Fresh Breeze Monster Operation instructions

ASSEMBLY OPERATION MAINTENANCE
MONSTER
MANUAL

2
MONSTER
TABLE OF CONTENTS
MANUAL
ASSEMBLY THE MOTOR
TECHNICAL DATES
FUEL AND OIL
CARBURETTOR
AND INTAKESILENCER
ENGINE
PULLSTARTER
GEARBOX
PROPELLER
ELECTRIC Standart
POWER IGNITION SYSTEM
E-STARTER
EXHAUST
THROTTLE RESPECT
THROTTLE AIRBOSS
HARNESS
WINGMAN CB
PRE-FLIGHT CHECK
CHECKLIST
SAFETY ADVISE
WINGMAN CBi
3
6
7
8
11
14
15-16-17-18
19-20
21
22
23
25
26
28-29-30
31-32-33
36
37-38
39
34-35
24
ELECTRIC Digital
27
40
WATER COOLING SYSTEM, WATERING UP AND VENTILATION

3
MONSTER
MANUAL
ASSEMBLY OF THE MOTOR
Open the pagage with care. Do not use long knife. Parts inside
the carton could be damaged.
Check the parts and proof for completeness.
Bring the four cageparts together and fix with velcostraps.
Put the motor in front of the completed cage.

4
MONSTER
MANUAL
ASSEMBLY OF THE MOTOR
Take the motor and press the cage against the black clipse.
Inside the black clips is a bolt which belong in the hole of the
cage.
The cage should fixed against the frame with the velcro.
After assembling all velcro´s should tighten again.

5
MONSTER
MANUAL
ASSEMBLY OF THE MOTOR
In case that you have a shellform-backstuffing fix it on the left
and rigth side.
Most maintainance you can make by yourself with the
original tools.
Contents:
• Hexagon 4/5/6 mm
• Wrench 8/10/24
• Wrench for sparking-plug and screw driver
• Beltdressing
The Shellform-backstuffing prevent that the motor will turn to
cause from torc.
The backstuffing will fixed also with velcro. The upper and
lower ends from backstuffing turn arround the upper and
lower rope.

6
MONSTER
MANUAL
TECHNICAL DATES
Motor Hirth 310ccm
Type 2-Stroke, 1 Cylinder
Power 20,6 kW
Cooling Air
Starter Manual / E-Starter
Carburettor Bing 84, 32mm
Exhaust Resonator
Propeller 4-Blade
Diameter 122 cm / 48“
Weight 26 Kg / 57 lb
Tank capacity 10 Liter
Max. take off weight 440 lb (200 kg)
NEXT DATES ARE DEPEND FROM:
WEATHER, ALTITUDE, PILOTS WEIGHT, GLIDER AND SIZE AS WELL AS ATMOSPHERIC HUMITY:
Consumtion arround 3l/h
Max. airbone time up to 3 h
RPM 0 - 5800 u/min
Staticthrust up to 176 lb (80 kg)
Climbrate up to 3m/sec.
RESULT FROM THROTTLELEVER-POSITION, FLIGHT-LEVEL, GLIDER AND SIZE AND PILOTSWEIGHT
FOR THE CONSUMTION:
Little throttle less consumtion
Big throttle high consumtion
Low flightlevel less consumtion
High flightlevel high consumtion
Small glider high consumtion high speed
Big glider less consumtion slow speed
Leightweight pilot less consumtion slow speed
Heavyweight pilot high consumtion high speed
Sparc pflug resisted BR8HS

7
MONSTER
MANUAL
FUEL AND OIL
The motor will delivered with two lid´s. The first is for flight
with a small hole. The second lid is closed for transport. If you
try to fly with the closed one the motor will have a ”in flight
shut down” after a while. It´s will establish inside the tank a
vacuum. The carburettor get fuel from tank through gravity.
The closed lid create inside the fueltank negative or positive
pressure. This can deform the fueltank. Before you start the
engine check the fueltank.
The fuel comes from tank through this filter. Check before
flight.
IMPORTANT INFORMATION
The fuel should have 98 octane or 100 LL. The best oil is
Castrol 2T. Mix 2 % in addition to the fuel.
For the first 10 h mix 4 % in addition to the fuel. In this time
use full throttle very careful.
This picture demonstrate a closed petroltap.
Fasten the velcro around the fuell tank permanent.
Check the gap between fuell tank and exhaust before
each flight.

8
MONSTER
MANUAL
CARBURETTOR AND INTAKESILENCER
The intake silencer ist attached to the cage with 2 bungee
cords (see picture).
In some flyingareas it´s necessary to use such a airfilter. Use
only original parts. Otherwise you risk to loose power.
HOW I CHANGE THE NEEDLE?
Open the lid with the two screws and pull out all parts which
are hanging on the cable.

9
MONSTER
MANUAL
CARBURETTOR AND INTAKESILENCER
Press the spring togehter and loose the cable from slider.
Now you hold slider and lid apart in your hand. The needle is
now loose inside the slider. At our factory we installed the 6L1
in the second position from top.
Here you see succsession from:
Lid/spring/giude piece/needle with ring/slider
WHY DO I HAVE TO ADJUST THE MAIN JET?
Prior to each engine delivery there is a careful and excessive
test run at Fresh Breeze. Usually a 165 main jet is chosen. But
due to different density heights (height of take-off area, tem-
perature, humidity and air pressure) the main jet may have to
be adjustet.
Especially if the take-off area is very high the motor may not
reach its final rpm (about 5600 1/min). Then we recommend a
160 main jet.
HOW TO CHANGE THE MAINJET?
Press the bow back. With the 8 mm wrench screw out the
jet.
ATTENTION:
Do not loose the small red filter.

10
MONSTER
MANUAL
CARBURETTOR AND INTAKESILENCER
Overfloating Carburettor. Fuel comes out of the two small
tubes. The two swimmer regulate the niveau inside the carb.
To reduce the quantity in the carb bend the little tongue ca-
reful.
If you hold the carb up side down,the swimmerforc is not par-
allel to the carburettorcase. If the carb overfloat while using
the motor the forc should look a little bit more upward.
Before you start the cold motor press down the choke. Start
the motor and after a few seconds release the choke.
The big screw regulate the idlerunning.
Turning right-high rpm. Turning left lower rpm.
The idlespeed should round about 2600 1/min.
The smaller screw is responsible for fuelmixture in idle.
Turning right-rich.Turning left-lean.

11
MONSTER
MANUAL
ENGINE
This picture demonstrate the nacked motor with gearboxhol-
der.
In flight the motor will become very hot. The most stressed
airea are the piston and the rings.Remove the exhaust and
have a look to appearenced piston with it´s rings. Test it with
screwdriver.The rings should be loose inside the slot.
HOW TO REPLACE THE PISTON?
At first remove the four nuts from the feed of the cylinder.
Now draw off the cylinder from piston.

12
MONSTER
MANUAL
ENGINE
Before you pull out the gudgeon pin remove the safety rings
on both sides. Than press out the gudgeon pin.
The pistonring can removed by hand.
With a help from a tweezer the safety ring can settled.
To the piston belongs two different rings. The upper ring is
marked with a “O”. This is faced to the top.

13
MONSTER
MANUAL
ENGINE
HOW TO CLEAN THE DECOMPRESSIONHOLE?
After many hour in service time the decompressionhole will
closed with carbon. If you use bad oil it will close earlier. For
cleaning remove the head with the 8 screw (6 mm x 35 mm 14
NM torc).
To reopening the hole use a 3,5mm drill. Bore from top and
from inside the cylinderwall with an angle from 45°.
To seal the head use our spezial high temperature liguidse-
aling.

14
MONSTER
MANUAL
PULLSTARTER
REPLACMENT OF THE STARTERROPE:
Unsrew the starter-lid, take off the façade plus 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 be pulled out of the disc.
To give the starter-rope advanced tension one,place the rol-
led up into the slot and rotate three times.

15
MONSTER
MANUAL
GEARBOX
The power-transmission of the gears happens via a Poly V
Belt (730 8 PK). The transmission ratio equals 1:2,64. The num-
ber of the revolution at full load equals 2200 rpm. The lifespan
of the belt is aprox. 50-100 hrs. Too little tension shorthens the
belt lifspan drastically.
During maintenance check the belt before each flight. The
belt should not be able to be turn over 45° degrees. After the
first flight it is essential to pay special attention to the belt.
HOW TO TIGHTEN THE BELT:
1. Loosen the central nut (width A/F 24 mm) a little bit
2. Screw the lock nut down and pull thereby the hub upwards.
The belt gets tight. Please make sure that the set screw
M8x80 (width A/F 5 mm) remains totally screwed in, locking
thereby the axle against turning. This set screw must be
secured with medium Loctite (blue).
3. Finally don‘t forget to fasten the central nut again (36 Nm)!

MONSTER
How do I change the belt?
1. If an electronic-starter is fitted at the engine,
the pinion must be dismantled.
2. Central-nut M16x1, 5 (key distance 24 mm)
unscrew a little.
3. Unscrew the 6 mm nut
4. Undoing thread pin with inside hexagon key.
5. As far as, the propeller-hub can be lowered
through releasing the stop nut, now the belt
can be taken of the pulleys.
The new belt can be established now for
tightening the screws we proceed in a
16
MONSTER
MANUAL
GEARBOX
reversed order.

17
MONSTER
MANUAL
GEARBOX
HOW TO REPLACE THE BELT?
1. Loosen the central nut (width A/F 24 mm) a little bit
2. Unscrew the lock nut (upwards). Thereby the hub moves
downwards. The belt gets loose.
3. If the hub remains in the upper position and doesn‘t move:
Unscrew the M8x80 set screw a little bit, this makes it
easier for the hub to move down. Important: Pull this set
screw tight afterwards using medium Loctite (blue). It se
cures the main axle against turning.
4. If the motor is equipped with an electric starter:
Screw a piston lock into the spark plug hole. Loosen the
central screw of the pinion. Loosen the 2 m6x50 screws.
Take the pinion off.
5. Replace the belt. Assemble the pinion again. Remove the
piston block and screw the spark plug into the cylinder
head. Secure the central pininon nut with medium Loctite
(blue).
6. Pull the belt tight as described before.
If the belt makes squeaking noises in spite of the proper ten-
sion, then spray twice onto the lower pulley. If the belt is slip-
ping in spite of proper tension, then it needs to be replaced.

18
Gear
Tighten/change the belt from model year january 2009
To loosen the clamp from the
the bolt with allen key 6mm
exenter propellerhup unscrew
To tighten the belt use the
clockwise.
allen key 10 mm and turn
the whole propeller hub
MANUAL
MONSTER

19
MONSTER
MANUAL
PROPELLER
The propeller consist of the two parts which, put together,
measure up to 122 cm in lengh. The weight is ca 900 gram. The
propeller is made of gfk or cfk, which allow 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 torc.
HOW TO BALANCED OUT THE PROPELLER?
The propeller has to be placed vertically onto the balancing-
out equip-ment. If turns to one side, then drill a 3,5 mm hole
into the lighter half of the propeller.
Then fill only as much resign into this hole until the propeller
doeas not want to turn to one side only.

MONSTER
MANUAL
PROPELLER
Likewise proceed as above in the horizontal position.
ATTENTION:
AN IMBALLANCED PROPELLER CREATED UNNESSECARY
VIBRATION IN THE ENGINE AND CAN DESTROY MANY OF
IT´S COMPONENTS.
REQUIRED MATERIALS FOR REPAIRS AND BALANCING-OUT!
The propeller balancing-out-resing with hardener,syringe and
a stored shaft for a free turning of the propellerblades
WHAT DO I REQUIRE FOR REPAIRING THE PROPELLER.
Fiberglas-spatula and abrasive paper.
Here now an example when a propellerblade must not be re-
paired again. If the damage is to large, then repair are dan-
gerous. The repairs sopt has not enough grip and may fall off
whern the propeller turns at high revolution. Danger of acci-
dent is thus programmed.