Hangar 9 Piper Pawnee 40 User Manual
Piper Pawnee 40 ARF
Assembly mAnuAl
Specifications
Wingspan ........................................80 in (2032mm)
Wing Area ..........................942 sq in (60.77 sq dm)
Length .......................................55.8 in (1417.3mm)
Weight ..........................................8–9 lb (3.6–4 kg)
Engine ..................................... .56–.82 Four-Stroke
....................................... .40–.52 Two-Stroke
...........................................Power 46 Electric
Radio..............5-Channel w/7 Servos (6 for electric)
Table of Contents
Using the Manual ..................................................................3
Required Tools and Adhesives ........................................................3
UltraCote Covering Colors ...........................................................3
Before Starting Assembly ............................................................3
Radio and Power Systems Requirements ................................................4
Recommended Servo Extensions ......................................................4
Recommended JR, JR SPORT and Spektrum Systems ......................................4
Recommended Setup–2-Stroke Glow ...................................................5
Recommended Setup–4-Stroke Glow ...................................................5
Recommended Setup–Electric ........................................................5
FS One ..........................................................................5
Field Equipment ...................................................................5
Warranty Period ...................................................................6
Limited Warranty...................................................................6
Damage Limits ....................................................................6
Safety Precautions .................................................................6
Questions, Assistance, and Repairs ....................................................7
Inspection or Repairs ...............................................................7
Warranty Inspection and Repairs.......................................................7
Non-Warranty Repairs...............................................................7
Safety, Precautions, and Warnings .....................................................8
Contents of Kit ....................................................................9
Section 1: Landing Gear and Rudder Installation .........................................10
Section 2: Aileron and Flap Servo Installation ...........................................16
Section 3: Wing Attachment .........................................................21
Section 4: Stabilizer/Elevator Installation ...............................................25
Section 5: Radio Installation .........................................................28
Section 6: 2-Stroke Engine Installation.................................................32
Section 7: 4-Stroke Installation.......................................................36
Section 8: Throttle Servo Installation ..................................................41
Section 9: Electric Motor Installation ..................................................43
Section 10: Cowling and Canopy Installation ............................................45
Section 11: Recommended Center of Gravity (CG)........................................47
Section 12: Control Throws .........................................................48
Section 13: Pre-Flight..............................................................49
Section 14: Adjusting the Engine .....................................................49
Section 15: Range Testing Your Radio .................................................49
2008 Official AMA National Model Aircraft Safety Code ....................................50
2
Using the Manual
This manual is divided into sections to help make assembly easier to understand, and to provide breaks between each
major section. In addition, check boxes have been placed next to each step to keep track of each step completed. Steps
with a single box (
repeating, such as for a right or left wing panel, two servos, etc. Remember to take your time and follow the directions.
) are performed once, while steps with two boxes ( ) indicate that the step will require
Required Tools and Adhesives
Tools
• Felt-tipped pen or pencil • Flat screwdriver
• Adjustable wrench • Drill
• Hobby knife • Masking tape
• Phillips screwdriver (large) • Phillips screwdriver (small)
• Ruler • Sandpaper
• Soldering iron • Solder
• Hex wrench: 3/32-inch
• Drill bit: 1/16-inch (1.5mm), 5/64-inch (2mm), 11/64-inch (4.5mm)
Adhesives
• Formula 560 Canopy Glue (PAAPT56) • Pacer Z-42 Threadlock (PAAPT42)
• Thin CA (cyanoacrylate) Glue (PAAPT07) • CA Remover/Debonder (PAAPT16)
UltraCote Covering Colors
• Turquoise HANU898 •Midnight Blue HANU885
• White HANU870
Before Starting Assembly
Before beginning the assembly of the Piper Pawnee 40, remove each part from its bag for inspection. Closely inspect
the fuselage, wing panels, rudder, and stabilizer for damage. If you find any damaged or missing parts, contact the
place of purchase.
If you find any wrinkles in the covering, use a heat gun or sealing iron to remove them. Use caution while working around
areas where the colors overlap to prevent separating the colors.
HAN101 – Sealing Iron
HAN100 – Heat Gun
HAN141 – Sealing Iron
Sock
HAN150 – Covering Glove
3
Radio and Power Systems Requirements
• 5-channel radio system (minimum) w/receiver • Large Servo Arm (JSP98060) (for use on flap servos)
• 700mAh Ni-Cd 4-cell (JSP91010)
• JR Standard Switch (JSP98010) or JR Chargeswitch (JRPA004)
• DS821 Digital Sport Servo (JRPS821) (7) or equivalent (6 when building electric version)
Recommended Servo Extensions
5-channel Radio System
Aileron
Y-harness (JSP98020)
9-inch Servo Extension JRPA097 (2)
Flaps
Y-harness (JSP98020)
6-channel Radio System
Aileron
Y-harness (JSP98020)
9-inch Servo Extension JRPA097 (2)
Flaps
12-inch Servo Extension JRPA098 (2)
7-channel Radio System
Aileron
6-inch Servo Extension JSP98110 (2)
9-inch Servo Extension JRPA097 (2)
Flaps
12-inch Servo Extension JRPA098 (2)
Recommended JR, JR SPORT and Spektrum Systems
• X9303 2.4
• XP9303
• XP7202
• DX7
• XP6102
JR X9303 2.4
Spektrum DX7
JR XP6102
JR XP7202
Spektrum is used with permission of
Bachmann Industries, Inc.
4
Recommended Setup–2-Stroke Glow
• Evolution® .52NX with Muffler (EVOE0520)
• Evolution Propeller 11 x 5 (EVO11050) to 11 x 6 (EVO11060)
Recommended Setup–4-Stroke Glow
• Saito™ .82 AAC w/Muffler (SAIE082A or SAIE082AGK)
• Evolution Propeller 13 x 8 (EVO13080) or 14 x 6 (EVO14060)
Recommended Setup–Electric
• E-flite® Power 46 BL Outrunner Motor (EFLM4046A)
• Castle Creations 60A ESC (CSEPHX60)
• Thunder Power 4S 3850–4500mAh Li-Po Battery Pack
• APC Propeller 13x6.5-inch (APC13065E) to 14x7 (APC14070E)
FS One
Evolution .52NX
EVOE0520
Saito .82 AAC
SAIE082A
Power 46 Brushless
Outrunner Motor,670Kv
EFLM4046A
With FS One® you get more than photorealistic fields, gorgeous
skies and realistic-looking aircraft. You get incredibly advanced
aerodynamic modeling that simulates every possible aspect
of real-world flight.
Field Equipment
• Propeller • Fuel
• Glow Plug Wrench (HAN2510) • Extra Long Glow Plug Igniter w/Charger (HAN7115)
• Glow Plug (EVOGP1) • Manual Fuel Pump (HAN118)
• Flight Pack Field Box (HAN130) • PowerPro HD 12V Starter (HAN162)
• Mosfet Power Panel (HAN106) • 12-volt 7Ah Sealed Battery (HAN102)
HANS2000
HANS4010
5
Warranty Period
Exclusive Warranty- Horizon Hobby, Inc., (Horizon) warranties that the Products purchased (the "Product") will be free
from defects in materials and workmanship at the date of purchase by the Purchaser.
Limited Warranty
(a) This warranty is limited to the original Purchaser ("Purchaser") and is not transferable. REPAIR OR REPLACEMENT
AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER. This warranty covers only
those Products purchased from an authorized Horizon dealer. Third party transactions are not covered by this warranty.
Proof of purchase is required for warranty claims. Further, Horizon reserves the right to change or modify this warranty
without notice and disclaims all other warranties, express or implied.
(b) Limitations- HORIZON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NONINFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCT. THE
PURCHASER ACKNOWLEDGES THAT THEY ALONE HAVE DETERMINED THAT THE PRODUCT WILL SUITABLY MEET
THE REQUIREMENTS OF THE PURCHASER’S INTENDED USE.
(c) Purchaser Remedy- Horizon's sole obligation hereunder shall be that Horizon will, at its option, (i) repair or (ii)
replace, any Product determined by Horizon to be defective. In the event of a defect, these are the Purchaser's exclusive
remedies. Horizon reserves the right to inspect any and all equipment involved in a warranty claim. Repair or replacement
decisions are at the sole discretion of Horizon. This warranty does not cover cosmetic damage or damage due to acts of
God, accident, misuse, abuse, negligence, commercial use, or modification of or to any part of the Product. This warranty
does not cover damage due to improper installation, operation, maintenance, or attempted repair by anyone other than
Horizon. Return of any goods by Purchaser must be approved in writing by Horizon before shipment.
Damage Limits
HORIZON SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR
PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCT, WHETHER SUCH CLAIM
IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. Further, in no event shall the liability of
Horizon exceed the individual price of the Product on which liability is asserted. As Horizon has no control over use,
setup, final assembly, modification or misuse, no liability shall be assumed nor accepted for any resulting damage or
injury. By the act of use, setup or assembly, the user accepts all resulting liability.
If you as the Purchaser or user are not prepared to accept the liability associated with the use of this Product, you are
advised to return this Product immediately in new and unused condition to the place of purchase.
Law: These Terms are governed by Illinois law (without regard to conflict of law principals).
Safety Precautions
This is a sophisticated hobby Product and not a toy. It must be operated with caution and common sense and requires
some basic mechanical ability. Failure to operate this Product in a safe and responsible manner could result in injury
or damage to the Product or other property. This Product is not intended for use by children without direct adult
supervision. The Product manual contains instructions for safety, operation and maintenance. It is essential to read
and follow all the instructions and warnings in the manual, prior to assembly, setup or use, in order to operate correctly
and avoid damage or injury.
6
Questions, Assistance, and Repairs
Your local hobby store and/or place of purchase cannot provide warranty support or repair. Once assembly, setup or
use of the Product has been started, you must contact Horizon directly. This will enable Horizon to better answer your
questions and service you in the event that you may need any assistance. For questions or assistance, please direct your
email to productsupport@horizonhobby.com, or call 877.504.0233 toll free to speak to a service technician.
Inspection or Repairs
If this Product needs to be inspected or repaired, please call for a Return Merchandise Authorization (RMA). Pack
the Product securely using a shipping carton. Please note that original boxes may be included, but are not designed
to withstand the rigors of shipping without additional protection. Ship via a carrier that provides tracking and insurance
for lost or damaged parcels, as Horizon is not responsible for merchandise until it arrives and is accepted
at our facility. A Service Repair Request is available at www.horizonhobby.com on the “Support” tab. If you do not
have internet access, please include a letter with your complete name, street address, email address and phone number
where you can be reached during business days, your RMA number, a list of the included items, method of payment
for any non-warranty expenses and a brief summary of the problem. Your original sales receipt must also be included
for warranty consideration. Be sure your name, address, and RMA number are clearly written on the outside of the
shipping carton.
Warranty Inspection and Repairs
To receive warranty service, you must include your original sales receipt verifying the proof-of-purchase
date. Provided warranty conditions have been met, your Product will be repaired or replaced free of charge. Repair or
replacement decisions are at the sole discretion of Horizon Hobby.
Non-Warranty Repairs
Should your repair not be covered by warranty the repair will be completed and payment will be
required without notification or estimate of the expense unless the expense exceeds 50% of the retail
purchase cost. By submitting the item for repair you are agreeing to payment of the repair without notification. Repair
estimates are available upon request. You must include this request with your repair. Non-warranty repair estimates will
be billed a minimum of ½ hour of labor. In addition you will be billed for return freight. Please advise us of your preferred
method of payment. Horizon accepts money orders and cashiers checks, as well as Visa, MasterCard, American Express,
and Discover cards. If you choose to pay by credit card, please include your credit card number and expiration date. Any
repair left unpaid or unclaimed after 90 days will be considered abandoned and will be disposed of accordingly. Please
note: non-warranty repair is only available on electronics and model engines.
Electronics and engines requiring inspection or repair should be shipped to the following address:
Horizon Service Center
4105 Fieldstone Road
Champaign, Illinois 61822
All other Products requiring warranty inspection or repair should be shipped to the following address:
Horizon Product Support
4105 Fieldstone Road
Champaign, Illinois 61822
Please call 877-504-0233 with any questions or concerns regarding this product or warranty.
7
Safety, Precautions, and Warnings
This model is controlled by a radio signal that is subject to interference from many sources outside your control. This
interference can cause momentary loss of control so it is advisable to always keep a safe distance in all directions around
your model, as this margin will help to avoid collisions or injury.
• Always operate your model in an open area away from cars, traffic, or people.
• Avoid operating your model in the street where injury or damage can occur.
• Never operate the model into the street or populated areas for any reason.
• Never operate your model with low transmitter batteries.
• Carefully follow the directions and warnings for this and any optional support equipment (chargers, rechargeable
battery packs, etc.) that you use.
• Keep all chemicals, small parts and anything electrical out of the reach of children.
• Moisture causes damage to electronics. Avoid water exposure to all equipment not specifically designed and protected
for this purpose.
8
Contents of Kit
Large Replacement Parts
A. HAN4031 Fuselage w/Hatch
B. HAN4032 Right Wing
C. HAN4033 Left Wing
D. HAN4034 Horizontal Stab and Elevator
E. HAN4035 Wing Struts
F. HAN4036 Rudder
G. HAN4037 Landing Gear
H. HAN4038 Wheels
I. HAN4039 Cowl
J. HAN4040 Canopy with Seat
K. HAN4043 Wing Tube Set
A
I
B
C
E
Small Replacement Parts
1. HAN4041 Assembled 11 oz fuel tank
2. HAN4044 Pushrod Set
3. HAN4045 Glow Motor Mount
4. HAN4046 EP Motor Mount Standoffs
5. HAN4047 Pin and Keeper Set
6. HAN4048 Tail Flying Wires
1
7. HAN4049 2
8. HAN4007 Tailwheel Assembly
/4-inch Spinner
J
F
D
G
K
H
1
2
7
4
3
8
5
6
9
Section 1: Landing Gear and Rudder Installation
Required Parts
• Wheel assembly (2) • Landing gear
• Landing gear strap (4) • Tail gear assembly
• Rudder • Fuselage
• 5/32-inch wheel collar w/setscrew (2)
• 3mm x 10mm sheet metal screw (8)
Required Tools and Adhesives
• Hex wrench (supplied) • Petroleum jelly
• Phillips screwdriver: #1, #2 • Thin CA
• 30-minute epoxy • Sandpaper
• Drill bit: 1/16-inch (1.5mm) •Pin drill
o Step 1
Use a small flat screwdriver to remove the cap from the
outer wheel hub as shown.
o Step 3
Slide the inner wheel hub onto the landing gear. The wheel
collar is then installed by tightening the setscrew onto the
flat spot on the axle using the supplied hex wrench.
Note: Make sure to use threadlock on the
setscrews to prevent them from vibrating loose.
o Step 2
Use a #1 Phillips screwdriver to remove the four sheet
metal screws holding the inner and outer wheel hubs
inside the wheel.
o Step 4
Slide the wheel back onto the inner wheel hub.
10
Section 1: Landing Gear and Rudder Installation
o Step 5
Slide the outer wheel hub back into the wheel. Slide the
supplied hex wrench into the screw hole in the outer
wheel hub, then into the screw hole in the inner wheel hub
to aid in aligning the screw holes.
o Step 6
Reinstall the four sheet metal screws to secure the inner
and outer wheel hubs in the wheel.
o Step 7
Snap the cap back in position on the outer wheel hub.
Step 8
Repeat Steps 1 through 7 to install the remaining wheel
onto the landing gear.
11
Section 1: Landing Gear and Rudder Installation
Step 9
Attach the landing gear to the fuselage using four landing
gear straps and eight 3mm x 10mm sheet metal screws
and a #2 Phillips screwdriver.
Step 10
Use sandpaper to roughen the wire so the epoxy will have
a rough surface to bond to.
Step 11
Apply a small amount of petroleum jelly to the top and
bottom of the tail gear bushing. Work the jelly into the
bushing to prevent epoxy from entering the bushing and
locking the tail gear wire.
Step 12
Use 30-minute epoxy to glue the tail gear bushing into
the fuselage. Make sure the bushing is pressed tight in
the fuselage, and has been slid down toward the bottom
of the fuselage as far as possible.
12
Section 1: Landing Gear and Rudder Installation
Step 13
Use a pin drill and 1/16-inch (1.5mm) drill bit to drill
a hole in the center of each hinge slot in the fin and
rudder. This will provide a tunnel for the CA to wick
into, providing a better bond between the hinge and
surrounding wood.
Step 14
Step 15
Slide each of the hinges into the rudder until the T-pin is
resting on the hinge line of the rudder.
Step 16
Test fit the rudder onto the tail gear wire, guiding the wire
into the pre-drilled hole in the rudder.
Place a T-pin in the center of each of the three CA
hinges. This will help in centering the hinges when they
are installed.
13
Section 1: Landing Gear and Rudder Installation
Step 17
As you slide the rudder onto the tail gear wire, slide the
hinges for the rudder into the slots in the fin. The rudder
should fit tight against the fin, and should not bind at the
balance tab when the rudder is in operation.
Step 18
Once you have checked the fit of the hinges and tail
gear wire, remove the rudder from the fin. Apply a small
amount of 30-minute epoxy on the tail gear wire and into
the hole in the rudder to secure it in the rudder. Repeat
Steps 16 and 17 to place the rudder back into position.
Step 19
Remove the T-pins from the hinges. Apply thin CA to
both sides of the three hinges. Allow the CA to cure
(without using accelerator) before proceeding to the
following steps.
Note: The CA must be allowed to cure without
the use of accelerator. Using accelerator
will not allow the CA to fully soak into the
hinge, and could produce a poor bond
between the hinges and surrounding wood.
Step 20
Once the CA has fully cured, gently pull on the fin and
rudder to make sure all the hinges are glued securely.
14
Section 1: Landing Gear and Rudder Installation
Step 21
Move the rudder right and left a number of times to
condition the hinges.
Step 22
Secure the tail wheel using two 1/16-inch wheel collars
and two setscrews. Tighten the setscrews using the
supplied hex wrench.
Note: Make sure to use threadlock on the
setscrews to prevent them from vibrating loose.
15
Section 2: Aileron and Flap Servo Installation
Required Parts
• Snap link (4) • Nylon clevis (4)
• Clevis retainer (4)
• Flap servo cover (right and left)
• Aileron servo cover (right and left)
• #2 x 3/8-inch sheet metal screw (16)
3
• 3
/4-inch (95mm) threaded pushrod (4)
• Servo mounting blocks,
3/4 x 9/16 x 5/16-inch (19 x 14 x 8mm) (8)
Required Tools and Adhesives
• Sandpaper • Pencil
• Drill • Pin drill
• Drill bit: 5/64-inch (2mm) • 30-minute epoxy
• Long servo arm (4)
• Servo extension, 9-inch (229mm)
oo Step 1
Secure a 9-inch (229mm) servo extension to the aileron
servo. String or a commercially available connector is
suggested to prevent disconnection inside the wing.
ooo Step 2
Position the servo onto the servo cover. The servo horn
will be centered and in line with the outer edge of the
cover as shown.
ooo Step 3
Mark the locations for the servo mounting blocks on the
servo cover using a pencil or felt-tipped pen.
16
Loading...