Great Planes GPMA1154 User Manual

INSTRUCTION MANUAL

Wingspan: 53.5 in [1360mm]
Wing Area: 395 sq in [25.5dm2]
Weight: 3-3.25 lb [1360-1470g]
Wing Loading: 18-19 oz/sq ft [55-58 g/dm2]
Length: 34.25 in [870mm]
Radio: 4-Channel with Two Micro-Mini and Two Micro Servos
Motor: Two 28-30-950 RimFire™ Brushless Motors and

Two ElectriFly SS-25 Speed Controls

WARRANTY

Great Planes® Model Manufacturing Co. guarantees this kit to

be free from defects in both material and workmanship at the date
of purchase. This warranty does not cover any component parts
damaged by use or modifi cation. In no case shall Great Planes’
liability exceed the original cost of the purchased kit. Further,
Great Planes reserves the right to change or modify this warranty
without notice.

In that Great Planes has no control over the fi nal assembly or
material used for fi nal assembly, no liability shall be assumed nor
accepted for any damage resulting from the use by the user of
the fi nal user-assembled product. By the act of using the user­assembled product, the user accepts all resulting liability.

If the buyer is not prepared to accept the liability associated
with the use of this product, the buyer is advised to return

™

this kit immediately in new and unused condition to the place
of purchase.

To make a warranty claim send the defective part or item to Hobby
Services at the address below:

Hobby Services

3002 N. Apollo Dr., Suite 1

Champaign, IL 61822 USA

Include a letter stating your name, return shipping address, as
much contact information as possible (daytime telephone number,
fax number, e-mail address), a detailed description of the problem
and a photocopy of the purchase receipt. Upon receipt of the
package, the problem will be evaluated as quickly as possible.

READ THROUGH THIS MANUAL BEFORE STARTING CONSTRUCTION. IT CONTAINS IMPORTANT

INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USE OF THIS MODEL.

Entire Contents © Copyright 2007

Champaign, Illinois

[phone], Ext 5

[e-mail]

GPMZ1154 for GPMA1154 V1.1

TABLE OF CONTENTS

INTRODUCTION ............................................................... 2

AMA .................................................................................. 2

SAFETY PRECAUTIONS .................................................3

LITHIUM BATTERY HANDLING AND USAGE ................ 3

DECISIONS YOU MUST MAKE ........................................ 3

Radio Equipment .......................................................3

Motor Recommendations ........................................... 3

ADDITIONAL ITEMS REQUIRED .................................... 4

Adhesives and Building Supplies ............................... 4

Optional Supplies and Tools .......................................4

IMPORTANT BUILDING NOTES ...................................... 4

ORDERING REPLACEMENT PARTS .............................. 4

KIT CONTENTS ................................................................ 5

PREPARATIONS ............................................................... 6

ASSEMBLE THE WING .................................................... 6

ASSEMBLE THE FUSELAGE .......................................... 9

Install the Stab, Elevators and Rudder ....................... 9

Install the Elevator & Rudder Servos & Pushrods .... 11

Install the Speed Control, Receiver & Batteries ....... 12

FINAL ASSEMBLY ......................................................... 14

Complete the Radio Installation ............................... 14

Finishing Touches .................................................... 14

GET THE MODEL READY TO FLY ................................. 15

Install & Connect the Motor Battery ......................... 15

Set the Control Throws ............................................ 16

Balance the Model (C.G.).........................................16

Balance the Model Laterally ..................................... 17

PREFLIGHT .................................................................... 17

Identify Your Model ................................................... 17

Charge the Batteries ................................................ 17

Balance Propellers ................................................... 17

Range Check ........................................................... 17

MOTOR SAFETY PRECAUTIONS ................................. 17

AMA SAFETY CODE ...................................................... 18

CHECK LIST ................................................................... 18

FLYING ............................................................................ 19

Takeoff ..................................................................... 19

Flight ........................................................................ 19

Landing ....................................................................19

INTRODUCTION

The PBY Catalina has had a long and glorious service through
the history of aviation, handling everything from search and
rescue to monitoring our coast line during times of war. With
the reliability and power of today's most advanced brushless
motors and batteries, the ElectriFly PBY Catalina is a reliable
and agile fl ying model of this famous twin engine airplane.

For the latest technical updates or manual corrections to the
ElectriFly PBY Catalina visit the Great Planes web site at
www.greatplanes.com. Open the “Airplanes” link, then select
the PBY Catalina ARF. If there is new technical information
or changes to this model, a “tech notice” box will appear in
the upper left corner of the page.

AMA

We urge you to join the AMA (Academy of Model Aeronautics)
and a local R/C club. The AMA is the governing body of model
aviation and membership is required to fl y at AMA clubs.
Though joining the AMA provides many benefi ts, one of the
primary reasons to join is liability protection. Coverage is not
limited to fl ying at contests or on the club fi eld. It even applies
to fl ying at public demonstrations and air shows. Failure to
comply with the Safety Code (excerpts printed in the back of
the manual) may endanger insurance coverage. Additionally,
training programs and instructors are available at AMA club
sites to help you get started the right way. There are over
2,500 AMA chartered clubs across the country. Contact the
AMA at the address or toll-free phone number below.

Academy of Model Aeronautics

5151 East Memorial Drive

Muncie, IN 47302

Tele: [phone]

Fax [phone]

Or via the Internet at:

http://www.modelaircraft.org

IMPORTANT!!! Two of the most important things you can do

to preserve the radio controlled aircraft hobby are to avoid
fl ying near full-scale aircraft and avoid fl ying near or over
groups of people.

2

PROTECT YOUR MODEL, YOURSELF

& OTHERS...FOLLOW THESE

IMPORTANT SAFETY PRECAUTIONS

1. Your PBY Catalina should not be considered a toy, but
rather a sophisticated, working model that functions very
much like a full-size airplane. Because of its performance
capabilities, the PBY Catalina, if not assembled and operated
correctly, could possibly cause injury to yourself or spectators
and damage to property.

2. You must assemble the model according to the instructions.
Do not alter or modify the model, as doing so may result in an
unsafe or unfl yable model. In a few cases the instructions may
differ slightly from the photos. In those instances the written
instructions should be considered as correct.

3. You must take time to build straight, true and strong.

4. You must use an R/C radio system that is in fi rst-class
condition, and a correctly sized motor and components
throughout the building process.

LITHIUM BATTERY

HANDLING & USAGE

WARNING!! Read the entire instruction sheet included with
the battery. Failure to follow all instructions could cause
permanent damage to the battery and its surroundings, and
cause bodily harm!

• ONLY use a LiPo approved charger. NEVER use a NiCd/
NiMH peak charger!

• NEVER charge in excess of 4.20V per cell.

• ONLY charge through the “charge” lead. NEVER charge
through the “discharge” lead.

• NEVER charge at currents greater than 1C.

• ALWAYS set charger’s output volts to match battery volts.

• ALWAYS charge in a fi reproof location.

• NEVER trickle charge.

• NEVER allow battery temperature to exceed 150° F (65° C).

• NEVER disassemble or modify pack wiring in any way or
puncture cells.

• NEVER discharge below 2.5V per cell.

• NEVER place on combustible materials or leave unattended
during charge or discharge.

• ALWAYS KEEP OUT OF REACH OF CHILDREN.

5. You must correctly install all R/C and other components so
that the model operates correctly on the ground and in the air.

6. You must check the operation of the model before every
fl ight to insure that all equipment is operating and that the
model has remained structurally sound. Be sure to check
clevises or other connectors often and replace them if they
show any signs of wear or fatigue.

7. If you are not an experienced pilot or have not fl own
this type of model before, we recommend that you get the
assistance of an experienced pilot in your R/C club for
your fi rst fl ights. If you’re not a member of a club, your local
hobby shop has information about clubs in your area whose
membership includes experienced pilots.

We, as the kit manufacturer, provide you with a top quality,
thoroughly tested kit and instructions, but ultimately the
quality and fl yability of your fi nished model depends
on how you build it; therefore, we cannot in any way
guarantee the performance of your completed model,
and no representations are expressed or implied as to
the performance or safety of your completed model.

Remember: Take your time and follow the instructions to
end up with a well-built model that is straight and true.

DECISIONS YOU MUST MAKE

This is a partial list of items required to fi nish the PBY Catalina
that may require planning or decision making before starting
to build. Order numbers are provided in parentheses.

Radio Equipment

❏ 4-Channel Radio (such as the Futaba
❏ Micro Receiver (If you choose to, a standard size receiver

will fi t in the radio compartment)

❏ Two S3103 Micro-Mini Servos (FUTM0037) for the ailerons

(or an equivalent servo with 17 oz-in of torque and servo
case dimensions of 0.9" x 0.4" x 0.8" [22 x 11 x 20mm])

❏ Two S3110 Micro Servos (FUTM0046) for the elevator and

rudder (or an equivalent servo with 22 oz-in of torque and servo
case dimensions of 0.9" x 0.4" x 0.8" [22 x 11 x 20mm])

❏ Two 6" [150mm] Servo Extensions (HCAM2701 for Futaba)
❏ Two Servo Y-Harnesses (HCAM2751 for Futaba)

®

4EXA)

Motor, Speed Control and
Battery Recommendation

❏ Two RimFire Brushless 28-30-950 Motors (GPMG4560)
❏ Two ElectriFly SS-25 Speed Controls (GPMM1820)
❏ One Deans U Parallel ESC adapter (GPMM3141)
❏ ElectriFly Power Series Lithium Polymer Battery.

2100mAh 11.1 Volt (GPMP0617), 3200mAh 11.1 Volt
(GPMP0623) or equivalent

❏ ElectriFly PolyCharge

3

™

4 Battery Charger (GPMM3015)

ADDITIONAL ITEMS REQUIRED

ORDERING REPLACEMENT PARTS

Adhesives and Building Supplies

This is the list of Adhesives and Building Supplies that are
required to fi nish the PBY Catalina.

❏ 1/2 oz. [15g] Thin Pro

™

CA (GPMR6001)

❏ 1/2 oz. [15g] Medium Pro CA+ (GPMR6007)
❏ Pro 6-Minute Epoxy (GPMR6045)
❏ Drill Bits: 1/16" [1.6mm] and a #57
❏ #1 Hobby Knife (HCAR0105)
❏ #11 Blades (5-pack, HCAR0211)
❏ R/C-56 Canopy Glue (JOZR5007)
❏ Denatured Alcohol (for epoxy clean up)
❏ Threadlocker thread locking cement (GPMR6060)

Optional Supplies and Tools

Here is a list of optional tools mentioned in the manual that
will help you build the PBY Catalina.

❏ 21st Century

®

Sealing Iron (COVR2700)

❏ 21st Century Iron Cover (COVR2702)
❏ CA Applicator Tips (HCAR3780)
❏ CA Debonder (GPMR6039)
❏ Epoxy Brushes (6, GPMR8060)
❏ Mixing Sticks (50, GPMR8055)
❏ Mixing Cups (GPMR8056)

IMPORTANT BUILDING NOTES

• When you see the term test fi t in the instructions, it means
that you should fi rst position the part on the assembly
without using any glue, then slightly modify or custom fi t
the part as necessary for the best fi t.

• Whenever the term glue is written you should rely upon
your experience to decide what type of glue to use. When
a specifi c type of adhesive works best for that step, the
instructions will make a recommendation.

• Whenever just epoxy is specifi ed you may use either 30-
minute (or 45-minute) epoxy or 6-minute epoxy.

• Photos and sketches are placed before the step they
refer to. Frequently you can study photos in following steps
to get another view of the same parts.

Replacement parts for the ElectriFly PBY Catalina ARF are
available using the order numbers in the Replacement Parts
List that follows. The fastest, most economical service can be
provided by your hobby dealer or mail-order company.

To locate a hobby dealer, visit the Great Planes web site
at www.greatplanes.com. Choose “Where to Buy” at the
bottom of the menu on the left side of the page. Follow the
instructions provided on the page to locate a U.S., Canadian
or International dealer.

Parts may also be ordered directly from Hobby Services by
calling [phone], or via facsimile at [phone],
but full retail prices and shipping and handling charges will
apply. Illinois and Nevada residents will also be charged
sales tax. If ordering via fax, include a Visa
number and expiration date for payment.

Mail parts orders and payments by personal check to:

Hobby Services

3002 N. Apollo Drive, Suite 1

Champaign, IL 61822

Be certain to specify the order number exactly as listed in
the Replacement Parts List. Payment by credit card or
personal check only; no C.O.D.

If additional assistance is required for any reason, contact
Product Support by telephone at [phone], or by
e-mail at [e-mail].

Replacement Parts List

Order Number Description How to Purchase

Missing pieces ............... Contact Product Support

Instruction manual .......... Contact Product Support

Full-size plans ...................................Not available

GPMA2188 Fuselage ....................................Contact Hobby Supplier

GPMA2189 Wing Set ....................................Contact Hobby Supplier

GPMA2190 Tail Surfaces ...............................Contact Hobby Supplier

GPMA2191 Wing Strut Set ............................Contact Hobby Supplier

GPMA2192 Battery Hatch .............................Contact Hobby Supplier

GPMA2193 Prop Adapter/ Hub (1) ................Contact Hobby Supplier

GPMA2194 Canopies (2) ..............................Contact Hobby Supplier

GPMA2195 Water Rudder .............................Contact Hobby Supplier

GPMA2196 Wing Tip Float Set ......................Contact Hobby Supplier

GPMA2197 Decal Set ...................................Contact Hobby Supplier

GPMA2198 Cowls (2) ....................................Contact Hobby Supplier

GPMQ6610 8" x 6" Propeller .........................Contact Hobby Supplier

®

or MasterCard®

4

KIT INSPECTION

Before starting to build inspect the parts to make sure they are of acceptable quality. If any parts are missing or are not
of acceptable quality, or if you need assistance with assembly, contact Product Support. When reporting defective or
missing parts, use the part names exactly as they are written in the Kit Contents list.

Great Planes Product Support

3002 N. Apollo Drive, Suite 1

Champaign, IL 61822

Telephone: [phone], ext. 5

Fax: [phone]

E-mail: [e-mail]

KIT CONTENTS

10

14

13

4

1. Left Wing with Aileron

2. Right Wing with Aileron

3. Wing Joiner

4. Tip Floats (2)

5. Nacelles (2)

6. Motor Mounts (2)

7. Prop and Prop Adapters (2)

11

12

55

7

6

3

1 2

11

9

6

8

4

8. Rudder

9. Stabilizer and Elevators

10. Fuselage

11. Blisters (4)

12. Wing Struts (4)

13. Foam Stand Cradles (2)

14. Stand Tubes (2)

5

PREPARATIONS

❏ 1. If you have not done so already, remove the major parts

of the kit from the box and inspect for damage. If any parts
are damaged or missing, contact Product Support at the
address or telephone number listed in the “Kit Inspection”
section on page 5.

❏ 2. Carefully remove the tape and separate the ailerons

from the wing and the elevators from the stab. Use a covering
iron with a covering sock on low to medium heat to tighten
the covering if necessary. Apply pressure over sheeted
areas to thoroughly bond the covering to the wood.

❏ ❏ 2. Insert the hinges and aileron into the slots in the

trailing edge of the wing. Adjust the aileron so there is a small
gap between the LE of the aileron and the wing. The gap
should be small, just enough to see light through or to slip
a piece of paper through. Be sure the aileron moves freely
up and down. Once you are satisfi ed with the positioning of
the aileron, apply a couple of drops of thin CA to the top and
bottom of each hinge. Do not use CA accelerator. After the CA
has fully hardened, test the hinges by pulling on the aileron.

❏ 3. Your kit includes a stand that can be used during the

assembly process and as a useful tool for transporting the
airplane. Slide the tubes into the foam cradles as shown.

ASSEMBLE THE WING

Assemble the right wing fi rst so your

work matches the photos.

❏ ❏ 1. Insert a hinge into each of the three hinge slots in

the aileron.

❏ ❏ 3. A servo extension has been pre-installed in the wing

and is taped to the wing just outside of the servo opening.
Untape the extension from the wing and remove the protective
wrapping from the connector. (Note:The connector matches

Futaba connectors but can be used with many other brand
servos as well. Check to be sure your connector wires match
the wires of this connector before using it. If you feel it is
necessary to replace the extension with one of your brand,
tie a string to one end of the connector before removing it
from the wing. After removing the extension the string can
be used to pull the new extension through the wing.) Plug

your servo into the extension. Secure the servo lead to the
extension with tape, a piece of shrink tube or some other
method to keep them from coming unplugged.

666