Fresh Breeze

HANDBOOK

RESPECT
AIRBOSS

Version of Juli 2001.

ASSEMBLY

OPERATION

SERVICING

http://flieg.com/fresh.breeze/
 


TABLE OF CONTENTS

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TABLE OF CONTENTS
02
ASSEMBLY THE PARAMOTOR - RESPECT
ASSEMBLY THE PARAMOTOR - AIRBOSS
OPERATIONAL SPECIFICATIONS
FUEL AND OIL SYSTEM
CARBURETTOR AND INTAKE SILENCER
ENGINE
REDUCTION DRIVE SYSTEM
PROPELLER
ELECTRIC
POWER IGNITION SYSTEM
E-STARTER
EXHAUST AND SILENCER
THROTTLE - RESPECT
THROTTLE - AIRBOSS
HARNESS AND SUSPENSION
PREFLIGHT CHECK
 
 

 

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ASSEMBLY THE PARAMOTOR - RESPECT

1. After reciept of the package ensure to open box with care. Do not use long knives, as the goods contained can easily be damaged.





2. To optain an overallview, place all contents of the package carefully out in front of you and compare with the list of all the parts.
3. To assemble the engine, first place the two bottom parts of the cage into the frame.

 

 

4. After completion of the previous step, place the two upper cageparts likewise into the frame, ensuring that the cageparts are placed into the right position to the white clips (Hole into plug).
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5. To keep the cage safely in the right position, all 11 velcrotapes have to be strapped onto the propper places.





6. The backpad is also held by velcrotape. It needs to wrapped around the top and bottom part of the framework.
7. It also must be wrapped around the two side parts of the framework.

 

 

8. This special backpad prohibits a wrenching of the engine on the back of the pilot, which the engine produces because of its great torque.


PROVIDED TOOLS
The picture to the right exhibits all the tools for every important job on the engine.

CONTENT:
Hexkey 4 /5 / 6 mm
Wrench 8 / 10 mm
Wrench 24 mm
Sparkpulgwrench with Screwdriver
Beltdressing

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ASSEMBLY THE PARAMOTOR - AIRBOSS

1. The back part with the engine should be placed onto a suitable subsoil.





2. Then the cage is interconnected and by means of the velcrotapes the cage parts are held together savely. One should begin with the lower cage parts.

3. The upper half stays opened to a little in order to put the cage more easily around the engine.

 

 

4. Now the cage is pressed into the white clips and by means of the velcrotapes the parts are fixed. After the assembling it should be checked, that all velcrotapes are proper shut.

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OPERATIONAL SPECIFICATIONS

TECHNICAL SPECIFICATIONS FALCON 210
Engine Solo 210 ccm
Type 2 stroke,
1 cylinder
Power 12 kw
Cooling air
Starter manual / e-start
Carburetor Bing 84, 32mm
Exhaust resonator
Propeller 2-blade
Diameter 44"
Weight 27 kg
Fuel capacity 10 Liter
Max. startweight 140 kg

IMPORTANT INFORMATION:
THE FOLLOWING DATA ARE DEPENDING ON WEATHER, CLIMATE, GEOGRAPHICAL VANTAGE POINT, WEIGHT OF THE PILOT, PARGLIDERTYPE AND ITS SIZE AS WELL AS THE HIGHT OF FLIGHT.

Mileage ca. 3L / hour
Flight Duration up to 3 hours
RPM 0 - 6000
Thrust up to 60 kp
Climbrate up to 2m / sec


EFFECTS OF GASLEVERPOSITION, HIGHT OF FLIGHT, CHUTETYPE AND ITS SIZE AND THE WEIGHT OF THE PILOT ON THE ENGINE EXHAUST.

Throttle little power low consumption  
Throttle high power low consumption  
Low flight low consumption  
High flight high consumption  
Small chute high consumption higher speed
Large chute low consumption slower speed
Light weight pilot low consumption slower speed
Heavy weight pilot high consumption higher speed

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FUEL AND OIL SYSTEM

Within the package is a tank with two lids. One, with the airinghole, is for the flight. The other one, which is closed for the transport. If one flighs with the closed lidded tank than the engine will stop working after a while, due to buildup of low pressure in the tank.


Thus no patrol can reach the carburettor.

The petrol reaches the fuelfilter via the bent vent. Followed by the fueltab with two positions ( open and close ). Afterwards the fuel will be conducted into the carburettor.

IMPORTANT INFORMATION:

The fuel be used is LEADFREE 92 OKTAN, the oil CASTROL 2T, fully synthesized 2-stroke oil. When filling the tank use an oil / patrol mixture of 1:50.

During the running-in phase of the engine should the following be noted. The engine contains within the first thirty hours of flight fuel mixture of 1:25. In this periode should full speed only be used at the start. Should the engine sputter at the cruising speed-level, then bring the carburettorneedle 6L1 one position down ( see chapter 4 ).

The fuelfilter can clean a fiar amount of polluted petrol. It should be exchanged according to the grade of accumulated pollution ( sigh test ). The tube between the fueltab and the carburettor should be exchanged after every 30 hours.
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CABURETTOR AND INTAKE SILENCER

The intake silencer should be often check by sight. Is the net support strongly torn, then the cross-section could become narrow and the engine may loose power. To remedy change the gray tube. The carburettor and gets the fuel from the tank through gravity.





Why to exchange the carburettorneedle? While or after the running-in phase, due to too fatty fuel mixture, the engine could begin to rattle at the cruising speed, wich feels like ignition interroptions. The remedy is a positionchange of the needle.
How to exchange the carburettorneedle? First open the carburettor lid. Then pull out the lid including the slide. Now the spring can be pressed together and bridgepull can be pulled out of the anchoring of the slide. It is now possible to take the needle out of the slide.





Should the needle be brought into a final position after the running-in of the engine, then the clasp has to be brought to the top most position ( from the top it has been in ). The installation has to carried out with the reverse steps.
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CABURETTOR AND INTAKE SILENCER (2)

Why exchange the mainjet? Due to a high altitudenal starting place or meteorological conditions it is possible that the engine will not come up to the full number of revolutions in spite of full-speed. Low airpressure can induce the fuel mixture to become rich. A remedy can be a small mainjet.



Attention! Should again a start be conductet on a much lower ground then the one before, the larger vent should be installed first. Otherwise an overheating could be the result. Would one like to fligh at high altitudes, it would be advisable to choose 150 or 145 mainvent insted of a 155 one.
How to exchange the mainjet? Press the securing clip of the floaterchamber to the side. Unscrew the mainjet with the 8mm Wrench. Attention: the small sieve around around the jet should not be forgotten.




The Choke. If the engine is started in a cold condition, then it is advisable to push the choke down. As a rule it only takes a few seconds running with the choke. The choke can then be pushed up again.

What to do, if the carburettor leeks fuel out of the two overflowtubes? The floaters regulate the fuelniveau in the carburettor. Should the carburettor overflows, then the float-tongue can be bent. The niveau in the floatchamber should now be lower.


SATIONARY FUEL PROPELLER AND NEUTRALGEAR FUELMIXTURE SCREW:

The large propellor controls the stationary gas. Turned right the stationary fuel revolutions highten. Turned to the left they lower. The stationary fuel revolutions should be ca. 2600 rpm.

The small screw is the fuelmixture screw. Is the engine running hard then one can turn the small screw. Turned inwards and the engine will become richer, turned outwards an d the engine become leaner so.

 
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ENGINE

This picture exhibits the engine without its extended components.





The engine does develop strong heat. Therefore the piston and the cylinderblock are under considerable stress. The piston with its two piston-rings will be partially visible once the resonator has been detached from the vent. Check these rings with a small screwdriver. They should be able to move within the grooves of the piston.
How to replace the piston? First the four nuts have to be taken off the bolts on the bottom of the cylinder. The cylinder can be pulled off the piston now, wich allows for the detachment of the piston-rings.





While repositioning the rings, it should be done exactly according to the installation position. The piston-security-rings can now be removed with pliers and the piston-bolt via turning it in any direction, can be pushed out. The piston is thus separated from the connecting-rod.
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ENGINE
(2)

The re-fitting has to be done in reverse order. The piston has an arrow at the bottom, wich points towards the vent. When the cylinder is being pushed over the piston, it has to be pressed together via a clamp.





How to clean the decompression-hole? Should the engine start to much force expenditure and runs heavy as well, then the decompression-hole has to be cleaned. First remove the cylinderhead off the cylinder, then unscrew the maggot-screw.
There is a pear shaped depression in the running groove. This should be scraped clean with an appropriate tool. Afterwards drill the canal free with an 4mm drill.





To re-fit the cylinder, ensure that the sealing liquid is applied to both surfaces of the seal (head and cylinder). The head can be tightened again after a 5 minute drying period via the 6 (M6 x 40) screws (14 NM).
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ENGINE
(3)

This picture exhibits one of the two sealing-rings of the crankshaft, which can wear out some time of usage. This can be noticed when the engine running poorly. For example, the engine is only running correctly when the choke is pressed. The sealing-rings can be leverd out from outside.





Replacement of the starter-rope: Unscrew the starter-lid, take off the facade plus the finger. The white disc should now be removed by pressing it against the tension-force. The white disc can now be taken out of the lid.

The starter-rope can now be pulled out of the disc.





To give the starter-rope some advanced tension one, place the rolled up rope into the slot and rotate three times.
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REDUCTION DRIVE SYSTEM

The power-transmission of the gears happens via a Poly V Belt (730 6 PK). The transmission ratio equals 1:2,57. The number of revolution at full load equals 2350 rpm. The lifespan of the belt is aproximately 100-150 hrs. Too little tension shortens the belts lifespan drastically.





During maintenance check the belt tension before each flight. The belt should be able to be turn over 45 degrees. Especialy after the first flight it is essential to pay special attention to the belt.
How to tighten the belt:
1. Pull off the security pin.
2. Loosen the central screw (24mm).





3. Lift the rotor-hub with the tension-screw (5mm) in order for the belt to either tighten or subside, thus the belt can be loosened. Turn right - belt tightens. Turn left - belt loosens.
4. Tighten central screw (36 NM) again.
5. Secure central screw via the security pin.
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REDUCTION DRIVE SYSTEM
(2)

How to replace the belt?
1. Remove security pin.
2. Loosen central-screw.
3. Loosen belt with tension-screw.
4. Screw in the piston-block into the spark-plug-hole.





5. Unscrew starter-pinion
6. Take off belt.
7. Place the new belt onto the pulley.
The re-fitting happens in the reverse order.





If the belt makes squeaking noises in spite of the proper tension, then spray twice onto the lower belt disc. If the belt is slipping in spite of proper tension, then it needs to be replaced.
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PROPELLER

The propeller consists of two parts wich, put together, measures up to 122 cm in length. The weight is ca. 900 gram. The propeller is made of GFK, wich allows for small repairs. But it is essential that after repair is accomplish, the propeller gets balanced out again.





The propeller is fixed onto the hub with 6 screws. Tighten the propeller use 12 Nm.
How to balanced out the propeller? The propeller has to be placed vertically onto the balancing-out equipment. If it turns to one side, then drill a 3,5mm hole into the lighter half of the propeller. Then fill only as much resin into this hole until the propeller does not want to turn to one side only.





Likewise proceed as above in the horizontal position. Attention: An imbalanced propeller creates unnessecary vibrations in the engine and can destroy many of it's components.

Required materials for balancing-out
the propeller Balancing-outresin with hardener, syringe and a stored shaft for a free turning of the propellerblades

What do I require for repairing the propeller?
Fiberglas-spatula, spatula and and abrasive paper.

Here now an example when a propellerblade must not be repaired again. If the damage is too large, then repairs are dangerous. The repaired spot has not enough grip and may fall off when the propeller turns at hight revolution. Danger of accident is thus programmed.



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ELECTRIC

ELECTRIC CIRCUT PLAN
1. Accu   6. High voltage coil
2. Controller   7. Sparkplug
3. First coil   8. Starterswitch
4. Altinator coil   9. Engine killswitch
5. E-motor 10. Ground
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POWER IGNITION SYSTEM

This engine is equiped with a powerful and service free ignition system. It consists of the components: stator, loading-coil of the ignition, generator coil for the supply of electricity and rotor. To be able to work on the coils, the following should be taken care off:





Remove the complete ignition-box including the lid of the starter. Now the rotor with the starter-pot is visible which is held into place by it's central screw.
Once the central screw has been removed, the rotor can then be pulled off via a puller. Because the rotor has to be in a specific position to the crankshaft, the rotors position with a suspensiondisc on the crankshaft is preordained.





To fine-tune the ignition timingpoint one has to loosen the two security screws of the stator. Turn the stator to the left maximally to the furthest point, now turn ca. 1mm to the right again. Retighten the security screws. The ignition timingpoint has now its correct adjustment. When reassembling take special care of the correct distance of the contact-surfaces to the rotor-magnets. Proof via contact-test that the distance of 0,25mm is observed and if nessecary readjust.
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ELECTRIC STARTER

If the engine is equiped with an E-starter, the power can be turned on just by pressing the botton on the throttle. The Accu is fixed on the side of the frame and sits in a holster. The Quick Out System of the Accu enables a quick exchange. Put the Accu with gentle force into the holster. The contacs for the plugs and its innards can be viewed with a quick glance. The Accu-pack consists 14 x 1,2 Volt NiCad Cells with max. 1700 mAh.





The cogwheelplay of the E-sarter should be checked after dismanteling the E-motor and needs retuning if nessecary. In order to accomplish this the three M4 screws and the security clamp needs to be loosened. The E-motor can now be adjusted. The individual teeth of the cog should engage properly. Too little cogwheelplay prohibits the light / smooth running of the cogs at the start. Is the cogwheelplay too large, then the teeth of the pinion. The cogwheelplay could change again after tightening, then a re-check is essential.
On the Accu cover there is a switch with 0 and 1 positioning. Set on 0 the engine can't be left running on the E-starter. Set on 1 the E-starter is functioning and ready to go. The Accu will only be charged while running and with the switch turned on at the position 1. The small photo shows the controller at his place of installation.





Via this plug a voltage of 12 Volt can be transmitted. The dynamo has a limit of max. 24 VA.
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EXHAUST AND SILENCER

The engine is equiped with a resonance exhaust which allows for an increase of performance and a decrease of excess noise. The white wrap-around tape is made of fiberglass and gummed up with silicon.





The complete exhaust is suspended flexibly as to prevent vibrational eruptions.
To keep the exhaust flexibly mobile we chose different types of fixtures. One is a rubber connection on the gear-plate and two a stress-bearing spring-gasket at the entry and the exit.





After 50-100 hrs the sealing-rings and their fastening screws needs to be checked.
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THROTTLE - RESPECT

The throttle is taken according to the building kind into the right or left hand. The strap has a variable size change. Before start the strap should be attracted firmly.





The Throttle of the Respect has in each case a switch at the tube end. The one is for the starting the engine ...
... the other one for killing the engine.





The throttle has also a travelling locking. After reaching the desired hight of flight, the throttle can be fixed via the clasp-lever. Since long halt of the throttle is hard in the hand, the throttle can be placed in position onto the legs. The hands are now free for other things.
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THROTTLE - AIRBOSS

The throttle of the Airboss has also a button for killing the engine and where appropriate about one for starting the engine, if an electric starter is available.





First the throttle is taken into the hand ...
... after that the steering line and at last the A-leash are grasped.





This picture clarifies the handling of the leashes and the throttle during the start.
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HARNESS AND SUSPENSION

This Harness is specially constructed for motoring enterprises. Throughout the usage of the machine, ensure that no lose ends are able to get into the propellerblades. The suspension for the pilot can be permanently in the snap links.





The Harness is secured via 3 springlocks; two legs spring and one breast spring lock. It has two adjustment possibilities. One there are the buckles wich are fastened onto the front of the seat. At the start theseshould be pulled on lightly, as to make the climbing into the harness easier at the lift-off. Before landing it is advisable to lower the seat fully, to enable a maximal favourable touch-down position. The leg loop does not need to be pulled too tightly.
All other adjustment options are regulated while flying. Are the straps pulled right, then one sits up straight, are they loose a slight back prone position can be adopted.





The harness has also two pockets, wich are easily reached at flight.
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HARNESS AND SUSPENSION
(2)

Now one kneels in fornt of the engine and pulls the carrying straps over the shoulders.

 

Now one gets up with the whole engine and goes to the chute. The chute will then be hang into the springlocks for the pilot suspension.

Thereafter the pilot suspension has to be hang into the dropping device of the engine. Usually the hind most hole is used for this. The dropping device should be activated at pending danger, for example at a water landing, fire at high altitude or a tree touchdown. The activation occurs when the two strings of the dropping device are pulled outwards. Because the engine is now not hanging over the suspension of the chute anymore, the pilot will be in a brought into a strong reclining position. Thus the engine can now slide easily over the shoulders. The landing proceeds from now on without the engine.


After all has been done, the throttle and the break-loop had to be taken into the hand. The engine will now be started and the starting run can begin.

 
RESCUE SUSPENSION

The picture shows an example of how to fasten the rescuedevice using the v-string. The rescuedevice should be connect with the pilot suspension using the v-string. So it's an optimal landing position in case of a possible release. The rescuedevice should not be hung in the harness using the spring hooks, because of supine in rescue release.

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PREFLIGHT CHECK

FOLLOWING POINTS SHOULD BE ENSURED BEFORE EVERY TAKE-OFF!
  01.   CLOSE EXAMINATION OF THE CAGE AND ITS FRAME FOR POSSIBLE DEMAGE !  
  02.   THE PROPELLER-HUB IS TIGHT ?  
  03.   CORRECT BELT - TENSION ?  
  04.   CLEAN FUELFILTER ?  
  05.   ENGINE, CARBURETTOR AND TANK ARE CLEAN AND TIGHT ?  
  06.   SUFFICENT FUEL ?  
  07.   PILOTSUSPENSION IS UNDEMAGED ?  
  08.   CHUTE IS UNDEMAGED ?  
  09.   POSITIONING OF THE THROTTLE ?  
  10.   TRAVELLING LOCK LOOSEND ?  
  11.   FUEL TAP OPEN ?  
  12.   VENTILATED TANK LID IS ON THE TANK ?  
  13.   PROPELLER FREE ? - START ENGINE !  
  14.   EXECUTE A FULL POWER TEST !  
  15.   TEST THE FUNCTION OF THE CIRCUT BREAKER !  
  16.   PILOT CORRECTLY SUSPENDED ?  
  17.   WHERE IS THE DIRECTION OF THE WIND AND HOW HIGH IS THE FORCE ?  
  18.   THE TAKE-OFF-RUN IS FREE ?  
  TAKE-OFF  









 

IMPRESSUM

Publisher/Content: Fresh Breeze Bissendorf, Deutschland

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last modification: Thursday, September 26th 2002 08:47:10 pm GMT
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