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CLIMAX C2 - Airborne Australia

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1. V G PULLEY og PULLEY BEARINGS NOTE FAIRED CORNER UNITS HAVE AIRBORNE ON CASTING MATERIAL LIST ITEM 32 27 LIMAX STREAMLINE OPTION ASSEMBLY DETAIL B 1 THE WIRES ARE FITTED INTO THE FAIRED KNUCKLES FIRST WITH THE LOCKING SHAFT 2 WASHERS amp 2 SCREWS HOLDING THEM IN PLACE NOTE USE LOCTITE 262 2 THERE IS A LEFT amp RIGHT HAND SIDE KNUCKLE AND WHEN 3 THEN THE V G ROPE MUST BE INSERT THROUGH THE RIGHT DOWNTUBE 4 THE KNUCKLES CAN BE FITTED TO THEIR DOWNTUBES NOTE GUIDE THE V G ROPE THROUGH THE V G PULLEY OPENING 5 FIT THE A FRAME CORNER KNUCKLES amp SIDE WIRES TO THE FAIRED KNUCKLES 6 THE SOCKET SCREW HOLDS THESE COMPONENTS IN PLACE CLIMAX ONLY REMEMBER TO INSERT THE V G ROLLER IN TO THE PULLEY NOTE USE LOCTITE 262 R m 28 22 24 CLEAT REAR 5 PTY ALL DIMENSIONS IN MILLIMETRES AirB WindSports LTD REV AMENDMENTS DATE UNLESS STATED OTHERWISE 1 CLIMAX ADDED 15 08 02 Drawn by Scale Date HG A FRAME FAIRED CORNER A4 7237 UNIT
2. Issue Date 24 08 04 Rev 4 Page 59 CLIMAX C2 Dive Strut Assembly Sprog Assembly Climax Dwg No A4 4978 23 06 2003 Id Part Details CL13IN CL13OUT CL14IN CL14OUT 1 104295 SPROG TUBE OUTBOARD CLIMAX 13 1 000 104296 SPROG TUBE INBOARD CLIMAX 13 1 000 104297 SPROG TUBE OUTBOARD CLIMAX 14 1 000 104298 SPROG TUBE INBOARD CLIMAX 14 1 000 2 104260 SPROG WIRE INNER CL14 1 000 104261 SPROG WIRE OUTER CL14 1 000 104262 SPROG WIRE INNER CL13 1 000 104263 SPROG WIRE OUTER CL13 1 000 104416 HEATSHRINK CLEAR 25 0 175 0 125 0 160 0 180 4 100561 EDGE MOULDING 0 070 0 050 0 070 0 050 5 100950 LOCKING RING 12MM 114 1 000 1 000 1 000 1 000 6 104209 CLEVIS PIN 3 16 X 1 1 32 1 000 1 000 104210 CLEVIS PIN 3 16 X 25 32 1 000 1 000 Issue Date 24 08 04 Rev 4 Page 60 2 Dive Strut Assembly A4 4978 AUSTRALIA ASSEMBLY MATERIAL PART LIST ID DESCRIPTION DWG PART NO REQD DESCRIPTION ASSM SPROG TUBE SPROG WIRE CLEAVIS PIN DIMX DIMY 1 SPROG TUBE LIST CLIMAX 13 OUTBOARD DIVE STRUT 104487 104295 104263 3 16 x 11 32 50mm dia 25x125 2 SPROG WIRE LIST CLIMAX 13 INBOARD DIVE
3. AUSTRALIA Climax Cam Junction Assembly A4 4981 X BAR SPROG 1 L EDGE 26 OT VG PLATE 11 BUNGY po E 60 19 J 0 SET POSITION 3 2 CLIMAX 13 DOWN 2 HOLES 4 p CLIMAX 14 ZERO NOTE SET SPROG 17 18 FULL TURNS OUT a 8 7 14 5 zm WIRE 2 ES H t 13 7 pe 4 p 6 Rev AMENDMENTS DATE 1 SPRONG SPACER 8 BRACKET CHANGE 10 08 01 AIRBORNE WINDSPORTS iw 2 CL13 TURNS OUT CHANGE 10 09 01 CLIMAX II ADDED 15 08 02 Drawn By Scale Date CLIMAX CAM 4 4981 4 SCREW REPLACES RIVET 15 06 03 CRIS NTS 06 06 01 JUNCTION ASSEM Issue Date 24 08 04 Rev 4 Page 47 CLIMAX C2 Climax Nose Junction Assembly Climax Nose Junction Assembly Dwg No A4 4828 23 06 2003 PartNo Details C2 13FRAME C2 14FRAME 1 100631 4 31 200 2 000 2 102273 AN4 41A 1 000 1 000 3 104491 BOLT MODIFIED AN4 30A 1 000 1 000 4 104274 PLATE 2 4MM BOTTOM 1 000 1 000 5 104273 NOSE PLATE HG 2 4MM TOP 1 000 1 000 6 100042 AN4 WASHE
4. CLIMAX C2 OWNER and SERVICE MANUAL Rev 4 AUSTRALIA PO Box 7042 REDHEAD NSW 2290 AUSTRALIA E mail fly airborne com au www airborne com au Phone 02 4944 9199 Int 61 2 4944 9199 Fax 02 4944 9395 Int 61 2 4944 9395 CLIMAX C2 MANUAL REVISION HISTORY AUSTRALIA Revision No Description Applicable Date Serial No m CL13 1 st 0 Original CL14 1 1 February 2001 CL13 1 st 1 Inclusion of drawings CL14 1 1 October 2001 lever standard positions changed Inclusion of CL13 97 st 2 performance tuning CL14 53 information C2 13 150 st 3 Climax C2 C2 14 100 1 September 2002 Pull back 2 1 4 Batten Clips pep 1 February 2003 C2 14 120 Sprog templet Issue Date 24 08 04 Rev 4 Page 2 CLIMAX C2 Issue Date 24 08 04 Rev 4 Page 3 2 TABLE OF CONTENTS TABLE OF CONTENTS Section 1 DESIGN FEATURES Section 2 SPECIFICATIONS Section OPERATING LIMITATIONS Section 4 WARRANTY STATEMENTS Section 5 ASSEMBLY PROCEDURES ASSEMBLING ON THE FRAME AUSTRALIA ASSEMBLING LYING FLAT Section 6 PRE FLIGHT INSPECTION HANG GLIDER DAILY INSPECTION Section 7 BREAK DOWN PROCEDURE Section 8 SHORT PACKING ASSEMBLE FROM SHIPPING LENGTH BREAKDOWN FOR SHIPPING Section 10 SAIL REMOVAL AND RE INSTALLATION REMOVING THE SAIL RE INSTALLING THE SAIL Section 11 FLIGHT TECHNIQUE
5. Rev AMENDMENTS Date E Ag 18 1 INCLUDE WASHER 8 25 05 02 AIRBORNE WINDSPORTS 2 CLIMAX II ADDED 13 UPDATE 15 08 02 ALL DIMENSIONS IN MILLIMETRES CLIMAX NOSE 3 TANG 21 ADDED 18 06 03 Drawn By Scale Date JUNCTION ASSEMBLY A4 4828 Rick NTS 18 01 01 Page 49 Issue Date 24 08 04 Rev 4 CLIMAX C2 Climax Rear Assembly Climax rear Keel Assembly Dwg No A4 4829 23 06 2003 Id Part Details C2 3FRAME C2 14FRAME 1 100037 5 NUT HALF NYLOC 1000 1 000 2 104310 HANG LOOP NYLON RETAINER 2 000 2 000 3 100820 NYLON WASHER M 8 XOD 2 000 2 000 4 104183 HANG LOOP PILLAR SPREADER 1000 1 000 5 104500 5 46 1 000 1 000 6 100012 AN4 32A 1 000 1 000 7 104184 HANG LOOP PILLAR BASE 1 000 1 000 8 100080 SADDLE TO SUIT 60MM TUBE 1 000 1 000 9 100042 WASHER 2 000 2 000 100035 4 NUT HALF NYLOC 2 000 2 000 11 100161 RIVET 5 32 MED 5 5 3 000 3 000 12 104215 PULLEY CHEEK BLOCK RIVET MNT 1 000 1 000 13 104252 PULLEY BRACKET VG CLIMAX 1 000 1 000 14 100003 4 11 1 000 1 000 15 101055 NYLON WASHER M 6 XOD 2 000 2 000 16 104276 QUICK CLIP BLOCK TYPE 3 1 000 1 000 17 104275 SPRING QUICK CLIP GATE 1 000 1 000 18 100009 AN4 26A 1 000 1 000 19 100034 NUT FULL NYLOC 1000 1 000 21 102379 ENDCAP FOR 42MM TUBE LUG WITH HOLE 1 000 1 000 22 104313 KEEL BUNG CLIMAX 1 000 1 000 23 104291 PULL BACK STRAP WITH
6. Perform a complete and thorough pre flight of the glider in accordance with the procedures outlined earlier in the manual Issue Date 24 08 04 Rev 4 Page 22 CLIMAX C2 Section 11 FLIGHT TECHNIQUE TAKE OFF DON T FORGET TO HOOK IN The VG should be in the full off position for launching The Climax has a slightly tail heavy static balance and is very easy to launch Hold the nose in a slightly elevated position approximately 20 degrees to the slope with the wings level run hard keeping the nose at the same angle It is important that the pilot accelerates smoothly during the launch run Taking increasingly larger steps until lift off is the preferred method Too fast an acceleration will cause the nose to rise rapidly with the risk of stall on launch TURNS The Climax can be easily directed into a turn even at slow speeds however for a fast roll rate and easier handling it is best to pull on a little extra flying speed The Climax will maintain a turn until the turn is removed by pilot input Allow yourself plenty of margin for safety Don t fly too slowly when flying close to the hill or other aircraft STALLS When practising stalls make sure you have sufficient altitude Push out slowly approx 1 mph per sec speed reduction the glider will tend to mush without dropping a wing The sink rate will increase in this mush mode more than two fold If you push out faster the nose will pitch higher a gen
7. 2900 2 000 2 000 2 000 2 000 2 000 100950 LOCKING RING 12MM RF114 2 000 2 000 2 000 2 000 2 000 2 000 12 104572 CLEVIS PIN 3 16 X 29 32 2 000 2 000 2 000 2 000 2 000 2 000 13 104457 D TUBE STREAMLINE SILVER 1700 2 000 2 000 MET STREAMLINE SILVER 165 _ STREAMLINE SILVER 1650 2 000 2 000 2 000 104810 D TUBE STREAMLINE SILVER 1750 2 000 REAR FLYING WIRE CLII 13 is PE 1 000 1 000 1 000 1 000 1 000 1 000 REAR FLYING WIRE CLII 14 104753 Mid 1 000 1 000 1 000 715 100022 1000 1 000 1 000 1 000 1 000 1 000 16 1 102332 WASHER SS 5 16 X 3 4 2 000 2 000 2 000 2 000 2 000 2 000 100037 NN NUT HALF NYLOC 1 000 1 000 1 000 1 000 1 000 1 000 19 102015 SPRINGCLIP1PINTYPE1 200 2 000 2 000 2 000 2 000 2 000 20 104308 s TOP KNUCKLE STREAMLINE 599 2 000 2 000 2 000 2 000 21 104462 ag KNUCKLE STREAMLINE 4000 1 000 1 000 1 000 1 000 1 000 22 104460 d KNUCKLE HG STREAMLINE 1 000 1 000 1 000 1 000 1 000 1 000 23 104461 KNUCKLE STREAMLINE 1 000 1 000 1 000 1 000 1 000 24 104459 e s ANSE ASS TRERMEINE 1 000 1 000 1 000 1 000 1 000 1 000 CLIMAX C2 Streamline Control Frame A4 4983 REQD RIGHT HAND SIDE DOWN TUBE ASSEM INTERNAL PARTS Rev
8. AMENDMENTS Date CLIMAX ADDED 15 08 02 LEFT HAND SIDE DOWN TUBE ASSEM DESCRIPTION ALL DIMENSIONS IN MILLIMETRES UNLESS STATED OTHERWISE FRONT VIEW CLIMAX 13 PART 104446 CLIMAX 14 PART 104521 CLIMAX 13 PART 104446 CLIMAX 14 PART 104521 AIRBORNE WINDSPORTS Drawn By Scale Date STREAMLINE CONTROL FRAME ASSEMBLY A4 4983 CRIS NTS 04 06 01 Issue Date 24 08 04 Rev 4 Page 55 CLIMAX C2 Micro Drag Control Frame Assembly Micro Drag Control Frame Assembly Dwg No A4 5317 23 06 2003 ld Part No Details MicroDRAG MisroDRAG 1 104479 FRNT FLYING WIRE CL13 STRMLNE MICRO 1 000 104480 FRNT FLY WIRE CL14 STLNE amp C214 MIC 1 000 2 104972 MICRO DRAG CARBON BASE BAR ASSEMBLY 1 000 1 000 104222 SPECTRA ROPE 1 000 1 000 4 104958 MICRO DRAG BASE BAR PIT PIN 1 000 1 000 6 104945 SIDE BOTT WIRE CL13 2 MICRODRAG FRM 2 000 104946 SIDE BOTT WIRE CL14 2 MICRODRAG FRM 2 000 8 100950 LOCKING RING 12MM 114 2 000 2 000 9 104572 CLEVIS PIN 3 16 X 29 32 2 000 2 000 10 104947 REAR FLYING WIRE CL13 2 MICRODRAG 1 000 104948 REAR FLYING WIRE CL14 2 MICRODRAG 1 000 11 104884 D TUBE MICRODRAG SILVER 1680 2 000 104885 D TUBE MICRODRAG SILVER 1730 2 000 12 100024 AN5 33A
9. Rotate the right tip Rotate the left tip If further adjustment is required the tip angle on the fast fitting anti clockwise fitting clockwise if wing is raised The tip plug can be rotated to raise or lower if viewed from the viewed from the rear the tip angle on either wing To raise the tip angle on the fast rear of the leading of the leading edge wing access the fibreglass tip bung through the zip at the edge one hole at a one hole at a time 2 end of the leading edge tube Remove the Philips screw and time adjust as outlined z The standard setting is 2 holes from the zero hole for the C2 13 and 1 hole for the C2 14 The fitting should not be adjusted more than two holes from the standard position per adjustment Reinstall the screw once adjustment is made TIP PLUG ADJUSTMENT TIP DOWN Rotate the left tip Rotate the right tip If the turn persists the tip angle can be lowered the slow fitting anti clockwise fitting clockwise if wing Access the fibreglass tip bung through the zip at the if viewed from the viewed from the rear end of the leading edge tube Remove the Philips screw and rear of the leading of the leading edge adjust as outlined edge one hole at a one hole at a time The standard setting is as above The fitting should not be time adjusted more than two holes from the standard position per adjustment Reinstall the screw once adjustment is made REAR SECTION ADJUSTMENT Use the Y tool to Use the Y tool
10. 1 000 1 000 13 102332 WASHER SS 5 16 X 3 4 2 000 2 000 14 100037 5 NUT HALF NYLOC 1 000 1 000 15 104966 5 PIN OD3 9X20L 4000 4 000 16 104967 CLEVIS PIN RING OD9X0 6T 4 000 4 000 17 104970 MICRO DRAG TOP DT KNUCKLE RHS 1 000 1 000 18 104971 MICRO DRAG TOP DT KNUCKLE LHS 1000 1 000 20 104962 MICRO DRAG LOWER DT KNUCKLE LHS 1 000 1 000 104963 MICRO DRAG LOWER DT KNUCKLE RHS 1 000 1 000 21 104964 MICRO DRAG SS BUSH OD8X 1 5L 2 000 2 000 22 104968 TUFFNOL ROLLER OD14 5XID8 1XW6 1 1 000 1 000 23 104965 MICRO DRAG SS BUSH OD6X15 7L 2 000 2 000 Issue Date 24 08 04 Rev 4 Page 56 CLIMAX C2 Mirco Drag Control Frame Assembly A4 4317 AUSTRALIA 15 16 AMENDMENTS 20 21 C2 14 MICRO DRAG CONTROL FRAME ASSEM PART NO 104949 C2 13 MICRO DRAG CONTROL FRAME ASSEM PART NO 104950 ALLDIVENSIONS IN MILLIMETRES UNLESS STATED OTHERWISE ID DESCRIPTION DWG REQD 1 FRONT FLYING WIRES 104479 104480 1 2 MICRO DRAG BAS BAR ASSEMBLY 104972 1 3 VG ROPE 104222 i 4 PIT PIN 104958 5 6 SIDE WIRES 104945 104946 2 7 8 CLEVIS LOCKING RING 100950 2 9 CLEVIS PIN 3 16 x29 32 104572 2 10 REAR FLYING WIRES 104947 10494B 1 11 MICRO DRAG DOWN TUBES 104884 104886 2 1
11. 104447 VELCRO 25MM LOOP BLACK ADHESIVE 0 075 0 075 0 075 0 075 12 104216 ROD END 5 16 UNF MALE 1 000 1 000 1 000 1 000 13 102424 NYLON WASHER 1 4 OBA THICK 1 000 1 000 1 000 1 000 14 104315 SCREW PHILIPS 4GX6MM 1 000 1 000 1 000 1 000 15 104245 BUNG FIBREGLASS RHS 1 000 1 000 104246 BUNG FIBREGLASS TIP LHS 1 000 1 000 16 100912 SCREW 10X3 4 305 CSK PHIL 1 000 1 000 1 000 1 000 17 104247 BUNG TUBE FIBREGLASS 1 000 1 000 1 000 1 000 104208 CLEVIS PIN 3 16 X 2 1 32 1 000 1 000 1 000 1 000 19 104229 L EDGE REAR CLIMAX RHS 1 000 1 000 104248 L EDGE REAR CLIMAX LHS 1 000 1 000 20 104610 TIP BUNG BUSH 1 000 1 000 1 000 1 000 Issue Date 24 08 04 Rev 4 Page 58 AUSTRALIA CLIMAX C2 Climax Rear Leading Edge Assembly 4 4825 BUNG SET UP LOCATING BUNG MARK OFFSET 2 13 2 HOLES DOWN C2 14 1 HOLE DOWN RHS LOCATING SCREW BUNG MARK OFFSET C2 13 2 HOLES DOWN C2 14 1 HOLE DOWN F Glass Tip Fitting ZEE lt Assembly 5 gt Assembly 2 AIRBORNE WINDSPORTS Date i ALL DIMENSIONS IN MILLIMETRES UI E CLIMAX REAR z BING OFFSET GATE Drawn By Scale Date A4 4825 SIMON NTS 25 01 01 L E ASSY
12. TAKE OFF DON T FORGET TO HOOK IN TURNS STALLS SPINS THERMALLING LANDING Section 12 TUNING PITCH TRIM PITCH STABILITY SYSTEM CHECKING THE CLIMAX STABILITY SYSTEM PREPARING THE TEMPLATE CHECKING THE SPRONG ANGLES ROLL YAW TRIM ROLL TRIM ADJUSTMENTS TIP LEVER ADJUSTMENT SPROG ADJUSTMENT FOR SYMMETRY HANDLING AND PERFORMANCE TUNING Issue Date 24 08 04 Rev 4 Page 4 CLIMAX C2 UE Section 13 PERIODIC INSPECTIONS and MAINTENANCE 31 MAINTENANCE SCHEDULE 31 LOG BOOK 31 NOTES ON PERIODIC INSPECTIONS 32 AIRFRAME TUBING 32 CARBON CROSS TUBES 32 BOLTS 32 INSPECTION AFTER HARD LANDING 33 DEFECT REPORTS 33 Section 14 TRANSPORTATION AND STORAGE 34 Section 15 MAINTENANCE RECORD 35 Section 16 HANG GLIDER COMPLIANCE SCHEDULES 36 GLIDER MODEL CLIMAX 13 36 GLIDER MODEL CLIMAX 14 37 Section 17 SPROG ANGLE TEMPLATES 38 GLIDER MODEL CLIMAX 13 36 GLIDER MODEL CLIMAX 14 37 Section 18 ASSEMBLY DRAWINGS 40 CLIMAX CENTER SECTION ASSEMBLY 4 5241 41 CLIMAX VG ASSEMBLY A4 5242 43 LEADING EDGE ASSEMBLY 4 4824 45 CLIMAX CAM JUNCTION ASSEMBLY A4 4981 47 NOSE JUNCTION ASSEMBLY 4 4828 49 CLIMAX REAR KEEL ASSEMBLY A4 4829 81 HG A FRAME FAIRED CORNER UNIT ASSEMBLY 4 7237 53 STREAMLINE CONTROL FFRAME 4 4983 55 MICRO DRAG CONTROL FRAME 4 5317 57 CLIM
13. The cross bar centre load bearing pin 845 mm 33 27 The pilot hang loop Fwd 1360 mm 53 54 Rear 1390 mm 54 72 Sail Dimensions Chord length at 3 ft outboard of centre line 1780 mm 70 08 Chord length at 3 ft inboard of tip 1120 mm 44 09 Span extreme tip to tip 10400 mm 409 45 Location of Information Placard Location of Test Fly Sticker Recommended Pilot Hook in Weight Range 75 120 kg 176 298 lbs Recommended Pilot Proficiency NB Conversions 0 4536 kg pound 25 4 mm inch 1 609km mile Issue Date 24 08 04 Rev 4 Page 37 AUSTRALIA SPROG ANGLE TEMPLATES GLIDER MODEL 13 CLIMAX C2 Section 17 MONY COHdS d CHTHIV UU L ee HENOED VERTICAL LONH IIL Lngd sa Page 38 Issue Date 24 08 04 Rev 4 La AUSTRALIA CLIMAX C2 GLIDER MODEL CLIMAX 14 55 su PSY umma nm SSULSATUA SNDISN3IMC TPF m NOLLIEOS DA 135 A3 Leno 3814 Odds 01 3dnd3ood
14. 403 33s 3015 NO AL JOH DNISIS Lfd DALS OH TV Page 39 Issue Date 24 08 04 Rev 4 2 Section 18 Climax Il Center Section Assembly Type 2 ASSEMBLY DRAWINGS Climax Il Center Section Assembly Type 2 Dwg No A4 5348 23 06 2003 AUSTRALIA Part Details EE 1 106172 SKT BUTTON SCREW M5 X 10 10 000 10 000 2 104231 CIRCLIP X BAR PIN 4 000 4 000 3 104973 X BAR HINGE PLATE CLIMAX II 2 000 2 000 4 104226 X BAR CLIMAX 13 2 000 104227 X BAR CLIMAX 14 2 000 5 104244 X BAR HINGE PIN CLIMAX 2 000 2 000 6 104270 X BAR WEDGE CLIMAX 1 000 1 000 7 105040 X BAR WEDGE REAR SLIDER 1 000 1 000 9 104284 X BAR HINGE PLATE SLIDER 1 000 1 000 10 101064 SHOCK CORD 3MM 0 550 0 550 11 100003 4 11 1 000 1 000 12 100547 4 12 1 000 1 000 13 104749 X BAR JUNCTION WASHER 4 000 4 000 14 105045 X BAR WEDGE STRAP REAR 2 1 000 1 000 15 100035 AN4 NUT HALF NYLOC 2 000 2 000 16 100584 AN3 13A BOLT 1 000 1 000 17 104285 X BAR WEDGE STRAP FRONT 1 000 1 000 18 100049 WASHER 2 000 2 000 19 101334 AN3 NUT HALF NYLOC 1 000 1 000 20 105036 PULL BACK WIRE CLIMAX C2 13 2 000 105037 PULL BACK WIRE CLIMAX C2 14 2 000 21 102021 SHACKLE PULL BACK 1 000 1 000 22 105110 PULL BACK ASSEMBLY 2 1 CL2 13 1 000 105111 PULL BACK ASSEMBLY 2 1 CL2 14 1 000 23 105107 THIMBLE BUSH OD18 1 000 1
15. 9600 mm 377 95 Front Front Recommended Pilot Hook Weight Range 55 90 kg 121 198 165 Recommended Pilot Proficiency Advanced NB Conversions 0 4536 kg pound 25 4 mm inch 1 609km mile Issue Date 24 08 04 Rev 4 Page 36 CLIMAX C2 GLIDER MODEL CLIMAX 14 MANUFACTURED BY AIRBORNE WINDSPORTS Pty Ltd NOTE These specifications are intended only as a guideline for determining whether a given glider is a certified model and whether it is in the certified configuration Be aware however that no set of specifications however detailed can guarantee the ability to determine whether a glider is the same model or is in the same configuration as was certified or has those performance stability and structural characteristics required by the certification standards An owner s manual is required to be delivered with each HGMA certified glider and it is required that it contain additional airworthiness information Metric Imperial Weight of glider with all essential parts and without cover bags and non 36 kg 79 lbs essential parts Leading Edge Dimensions Nose Plate anchor hole to crossbar attachment hole 3375 mm 132 87 Nose Plate anchor hole to rear sail attachment point 5955 mm 234 45 Overall pin to pin length from leading edge attachment point to hinge bolt 3141 mm 123 66 at glider centre line Largest outside diameter 2 95 Keel dimensions
16. ASSEMBLY TYPE AB JADY HALF SIZE 28 5 91 Issue Date 24 08 04 Rev 4 Page 53 CLIMAX C2 STREAMLINE CONTROL FRAME STREAMLINE CONTROL FRAME Dwg No A4 4983 23 06 2003 AUSTRALIA FRAME SIDE BOTT WIRE CL14 2 AB SLINE 104809 FRAM SIDE BOTT WIRE CL2 13 AB SLINE 104912 rere 1 000 1 000 1 000 Part No Details 13 0113 5 4 5 RETRO FRNT FLYING WIRE 13 1 104479 NE MICRO 1 000 1 000 1 000 1 000 1 000 1 000 104480 FLY WIRE CL14 STLNE amp C214 Too 1000 104807 CLII 14 STREAMLINE FRONT WIRE 1 000 2 104222 SPECTRA ROPE 3MM 1 000 1 000 1 000 1 000 1 000 1 000 ET 104481 U BAR STREAMLINE 1380 1 000 1 000 1 000 1 000 1 000 1 000 4 102148 jPIPPIN38WITHCAP 2 000 2 000 2 000 2 000 2 000 2 000 BOLT 6 STREAMLINE BOTTOM 5 104553 Boc T 2 000 2 000 2 000 2 000 2 000 2 000 6 104475 BEARING STRMLINE VG 4 7X12 7X5 1 000 1 000 1 000 1 000 1 000 1 000 7 HE REARING FN STE AMINE PIN STREAMLINE FRAME 1 000 1 000 1 000 1 000 1 000 1 000 8 104524 NYLONWASHER 15 1 2 000 2 000 2 000 2 000 2 000 2 000 SIDE BOTT WIRE CL13 AB SLINE 9 104402 BAME 1 000 mp BOTT WIRE 14 AB SLINE 3 086 Issue Date 24 08 04 Rev 4 Page 54 710 102015 SPRINGCLIP1PINTYPE1
17. CL13 97 and after Position D Position B 3mm CL14 53 and after Position C 7mm Position B 7mm Prior to CL13 97 2 Prior to CL14 53 Position A Position C 3mm Position D 4mm SPROG ADJUSTMENT FOR SYMMETRY ADJUSTMENTS WHEN THE GLIDER IS CONFIGURED 1 2 ON TO FULL ON ADJUSTMENT METHOD Remedy for left turn Remedy for right tum OUTBOARD SPROG ADJUSTMENT The glider Raise the right sprog by Raise the left sprog should be assembled with the VG off Unzip the outer rotating the cone by rotating the cone sprog and fold forward Remove the ring and clevis anticlockwise by 1 2 anticlockwise by 1 2 from the front of the tube Make appropriate tum turn a adjustment and install clevis pin and ring Install z sprog OUTBOARD SPROG ADJUSTMENT If the glider still Lower the left sprog by Raise the left sprog turns the opposite sprog can be lowered as rotating the cone by rotating the cone described clockwise by 1 2 turn anticlockwise by 1 2 turn If after following the procedure as outlined above the glider still tends to roll one way please contact your AirBorne dealer or call the AirBorne factory Issue Date 24 08 04 Rev 4 Page 29 CLIMAX C2 HANDLING AND PERFORMANCE TUNING The following table is designed to allow a pilot to reference methods of tuning the Climax to suit the individual Varying wing loading will affect the way the glider behav
18. Keep wings level whilst looking straight up your runway When the glider reaches trim speed a full flare is required Flare aggressively in light or no wind holding the uprights out and up It is important that the pilot does not swing the legs forward whilst flaring This results in the pilot s centre of gravity moving forward which will cause the nose to drop Upon touchdown the pilots legs must provide a gentle deceleration coasting to a stop No aircraft lands well with the brakes locked on In strong wind it is possible to fly the glider onto the ground slowing up gradually Be careful not to push out too hard in windy conditions Issue Date 24 08 04 Rev 4 Page 24 2 Section 12 TUNING Your Climax was test flown and delivered to you in good trim by either your dealer or by factory pilots If however any adjustments are made to your glider we recommend that they be recorded in your maintenance log at the rear of this manual If you feel that the glider requires adjustment to trim in the roll or pitch axis you should check that the problem is not caused by something asymmetrical in the frame or battens In order of priority check the following Ensure that the wires are correctly routed Check the battens against the profile Check that the batten bungies have the same tension on both sides Spring battens should be checked for normal operation Check that the keel is straight Check that
19. STRUT 104485 104296 104262 3 16 x 25 32 70mm dia 25x175 3 HEAT SHRINK CLEAR 25 104416 CLIMAX 14 OUTBOARD DIVE STRUT 104488 104297 104261 3 16 x11 32 50mm dia 25x180 CLIMAX 14 INBOARD DIVE STRUT 104486 104298 104260 3 16 25 32 70 dia 25x160 4 EDGE MOULDING 100561 5 LOCKING RING 12mm RF114 100950 6 CLEVIS PIN 3 16 x 1 1 32 104209 6 CLEVIS PIN 3 16 x 25 32 104210 NOTE WIRE NOT SHOWN IN TOP VIEW 5 C gt NOTE CHAMFER TO TOP IN BOARD STRUTS p w 7 Rev AMENDMENTS Date 1 SPROG WIRE UPDATE 18 09 01 AIRBORNE WINDSPORTS i 2 5 CHANGED NOTE ADDED 15 11 01 DIVE STR UT ALL DIMENSIONS IN MILLIMETRES Drawn By Scale Date ASSEMBLY 4 4978 UNLESS STATED OTHERWISE CRIS NTS 28 05 01 Issue Date 24 08 04 Rev 4 Page 61
20. TANGS 1000 1 000 24 101064 SHOCK CORD 3MM 1050 1250 25 101064 SHOCK CORD 3MM 1 250 1 400 26 100162 POP RIVET 1 8 2 000 2 000 27 105179 HANG LOOP PILLAR SPACER C2 1000 1 000 Issue Date 24 08 04 Rev 4 Page 50 CLIMAX C2 Climax Rear Keel Assembly A4 4829 AUSTRALIA NOTE ROCKER ROTATED FOR C2 WITH PILLAR SPACER NOTE FOR PARTS ASSEMBLY SEE A FRAME ASSEM A4 7237 Bowline AIRBORNE WINDSPORTS Q 0 27 s 8 prx STD GRAVITY ON 2ND Sail HOLE FROM BACK CL13 4 NS STD GRAVITY ON 2ND k HOLE FROM BACK CL 14 Rear Wire gt SIDE VIEW Rev AMENDMENTS Date CL13 104278 1 STD GRAVITY NOTE amp 26 ADDHDI2 09 01 CL14 PART 104279 2 STD GRAVITY NOTE REVISED 27 11 01 CL II 13 PART 104747 ALL DIMENSIONS IN MILLIMETRES 3 CLIMAX Il ADDED 15 08 02 CL 1114 104748 Drawn Scale Date 4 ROCKER ROATED SPACER 14 5 06 03 Rick NTS 18 01 01 CLIMAX REAR KEEL ASSEMBLY A4 4829 Issue Date 24 08 04 Rev 4 Page 51 CLIMAX C2 HG AFrame Faired Corner Unit Assembly Type 2 HG AFrame Faired Corner Unit Assembly Type 2 Dwg No A4 7237 23 06 2003 AUSTRALIA PartNo D
21. an indication that the sprogs are not set symmetrically The following tables outline procedures for adjustments Adjustments should be made to the glider in the sequence as shown The glider should be tuned firstly in the VG off setting and then checked VG on If necessary the sprogs must be tuned as outlined in the second table NOTE We refer to the fast wing as the wing on the high side of the turn ie The right wing is the fast wing if the wing is turning left and vice versa Issue Date 24 08 04 Rev 4 Page 27 CLIMAX C2 ROLL TRIM ADJUSTMENTS AUSTRALIA ADJUSTMENTS WHEN THE GLIDER IS CONFIGURED VG OFF TO 1 2 ON ADJUSTMENT METHOD Remedy left turn Remedy right turn DIFFERENTIAL LEADING EDGE TENSION Attach the sail to the Attach the sail to the The tip levers have small inserts as shown on the drawing left tip lever to right tip lever to Fig 1 To remedy a mild turn the sail tip screw should be increase the sail increase the sail removed and the insert on both sides rotated 180 deg as tension Attach the tension Attach the shown in figure 1 page 29 The tip levers should be sail to the right tip sail to the left tip reattached to the sail to adjust a turn as outlined Specific lever to decrease the lever to decrease settings are referred to in the table following the tip lever sail tension the sail tension adjustment drawing Adjust 3 4mm per side initially TIP PLUG ADJUSTMENT TIP UP
22. the nose plate assembly ensuring that the VG routing is normal Sight along both leading edges checking for similar curves Walk towards the tip feeling for dents in the leading edge Check cross bar leading edge junction through the zipper access Check sail tip lever is fully closed and the sail is not damaged Check the tip rod is properly located and the rear leading edge is undamaged Walk towards the keel checking all battens are secured Check the sprogs are in order and the zips are fully closed Check the cross bar retaining shackle is secured on the quick clip Repeat the above steps for the other side wing in reverse order Check all lower rigging is correctly routed and free from damage The most likely area for damage on wires is around the swage and thimble area Check Control Bar corners are correctly assembled with pip pin and cover Ensure the hang loop rocker is rotated 90 degrees to the keel and that hang loops are securely positioned and in good order The hang loop should be free to move in both directions Issue Date 24 08 04 Rev 4 Page 15 CLIMAX C2 Check control bar top assembly and ensure that the down tubes are straight Unzip under surface and check cross bar hinge and restraining straps The VG should be operated and inspected to ensure it is functioning properly Ensure that the double surface is zipped up and nose fairing is secure Clip your harness into the main and back up hang loops
23. time you rig and before you fly Issue Date 24 08 04 Rev 4 Page 12 CLIMAX C2 ASSEMBLING LYING FLAT UNZIP THE BAG Lay the wing down with zip up and the nose facing into the wind Unzip the bag and unclip centre ties ASSEMBLE CONTROL FRAME Spread the control bar down tubes and insert the base bar The pip pin is then inserted with the cover firmly secured Check that all the rigging wires are outside the control frame ROTATE GLIDER Rotate the glider so that the control frame is under the wing Make sure the rigging is not tangled REMOVE BAG Remove the glider bag and unclip all of the ties The Sprog tube covers should also be removed at this time INSERT NOSE BATTEN Load the nose battens on to the locating pins at this time Failure to do so will make it difficult to locate the battens after the sail is tensioned SPREAD LEADING EDGES Carefully spread both leading edges out half way firstly then spread leading edges to their approximate flying position Check the side wires are not twisted IT IS ESSENTIAL THAT THE KEEL AND THE LEADING EDGES ARE KEPT IN THE SAME PLANE OR DAMAGE WILL RESULT INSERT TIP RODS Remove the tip bags and insert the tip rod into the fitting at the rear of the leading edge Ensure that the rod is inserted all of the way LOAD TIP ROD Move to the front of the wing For the left tip hold the rear leading edge with your left hand and the end of the sail with your right Bend the tip t
24. to If the turn still persists after the tip plug rings have been rotate the right step rotate the left step 2 rotated the front leading edge step down rear eccentric ring down ring anti down ring clockwise canbe adjusted The angle that the rear section protrudes clockwise if viewed if viewed from the 2 from the front section can be altered by rotation of the outer from the rear of rear of the leading eccentric plastic ring The location of this ring is fixed with leading edge one hole edge one hole This a small screw Remove screw and reinstall once adjustment This raises the RHS raises the LHS rear 5 rear leading edge leading edge straighten the glider If the glider tends to turn the opposite direction after the rear section adjustment the tip plugs should be adjusted to LOCATING PIN REFERENCE LINE RHS rear leading edge shown Issue Date 24 08 04 Rev 4 RHS leading edge step down shown Page 28 CLIMAX C2 LEVER ADJUSTMENT FIGURE 1 POSITION B POSITION A REFERENCE POINTS POSITION D POSITION C INSERT ROTATED TO ACHIEVE ADDITIONAL ADJUSTMENT The following table shows standard sail position and variations to the standard setting Note that there are two standard positions Check the glider serial number prior to making any adjustments APPLICABLE GLIDER STANDARD POSITION ADJUSTMENTS Position 4mm
25. 000 19 100055 WASHER SS 3 16 X 7 16 304 FLAT 4 000 4 000 4 000 4 000 4 000 4 000 20 106171 A FRAME LOCK SHAFT 20MM 2 000 2 000 2 000 2 000 2 000 2 000 21 100035 AN4 NUT HALF NYLOC 1 000 1 000 1 000 1 000 1 000 1 000 22 100042 AN4 WASHER 1 000 1 000 1 000 1 000 1 000 1 000 23 101757 SPEED BAR 2 1400 WITH CLEAT 1 000 1 000 1 000 1 000 1 000 1 000 24 101333 AN4 13A 1 000 1 000 1 000 1 000 1 000 1 000 25 106050 PIP PIN 33 WITH CAP 1 000 1 000 1 000 1 000 1 000 1 000 26 102015 SPRING CLIP 1 PIN TYPE 1 2 000 2 000 2 000 27 100023 5 32 1 000 1 000 1 000 28 100036 5 NUT FULL NYLOC 1 000 2 000 1 000 29 103999 1 TOP KNUCKLE FAIRED FIG 2 000 2 000 2 000 2 000 2 000 2 000 30 102332 5 55 5 16 X 3 4 2 000 2 000 2 000 2 000 2 000 2 000 3i 104476 BEARING AB VO CORNER PULLEY 2 000 2 000 2 000 2 000 2 000 2 000 6X10X3 Issue Date 24 08 04 Rev 4 Page 52 2 AUSTRALIA HG A Frame Faired Corner Unit Assembly Type AB A4 7237 ALL PARTS ASSEMBLED TO MAKE WING LEFT HAND SIDE KNUCKLE RIGHT HAND SIDE KNUCKLE L 13 NN NOTE m CLEVIS PIN AND RING USED M 9 ONLY ON TANDEM GLIDER fv 9 B ECT 18 5 2 6 19
26. 000 24 101169 HEATSHRINK CLEAR 20 0 050 0 050 25 104416 HEATSHRINK CLEAR 25 0 060 0 060 26 104823 REAR KEEL COVER CLIMAX II 1 000 1 000 Issue Date 24 08 04 Rev 4 Page 40 CLIMAX C2 Climax Center Section Assembly 4 5348 mm PLACES PLACES fi 4 Cp Side View From Back End of Assembly Se s 1 CLIMAX CENTER SECTION ASSEMBLY SEE A4 4826 Front View CLIMAX CENTER SECTION ASSEMBLY SEE A4 5241 FOR GLIDERS UP TO C213 SERIAL NO 160 C2 14 SERIAL NO 111 Bottom View m 2 IN 4 A dis Gy 24 25 10 BUNGIE FOR ROCKER SU c 7 QLi3 14 550mm Climax Center Section Assembly Type 2 Rev AMENDMENT Date Drawn By Scale Date CLIMAX 13 FRAME 104747 A4 5348 CLIMAX 14 FRAME 104748 CRIS NTS 17 01 03 SHEET 1 OF 1 Issue Date 24 08 04 Rev 4 Page 41 CLIMAX C2 Climax VG Assembly Climax VG Assembly Dwg No A4 5242 23 06 2003 Id Part No Details 1 101334 AN3 NUT HALF 2 000 2 000 2 104303 VG PULLEY SLIDER PLATE 1 000 1 000 3 104757 CLIMAX 13 VG PULLEY ROPE
27. 1 000 104758 CLIMAX 14 VG PULLEY ROPE 1 000 4 104305 DRILLED RF615 2 000 2 000 5 104277 VG PULLEY SLIDER 1 000 1 000 6 101064 SHOCK CORD 0 300 0 300 7 102927 10 BOLT 2 000 2 000 8 100406 SHACKLE RF615 1 000 1 000 9 104761 NOT Found 2 000 2 000 10 104222 SPECTRA ROPE 7 900 7 900 11 104257 WIRE CLIMAX 13 2 000 104259 WIRE CLIMAX 14 2 000 12 101064 SHOCK CORD 3MM 0 300 0 300 13 101488 BUSH 10 DX 6L 1 000 1 000 Issue Date 24 08 04 Rev 4 Page 42 CLIMAX C2 Climax VG Assembly A4 5242 PULLEY BUNGIE TO SAIL 300mm THROUGH FRONT PULLEY M END CLIMAX VG ASSEMBLY 4 4827 AIRBORNE WINDSPORTS ALL DIMENSIONS IN MILLIMETRES Drawn By Scale Date CLI MAX II A4 5242 Oris NOSCALE 6 08 02 VG ASSEMBLY Issue Date 24 08 04 Rev 4 Page 43 CLIMAX C2 Climax Cross Bar Leading Edge Assembly Climax Cross Bar Leading Edge Assembly Dwg No A4 4824 23 06 2003 No Details FRAME 2 100549 AN4 22A 2 000 104485 SPROG ASSEMBLY INBOARD 13 2 000 104486 SPROG ASSEMBLY INBOARD CLIMAX 14 4 100035 4 NUT HALF NYLOC 4 000 5 101055 NYLON WASHER M 6 XOD 2 000 7 100037 A
28. 141 sqft 14 3 sq 154 sq ft meter meter WING SPAN 31 5 feet ASPECT RATIO NOSE ANGLE 128 133 degrees 128 133 degrees 92 DOUBLE SURFACE 92 BATTENS 2246 2446 GLIDER WEIGHT 33 kg 73 pound 36 kg 79 pound ASSEMBLY TIME PACK UP LENGTH 16 feet 17 3 feet SHORT PACK LENGTH 12 6 feet 13 6 feet RECOMMENDED PILOT HOOK 55 90 kg 121 198 75 120 kg 165 264 IN WEIGHT RANGE pounds pounds Includes Equipment VNE Recommended Maximum 85 km h 53 mph 85 km h 53 mph Velocity VA Recommended Maximum 74 km h 46 mph 74 km h 46 mph Rough Air Manoeuvring Velocity Velocity Note The stall speed of the Climax at maximum recommended wing loading is less than the minimum requirement of 25 mph 40 km h The minimum or steady state speed is at least 35 mph 56 km h for a prone pilot with correctly adjusted harness Conversions 0 4536 kg pound 25 4 mm inch 1 609 km mile Test speed x 0 707 Vne Test Speed x 0 816 Issue Date 24 08 04 Rev 4 Page 7 2 Section 3 OPERATING LIMITATIONS WARNING Hang Gliding is a high risk sport The safe operation of this hang glider ultimately rests with you the pilot We believe that in order to fly safely you must maturely practice the sport of hang gliding You should never fly this hang glider beyond the placard limits The velocity never to exceed VNE for your glider is given in Section 2 as is the maximum speed for manoeuvres or f
29. 2 5 33 100024 1 13 SS WASHER 5 16 x3 4 102332 2 14 5 HALF NUT NYLOC 100037 1 15 CLEVIS PIN OD3 9x20L 104966 4 16 CLEVIS LOCKING RING 104967 4 17 TOP DT KNUCKLE RHS 104970 1 18 TOP DT KNUCKLE LHS 104971 1 20 LOWER DT KNUCKLES 104962 10496B 1 21 SS BUSH OD8x21 5L 104964 2 22 TUFFNOL ROLLER 104968 1 23 SS BUSH OD6x15 7L 104965 2 KEEL PE 19 E O FRONT VIEW AIRBORNE WINDSPORTS iw MICRO DRAG CONTROL Drawn By Scale Date FRAME ASSEMBLY A4 531 7 Cris NTS 9 12 2002 Issue Date 24 08 04 Rev 4 Page 57 CLIMAX C2 Climax Rear L Edge Assembly Climax Rear L Edge Assembly Dwg No A4 4825 23 06 2003 PartNo 100035 4 NUT HALF NYLOC 2 000 2 000 2 000 2 000 2 104487 SPROG ASSEMBLY OUTBOARD CLIMAX 13 1 000 1 000 104488 SPROG ASSEMBLY OUTBOARD CLIMAX 14 1 000 1 000 104251 SPROG BRACKET OUTBOARD 1 000 1 000 1 000 1 000 4 104202 MACH SCREW 524694 5106 1 4 1 7 32 1 000 1 000 1 000 1 000 5 104490 BOLT MODIFIED AN4 26A 1 000 1 000 1 000 1 000 6 100950 LOCKING RING 12MM RF114 2 000 2 000 2 000 2 000 7 104210 CLEVIS PIN 3 16 X 25 32 1 000 1 000 1 000 1 000 8 104509 COVER MYLAR SPROG CLIMAX 1 000 1 000 1 000 1 000 9 104301 SPROG ROD END EXTERNAL SPACER 2 000 2 000 2 000 2 000 10 104250 SPROG CONES 19MM TUBE CLIMAX 1 000 1 000 1 000 1 000 11
30. AX REAR LEADING EDGE ASSEMBLY A4 4825 59 DIVE STRUT ASSEMBLY A4 4978 61 Issue Date 24 08 04 Rev 4 Page 5 2 Section 1 DESIGN FEATURES Designed and manufactured by AirBorne Windsports the Climax is one of the most advanced high performance topless hang glider on the market The Climax C2 is the result of further refinements to the design Attention to detail and weight saving has allowed the Climax to have excellent static balance A larger than average VG range provides the Climax with ease of handling and a large flare window without compromising outstanding glide performance throughout the speed range The Climax has an elliptical tip which in the VG full setting allows a very tight mainsail whilst maintaining a progressive washout line right through to the tip AirBorne s original cam VG system has been improved allowing an increase in VG travel Not only does the wing pull exceptionally flat when full on the VG off setting is quite loose resulting in extremely light handling and improved climb ability There are several advantages using the cam VG system The drag in the pulley actuating system and lack of movement in the high load junctions allow for much lower operating pressures The cam VG system also maintains constant anhedral which significantly reduces glider oscillation throughout the VG range A combination of internal cloth ribs and Velcro tabs between the upper and lower battens c
31. Id Details Ee 1 100160 RIVET 3 16 SHORT 6 4 6 000 6 000 2 104268 SPROG X BAR BRACKET LHS CLIMAX 1 000 1 000 104269 SPROG X BAR BRACKET RHS CLIMAX 1 000 1 000 3 104180 FRONT CLIMAX 14 1 000 1 000 104233 L EDGE FRONT CLIMAX 13 1 000 1 000 4 104497 CRESCENT REDUCER OUTER CLIMAX 2 000 2 000 6 102713 ROLL PIN 3 32 X 1 2 SS 1 000 1 000 7 105140 SCREW SELF TAPPING 1 4X8G 30455 2 000 2 000 8 100950 LOCKING RING 12MM RF114 2 000 2 000 9 104228 L EDGE SLEEVE 52 ASSEM CLIMAX 2 000 2 000 104821 L EDGE SLEEVE ASSEM CL II LITE 1 000 1 000 10 104207 CLEVIS PIN 3 16 X 2 15 32 2 000 2 000 11 100035 AN4 NUT HALF NYLOC 6 000 6 000 12 104555 SPROG ROD END INTERNAL SPACER LONG 2 000 2 000 13 104288 ALUMINIUM SPACER FOR VG CAM CLIMAX 2 000 2 000 14 104516 CAM PLATE ASSEMBLY 2 000 2 000 15 100001 4 7A 2 000 2 000 16 100587 4 24 2 000 2 000 17 104554 SPROG ROD END INTERNAL SPACER SHORT 2 000 2 000 18 104249 SPROG CONES 25MM TUBE CLIMAX 2 000 2 000 19 104216 ROD END 5 16 UNF MALE 2 000 2 000 20 104301 SPROG ROD END EXTERNAL SPACER 2 000 2 000 22 104447 VELCRO 25MM LOOP BLACK ADHESIVE 0 200 0 200 23 102018 WASHER SS 1 4 X 3 4 4 000 4 000 24 101055 NYLON WASHER M 6 XOD 4 000 4 000 25 100002 4 6A 2 000 2 000 26 100034 4 NUT FULL NYLOC 2 000 2 000 27 100012 4 32 2 000 2 000 Issue Date 24 08 04 Rev 4 AUSTRALIA Page 46
32. N5 NUT HALF NYLOC 2000 8 102018 WASHER SS 1 4 X 3 4 4 000 9 100080 SADDLE TO SUIT 60MM TUBE 2 000 10 104483 BUSH X BAR CLIMAX 2000 11 100022 AN5 31A 2 000 12 104508 COVER MYLAR SAIL PROTECTOR CLIMAX 2 000 13 101064 5 CORD 3MM 0400 14 104249 5 CONES 25MM TUBE CLIMAX 1 000 15 100950 1 RING 12MM RF114 2 000 16 104209 CLEVIS PIN 3 16 X 1 1 32 2 000 17 104294 COVER CLIMAX 2 000 18 104489 MODIFIED AN4 22A 2 000 19 100624 MYLAR WASHER 2 000 20 100043 AN5 WASHER 2 000 Issue Date 24 08 04 Rev 4 Page 44 CLIMAX C2 Climax X Bar Leading Edge AssemblyA4 4824 A AUSTRALIA gt 4 AMENDMENTS DATE 20 ADDED 10 09 01 WASHER NO UPDATE CLIMAX II ADDED 15 08 02 N CAM PLATE ALL DIMENSIONS IN MILLIMETRES ar FA SIDE WIRE CLIMAX 13 FRMASSEM PART 104747 CLIMAX 14 FRMASSEM PART 104748 CLIMAX 13 ASSEM PART 104278 CLIMAX 14 ASSEM PART 104279 Climax X Bar L Edge UNLESS STATED OTHERWISE Assembly Drawn By Scale Date A4 4824 SIMON NTS 21 01 01 SHEET TOES Issue Date 24 08 04 Rev 4 Page 45 CLIMAX C2 Climax Cam Junction Assembly Climax Cam Junction Assembly Dwg No A4 4981 23 06 2003
33. R 8 000 8 000 7 100035 4 NUT HALF NYLOC 3 000 3 000 8 104180 L EDGE FRONT CLIMAX 14 2 000 104233 L EDGE FRONT CLIMAX 13 2 000 9 104178 KEEL TUBE ASSEM FRONT CLIMAX 14 1 000 104255 KEEL TUBE ASSEM FRONT CLIMAX 13 1 000 10 100820 NYLON WASHER M 8 XOD 1 000 1 000 11 102271 SADDLE TO SUIT 45MM TUBE 3 000 3 000 12 101455 WASHER SS 1 4 X 1 1 000 1 000 13 104280 PULLEY COVER ASSEMBLY 1 000 1 000 14 104212 PULLEY 50MM BEARING RF1767 1 000 1 000 15 104275 SPRING QUICK CLIP GATE 1 000 1 000 16 104520 NOSE CLIP TYPE 3 1 000 1 000 17 100034 NUT FULL NYLOC 1000 1 000 18 104276 QUICK CLIP BLOCK TYPE 3 1 000 1 000 19 104503 NOSE SAFETY CATCH 1 000 1 000 20 102424 NYLON WASHER 1 4 OBA THICK 1000 1 000 21 103290 TANG 1 4 EYELET HOLE 1000 1 000 Issue Date 24 08 04 Rev 4 Page 48 2 Nose Junction Assembly 4 4828 NOTE 17 REPLACED WITH ITEM 7 WHEN USING ITEMS 18 19 amp 21 7 I qu i 21 _ _ 8 J A 10 7 ALTERNATIVE CONSTRUCTION FRONT VIEW _ 5 SIDE VIEW
34. and perform a hang check Make sure that your harness is the correct distance from the base bar your leg loops are secure and your carabina is locked HANG GLIDER DAILY INSPECTION Inspection of the following items after every assembly of the glider is required Check for bends dents scratches all tubes Check wire ends for bolt and or other fastener security Check wires for twisted or jammed thimbles Check wires are free of kinks frays abrasions broken strands etc Nose plate connections spring clip retains front wires Tips secure tip rod and lever undamaged zipper closed Battens and bungies springs functioning smoothly and no frays on bungies A frame connection on both sides spring pins located correctly Variable geometry operation full and free movement Rear keel connections spring clip retains shackle and tensioner cable Crossbar tension wire free of kinks frays abrasions broken strands Crossbar operation free floating Sprog tubes and rod ends and clevis pins secure Sail condition no tears symmetrical appearance Harness straps and webbing secure height adjustment correct Emergency parachute secure correctly mounted and attached operating handle accessible Issue Date 24 08 04 Rev 4 Page 16 2 Section 7 BREAK DOWN PROCEDURE To break down your Climax just reverse the set up procedure steps as described Included here are a few guidelines to follow whi
35. ar leading edge with your right hand and the end of the sail with your left Align the lever plug and bend the tip tube towards the trailing edge as you tension the sail Locate the plug on the end of the tube When installing the left tip rod the leading edge should be held with your left hand INSERT REMAINING MAINSAIL BATTENS Slide batten into sail pocket Unclip pivot beak from threaded end Rotate pivot beak and locate in sail as shown While supporting the underside of the batten clip the pivot beak into threaded end To adjust batten load tension release pivot beak from sail and rotate batten clip Ensure battens have an even tension distibution Page 11 AUSTRALIA CLIMAX C2 AirBorfie LOAD SPROGS The sprogs should be rotated into position over the red webbing loops and the zips closed fully It is a good time to inspect the junctions prior to closing all zips INSERT UNDER SURFACE BATTENS The under surface battens should be inserted as far as possible The batten should then be pushed in with your thumb Use the string to pull the batten to the rear of the pocket INSTALL NOSE FAIRING Attach the nose fairing applying the top velcro first then gently tension over the nose plates and attach the velcro to the under surface PRE FLIGHT INSPECTION You are now ready for the wing pre flight inspection as outlined in the next section It is imperative that you carry out this inspection every
36. bag is installed back to front because it is tapered and the glider is more bulky at the rear when short packed Issue Date 24 08 04 Rev 4 Page 20 2 Section 10 SAIL REMOVAL AND RE INSTALLATION Many of the maintenance requirements outlined in this manual will require the removal of the sail from the airframe When outlining the procedure to remove the sail we assume that you have had some experience in removing a sail from a glider If you have not we suggest that you have some one help you that does have experience or have an authorised Airborne dealer remove and re install the sail for you It is important to re install hardware as you disassemble so that components are not misplaced REMOVING THE SAIL You will need a clear area of approximately 2 meters by 10 meters A rough surface such as concrete should have a tarp laid down prior to working on the glider Lay the glider on the ground and unzip the bag and remove all ties Remove the base bar from the control frame Remove the Phillips screw which secure the webbing on the rear leading edge Remove the sail tangs from the nose plate bolts Undo the front under surface zip completely Remove hang loop Undo front VG pulley bungie from sail Remove the rear wires and keel pocket tang from the rear quick clip Remove the side wires from the cross tube and pull the wires outside of the sail With the leading edges spread approximately meter ge
37. ch will save you time and prevent potential wear areas on your sail It is possible to leave the nose battens in during daily operations Remove nose fairing Unzip sprogs and rotate them towards each other The sprogs remain outside the sail Remove four or five tip battens and the under surface battens Unload tip lever and remove tip rod Fold tip lever towards sail and roll sail whilst keeping tension along the trailing edge Fit tip bags Let off the sail tension and pull each wing in slightly Pull out the remaining battens Attach top control bar padding Fold both wings in symmetrically bringing both leading edges back at the same time or in small steps side to side Place padding over the keel end and rear quick clip Place sprog covers over sprogs Roll the sail up parallel to the leading edge One tie should be wrapped around the keel and leading edge to hold them together whilst the other side wing is rolled Ensure that the sail is rolled into the leading edge pockets It is important that the ties are not over tensioned as this can damage the mylar insert Position glider bag Roll glider over and undo control bar pip pin Fold base bar rearward Attach base bar padding around down tube base Place padding over the speed bar Undo the two centre ties and fold the control bar down between the leading edge pockets Lay the wires smoothly to avoid kinking Secure the centre ties and zip up bag Issue Date 24 08 04 R
38. es in pitch and roll trim For example a heavier loaded glider will tend to increase the flex in the leading edge tube causing more washout This increase in washout will tend to make the glider more spirally stable A lightly loaded glider will tend to be less spirally stable requiring more high siding from the pilot Adjustments are described assuming that the glider is straight and all adjustments are symmetrical TUNING HANDLING PERFORMANCE BAR PRESSURE CENTER OF GRAVITY Increase in pitch pressure No change Increase in pitch pressure when CG moved rearward when CG moved rearward Decrease in pitch pressure No change Decrease in pitch pressure when moved forward when moved forward TIP PLUGS Rotating the tip plugs Slightly reduced Increase in bar pressure Rotating the tip plug ref down reduces high siding performance line down results in an on a bank increase in glass tip angle Rotating the tip plugs up Slightly better performance Reduction in bar pressure ie Left tip ring clockwise amp increases the amount of Right tip ring anticlockwise high siding required INNER RING Rotating the inner ring Does not effect No Change with small Rotating the inner rings down results in an increase in the leading edge dihedral ie Left leading edge inner ring clockwise amp Right leading edge inner ring anti clockwise down reduces high siding on a bank performance adjustments Rotating the inner r
39. es so that the rear keel tube is not bending under the gliders own weight Issue Date 24 08 04 Rev 4 Page 26 AUSTRALIA CLIMAX C2 AirBorfie Align the top of the template to the front of the 42 mm keel tube just behind the step down section The string line should line up with the vertical line once the keel is perfectly horizontal Secure the keel so that the glider will not rotate around the control frame once the zero angle is achieved Re check the angle The sprog tubes can move span wise within the red webbings which will cause discrepancies in the angle readings The sprog tubes should be pushed to the tip side of the webbing prior to checking as this produces the lowest angle Place the template under the sprog tube Push up enough so that the side flying wire goes tight and check the string is aligned with the appropriate line on the template To adjust the angle fold the sprog out and remove the clevis pin at the front of the tube Rotate the threaded cone anti clockwise to raise the rear of the sprog Rotate the threaded cone clockwise to lower the rear of the sprog ROLL YAW TRIM Turns in your gliders occur when the glider is asymmetrical If you have a turn in your glider you should confirm that the 7 possible variables outlined at the beginning of this section have been checked The glider may have a turn due to several factors If the turn only appears at VG settings from on to full on it is generally
40. etails HE AG UE AG C2 13 SUE C2 14 EE 1 101339 D TUBE A FOIL SILVER 1700 2 000 2 000 103957 D TUBE A FOIL SILVER 1700 SLEEVED 2 000 300010 D TUBE A FOIL SILVER 1650 2 000 2 000 2 000 2 101743 D TUBE KNUCKLE FAIRED ABLHS 1 000 1 000 1 000 1 000 1 000 1 000 3 101742 D TUBE BTM KNUCKLE FAIRED AB RHS 1 000 1 000 1 000 1 000 1 000 1 000 4 101713 C BAR KNUCKLE HG TYPE 2 2 000 2 000 5 104402 SIDE BOTT WIRE CL13 AB SLINE FRAME 2 000 2 000 104403 SIDE BOTT WIRE CL14 AB SLINE FRAME 2 000 2 000 104809 SIDE BOTT WIRE CL14 2 AB SLINE FRAM 2 000 SIDE BOTT WIRE CL2 13 AB SLINE 104912 2 000 6 101745 BOLT M6 D TUBE BOTTOM KNUCKLE 2 000 2 000 2 000 2 000 2 000 2 000 7 102010 VG ROLLER 1 000 1 000 1 000 1 000 1 000 1 000 13 102015 SPRING CLIP 1 PIN TYPE 1 2 000 2 000 2 000 2 000 2 000 2 000 14 101055 NYLON WASHER M 6 XOD 4 000 4 000 4 000 4 000 4 000 4 000 16 104406 FRNT FLYING WIRE CL13 AB FRAME 1 000 1 000 1 000 104407 FRNT FLYING WIRE CL14 AB FRAME 1 000 1 000 104808 CLII 14 FRAME FRONT WIRE 1 000 17 104408 REAR FLYING WIRE CL13 AB FRAME _ 1 000 1 000 104409 REAR FLYING WIRE CL14 _ 1 000 1 000 104750 FLYING WIRE 13 AB FRAME 1 000 104752 REAR FLYING WIRE CLII 14 AB FRAME 1 000 18 106172 SKT BUTTON SCREW M5 X 10 4 000 4 000 4 000 4 000 4 000 4
41. ev 4 Page 17 CLIMAX C2 Climax has 1x19 wires to minimize drag wires are more prone to kinking and should be treated with care For de rigging flat attach top control bar padding Undo nose wires and pull wing forwards then follow steps as above If resistance is encountered during any phase of set up or break down procedure stop and investigate Issue Date 24 08 04 Rev 4 Page 18 AUSTRALIA CLIMAX C2 AirBorne Section 8 SHORT PACKING ASSEMBLE FROM SHIPPING LENGTH If your Glider was delivered to you in the short pack form the following procedure should be used Unzip bag and remove ties Remove all padding from the tube ends Assemble the control frame as described in the set up procedure section Rotate the glider on to the control bar lying flat on the ground Spread both leading edges approximately metre Remove the tip bags which have been used as protection on the rear of the front leading edges Check rear leading edges for R right and L left Insert rear leading edges in the appropriate side of the front leading edge Align and push on the leading edge then rotate slightly to ensure it is located correctly It should be impossible to rotate leading edge if correctly installed Ensure outer sprong exits through the zipper as shown right Attach inner sprog to sprog cone with the clevis pin and locking ring as shown For details see page 45 You are now ready to te
42. ice and which if kept uncorrected would compromise the continued safe operation of the hang glider should be reported to Airborne as soon as practicable Issue Date 24 08 04 Rev 4 Page 33 2 Section 14 TRANSPORTATION AND STORAGE Avoid damage to your glider by using well padded racks Careless transportation can cause considerable damage to your glider We recommend that you support the glider in at least 3 places to spread the load The glider should be transported with the control frame down to minimise the chance of damage to the cross tubes Flat straps should be used for tie downs to avoid damage to leading edge mylar Store the glider in a dry room off the ground Air the glider out regularly to avoid mildew and never store wet SAFE FLYING TEAM AIRBORNE Issue Date 24 08 04 Rev 4 Page 34 2 Section 15 MAINTENANCE RECORD AUSTRALIA Date Details of Repair or Maintenance Cartied out by Issue Date 24 08 04 Rev 4 Page 35 2 Section 16 GLIDER MODEL CLIMAX 13 AUSTRALIA HANG GLIDER COMPLIANCE SCHEDULES MANUFACTURED AIRBORNE WINDSPORTS Pty Ltd NOTE These specifications are intended only as a guideline for determining whether a given glider is a certified model and whether it is in the certified configurati
43. ing up increases the amount of high siding required Does not effect performance No Change with small adjustments LEADING EDGE TENSION Refer to Fig 1 to vary leading edge tension settings Increase in leading edge tension slows roll rate A slight increase may improve performance but over tensioning will cause the tip to bend up effectively reducing performance No Change with small adjustments Decrease in leading edge tension improves roll rate Loss of performance if tension is reduced to the point where the leading edge starts to deform No Change with small adjustments Issue Date 24 08 04 Rev 4 Page 30 2 Section 13 PERIODIC INSPECTIONS and MAINTENANCE MAINTENANCE SCHEDULE 1 Clean and service 2 Check as directed 3 Check for security cracks wear and faulty operation 4 Remove inspect and replace if necessary 5 Recommend replacement or overhaul MAINTENANCE REQUIREMENT Maintenance Period Maintenance Period 2 Period gt Daily Monthly Three Six Every Every 2 Every 4 Months Monthly Year Years Years a Check leading edges keel amp A Frame structural members and check for fatigue cracks radiating from drilled holes Remove hinge bolt and inspect bushes bolt and hole heck Inspection Zips heck Variable Geometry pulleys and cleats showing outside each nut Check Saddles andfittingsfo
44. ip is positively locked INSTALL NOSE FAIRING Attach the nose fairing applying the top velcro first then gently tension over the nose plates and attach the velcro to the under surface LOAD SPROGS The sprogs should be rotated into position over the red webbing loops and the zips closed fully It is a good time to inspect the junctions prior to closing all zips INSERT UNDER SURFACE BATTENS The under surface battens are inserted then pulled back into the rear of the batten pocket with the string handle PRE FLIGHT INSPECTION You are now ready for the wing pre flight inspection as outlined in the next section It is imperative that you carry out this inspection every time you rig and before you fly Issue Date 24 08 04 Rev 4 Page 14 2 Section 6 PRE FLIGHT INSPECTION The wing was designed so that drag would be kept to a minimum This means that most of the pre flight check points are enclosed A thorough pre flight inspection is mandatory for any aircraft and the best technique is a circular walk around the wing The nose area is the ideal place to start your pre flight check followed by each assembly point Keep in mind the three most critical set up areas THE NOSE QUICK CLIP CONTROL BAR BASE TUBE FASTENERS THE CROSS BAR TENSIONER QUICK CLIP Starting at the nose we suggest the following checklist ensuring all bolts and fasteners have the appropriate thread protruding beyond the nut Check
45. lying in rough air V The indicated airspeeds given are for calibrated instruments mounted on or near the base bar of the control frame It is recommended that you fly your Climax with an airspeed indicator as it is relatively easy in the VG on configuration to exceed the placard limitations Flight operations should be limited to non aerobatic manoeuvres where the pitch angle does not exceed 30 degrees up or down to the horizon and where the bank angle does not exceed 60 degrees Aggressive stalls and spins should not be attempted Operations outside the recommended flight envelope such as aerobatic manoeuvres or erratic pilot technique may ultimately produce equipment failure Your glider was designed for foot launched soaring and should not be flown by more than one person at a time It should not be flown backwards or inverted The setting up and breaking down of a hang glider transportation on cars and flying itself will have an effect over time on its structural integrity The glider will require maintenance as outlined in the maintenance section of this manual Like any aircraft safety depends on a combination of careful maintenance and your ability to fly intelligently and conservatively The owner and operator must understand that due to inherent risks involved in flying a hang glider no warranty of any kind is made or implied against accidents bodily injury and death other than those that cannot by law be excluded We hope that your ne
46. m that the sprogs are correctly set the VG must be in a definitive position The method used checks the sprog angle relative to the root angle of the glider This method is simpler to use than a string line on the trailing edge and is very accurate if the correct procedure is used PREPARING THE TEMPLATE A template is supplied in the rear of the manual which is used to check the sprog settings Cut accurately along the top doted line It is important that the cut is accurate as this edge is lined up with the sprogs and determines the relative angle to the keel Cut a piece of cardboard to the same size as the paper and glue the template to the cardboard Thick cardboard of around 3 5mm is best Once again it is important to accurately cut the top edge Glue the paper template to the cardboard with the top edges accurately aligned Punch a small hole at the top left hand corner of the template where marked A piece of 2mm string around 1 meter long with a small weight is used as the plum bob The string is passed through the hole with a knot on the rear side of the template to secure the line CHECKING THE SPRONG ANGLES Fully assemble the glider on a flat even surface Set the VG as shown on the diagram on the set up template The inner sprog compensation requires this setting to be accurate Use a stand or step ladder to achieve a zero keel angle horizontal The glider should be supported as close as possible to the rear wir
47. nsion the sail There is a webbing strap attached inside the sail with small tang Tension this tang using a small rope as a handle and attach to the rear leading edges with the self tapping screw tang fits into a slot milled into the end of the plastic bung which locates the tip rod cup Repeat for the other leading edge Issue Date 24 08 04 Rev 4 Page 19 CLIMAX C2 If you find the above technique to tension the sail difficult the following method can be used Remove the nose webbing tangs from their bolts at the nose plate Locate the tip webbing tangs with the screws as described previously Slowly spread the leading edges out Ensure the sail is able to move forward as the leading edges are spread and is not caught on the nose pulley or damage will result Fit both nose battens onto the locating pins The cross bars can now be tensioned Check once again the sail is OK at the nose Locate nose webbing tangs to original positions then let cross bar tension off Your glider can now be fully assembled as outlined in the Set Up Procedure BREAKDOWN FOR SHIPPING Reverse the procedure above ensuring that all possible wear points are padded Be careful when folding the sail as the mylar leading edge insert may be damaged When you have finished packing the glider place the front of the glider bag over the rear of the short packed glider Zip up bag carefully and place the rest of the bag inside the package The
48. ntly slide the frame forward out of the sail Be careful that the frame hardware particularly the cam plates and sprogs do not catch on the internal cells or velcros Do not force the removal of the frame otherwise damage will result If the sail is to be sent to the factory for repair the transverse battens should be removed The mylar can be left in but care should be taken not to damage the mylar when folding the sail Issue Date 24 08 04 Rev 4 Page 21 CLIMAX C2 RE INSTALLING THE SAIL Install the transverse battens Fold the sail so that the mylar pockets are together The under surface should be on the outside Lay the sail flat and open up the nose area slightly Prepare the frame by taping the sprogs so that they are folded towards each other If possible it is best to have a cover over each leading edge as this will reduce the chances of the frame snagging on the cells or velcros Position the frame with the leading edges together and in the correct orientation ie cross tubes to the top of the sail Slowly slide the frame into the sail through the main centre zip ensuring that the tubes are forward of all velcros and cells Make sure that the keel passes through the keel pocket You will need to periodically check that the sail is clearing all internal cells and velcros Be careful and slide the frame in slowly otherwise damage will result As the frame is around half way in route the inner sprog tubes through the s
49. on Be aware however that no set of specifications however detailed can guarantee the ability to determine whether a glider is the same model or is in the same configuration as was certified or has those performance stability and structural characteristics required by the certification standards owner s manual is required to be delivered with each HGMA certified glider and it is required that it contain additional airworthiness information Weight of glider with all essential parts and without cover bags and non essential parts Leading Edge Dimensions Nose Plate anchor hole to crossbar attachment hole 3080 mm 121 26 Nose Plate anchor hole to rear sail attachment point 5490 mm 216 14 Outside diameter at nose Outside diameter at cross bar Metric Imperial 33 kg 73105 60 2 36 62 mm 2 44 Outside diameter at rear sail attachment point 12mm Crossbar Dimensions E Overall pin to pin length from leading edge attachment point to hinge bolt at glider centre line Largest outside diameter Keel dimensions 2871 mm 113 03 75 mm The cross bar centre load bearing pin 760 mm 29 92 The pilot hang loop Fwd 1275 mm 50 20 Rear 1305 mm 51 38 Sail Dimensions Chord length at 3 ft outboard of centre line 1620 mm 63 78 Chord length at 3 ft inboard of tip 1020 mm 40 18 Span extreme tip to tip Location of Information Placard Location of Test Fly Sticker
50. on the control frame is the most popular method of assembly in light winds This method is preferable as the sail is less prone to being soiled or damaged during assembly In higher winds it is preferable to lay the glider flat for assembly with the nose into the wind until ready to launch ASSEMBLING ON THE FRAME UNZIP THE BAG Lay the wing down with zip up and the nose facing approximately 120 degrees from the wind direction ASSEMBLE CONTROL FRAME Spread the control bar down tubes and insert the base bar The pip pin is then inserted with the cover firmly secured Check that all the rigging wires are outside the control frame STAND GLIDER UP Rotate the control frame to the vertical position and rotate the wing 180 degrees so that it is sitting on the base bar REMOVE BAG Remove the glider bag and unclip all of the ties The Sprog tube covers should also be removed at this time INSERT NOSE BATTEN Load the nose battens on the locating pins at this time If you fail to load the battens prior to tensioning the glider the VG should be pulled full tight before attempting to load the battens SPREAD LEADING EDGES Carefully spread both leading edges out half way firstly then spread leading edges to their approximate flying position Check the side wires are not twisted IT IS ESSENTIAL THAT THE KEEL AND THE LEADING EDGES ARE KEPT IN THE SAME PLANE OR DAMAGE WILL RESULT ATTACH FRONT FLYING WIRES Ensure that the front flying wi
51. ontrol the under surface blow down at lower angles of attack Not only does this minimise glider oscillation the resulting pitch pressure is progressive and predictable Wire braced washout tubes or sprogs are used in the Climax The centre sprog has a compensating system which causes the sprog to raise approximately 120 mm when the VG is released Certification pitch testing has confirmed the stability of the system with excellent pitching moment results throughout the VG range The Climax is easy to assemble or break down It may be set up on the A Frame or laid flat thereby accommodating for personal preference or site characteristics and restrictions Pip pins and quick clips are used with integrated spring battens to speed up assembly The sprog tubes are secured by simply closing the zips Easy operating internal tip levers are used to load the tip rods At AirBorne we have a well developed quality assurance program ensuring that every glider is built in accordance with the standard it was designed and tested to This gives even the most experienced pilot a sense of security We hope that you have hours of great flying with your new glider Fly high and safely Rick Russell and Shane Duncan Rob Hibberd and Paul Mollison AirBorne WindSports Issue Date 24 08 04 Rev 4 Page 6 2 Section 2 SPECIFICATIONS CLIMAX 13 amp C2 13 CLIMAX 14 amp C2 14 METRIC MPERIAL METRIC IMPERIAL SAIL AREA 13 1 sq
52. ould also be thoroughly checked for damage or cracking at the bond line torch should be used to check that the tubes show no signs of damage on the inside BOLTS Installation amp Removal After tightening all bolts should have at least one and a half to two threads showing All self locking nuts should not be installed more than two times Be sure not to over torque bolts when installing Inspection Check bolts for worn shanks bad threads or corrosion Issue Date 24 08 04 Rev 4 Page 32 CLIMAX C2 AirBotfie SAILS Sail Inspection Check for tears in the sailcloth or any loose or unravelled seams Check all inspection zippers to see if they function smoothly and close completely Inspect tip webbing for damage Sail may be repaired with appropriate sail tape or a sewn on patch Airborne or an authorised agent should be consulted about sail repairs Keep the sail clean of oil and dirt by washing the sail with soap and water Keep the sail covered when not in use CONTINUED EXPOSURE TO SUN DRAMATICALLY SHORTENS THE LIFE OF SAILS possibly to as little as six months INSPECTION AFTER HARD LANDING It is necessary to do a detailed inspection following any unusual stressing of the Hang Glider this full inspection should include all details listed for the six monthly maintenance The inspection should be noted in the logbook and any replacement to be recorded DEFECT REPORTS Details of any defect which develops in serv
53. prog zips When the frame is in all the way the sail can be pulled on further at the tip to allow the rear sprogs to exit the respective zip After the frame is fully installed attach the rear webbing to the rear leading edge bung When tightening the screw ensure that the tang is located in the slot Using a piece of string on the nose webbing tension the leading edge pocket so that the tang is installed on the nose plate bolt Attach the front pulley bungie to the sail Re connect the bottom surface zip checking that the two sides are aligned Re tie the bungie between the eyelets so that it secures the excess zip Route the side wires through the sail and install them on the cross bar bolts with the side wire positioned between the VG actuating cable and the leading edge Do not over tighten as the carbon tube can be damaged Attach the keel pocket tang and the rear wires to the quick clip bolt Ensure that the quick clip is oriented correctly before tightening Make sure that the flat spring is located properly Attach the base tube and rotate the glider on to the control frame Spread the wings slowly checking that nothing has fouled and that the velcros and cells are the rear side of the cross tubes Attach the back up hang loop around the keel and install the main loop to the rocker Make sure that each side of the main loop passes through the slots in the under surface Assemble the glider completely as described earlier in the manual
54. rcracks 2 2 2 4 4 It is recommended that Items marked 1 2 and 3 should be performed by the owner of the glider Items marked 4 be performed by the owner in conjunction with another pilot and Items marked with a 5 be performed by Airborne or an accredited Airborne service agent LOG BOOK When maintenance is performed always check appropriate square and make an entry in the maintenance log at the rear of this manual Issue Date 24 08 04 Rev 4 Page 31 CLIMAX C2 NOTES ON PERIODIC INSPECTIONS AIRFRAME TUBING Installation amp Removal When removing tubing do not bend or force tubes If resistance is encountered stop and check for the cause Do not force the tube Inspection Inspect tubing for cracks damage from abrasion elongated holes or distortion in tube surface Never attempt to repair tubing always replace with new part Inspect tubing for corrosion in and out If corrosion is present the component should be replaced Replacement Aluminium tube comes in many different sizes and grades It is important that the correct replacement parts are used CARBON CROSS TUBES Installation amp Removal To comprehensively check the carbon spars and junction the sail should be removed from the airframe as outlined in this manual Inspection The carbon cross tubes should be thoroughly inspected for cracks The aluminium plug which is bonded into the carbon tube at the centre section sh
55. res are secure and that the quick clip is positively locked INSERT MAINSAIL BATTENS 1 4 Remove the battens from the bag The red battens are for the left side and the green for the right Insert the battens from the centre to the tip with gentle pressure until the batten meets resistance Shake the sail at the trailing edge whilst maintaining gentle pressure on the batten to allow the batten to be inserted over the cross bar DO NOT FORCE THE BATTENS spring battens should be located securely in the trailing edge fold Issue Date 24 08 04 Rev 4 Page 10 CLIMAX C2 TENSION CROSS BARS The cross bars are now tensioned by pulling the 2 1 pull back rope until the shackle is positioned on the Quick Clip Ensure that the catch is positively locked INSERT TIP RODS AUSTRALIA Remove the tip bags and insert the tip rod into the tip plug fitting at the rear of the leading edge Ensure that the rod is fully inserted CLOSE TIP LEVER Move to the tip Place you left thumb in the rope loop of the tip lever and close the lever The lever should be held in the same plane as the trailing edge Do not let the lever close rapidly as damage may result Check that the lever is against the fibre tube and is not being forced above or below the tube Close the zip once the lever is properly closed Issue Date 24 08 04 Rev 4 LOAD TIP ROD Move to the front of the wing For the right tip hold the re
56. the sail is correctly mounted on the leading edges Checks that both sprog assemblies are not damaged Check leading edges are straight and the rear leading edges are located correctly PITCH TRIM To make the glider trim faster move the main hang strap forward and to trim slower move the hang loop rearward The hang loop should be adjusted one hole at a time A heavier pilot may make the glider trim slower than a lighter pilot The heavier pilot causes an increase in twist through extra leading edge flex Minor changes in hang loop position should be used to fine tune the glider for the particular pilot PITCH STABILITY SYSTEM Stability in the pitch axis is provided by maintaining twist outboard of the cross bar leading edge junction Internal washout struts sprogs are used to maintain a minimum amount of twist to maintain the required level of pitch stability Correct attachment and adjustment of the sprogs is essential for maximum stability Do not lower your sprogs below the factory standard settings Lowering your sprogs will result in reduced pitch stability Alterations to the lengths of rigging airframe or adjustments to the airfoil can also have adverse effects on pitch stability Issue Date 24 08 04 Rev 4 Page 25 CLIMAX C2 CHECKING THE CLIMAX STABILITY SYSTEM The Climax has a compensated internal sprog As the VG pulls the sail flatter the Inboard sprog automatically lowers with the trailing edge To confir
57. tle pitch down follows until the glider regains flying speed and recovers from the stall A stall at full VG will result in a much more rapid pitch down and should be avoided Never stall the glider with the nose pitched up too high This is a dangerous manoeuvre and can result in a tail slide and severe tumble As a guideline the angle at which the glider stalls results in a similar negative angle to recover If you push out too much in a turn the glider will turn tighter unless you are flying very slowly in which case you may tip stall So keep on a little extra speed in turns until you get used to the glider SPINS As with all recent gliders the Climax will resist spinning If you do stall a wing in a turn and enter the initial stages of a spin move your weight forward and to the high side of the rotation and the glider will recover Issue Date 24 08 04 Rev 4 Page 23 CLIMAX C2 THERMALLING The optimum speed for thermalling is a little above stall speed it may be necessary to fly faster than this in rough conditions to maintain good control Depending on the nature and area of the thermal a bank angle of between 10 and 50 degrees can be used LANDING Landing is easy in the Climax Your final approach should be a straight glide into the wind faster than trim speed You should feel positive nose up bar pressure The VG should be in the off position Reduce air speed slowly by relaxing the bar pressure smoothly
58. ube towards the trailing edge as you tension the sail Locate the tip lever on to the tip rod When installing the right tip rod the leading edge should be held with your right hand CLOSE TIP LEVER Move to the trailing edge Place you right thumb in the rope loop of the tip lever and close the lever The lever should be held in the same plane as the trailing edge Do not let the lever close rapidly as damage may result INSERT MAINSAIL BATTENS Remove the battens from the bag The red battens are for the left side and the green for the right Insert the battens from the centre to the tip with gentle pressure until the batten meets resistance Shake the sail at the trailing edge whilst maintaining gentle pressure on the batten to allow the batten to be inserted over the cross bar DO NOT FORCE THE BATTENS The spring battens should be located securely in the trailing edge fold The tip batten should have the bungie doubled for additional tension Issue Date 24 08 04 Rev 4 Page 13 CLIMAX C2 TENSION CROSS BARS The cross bars now tensioned by pulling the webbing loop until the shackle is positioned on the Quick Clip Ensure that the catch is positively locked When tensioning with the glider lying flat the keel can be raised approximately 200 mm to allow the side flying wires to be loose ATTACH FRONT FLYING WIRES Lift glider and attach front flying wires Ensure that the front flying wires are secure and that the quick cl
59. w glider will provide you with many hours of safe flying AIRBORNE Issue Date 24 08 04 Rev 4 Page 8 CLIMAX C2 Section 4 WARRANTY STATEMENTS This warranty extends to new Hang Gliders and or accessories and equipment manufactured by AIRBORNE WINDSPORTS PTY LTD Airborne and shall not embrace any other accessories or equipment in the sale AIRBORNE warrants to the customer the hang glider and or accessories manufactured or supplied by AIRBORNE to be free from defect in material and workmanship under normal use and service and of merchantable quality and fit the purpose for which they are ordinarily used This Warranty will apply for a period of ninety 90 days from the date of dispatch of the hang glider not withstanding the number of hours flown but subject to the hang glider remaining the property of the customer This warranty does not exclude any rights implied in favour of any customer by any applicable Federal and State legislation AIRBORNE will make good any parts required because of defective material or workmanship as set out in the Warranty THE WARRANTY WILL NOT APPLY TO Any mechanical adjustments parts replacements repairs or other servicing that in the judgement of AIRBORNE are made or should be made as maintenance Any defect caused by any alteration or modification not approved by AIRBORNE Any defect caused by the fitment of parts that are not made or approved by AIRBORNE Any defect caused b
60. y misuse accidents negligence or failure to carry out proper maintenance service Damage caused by continued operation of the hang glider after it is known to be defective Any defect or consequential loss damage or injury caused by overloading Loss of use of the hang glider loss of time inconvenience damages for personal injuries loss of property or other consequential damages Failure due to wear and tear accident fire incorrect or incomplete rigging and or assembly exposure to the elements operation outside the placarded limitations and repairs attempted or made other than by AIRBORNE or 1 authorised agent AIRBORNE replace free of charge any original part that is determined by it to be defective under the terms of this Warranty and reserves the right to pay monetary compensation or make good the defect in any manner it deems appropriate The customer is responsible for transporting the hang glider or parts to and from AIRBORNE or its authorised agent when making claims under this Warranty The hang glider or parts are at the customer s risk whilst in transit to and fronAIRBORNE or its authorised agent NOTE Warranty service is available to the customer from AIRBORNE WINDSPORTS PTY LIMITED or authorised agent Issue Date 24 08 04 Rev 4 Page 9 CLIMAX C2 Section 5 ASSEMBLY PROCEDURES The wing can be assembled in two positions either lying flat or standing on the control frame Assembling the Climax

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