Hangar 9 Pulse XT 40 User Manual

Pulse XT 40 ARF

5.

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Assembly mAnuAl

Specifications

Wingspan ................................. 60.7 in (1540.5mm)

Wing Area

Length ............................................ 50 in (1270mm)

.............................. 667 sq in (43 sq dm)

Weight ................ Glow: 5.5–6.25 lb (2.5 kg–2.8 kg)

..... Electric w/o battery: 4.7–5lb (2.1–2.3 kg)

Table of Contents

UltraCote Covering Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Radio and Power Systems Requirements
Contents of Kit
Required Items for Electric Installation
Field Equipment Required
Optional Field Equipment
Required Tools and Adhesives
Limited Warranty & Limits of Liability
Safety Precautions
Questions, Assistance, and Repairs
Questions or Assistance
Inspection or Repairs
Warranty Inspection and Repairs
Non-Warranty Repairs
Warranty Information
Before Starting Assembly
Using the Manual
Section 1: Aileron Installation

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Section 2: Hinging the Stabilizer
Section 3: Hinging the Rudder
Section 4: Landing Gear Installation
Section 5: Servo Installation
Section 6A: Tail Installation
Section 6B: Gluing the Tail (Optional)
Section 7A: Electric Motor Installation
Section 7B: Glow Engine Installation
Section 8: Final Assembly
Control Throws
Recommended Center of Gravity (CG)

Pre-Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Range Test Your Radio
Adjusting the Engine (Glow)
Maintaining Your Pulse XT ARF
Glossary of Terms
2006 Official AMA National Model Aircraft Safety Code

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2

UltraCote® Covering Colors

• True Red HANU866 • White HANU870

• Silver HANU881

Contents of Kit

A

B

E

C

G

F

D

Replacement Parts

A. Fuselage HAN4101
B. Wing w/o Aluminum Tube HAN4102
C. Tail Set HAN4104
D. Canopy HAN4108
E. Landing Gear HAN4107
F. Painted Cowl HAN4105
G. Painted Wheel Pants HAN4106

Items not shown

Pushrod Set HAN4109
Decal Set HAN4112
Aluminum Wing Tube HAN4103
Wing Bolt Set HAN4110
EP Motor Mount HAN4111

Radio and Power Systems Requirements

• 4-channel radio system (minimum) w/receiver

• 537 Standard Servo (JRPS537) (5) or equivalent
(4 required when building the electric version)

• 9” Servo Lead Extension (JRPA097) (2)

• 6” Y-Harness (JSP98020)

Recommended JR® Systems

• XP9303

• XP6102

• XP662

• XF631

• XF421EX

Recommended Power Systems

• .40–.48 2-stroke

• .40–.82 4-stroke

• Power 46 Brushless Outrunner

Evolution .46NT

EVOE0460

JR XP9303

Saito .82 AAC

SAIE082A

JR XP6102

Power 46 Brushless

Outrunner Motor,670KV

EFLM4046A

3

Required Items for Electric Installation

• Female Deans connector w/wire • Male Deans connector (3)

• Soldering iron • Solder

• Phoenix-60 Speed Control (CSEPHX60) • Electric Propeller,13 x 6.5E (APC13065E)

• Heat shrink tubing: 1/4" (6mm)

• 4200mAh 2S2P 7.4V Li-Po, 13GA (THP42002S2PPL) (2)

Field Equipment Required

• Propeller • Fuel

• Long Reach Glow Plug Wrench (HAN2510) • Metered Glow Driver w/Ni-Cd & Charger (HAN7101)

• 2-Cycle Sport Plug (HAN3001) • 2-Cycle Super Plug (HAN3006)

• 4-Cycle Super Plug (HAN3011) • Manual Fuel Pump (HAN118)

Optional Field Equipment

• Fieldmate™ Pre-built Flight Box (HAN117) • Cleaner & towels

• Blue Block After Run Oil (EVOX1000) • Power Panel (HAN106)

• 12V 7Ah Sealed Battery (HAN102) • PowerPro™ 12V Starter (HAN161)

Required Tools and Adhesives

Tools

• Adustable wrench • Drill

• Drill bit: 1/16" (1.5mm), 5/64" (2mm), 9/64" (3.5mm), 5/32" (4mm)

• Hobby knife • Masking tape

• Phillips screwdriver (large) • Phillips screwdriver (small)

• Ruler • Sandpaper

• Square • Straight edge

Adhesives

• 6-minute epoxy • 30-minute epoxy

• Thin CA (cyanoacrylate) glue • CA remover/debonder

• Pacer Z-42 Threadlock

Other Required Items

• Epoxy brushes • Felt-tipped pen or pencil

• Mixing sticks for epoxy • Paper towels

• Petroleum jelly • Rubbing alcohol

• Sandpaper • String

• T-pins

4

Limited Warranty & Limits of Liability

Pursuant to this Limited Warranty, Horizon Hobby, Inc. will, at its option, (i) repair or (ii) replace, any product determined
by Horizon Hobby, Inc. to be defective. In the event of a defect, these are your exclusive remedies.

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 an authorized Horizon Hobby, Inc. service
center. This warranty is limited to the original purchaser and is not transferable. In no case shall Horizon Hobby’s
liability exceed the original cost of the purchased product and will not cover consequential, incidental or collateral
damage. Horizon Hobby, Inc. 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 Hobby, Inc. Further, Horizon Hobby reserves the right to
change or modify this warranty without notice.

REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE CONSUMER.
HORIZON HOBBY, INC. SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

As Horizon Hobby, Inc. 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.

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.

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 Hobby, Inc. directly. This will enable Horizon to better answer
your questions and service you in the event that you may need any assistance.

Questions or Assistance

For questions or assistance, please direct your email to [e-mail], or call 877.504.0233 toll
free to speak to a service technician.

5

Inspection or Repairs

If your 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 Hobby, Inc. is not responsible for merchandise until it arrives and is accepted at
our facility. Include your complete name, address, phone number where you can be reached during business days, RMA
number, and a brief summary of the problem. Be sure your name, address, and RMA number are clearly written on the
shipping carton.

Warranty Inspection and Repairs

To receive warranty service, you must include your original sales receipt verifying the proof-of-purchase date. Providing
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. Horizon Hobby, Inc. guarantees this product to be free from defects
in both material and workmanship at the date of purchase.

Non-Warranty Repairs

Should your repair not be covered by warranty and the expense exceeds 50% of the retail purchase cost, you will be
provided with an estimate advising you of your options. You will be billed for any return freight for non-warranty repairs.
Please advise us of your preferred method of payment. Horizon Hobby 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.

Electronics and engines requiring inspection or repair should be shipped to the following address (freight prepaid):

Horizon Service Center

4105 Fieldstone Road

Champaign, Illinois 61822

All other products requiring inspection or repair should be shipped to the following address (freight prepaid):

Horizon Product Support

4105 Fieldstone Road

Champaign, Illinois 61822

6

Warranty Information

Horizon Hobby, Inc. guarantees this kit to be free from defects in both material and workmanship at the date of purchase.
This warranty does not cover any parts damage by use or modification. In no case shall Horizon Hobby’s liability exceed
the original cost of the purchased kit. Further, Horizon Hobby reserves the right to change or modify this warranty without
notice. In that Horizon Hobby has no control over the final assembly or material used for the final assembly, no liability
shall be assumed nor accepted for any damage resulting from the use by the user of the final user-assembled product. By
the act of using the user-assembled product, the user accepts all resulting liability.

Once assembly of the model has been started, you must contact Horizon Hobby, Inc. directly regarding any warranty
question that you have. Please do not contact your local hobby shop regarding warranty issues, even if that is where you
purchased it. This will enable Horizon to better answer your questions and service you in the event that you may need any
assistance. 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.

Horizon Hobby

4105 Fieldstone Road

Champaign, Illinois 61822

[phone]

Before Starting Assembly

Before beginning the assembly of the Pulse XT, 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

HAN141 – Sealing Iron

Sock

HAN100 – Heat Gun

HAN150 – Covering Glove

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

7

Section 1: Aileron Installation

Required Parts

• Wing panel (right and left) • Aileron (right and left)

• Servo w/hardware (2) • Clevis w/retainer (2)

• CA hinge (8)

• Servo extension, 6" (152mm)

• Aileron linkage, 4" (102mm) (2)

• Control horn w/backplate (2)

• 2mm x 16mm screw (4)

• 2mm x 12mm screw (2)

Required Tools and Adhesives

• Thin CA • Drill

• Hobby knife • Felt-tipped pen

• T-pins • Phillips screwdriver

• Drill bit: 1/16" (1.5mm), 5/64" (2mm)

  Step 1

Locate four CA hinges. Place a T-pin in the center of each
of the four hinges.

Note: The hole will allow the CA to penetrate
the hinge farther into the surface, providing
a better bond between the hinge and wood.

  Step 3

Slide the hinges into the aileron. The T-pins will rest
against the hinge line of the aileron.

  Step 2

Use a 1/16" (1.5mm) drill bit to drill a hole in the center of
each hinge slot. Drill holes for both the wing and aileron.

  Step 4

Slide the aileron onto the wing. Press the aileron
tightly against the wing, and then remove the T-pins
from the hinges.

8

Section 1: Aileron Installation

  Step 5

Position the aileron so it can move freely and not
bind at the wing tip or wing root. Deflect the aileron
without changing the hinge gap, and apply thin CA to
each of the four hinges. Apply CA to both the top and
bottom of the hinges.

  Step 7

Flex the aileron up and down a number of times to break
in the hinges.

Note: Do not use CA accelerator
on the hinges; the CA must be
allowed to soak into the hinge.

  Step 6

Once the CA has fully cured, gently pull on the aileron to
make sure the hinges are secure. Avoid too much pressure
which could cause damage to the wing and aileron.

  Step 8

Prepare an aileron servo by installing the grommets
and brass eyelets provided with the servo. Secure
a 6" (152mm) servo extension to the servo using a
commercially available connector or with string or
unwaxed dental floss.

9

Section 1: Aileron Installation

  Step 9

Slide one of the longer pushrod wires into the wing.
Attach the servo extension to the “Z” bend of the
pushrod wire.

  Step 11

Place the servo into the opening with the servo output
towards the trailing edge of the wing. Use a felt-tipped pen
to mark the locations for the four servo mounting screws.

  Step 12

Remove the servo and drill the locations for the servo
mounting screws using a 1/16" (1.5mm) drill bit.
Apply a couple drops of thin CA to each hole to harden
the wood, which will help in preventing the screws from
damaging the wood.

  Step 10

Pull the servo lead through the wing using the pushrod
wire. The lead will exit the hole on the top of the wing.
Use a piece of tape to keep the extension from falling back
into the wing.

10

Section 1: Aileron Installation

  Step 13

Secure the servo using the screws provided with
the servo.

  Step 14

Slide a clevis retainer onto a clevis. Thread the clevis
onto the 4" (102mm) aileron pushrod wire.

Note: You may want to use tape at the
wing tip and wing root to hold the aileron
in position for the next few steps.

  Step 16

Plug the aileron servo into the radio system. With the
radio on, center the aileron stick and trim. Position the
aileron servo arm parallel to the hinge line. Thread the
clevis so the pin in the clevis is aligned with the trailing
edge of the wing.

  Step 15

Enlarge the outer hole of the servo arm using a 5/64"
(2mm) drill bit. Attach the “Z” bend to the servo arm.

  Step 17

Remove the backplate from a control horn using a hobby
knife. Attach the clevis to the center hole of the control
horn. Use a felt-tipped pen to mark the locations on the
aileron for the three aileron control horn screws.

11

Section 1: Aileron Installation

  Step 18

Use a 5/64" (2mm) drill bit to drill the locations for the
control horn screws. Place a few drops of thin CA into
each hole to harden the underlying wood. This will help
in preventing the wood from crushing when tightening the
control horn screws.

  Step 19

Attach the control horn using two 2mm x 16mm screws, a
2mm x 12mm screw and the control horn backplate. The
shorter screw goes towards the trailing edge of the aileron.

12

 Step 20

Repeat Steps 1 through 19 for the remaining wing panel
and aileron.