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Avian JAVA 140, Owner'S Manual

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JAVA 140 

Owner's Manual

BHPA certificate of air worthiness

 number: 9712135

Serial Number

......................

Before flying your glider please read this manual completely,

check all your battens against the batten profile (adjusting

them if necessary) and do a thorough pre-flight check.  

AVIAN LTD.

Stretfield

Bradwell

Hope Valley

S33 9JT

UK

Summary of Contents for JAVA 140

Page 1: ...ss number 9712135 Serial Number Before flying your glider please read this manual completely check all your battens against the batten profile adjusting them if necessary and do a thorough pre flight check AVIAN LTD Stretfield Bradwell Hope Valley S33 9JT UK ...

Page 2: ...Java 140 Owner s Manual Tel 01433 621308 Fax 01433 621753 E mail avian hanggliding co uk www hanggliding co uk 2 ...

Page 3: ...E FLIGHT CHECKLIST 10 FLYING THE JAVA 12 DE RIGGING 13 POST FLIGHT INSPECTION 15 VB VARIABLE BILLOW 15 TUNING INSTRUCTIONS 16 BATTENS AND BATTEN PROFILE 17 CHANGING HANG POSITION 19 MAINTENANCE 20 RECOMMENDED COMPONENT LIFE 25 REPAIR 25 TRANSPORTATION AND STORAGE 25 TROUBLE SHOOTING 27 OWNERSHIP 30 APPENDIX ASSEMBLY DRAWINGS 31 3 ...

Page 4: ...solutions If you are still not sure contact your local dealer or the Avian factory Both will be pleased to help you Make sure your first flight on your new glider is in perfect conditions from a site that you are familiar with PLEASE NOTE Avian Ltd do not have commercial product liability insurance Avian hang gliders are built using materials and fittings to the industry standard or better Avian h...

Page 5: ...ot 3 Hang Glider Payloads Pilot Clip in Weight range Min Max 8 Stone 8lb 13 Stone 3lb 120lbs 185lbs 55Kg 85Kg 4 Hang Point Position Range Pitch trim This is a king post hang point glider There are three settings to alter the position of the KINGPOST and therefore the hang point These are on the kingpost channel see appendix part 3 The standard factory setting is the centre hole Centre hole 58 3 8 ...

Page 6: ... 10 3kg m2 Max L D ratio 13 Speed range 15 70 mph 24 113 km h Maximum speed rough air VNE rough air 45mph 72km h Maximum speed smooth air VNE 70mph 113km h Normal packed length 18 5 5 6m Breakdown length 14 1 4 3m Glider weight rigged 60 lbs 27 5 Kg Glider weight in bag 64 lbs 29 Kg Speeds measured using Davron 808 vario and internal ASI Air speed indicator 6 ...

Page 7: ...see what is causing it and free the problem before continuing Do not attempt to force the wings apart 4 Put the bottom bar on and insert the two stainless pins from the back of the base bar and fit the safety rings PUT THE RINGS IN IMMEDIATELY DO NOT LEAVE IT UNTIL LATER Thread the VB cord through the eye of the quick ring and through the cleat on the base bar Tie a knot in the end of the cord 5 L...

Page 8: ... the nose batten This is easier with the VB on full Some people prefer to put the nose batten in before the wings are moved out at all or to leave the nose batten in the glider when packed If you do this don t forget to check its profile when you check the profile of the other battens It will go flat 12 Make sure that the wires are not twisted then stand the glider on its control frame and attach ...

Page 9: ...d Now making sure that the wires are not kinked attach the swan catch pip pin and safety washer You should always hook in the top rear rigging before attaching the swan nose catch 6 Lay the battens on the ground and pair them up red with green and check that corresponding batten pairs have the same profile This is a good habit to get into as it will reduce the chances of taking off on a glider wit...

Page 10: ...en tensioned They should be pushed home so that only the rope projects from the batten pocket Put the most outboard U S batten in first The under surface battens can be pushed home with another under surface batten 12 Put the nose batten in and locate it on its seat just in front of the nose plate This operation is easier if the VB is pulled on first When the batten is in release the VB Some pilot...

Page 11: ...ction of keel pocket and sail etc 5 Battens correct shape and undamaged with no cracks or splits in the fibreglass section 6 All nuts and bolts secure 7 All quick release fittings secure i cross tube tensioner ii nose catch check the clevis pin and split ring as well iii washout rods correctly located iv tip battens correctly located on leading edge v quick pins and rings on bottom bar secure vi o...

Page 12: ...EMBER IF IN DOUBT DO NOT FLY RETURN YOUR GLIDER TO AVIAN LTD FOR A THOROUGH STRIP DOWN 22 Check operation of the VB Pull the VB rope and check that it pulls on smoothly and releases If it is jammed check and release if caught NOTE If instruments are attached to the right hand upright it may interfere with the VB operation The VB cord runs down the rubber back of the right hand upright Crushing the...

Page 13: ...o A wing close to the stall becomes difficult to control For both these reasons the glider should be flown with sufficient airspeed close to the ground hill or any other aircraft Spin Hang gliders are generally resistant to spin It is very unlikely that you will ever experience a spin in normal flight To recover from a spin pull the bar in and increase speed BEFORE applying opposite bank Flying wi...

Page 14: ...he wings can then be closed further and the king post lowered The luff lines should be clipped to the ring sewn to the edge of the king post hole 3 Place the padding around the tension bolt Bring the leading edges in further and then dismantle the A frame Make sure that the packing wings the pieces of packing sewn to the sail are out of the sail and alongside the top of the uprights Check that the...

Page 15: ...the wing tips 2 Roll the last few feet of the sail and put the protection socks on the wing tips 3 Make sure that the packing wings are out of the sail and alongside the top of the uprights 4 Release the X tube tension and move the wings in slightly The keel remains on the ground 5 Remove the rest of the battens except the nose batten 6 Remove nose cone and release the lower nose wires 7 Unhook th...

Page 16: ...g characteristics of the glider while in flight As mentioned else where in this hand book when the glider is rigged the VB cord should be threaded through the cleat on the speed bar and knotted This is a good habit to get into The knot will prevent the end of the VB cord being lost The VB should only be operated when the glider is standing fully rigged on its A frame Operating the VB while the gli...

Page 17: ...e glider untwisted VB Set up The VB on your glider should be factory set However the ropes do stretch a little and you may need to adjust or change a rope in time Please refer to the appendix for diagrams of the VB The white retaining cord 2 limits the travel of the rear triple pulley block 3 If this is too long the block will come out of the keel pocket with the VB in the released position When p...

Page 18: ...red Mark the leading edge with a pen or pencil before removing the self tapping screw and ONLY ALTER THE WASHOUT AT THE TIP IN SMALL INCREMENTS MAXIMUM 3mm at a time The total movement should NOT exceed 10mm each side of the datum the hole for the self tapping screw DON T FORGET TO REPLACE THE SELF TAPPING SCREW Other tuning should NOT be carried out without reference to Avian Ltd or an approved d...

Page 19: ...s is because the cut of the sail will tend to flatten the batten if it is over cambered The objective with the nose batten is to get the sail to fit tightly around the nose area How to alter the shape of the batten The objective is to get a smoothly curved batten but it is not quite as easy as it looks It is very difficult to bend the batten very close to its front end Do not attempt to alter the ...

Page 20: ...Java 140 Owner s Manual All other battens are made from 10 8mm OD 7075 tube 6082 Aluminium is easier to bend 7075 aluminium is brittle and more difficult to bend but it holds its shape much better 20 ...

Page 21: ... and the glider flat on the ground the kingpost channel can be worked on from above Perhaps more easily with the glider fully rigged tail into wind and working from below the sail This can only be done in light winds In this case release the nose catch and unclip the tack hook on the top rear wire Place an Allen key in both of the Allen screws 1 Undo one of the Allen screws 1 Using an Allen key pu...

Page 22: ...d job of it Both Allen screws are locked in position using thread lock If the wrong type of thread lock is used the Allen screws may be almost impossible to remove If thread lock is not used the screws could work loose When putting the thread lock on the second screw fluid should be put in the barrel as well as on the screw If it is just put on the screw it is possible for hydraulic action to prev...

Page 23: ...any one of the structural members is serious and the only remedy is replacement Insufficient care during ground handling or transportation can lead to tube abrasion or indentation The former accelerates fatigue fracture and the latter reduces the strength of a component Keep a regular watch for tell tale hair line cracks which are most likely to occur in high stress areas such as around bolt holes...

Page 24: ...ead kite string or fishing line This line should be threaded between the luff line eyelets and pulled taught A light strong thread is an advantage as it will not sag too much The line should pass in a straight line between the two eyelets If you are measuring number 1 luff line the line closest to the keel the thread will have to pass from the left hand number one luff line eyelet in front of the ...

Page 25: ... to swivel the tangs with light thumb pressure Once a cable has a kink the strands are damaged and replacement is the only cure The side cables are particularly important and should receive a frequent detailed inspection Check for cable damage along the length but the main failure area lies immediately adjacent to the swaged fitting Look carefully for signs of strand fracture at this position Corr...

Page 26: ...aning It is without doubt better to keep the wing clean than to try and clean it Some dirt never comes off completely If you decide you do need to wash your wing then select a dry day and have access to a good hose and clean water supply Never use bleaches strong soaps or detergents The soap residue can react with ultra violet light and degrade the fabric We recommend a very mild liquid soap washi...

Page 27: ...requires skilled and qualified attention We do not recommend self repair or re assembly by other than Avian or Avian nominated repair agents No replacement parts should be fitted unless they are factory supplied and identified as such Repairs should only be undertaken by Avian approved personnel Sail repairs are only to be undertaken by the Avian factory Repairs of all other parts by replacement o...

Page 28: ...ing edge has been specially designed in two main sections the inner nose to out board of the cross tube leading edge junction and the outer tip section of the leading edge These can be separated to allow a reduction in total glider packed length This facility will be found useful for transport overseas or storage It may also reduce the cost of a damaged leading edge should the damage be confined t...

Page 29: ...at it disappears into the keel when fully rigged Also check that the strop has no twists in it and that the elastic loop is on the outside of the stainless tang i e not next to the keel when the tension is released The tension strop is difficult to pull on 1 The tension strop might be twisted around the cross tube centre bolt When freed inspect the strop for damage and replace if necessary Try and...

Page 30: ... obvious If both the elastics go into the keel without being twisted the tension strop should not be twisted If it is you must have a twist first one way and then the other Carefully untwist the webbing The VB is no longer as easy to pull on This may be a number of reasons but is generally because the rope is fouling something Check the rope The VB is no longer as easy to pull on but I have change...

Page 31: ...ght on The Kingpost channel or with the wings further in the end of the nose batten Release the tension strop and continue to move the wings inboard The back of the kingpost gets caught on the sail when rigging Check the rigging instructions The kingpost should be raised before the wings are moved out When the kingpost is raised the kingpost hole should be held back to allow the base of the kingpo...

Page 32: ... bar in with out realising On a smooth day when you have a safe ground clearance and are clear of all other aircraft slowly release your grip on the base bar and check the bar position and trim speed without putting any load on the speed bar 2 As above this might be caused by a backup loop that is caught and interfering with the main loop when flying Free the loop so that you are sure it is loose ...

Page 33: ... is out as best you can The problem is usually caused by the storage of the battens in the leading edge pocket which tends to fill the pockets with debris and encourages mildew DO NOT STORE YOUR BATTENS IN THE LEADING EDGE POCKET 33 ...

Page 34: ... the unfortunate case of having to recall components or gliders Please keep a record of all work done on your hang glider Please let us know of any ideas for changes that you think would improve our hand book hang gliders or company We are interested and would also like to hear if you have any complaints about the gliders or our service We would be most grateful to receive any interesting photogra...

Page 35: ...Java 140 Owner s Manual APPENDIX ASSEMBLY DRAWINGS KINGPOST KEEL JUNCTION 1 M6 10mm button head Allen screw 2 M8 nylon washer 3 Kingpost channel 4 1 1 4 8mm stainless barrel 35 ...

Page 36: ...r s Manual NOSE ASSEMBLY 1 Nylon spacer bush 7 5mm 2 M6 nyloc nut 3 Nylon leading edge bush 4 M6 nut cap 5 Nose channel 6 Keel saddle M6 hole 7 M6 Bolts 8 Stainless M6 washer 9 Leading edge bung 10 Keel nose bung 36 ...

Page 37: ...p 2 M8 nyloc nut 3 M8 nylon washer 4 HRS single 8mm hole 5 Cross tube saddle 8mm hole 6 Leading edge saddle 6mm hole 7 HRS double 6mm hole 8 M8 nut cap retaining washer 9 M8 nut cap 10 30º tang for rigging wire 11 M8 60mm bolt 12 M6 leading hinge bolt 13 Aluminium hinge spacer 37 ...

Page 38: ...ss tube shackle 4 Cross tube centre nut cap 5 Cross tube hinge centre bolt M6 Allen head 6 M6 nyloc nut 7 M6 rubber cap 8 M6 nylon washer 9 Cross tube centre rubber foot 10 Cross tube centre sealed bearing pulley 11 Nylon cheeks for cross tube centre pulley 12 Cross tube ball socket 13 Cross tube centre ball 38 ...

Page 39: ...etaining cord 3 Triple block pulley with becket 4 Top of upright pulley block 5 Cross tube centre sealed bearing pulley 6 Cross tube VB rope 7 Tension strop static side only part shown 8 Rear of keel single block 9 Tension strop moving side only part shown 10 Cross tube VB rope attachment to tension strop 39 ...

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