ASSEMBLING OPERATION SERVICE SKY 100 MANUAL

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Rosemary Cook
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1 ASSEMBLING OPERATION SERVICE

2 2 IMPORTANT NOTICES 03 ASSEMBLING OF THE PARAMOTOR 05 HARNESS AND DISTANCE BARS 07 ASSEMBLING OF THE PROPELLER 10 ASSEMBLY INSPECTION 11 TECHNICAL DATA OF THE ENGINE 12 CARBURETOR FUEL AND OIL 14 IGNITION AND ELECTRIC 15 JOYSTICK 17 PRE-FLIGHT CHECK 18 SPARE PARTS LIST 19 DIAGNOSING AND STARTING A FLOODED ENGINE 20 REGULAR CHECKS AND MAINTENANCE 22 TERMS OF GUARANTEE 23 WARRANTY ZERTIFICATE 24

3 3 IMPORTANT NOTICES * * C O N G R A T U L A T I O N S * * Thank you for choosing an excellent paramotor. Please take the time to read this manual carefully, with this manual we will try to give advice on the maintenance and operation that will help you have a reliable paramotor and to preserve your investment. Furthermore, we invite you to give this manual with the paramotor if you sell it, so it can be useful for the next owner as well. The manufacturer and the resellers are ready to answer your questions and, if necessary, to solve problems, because the safety of yourself and the others is the most important thing for us. When you will receive the motor, it will already have overcome a test of 1 hour in the factory, verifying the operation of all the components and the operation to every speed. All the paramotors are tested before the delivery. We reserve the right to change specifications, components, details of the motor, in relationship to the model in production without incurring in some obligation. The reliability, the performances and the duration of your paramotor will also depend on your understanding of the correct maintenance and operation of the engine. This manual describes the paramotor, its installation, use and control. This PPG is not covered by product liability insurance. Do not start it or fly it unless you are willing to assume all risks inherent in the sport of Powered Paragliding and all responsibility for any property damage, injury or death which may result from the use of this product.

4 4 You must be aware that any engine can fail and breakdown at any moment, this could lead a landing in less than ideal areas with the possibility of injury to the pilot or other people. Any powered paramotor must only fly in permitted areas, and never to fly low above a crowd of people. Inhabited zones, water, and areas that are difficult to land should be avoided, always remember that the engine could stop. Some atmospheric conditions can cause the engine to perform differently than normal. Before beginning every flight, you must test the paramotor on the ground. Start the engine on a flat surface that is free from stones, sand or small parts that could be sucked in by the propeller. Be sure any persons nearby are well clear off the thrust from the propeller and not near the propeller at any time the motor is running. A good safety distance is 50 meters for all directions of projection of the propeller and 20 meters for the others directions. Do not use a paramotor that has not been correctly maintained or not been used for some time, or if you know that is not in good condition. The use of not original spare parts can make the paramotor dangerous and immediately voids the warranty. Changes to the reduction or propellers can reduce safety and reliability of the aircraft. Before every use or test, check the condition of the propeller and the torque of bolts of the propeller. If the propeller is damaged do not use it, this can lead to a breakup of the propeller in rotation or to strong vibrations that will transmit to the motor and may cause damage, or loosen bolts or components. Never use the motor without propeller or without reduction drive.

) 4x middle supports Top position: Middle position: Bottom position:

5 5 ASSEMBLING OF THE PARAMOTOR FRAME The frame consists of: - a.) central module - b.) cage - c.) 2x long supports - d.) 4x middle supports Top position: Middle position: Bottom position: long supports middle supports middle supports Assemble the complete cage and close all velcro straps

6 6 Insert assembled cage first in top position after that insert middle and bottom position. Close bottom velcro straps on both sides. Close netting with carabineer on both sides.

7 7 ASSEMBLING OF THE HARNESS AND THE DISTANCE BARS Harness has to be connected with the special buckles. Conncet harness with both buckles to the frame.

8 8 Fix the distance bars with the special pin. Distance bars are moveable vertically and horizontally. Fix the shoulder strap correctly to the harness.

9 9 ADJUSTING OF THE HARNESS The best way to familiarize yourself with the harness and your personal flying position is to use a simulator. Sit in the harness and adjust the shoulder straps correctly. The weight should be constantly shared on the shoulders. Find your seat position and adjust the straps accordingly to sit relaxed. The shoulder straps are adjusted depending on pilot weight. The flight position is optimal when the propeller shaft line is 5 to a maximum of 10 below the horizontal line. horizontal line propeller shaft line

propeller with the six M6 screw with a torque of 10Nm.

10 10 ASSEMBLING OF THE PROPELLER On the SKY paramotor can be mounted a wood or carbon propeller Mount the propeller with the six M6 screw with a torque of 10Nm. Please use only original propellers otherwise you lose your warranty.

11 11 ASSEMBLY INSPECTION It is very important to fully inspect the assembly of your paramotor to find and remedy any potential problem areas before proceeding. The inspection should contain, at a minimum, the following items: Review each assembly step above Examine all nuts, bolts, and fasteners for security Check the harness for correct mounting, that all straps are secure, that there are no twists on any straps Examine prop cage for correct assembly, that it is strong, the netting is tight and on the correct side Check that nothing can get in the prop. The prop should clear the cage by same distance at all points. Check the fuel tank and fuel delivery system. Check for correct mounting of prop, and correct torque of prop bolts.

12 12 TECHNICAL DATA OF THE ENGINE Engine Type Power Cylinder Capacitiy Carburetor Starter Exhaust Propeller Diameter Weight Engine Tank max. Piloten Weight SKY ENGINES 2 Stroke 1 Cylinder 18 HP / rpm 110 ccm Walbro WG8 Manual Starter Tuned Exhaust Pipe 125 cm 13.9 kg 12 Liter < 90 kg Consumption ca. 3 4 L / hour Flight Time up to 4 hours U/min Thrust up to 55 kg Climbing Rate up to 2 m/sec.

13 13 CARBURETOR FUEL AND OIL IMPORTANT INFORMATION We recommend using super gasoline and full synthetic oil (Castrol TTS) at 2.5%. Mix fresh fuel and oil before each flying session. Store your fuel/oil mixture in an approved, sealed container. Dispose of fuel/oil mixture that is older than 1 month. During running in we recommend using 4.0% oil mixture and use only full power during starting. Mixture table: fuel 95/98 octan LITER 0, full synthetic oil Castrol TTS 1:25 (4%)during running in time ml 20 ml 40 ml 80 ml 120 ml 160 ml 200 ml 400 ml full synthetic oil Castrol TTS 1:40 (2.5%) normal use ml 13 ml 25 ml 50 ml 75 ml 100 ml 125 ml 250 ml The fuel oil mixture should not be older than 1 month!

14 14 IGNITION AND ELECTRIC Spark plug : NGK BR7ES

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16 16 JOYSTICK We supply with this paramotor a special build joystick which is a novum in the paramotor market. Since it s important to know how to stop the engine once it s started, let s cover Stopping the Engine first. To stop the engine, simply depress the STOP button and hold it until the engine comes to a complete stop.

17 17 PRE-FLIGHT CHECK THE FOLLOWING POINTS SHOULD BE CARRIED OUT BEFORE EACH START! 01 VISUAL INSPECTION OF CAGE AND FRAME FOR FRACTURES 02 PROPELLER HUB WITHOUT CLEARANCE? 03 REDUCTION GEAR LEAK-PROOF? 04 EXAMINATION OF EXHAUST AND MOTOR RUBBER ELEMENTS! 05 PETROL FILTER UNPOLLUTED? 06 MOTOR, CARBURETOR AND TANK ARE LEAK-PROOF? 07 SUFFICIENT SUPPLY OF FUEL AND OIL IN FUEL (DON T USE MIXTURE OLDER THAN 1 MONTH)? 08 PILOT SUSPENSION UNDAMAGED? 09 CANOPY UNDAMAGED? 10 GAS LEVER POSITION CHECK THE FREE MOVEMENT! 11 VENTILATED TANK LID ON TANK? 12 PROPELLER CLEAR START PARMOTOR NO PERSONS NEAR BY STARTING THE PARAMOTOR 13 CARRY OUT A TEST AT FULL THROTTLE AFTER WARMING UP! 14 TEST THE SWITCH-OFF FUNCTION! 15 PILOT PROPERLY HOOKED IN? 16 WIND DIRECTION AND WIND FORCE? 17 TAKE OFF AREA CLEAR? 18 TEST FOR LEAKS?

18 18 SPARE PARTS LIST

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23 23 DIAGNOSING AND STARTING A FLOODED ENGINE A flooded engine can be identified by the smell of unburned gasoline coming from the exhaust pipe, or by periodic weak firing and puffs of black smoke during starting attempts. If you have a flooded engine, follow the procedure below: Remove the spark plug and thoroughly dry it. (Note another indication of a flooded engine is a spark plug that is dripping with gas). With the spark plug removed push the starter button for a few seconds while holding the throttle in the full-open position. This will remove excess fuel from the engine. Install the dry spark plug, and start using the normal procedure. WARNING! Ensure you have placed the spark plug cap away from all fuel sources before pulling the starter cord or a fire could occur! WARNING! Do not use a flooded engine procedure whereby you hold the throttle wide-open and then attempt to start the engine. If the engine starts, the prop would rapidly spin to full RPM and damage or injury would most likely occur! ENGINE PROBLEMS DIAGNOSTIC REASON REMEDY The engine doesn t start Out of petrol Add petrol Petrol doesn t reach the carburetor Check the fuel system circuit Old or wrong petrol Empty the tank and the fuel system circuit and replace the petrol Flooded engine Remove the spark plug, start the engine, dry or replace the spark plug. Defective spark plug Replace it Blockened spark plug or wet Clean and dry the spark plug or replace it Earthened switching off cable Check the wiring Spark plug hood Check it

24 24 Carburetor has problems Clean and check it, eventually replace the diaphragm No spark Check the ignition, coil and wiring The engine doesn t idle Dirty carburetor Calibrate the carburetor Out-of-adjustment screws Clean and check it, eventually replace the diaphragm Defective spark plug Replace it The engine doesn t reach the maximum rpm Engine revved up when idling Wrong carburetion The carburetor has problems The reed valve has problems Dirty air filter Dirty exhaust system Out-of-adjustment screws Air through the gaskets Calibrate the carburetor Clean and check it, eventually replace the diaphragm Replace the reeds or the whole reed valve Clean or replace it Clean or replace the deadening material Calibrate the carburetor Replace the gaskets and seals

25 25 REGULAR CHECKS AND MAINTENANCE At every use After the first 10 hours Every 25 hours Every 100 hours or every year Every 100 hours Every 200 hours Every 400 hours Check the bolts and screw tightening Check the silent-block conditions Change the gear oil Check carburetion Replace the spark plug Clean the air filter Change the gear oil Replace the muffler springs Replace the air filter Replace the starter rope Replace the diaphragm and clean it Replace the silent-block Replace the fuel system pipes Replace the reed valves Check the piston and piston rings Replace the pin and rollers cage Decarbonise and clean the decompression hole Replace the silencer deadening material Disassemble the reduction gear and check the clutch and bell wear Replace the piston and piston rings Replace the reed valve Replace all the bearings and seals Replace the crankshaft

26 26 TERMS OF GUARANTEE G-Force Paramotors will warrant their product to be free from defects in materials and workmanship for a period of twelve (12) months from the date of purchase. This warranty applies to the product in normal usage situations only. The dealer, from whom you purchased the product, or G-Force Paramotors, will repair the product free-of-charge. To obtain warranty service, please contact your dealer or G-Force Paramotors, and then either bring the product in or have it shipped. Shipping charges are the responsibility of the purchaser. This warranty does not apply even during the warranty period, and the purchaser shall pay repair or replacement charges if: The cause of malfunction is due to misuse, neglect, negligence, etc. This includes seize of the engine due by an improper carburetor adjustment or improper fuel/oil mix The malfunction is caused by incorrect pilot operation, i.e. a crash, whack, dork, bang, splat, ding, prong, bend, tweak, trip, fall, bounce, or any other piloting eventuality. The malfunction is caused by lack of normal maintenance, or modification, i.e. loose parts falling off and breaking the propeller. The malfunction is caused by an Act of God, including but not limited to fire, earthquake, hurricane, flood, or other natural calamity. Purchaser has no warranty-certificate

27 27 WARRANTY ZERTIFICATE Name of buyer: Model: Date of purchase: Address: This warranty certificate is valid 1 year after purchase. Please read this manual carefully. For further question please ask your dealer or direct G-Force Paramotors. DEALER G-Force Paramotors G-Force Paramotors Paurach 55, A-8332 Edelsbach Tel.: +43 (0) sales@gforce-paramotor.at

IMPORTANT NOTICES 03 ASSEMBLING OF THE PARAMOTOR 05 HARNESS AND DISTANCE BARS 07 ASSEMBLING OF THE PROPELLER 10 ASSEMBLY INSPECTION 11

2 IMPORTANT NOTICES 03 ASSEMBLING OF THE PARAMOTOR 05 HARNESS AND DISTANCE BARS 07 ASSEMBLING OF THE PROPELLER 10 ASSEMBLY INSPECTION 11 TECHNICAL DATA OF THE ENGINE 12 CARBURETOR FUEL AND OIL 14 IGNITION