreeChargecanpowermany12VDCaccessoriesviathecigarettelighteroutputsocket.AswitchablevoltageDCoutputcable(notsupplied)isavailableasanaccessory,enablingtheFreeChargetopowerarangeofDCappliancesofupto12Vwithapowerconsumptionofupto0.4Amperes.StabilizerArmInputLeverControlPanelFigure1Figure3Figure4Figure6Cranktheenginein5secondcycleswithrestsinbetweenasspecifiedabove.IntheeventthattheFreeChargebatteryisinastateofdischargethestepinputsystemmaybeusedtochargethevehiclebatterydirectly.Todothis,followtheprocedurebelow:disconnecttheFreeChargeinternalbatteryusingthebatterydisconnectswitchlocatedbehindtherubbercoverontheoutercasing.Loosenbothboltsandslidethemetalswitchcompletelytotheleft.Re-tightentheboltstoretainthemetalswitchinthe“open”position.SwitchofftheignitionandotherpowerconsumingsystemsandconnectthejumpercablesasdetailedOperatethestepinputpedalatarateof60-70treadsperminuteforseveralminutes.Largerenginesmayrequireinexcessof5minutesofinputeffortinordertoprovidethevehiclebatterywithenoughenergytocranktheengine.BecauseyouhavedisconnectedtheFreeChargeinternalbattery,alltheenergyyouaregeneratingisusedtochargethevehiclebatterydirectly.Aftertheenginehasstarted,disconnecttheblacknegativeclampandthentheredpositiveclampfromthebatteryterminals.Finally,removethejumpercablesfromtheFreeCharge,ensuretheinsulatedclampingnutsaresecuredontheterminalpostsandrestorethe“batterydisconnectswitch”totheclosedposition(completelytotheright)withits2boltssecurelyfastened.TheFreeChargecontainsasealedLeadAcidbatterythatshouldnotbestoredinafullydischargedstate.ProlongedstorageofatotallydischargedLeadAcidbatterymaydamageit.FullyrechargetheFreechargebeforestorage.PositiveJumperTerminalNegativeJumperTerminalDisplayBar12VDCOutputCigaretteLighterSocketDCInputSocketBatteryLevelDisplaySwitche2-controlpanelFigure5ENGLISHQ:IsusingtheStepInputtheonlymeanstochargemyFreeCharge?Q:HowlongwillittaketochargemyFreeChargefromthewallsocketwiththeAC/DCchargingQ:CanIchargemy12VDCdevicewhiletheFreeChargeisbeingchargedeitherthroughtheDCinputorviatheCrank?Q:WhatmaterialsareusedintheFreeChargeandaretheyrecyclable?Q.Howlongwillafullychargedbatteryretainitscharge?Q.WillIdamagetheFreeChargeifIcrankthepedaltoofast?Q:CanIover-cranktheunit-doesiteverstopyoufromcranking?Q:WhattypeofrechargeablebatteryisusedintheFreeCharge?Q:Howlongdoesthewarrantylast?Q:CanIleavemyFreeChargechargingfromanACwallchargerallthetimeandunplugitwhenIneedtouseit?Q:ShouldIdischargetheFreeCharge'sinternalbatterybeforerecharging?A:No.TheFreeChargecanalsobechargedfromeitheraDCorACpowersource.A:Itwilltakeapproximately8hourstofullychargetheFreeCharge.A:Yes.A:Thecasingsaremadeofpolypropyleneandglass-fillednylon.Thetransmissionismadeofacombinationofacetyl,glass-fillednylonandaluminum,whiletheinputlevers,pedalandstabilizerarmsconsistofaglass-fillednylon.Allplasticmaterialsusedarethermoplasticsandcanberecycled.TheFreeChargecontainsanon-spillrechargeableLeadAcidbattery,whichneedstoberecycledaccordingtoregulationsstipulatedbyyourlo
calauthority.Pleaseconsultyourusermanual
calauthority.PleaseconsultyourusermanualorcontacttheFreeplayCustomerSupportCenterformoreadvice.A:Thebatterywillself-dischargeat5%permonthwhentheunitisstoredatatemperatureof68F.Theself-dischargerateincreaseswithanincreaseinambienttemperature.A.No,thefasteryoucrankthemoreenergyyoustoreintheinternalbattery.A.No,youcannotover-cranktheinternalmechanism.Itconsistsofsimplegearbox,whichdrivesanalternator,providingpowertotheinternalbattery.A.TheFreeChargeincorporatesanon-spillrechargeable12V7AmphourLeadAcidbattery.A.TheFreeChargehasa2yearwarrantyA:TheFreeChargeshouldnotbeleftonchargeforlongerthan24hours.A:No.TheFreeChargecontainsanon-spillLeadAcidbattery,whichdoesnotrequiretotaldischargebeforerecharging.LeavingaLeadAcidbatteryinafullydischargedstateforanextendedperiodoftimewillcausedamagetothebatteryandlimititslife.ThedisplaybardoesnotilluminatetoshowthattheFreeChargeisreceivingacharge.TheFreeChargewillnotacceptaChargefromaDCsource.TheFreeChargewillnotacceptachargefromtheAC/DCadapter.ThedisplaybardoesnotilluminateafterplugginginandswitchingontheAC/DCadapterTheDCsourcehasinsufficientpowertochargetheFreeChargeorisfaulty.TheFreeChargewillnotacceptachargefromaDCsourcethathasavoltagelowerthan13volts.DisconnecttheFreeChargefromtheDCsource.ChargetheFreeChargebyusingeithertheStepInputortheACchargingadapter.ThevoltageoftheDCsourceistoohighfortheFreeCharge(over25Volts)andhasburntoutthechargeelectroniccircuitry.Replacethecontrolpanelunit.AfaultychargingcableReplacechargingcableIncorrectpolarityCheckpolarityPossibleCauseSolutionPossibleCauseSolutionTheFreeChargecannotoperateorchargeanappliancefromiscigarettelighterDCoutputsocket.Theappliancedoesnotoperate.AfaultyACadapterCheckorReplacetheACadapterTheFreeChargecannotjumpstartaboatorvehicle'sengine.Theengineisnotturningover**CrankingAmpsareameasureofhowmuchpowerabatterycansupplytostartanengineat32ºF.TheInputarmiseitherstuckorhasnoresistance.TheStepInputdoesnotworkTheFreeCharge'sinternalbatteryisdamagedReplacetheinternalbatteryTheFreeCharge'sbatteryisnotsufficientlyRechargetheFreeChargeusinganACorDCsource.AfterchargingconfirmthechargestatusbypressingtheDisplayBatteryLevelbutton.Alternatively,disconnecttheFreeChargesinternalbatterywiththebatterydisconnectswitchandusethestepchargeinputtorechargethereceivingbatterydirectly.Theenginereceivingisinpoorcondition.Replacethereceivingbattery.Theengine'scrankingampsrequirementsexceedstheFreeCharge'sjumpstartcapability**ItisnotpossibletojumpstartthisparticularengineusingFreeCharge.TheFreeCharge'sinternalbatteryisdischarged.RechargetheFreeChargeusing,eitheranACsource,DCsourceorthestepinput.AfterchargingconfirmthechargestatusbypressingtheDisplayBatteryLevelbutton.PossibleCauseSolutionPossibleCauseSolutionPossibleCauseSolutionInternalgearsandmechanismaredamaged.ConsulttheServicemanualorcontacttheFreeplayCustomerServiceCenter.ThedisplaybardoesnotworkThedisplaybardoesnotilluminate.TheFreeChargeistotallydischarged.RechargetheFreeCharge.TheFreeChargeinternalbatteryisdamaged.Replacetheinternalbattery.PossibleCauseSolutionconsiderableresistanceduetothealternatormagnets).Loosenthe4boltsandremovethealternator,drawingits3wiresfromtheconduittothebatterycompartment.Pulltherotorcupoffthebaseplateofthereplacementalternator.Boltthebaseplatetoitsmountingsontheleftinnercasing.Feedthe3wiresthroughtothebatterycompartmentandreconnectattheconnectorblockinthebatterycompartmentTheorderofconnectiondoesnotmatter.Replacetherotorcup.Replacetheothercomponentsbyreversingthedisassemblyprocedure.Removetherightinputleverandrightstabiliserarm.Removetherightsideoutercasingbyremovingits5(Figure8,A).(figure9,C)7.ReplacingtheDriveShaftAssemblyortheDriveBeltandSpringbolts.Removethebatteryandcontrolpanel,asdescribedpreviously.Removethe5boltswhichlocktheinnercasingsandthecirclipandwasherontheinputshaftDisconnectthe3alternatorwiresattheconnectorblock.Pullawaytherightinnercasingfeedingthealternatorwiresthroughtheirconduitandleavingtheinternalpartsassembledintheleftinnercasing.UnhookthespringfromthestabilizerarmpivotshaftandpullthedriveshaftassemblytogetherwiththeattachedbeltandspringfreeRemove2boltstodetachthebelttogetherwiththespringfromthedriveshaftassembly.Reversethisproceduretore-assemblemakingsurethatthebeltistrackedcorrectlyunderthebeltretainingbushandoverthetoothedinputpulleybeforere-hookingthespringendtothestabilizerpivotshaft.Makesurethattheinputleverarmsareindexedcorrectlytothedriveshaftassemblywhenre-assembling.(figure8,E)(figure8,C).(figure8,A)(figure10,A)(Figure10,B).(figure10,C)(figure10,D)(figure10,E)(figure10,(figure7)9.SERVICEMANUALDISASSEMBLINGTHEFREECHARGEWEZAPARTREPLACEMENT3.ReplacingtheBattery5.ReplacingGearComponents6.ReplacingtheAlternatorSequenceofdisassemblyTheFreeChargeissuppliedwithatoolkittoenabledisassembly.-thesearedefinedwhenviewingtheFreeChargefromitspedalend.Theinputleversandstabilizerarmsmustfirstberemovedbeforetheouter,andthentheinnercasingscanbeopened.Thegearboxandalternatorarelocatedundertheouterleftcasing.Thebatteryandboltstoreleasethecontrolpanelassemblyarelocatedundertherightoutercasing.The5boltstosplittheinnercasingsarelocatedintheinnerrightcasing(batterycompartment)andareaccessedbyremovingtherightoutercasing.Thedriveshaftassembly,drivebeltandreturnspringarelocatedwithintheinnercasings.(Figure11)LeftandrightcomponentsDONOT1.ReplacinganInputLeverandPedal2.ReplacingaStabilizerArm4.ReplacingtheControlPanelremovethestabilizerarmpivotshaftfromthemainassemblyifyouarenotintendingtosplitthe2innercasings,astheinternalspringisattachedtothisshaft.Theinputleversandsplineddriveshafthaveanindexingtooth(whichhasaroundedtip)andshouldonlybeassembledintheircorrectindexedorientation.Removetheinputleverbyunscrewing2bolts,onelocatedatthepivotendoftheinputleverandtheotheratthepedalend.Worktheinputleveroffthedriveshaftandthepedalshaft.Thepedalconsistsof2halveswhichcanberemovedonceoneoftheinputlevershasbeenremoved.Theinputleversandsplineddriveshafthaveanindexingtoothandshouldonlybere-assembledintheircorrectindexedorientation.Thepedalhalvesshouldbeassembledwiththediamondpatternfacingupward.Removeastabilizerarmbyremoving2bolts.Workthestabilizerarmoffthestabilizerpivotshaftandthestabilizerlockingshaft.DONOTremovethestabilizerarmpivotshaftfromthemainassemblyifyouarenotintendingtosplitthe2innercasings,astheinternalspringisattachedtothisshaft.Reversethisproceduretore-assemble.Removetherightinputleverandrightstabilizerarmasdescribedabove.Removetherightsideoutercasingbyremovingits5bolts.Thecasingwillcomeawaypartly,asthebatteryisattachedtoit.Thebatteryshouldnowbevisibleandits2terminalsshouldbeaccessible.Disconnectthewiresfromthebatterybyundoingtheboltsandremovethebattery.Toinsertanewbattery,reversetheprocedureabove.Ensurethatthewiresareconnectedtothecorrectterminals.Theredwiretothepositiveterminalandtheblackwiretothenegativeterminal.Removethebatteryasdescribedpreviously.Removetheleadstothebatterydisconnectswitchterminalslocatedintherightoutercasing.Disconnectthe3alternatorwiresattheconnectorblockandreleasethewiresfromtheircleats.Removethe2boltsthatholdthecontrolpanelinplace.Thecontrolpanelunitcannowbepulledfree,feedingthecablesandthe3alternatorwiresthroughtheapertureintherightinnercasing.Thecontrolpanelisreplacedbyreversingthisprocedure.Removetheleftinputleverandleftstabilizerarmasdescribedpreviously.DONOTremovethestabilizerarmpivotshaftfromthemainassemblyifyouarenotintendingtosplitthe2innercasings,astheinternalspringisattachedtothisshaft.Removetheleftoutercasingbyremoving5bolts.Removethegearplatebyremoving3bolts.Thesecondarygearcannowberemovedorreplaced.Removethecirclipfromtheinputshaftoremoveorreplacetheinputgear.Removetherightandleftinputleverandtherightandleftstabilizerarmsasdescribedabove.DONOTremovethestabilizerarmpivotshaftfromthemainassemblyifyouarenotintendingtosplitthe2innercasings,astheinternalspringisattachedtothisshaft.Removetherightoutercasingbyremoving5bolts.Disconnectthebatteryasdescribedabove.Disconnectthe3alternatorwiresattheconnectorblock.Removetheleftoutercasingbyremoving5bolts.Removethegearplatebyremoving3bolts.Removethesecondarygear.Togainaccesstothe4boltsthatfastenthealternatortotheleftinnercasing,pulltherotorcupoffitsbaseplate.Donotlevertherotorcupoff,butpullinastraightlinesoasnottocausedamage.(Therewillbe(Figure8,D)(Figure10,A)(Figure7)(figure8,D)(figure8,A)(figure8,B)(Figure9,A)(Figure8,A)(Figure9,A)(figure9,C)(Figure7)(Figure8,E)(figure9,B)Figure7Figure10Figure9Theelectroniccircuitryisdamaged.ContacttheFreeplayCustomerServiceCenter.118112114116110110Figure11PARTNAMELeftInputLeverLeftStabilizerArmLeftOuterCasingLeftRearFootLeftFrontFootLeftInnerCasingControlPanelGasketRightInnerCasingRightFrontFootRightRearFootRightOuterCasingRightInputLeverBatterySwitchCoverPedalTopPedalShaftPedalBottomRightStabilizerArmPARTNo.114-ILL-GOL011-FBR-GOL115-ILR-GOL120-PT-GOL118-LB-GOL110112114116118PARTNAMEStabilizerLockingShaftStabilizerPivotShaftPositiveClampingNutNegativeClampingNutGearPlateSecondaryGearBearingSecondaryGearInputGearInputShaftClutchBearingToothedPulleyDriveBeltInputShaftWasherDriveShaftAssemblyReturnSpringPARTNo.100-ALT-GOL112-CB-GOL111-TP-GOL125-ISW-GOLPARTNAMESerratedWasherSerratedWasherWasherCountersunkBoltPositiveJumperCableNegativeJumperCableControlPanelUnitBatterySwitchLeadBatterySwitchAC/DCChargingAdapterDCChargingCableSelectableDCOutputAdapter(notsupplied)PARTNo.200-W-S-M10200-W-S-M6200-W-M6300-BAT-GOLFigure8