Assembly Manual for - Chief Aircraft Inc.

Assembly Manual for - Chief Aircraft Inc.
Assembly Manual for
Decathlon 107”107”-180”
Wingspan: 88 in
Wingarea: 1479.8 sp in
Length: 78.8 in
Engine: 50CC
www.pilot--rc.com
www.pilot
1
INTRODUCTION
Thank you for purchasing our
Decathlon plane. At Pilot we strive
to build the best performing Quick
Build ARF aircraft available today.
The Decathlon is manufactured
using advanced building
techniques for maximum strength
and lightest weight. The kit features
many premium light weight carbon
fiber components, hardware,
genuine Oracover(Ultracote)
covering, laser cut wood, and the
best adhesives. The Decathlon’s
light weight allows optimum flight
performance from exciting
aerobatics or just relaxing.
At Pilot we make every effort to
provide the highest quality
products and customer service.
Our goal is a happy customer
having a wonderful time
assembling and flying Pilot model
aircraft.
More information on website
www.pilot--rc.com
www.pilot
2
WARRANTY
■
All Pilot-RC products are guaranteed against
defects for 30 days of receiving your airplane. This
warranty is limited to construction or production
defects in both material and workmanship , it does not
cover any component parts damaged through use or
modification .
■
The manufacture cannot supervise the assembly,
operation or maintenance, and is not responsible for
radio malfunctions. Please ensure your radio system
is in good condition. We are not responsible for any
accident or damage while using this product. It is
impossible to determine for certain whether crash
damage was the result of improper installation of our
products, a radio system failure, or pilot error. Model
airplane owners use our products at their own risk.
■
Pilot-RC will not be liable for any costs, unless
agreed and proved beyond doubt the failure was due
to faulty materials or fabrication. Any agreed cost will
not exceed the cost of the airframe and not include
engine, radio equipment or third party claims.
■
Should you wish to return a product or receive
replacement parts, all shipping cost must be paid by
the customer.
3
ATTENTION
■
Do not regard this plane as a toy!
■
To ensure safety, please read the instruction
manual thoroughly before assembly.
■
Building and operating an RC Plane of this nature
requires previous experience and competence to an
experienced level. This plane is not for a beginner!
■ If you are in doubt have an experienced pilot at
hand. Diligent practicing and correct guidance is
essential, accidents can cause bodily harm and
property damage.
■
Seek assistance from an experienced person or
airplane model clubs in assembly, operation and
maintenance to ensure successful training.
Fly only in a registered RC model club
airfield that is approved by your local Academy of
Model Aeronautics (AMA).
■
Pilot-RC has the right to revise the plane, the
instructions and the limited warranty without
notice. If you have any problems and questions
please contact Pilot –RC at:
Email: pilot-rc@139.com , info@pilot-rc.com
Cellphone:+86 760 88781293
FAX: +86 760 88780293
Address: No.34, Chengnan Er Road , Zhongshan city, 528400, Guangdong
Province, China
4
INDEX
Introduction………………….………..….…….…………
Warranty…………………….……..….…..………………..
Attention…………….…………..….……..………………..
Fuselage
Rudder Assembly
Rudder Control Horns………..…….…...…………….
Tail Wheel Installation…………..…….......................
Landing Gear Assembly
.
Main Landing Gear Installation………….…..……….
Pants Installation…………..….……………………….
2
3
4
6
8
10
11
Servos
Wing Servo Assembly
Servo Arm Installation………….….………………….
Aileron Control Horns………….……….……………..
Servo Installation…….…………..……………………
Rudder Servo Assembly
Servo Tray Installation….…….….......………………
Servo Installation……….….……...………………….
Elevator Servo Assembly
Servo Arm Installation………….…………………….
Elevator Control Horns……………....….……………
Servo Installation……………….....………………….
13
14
15
17
19
23
24
25
Engine installation
Firewall Assembly……….…….....…………………..
Engine Assembly……….…..……..………………….
Throttle Servo Assembly….….…...…….……………
Ignition Module………….…….………………………
Hatch And Fuel Tank………….….……....…………..
Final Assembly
Switch Assembly………….….……....……………….
Wing Assembly………….….……....…………………
Elevator Assembly……………….….……....………..
CG And Control Throws………………………………
Flight Preparation…...…………….….…..…………..
Led Option…..………….….……....………………….
28
29
30
31
32
34
35
37
39
40
42
5
Fuselage
Rudder Assembly
Rudder Control Horn
1. Tear off the cover on the horns and
locking plates.
2. Slice covering over factory installed
slots. Press control horn into position.
Trace around the locking plate with a
knife and remove the covering.
3. Scuff the middle of horns with a
piece of sand paper for good glue
bond. Wipe off sanding dust prior to
gluing.
6
Rudder Assembly
4. Apply the 30 minutes epoxy
inside the pre-cut slot, and coat the
horn with epoxy as shown.
Make sure the horn is perpendicular
to the rudder.
5. Slide the horn into slots with
locking mount plates. Wipe away
excess glue with rubbing alcohol.
7
Tail wheel
Tail Wheel Installation
1. Draw a center line with a fine line
marker as shown.
2. Locate and drill holes in the tail
wheel mounting block as shown.
3. Install the blind nuts through the
opening in the rear of the fuselage.
Mount the tail wheel assembly
using blue Loctite on the threads
screws.
8
Tail wheel
4. Install the hatch over the opening
in the rear of fuse with 3 screws in
accordance with the pre-drilled holes
Ensure the spring is under slight
tension.
5. Drill a 1mm hole in the bottom of
the rudder and mount steering spring
with a wood screw as shown. Cut off
excess wire from the spring.
9
Landing Gear Assembly
Main Landing Gear Installation
NOTE: The main landing mounting direction.
Taper to
rear
Straight
edge to
front
10
Landing Gear Assembly
1. Install the landing gear with the
bolts and locking nuts. Do not over
tighten the hardware.
3. Tighten the lock nut against the
landing gear strut making sure the flat
sides of the axle bolt vertical with
ground.
2. Install the landing gear axles with
lock nut.
4. Install wheels and wheel collars
using Blue Loctite on the set screws.
11
Landing Gear Assembly
Wheel pant installation
2. Drill the holes for the mounting
bolts and install the blind nuts.
1. Level the fuselage and place the
wheel pants over the wheels. The cut
out in the wheel pant is cut to fit the
hex nut on the axle. Check for proper
clearance over the wheels and that
wheel pants are level with the
fuselage.
3. Finish the wheel pant mounting
with the bolts and use Blue Loctite
on the threads.
12
Wing servos
Wing Servo Assembly
Servo Arm Installation
Minimum servo specs:
180 in. oz / Metal Gear / Digital
2. Locate and drill 2mm holes into
nylon servo arm to attach the included
fiberglass servo arms.
Use a few drops of CA
to hold arm in place for
drilling.
1. Turn on your transmitter and
make sure servos are centered
before putting on servo arms.
3. Mount the screws and nuts.
Use a drop of CA
glue on each nut.
13
Wing Servos
Aileron Control Horns
2. Slice covering over factory
installed slots. Press control horn into
position. Trace around the locking
plate with a knife and remove the
covering.
1. Tear off the cover on the horns and
locking plates
3. Scuff the horns with a piece of
sand paper for good glue bond. Wipe
off sanding dust prior to gluing.
14
Wing Servos
Servo Installation
4. Apply the 30 minute epoxy inside
the pre-cut slot for horn and coat the
horn with epoxy as shown.
5. Slide the horn with locking plate
into place. Wipe away excess
epoxy with rubbing alcohol. Note:
Some trimming of the horn might
be required for the horn to fit flush.
2. Add a servo extension to each
aileron servo. Install connector safety
clip to as shown to connection.
3. Locate servo cut outs and remove
the covering with a knife. Tape the
servo lead securely to the pull-string.
15
Wing servos
4. Pull the extension lead through to
the root of the wing.
6. Install the servo arm facing
outboard toward the wing tip. Adjust
pushrod length so the servo arm is at
90 degrees and aileron panel in
neutral position.
5. Use a 1mm drill bit to drill for the
servo mounting screws. Install servo
with output shaft toward the leading
edge of the wing.
16
Rudder servo Assembly
Rudder servo installation
The rudder servo can be mounted
forward in the cabin using cables or
mounted in the tail using a push rod.
7. Repeat steps for the other aileron
and flaps.
(A)
(B)
(B)
Pick the rudder servo mounting
location based on CG needs.
17
Rudder Servo Assembly
Minimum servo specs:
180 in. oz. / Metal Gear / Digital
1. Turn on your transmitter and make
sure servos are centered before
installing the rudder servo arm.
2. Drill holes with a 2mm bit
for hardware.
3. Mount the screws and nuts.
A drop of CA glue
here on nuts.
Hold with tape or a few
drops of CA to the
edges.
18
Rudder Servo Assembly
Rudder Servo (A)
2. Install the rudder servo arm with
The rudder cables and couplers come cable attach points aft.
factory installed as shown.
1. Drill 1mm holes and mount the
rudder servo with the output shaft
facing forward.
3. Tape the rudder to the vertical
fin in the neutral position to help
with the rigging.
19
Rudder Servo Assembly
4. Mount the cables with the pre5. Install ball link to rudder control
installed ball link cable ends to the
horn temporarily.
rudder servo arm. Cut the covering in
the tail to expose cable exit slots. Run
the cables out the slots. Make sure
the cables cross in the middle.
5. The flat surface of the ball link
gets screwed against the servo arm.
6. Prior to connecting rudder cable to
the ball link, slide a section of heat
shrink tubing and copper tubing. Run
cable as shown looping around
tubing. Remove excess slack from
cable and crimp with diagonal pliers.
20
Rudder Servo Assembly
7. This is what a completed cable
should look like. Cut off excess cable
after crimping. Repeat process for
opposite rudder cable.
9. Adjust the rudder cable threaded
fair leads to obtain appropriate cable
tensions. Remove tape that was
holding rudder straight.
10..
8. Shrink the heat shrinking tube over
the crimp for a clean appearance.
10. Tighten jam nut to lock ball link in
position and permanently install ball
link to rudder horn.
21
Rudder Servo Assembly
Rudder Servo Plan B
1. The process for the rudder servo
installation is the same process as for
the ailerons.
22
Elevator Servo Assembly
Servo Arm Installation
Minimum servo specs:
180 in. oz / Metal Gear / Digital
2. Ensure the servo arm is 90
degrees with servo as shown. Then
mark and drill holes with 2mm bit.
Use a few drops of CA
to hold arm in place for
drilling.
1. Turn on your transmitter and
make sure servos are centered
before putting on servo arms.
3. Mount the screws and nuts.
Use a drop of CA
glue on each nut.
23
Elevator Servo Assembly
Elevator Control Horns
2. Slice covering over factory installed
slots. Press control horn into position.
Trace around the locking plate with a
knife and remove the covering.
1. Tear off the cover on the horns and 3. Scuff the horns with a piece of
sand paper for good glue bond. Wipe
locking plates
off sanding dust prior to gluing.
24
Elevator Servo Assembly
4. Apply 30 minutes epoxy inside the
pre-cut slot for horn, and coat the
horn with epoxy as shown.
5. Slide the horn with locking plate
into place. Wipe away excess
epoxy with rubbing alcohol.
Servo Installation
1. Connect the servo extension to
the servo and install safety clip.
25
Elevator Servo Assembly
2. Snake the elevator servo leads into 4. Cut the covering on the pre-drilled
the fuselage using the factory installed hole for stab mounting. Insert carbon
pull string. (same process as ailerons) spars and slide horizontal stab into
position.
3. Use 1mm bit to drill the mounting
holes. Install the servos with the out
put shaft facing forward.
5. Install the stab with mounting bolts
and washers. Apply Loctite to threads
before installation.
26
Elevator Servo Assembly
6. Install the servo arm facing down.
Adjust pushrod length so the elevator
is neutral and the servo horn is at 90
degrees.
7. Repeat steps for the other elevator
servo.
27
Engine installation
1. Using a template, locate, drill, and
install the engine centered to the
firewall.
3. Remove cowl and mount fire wall at
present location. Drill 3mm mounting
holes for hardware through the motor
box into aluminum angle brackets.
File photo
2. Fit the firewall with the attached
engine into the motor box (without
glue). Install the engine cowl over the
engine. Install the spinner bulkhead
onto the engine and center the
spinner bulkhead with the cowl.
4. Glue the firewall at that location with
30 minute epoxy. Triangle stock is
included to reinforce firewall.
File photo
File photo
move
28
Engine Assembly
Engine Installation
Note: Use Blue Loctite on final
installation of engine mounting screws.
29
Throttle servo Installation
Throttle Servo Installation
1. Install the throttle servo in the
included mounting tray. Mount the
tray in the engine box behind the fire
wall. Make pushrod path is in a
straight line for a precise throttle
linkage connection. Epoxy and screw
the tray in place.
2. Make a hole for push rod path with
a Dremel tool. Measure and bend to a
sharp “Z” bend as shown. Cut off extra
length wire. Mount the throttle pushrod
ball end to the throttle arm and “Z”
bend to the servo arm.
5. Finish the servo installation with
two additional mounting screws.
A drop of glue on nut
30
Ignition Module
Ignition Module
1. Attach foam rubber to the bottom
of ignition with double sided tape and
install spiral wrap cover to ignition
lead as shown.
2. Stick the ignition to the outside of
the engine box with double sided tape.
Allow room for spark plug leads and
wire connections. Drill holes in motor
box for zip ties and secure module
with ties.
3. The ignition battery installs the
same manor except under the engine
box. Lock the connectors with the
provided safety clip to prevent
vibration from loosening connections.
31
Hatch and fuel tank
Engine Box Hatch
Fuel Tank And Dot
Fuel line
Fuel Fill Line
Epoxy the hatch in place and install
self-tapping screws.
Mount the fuel tank with Velcro straps.
There is a factory laser cut hole for the
fueling dot aft of the engine cowl on
the left hand side of the fuselage.
Secure all fuel lines connections with
zip ties.
32
Cowl Assembly
Cowl Assembly
1. Use a Dremel cutting tool to rough
cut the cowl for clearance for the
exhaust system and for additional
cooling. The air exit hole must be
larger in diameter then the air inlet
for sufficient cooling. Remove any
rough edges with sandpaper.
2. Install the plastic cooling air
deflector(only offer for 107-122”
decathlon) to the inside of the cowl.
Secure with thick CA or silicone. Some
trimming might be necessary for
clearance with the engine.
Note: An extended Allen wrench is
needed to reach the hardware to
remove and install the cowl.
Extend a ball driver tool by cutting
standard ball driver in half and adding
a section of copper tubing a small
heat shrink tubing.
Note: Avoid
sharp corners
to prevent
stress cracking
from vibration.
33
Final Assembly
Switch Assembly
1. Opening the cabin door exposes two
additional pre cut switch locations in the
servo mounting plate.
Note: Factory installed laser cut switch
mounting holes are located under the 2. Finish the mounting the switch with
covering on either side of the fuselage screws and nuts.
for your convenience.
34
Wing Assembly
Wing Assembly
2. Layout, identify, and assemble lift
strut components. Do not fully tighten
hardware at this time.
Wing brackets
Short side
1. Install the brackets at
mounting locations
under side of wing. Use
Loctite on threads.
35
Wing Assembly
Use the included spacers and mount the
lift struts to the wing. Thin spacers are for
the out board brackets and thick spacers
for the inboard brackets. Leave hardware
lose. Install wings on fuselage and make
sure every thing is aligned. Tighten all
hardware.
36
Elevator Assembly
Elevator Assembly
1. Install the aluminum brackets onto
the tail for the wire bracing. There are
a total of seven brackets for the tail
assembly. There are four identical
brackets that are for the horizontal
stabilizer, two with steeper bands that
are for the vertical stabilizer, and a
double sided bracket that mounts on
the aft screw of the tail wheel bracket
under the fuselage.
2. Attach the nylon clevises and
threaded cable ends to the metal tail
brackets. Install the included cables
and crimp into position. Balance
cable tensions.
37
Elevator Assembly
Note: make
sure cable
tensions are
balanced to
prevent
warping.
38
CG And Control Throws
Center Of Gravity
The center of gravity is near to the wing
tube .For more plane please refer to the
CG list
The First Flight set up
Throttle:
Adjust idle –full
Elevator: 40 Degrees on High rate
12 Degrees on Low rate
Aileron:
30 Degrees on High rate
12 Degrees on Low rate
Rudder:
Avoid adding weight to your
Decathlon for CG purposes. Position
the batteries where required in order
to correctly balance your model.
Mount batteries on a bed of foam and
secure with Nylon ties or Velcro
straps.
45 Degrees on High rate
40 Degrees on Low rate
After you have a few flights under
you belt you can change control
deflections based on personal
preference as well as adjust the CG
back in 1/4" intervals.
■
Set exponential up to
approximately 40% on your elevator
to make great landings on low rates
and 70% exponential on High Rate.
■
39
Center of gravity
The CG list of Pilot-RC products
PLANE
CG location
DECATHLON 107”
DECATHLON 122’’
DECATHLON 150’’
DECATHLON 180’’
133mm/5.2inch
145 mm/5.7inch
182 mm/7.2inch
217 mm/8.5inch
YAKM55 73”
YAKM55 88’’
YAKM55 107’’
YAKM55 122’’
165mm/6.5inch
216 mm/8.5inch
267 mm/10.5inch
287mm/11.3inch
YAK-54 53’’
YAK-54 73’’
YAK-54 87’’
YAK-54 107’’
YAK-54 121’’
YAK-54 129’’
YAK-54 148’’
YAK-54 180’’
EXTRA-300/330 73’’
EXTRA-300/330 88’’
EXTRA-300/330 107’’
EXTRA-300/330 122’’
Sbach 342
Sbach 342
Sbach 342
Sbach 342
Sbach 342
Sbach 342
53’’
73’’
87’’
107’’
122’’
148’’
126mm/5.0 inch
156 mm/6.1inch
183 mm/7.2inch
225 mm/8.9inch
266 mm/10.5inch
273 mm/10.7inch
314 mm/12.4inch
401 mm/15.8inch
154mm/6.06inch
170mm/6.7inch
211mm/8.3inch
236mm/9.3inch
116mm/4.6inch
145mm/5.7inch
173mm/6.8inch
234mm/9.2inch
269mm/10.6inch
305mm/12 inch
This recommendation balance point is for
your first flight.The CG can be moved
around to fit your personal taste.
Columbia 400 128’’
Columbia 400 150’’
Edge-540
Edge-540
Edge-540
Edge-540
73’’
87’’
107’’
122’’
EXTRA-260
EXTRA-260
EXTRA-260
EXTRA-260
73’’
87’’
106’’
122’’
136mm/5.35inch
141mm/5.6inch
116mm/4.5inch
136mm/5.35inch
141mm/5.6inch
166mm/6.5inch
140mm/5.51 inch
170mm/6.7inch
202mm/7.95inch
248mm/9.8inch
The location of CG has been
marked inside plane as show.
Usually it is near the wing tube.
40
Flight Preparation
Make sure you have the right model programmed into your
transmitter.
■ Check the direction of each control surface before flight.
■ Remember something wrong on the ground, never improves
in the air.
■ Do a range check of the radio system with the engine
running and check with.
■ Monitor battery voltage after each flight in case one servo is
draining your battery.
■ Recheck all screws, horns and linkages for slop after your
maiden fight and always check for damage in the event of a
rough landing.
■ Have an experienced pilot perform the maiden flight if you
have any doubts in your skills.
■ Take a break after you first flight and let the adrenaline burn
off by bragging to your fellow members how good it flies.
■ Fly conservatively your first few flights.
■ Listen to your engine run and have an observer with you to
remember what you talked about during the flight and encase
you get into trouble.
■ Always balance your props, vibration is a killer.
■ Remember nose heavy airplanes fly all the time, tail heavy
airplanes fly only once. Be on the CG!
■ Fly 3D two mistakes high in the beginning and not close to
people, other planes, or the run way.
■ Being a center of the runway hog does not endear you to
fellow modelers.
■
41
Flight Preparation
Check with the engine manufacturer’s for recommended running
temperature and make sure that it is not exceeded.
■
Pilot-RC doesn't accept responsibility for any damage from
improper engine cooling.
■
42
LED Assembly option
LED Assembly
Pilot-RC Optional LED lighting kit.
Some
soldering is
required.
43
Pilot
RC
Control
Horn
Installation
(50cc and larger have dual control horns & 30cc Aircraft have a single control horn)
• Rubber/Latex Gloves.
• Epoxy (30 Minute or Stronger)
• Epoxy Mixing Cups
• Epoxy Mixing Sticks (Any mixing stick that will fit into the slot)
• Denatured Alcohol or Acetone.
• Paper Towels
• Sand Paper
• X-Acto Knife
• Dremel and Small Drill Bit (Optional and Not Always Needed)
Then Prepare your parts..
Then you will need to test fit your parts together before gluing in place. Please note that
sometimes the slots need to be cleaned out a little bit and can be done with a dremel and a
small drill bit or an x-acto knife.
Force your epoxy into the slots. Also apply a thin layer of epoxy on the control horn and
bottom of the guide plate.
Install your horns. Make sure to clean off any epoxy that comes out from under the plate
with a paper towel and alcohol.
Pilot RC
Wing & Elevator Servo Installation
You will need:
• Hobby Iron
• X-Acto Knife
• Thin CA “Super Glue”
• Drill and Drill Bit
First find the servo mounting hole and iron around to assure that the covering is stuck to
the surrounding wood.
Then cut like this or to your preference.
Then press and iron excess covering down into the servo slot.
Now you can pre fit the servo.
Make sure your grommets are installed and drill the holes for the servo screws.
Now apply a small amount of the CA to the already drilled servo screw holes and if needed run your extension wire through. (Don’t forget the safety clip!!)
Now you can install the servo with your choice of screws and attach the linkage.
Final adjustment of turnbuckles and it ready for servo adjustment.
Pilot RC Optional Rudder
Installation for 50-150cc Aircraft
Shorten the rudder wire so that it will not pierce the covering at the top of the rudder and
leave about 3/4” hanging out the bottom. Bend the bottom at a 90 degree angle, and then
trace around the wire (See Photos). You then carve out a channel for the wire to fit into, it
only needs to be a deep as the wire is thick.
The Tail wheel bracket will
lock it in to place. Make sure
it overhangs the slot when
you install the TW bracket.
Center of gravity
The CG list of Pilot-RC products
p
PLANE
CG location
DECATHLON 107”
DECATHLON 122’’
C
O 150’’
50
DECATHLON
DECATHLON 180’’
133mm/5.2inch
145 mm/5.7inch
182
8 mm/7.2inch
/
c
217 mm/8.5inch
YAKM55 73”
YAKM55 88’’
YAKM55 107’’
YAKM55 122’’
165mm/6.5inch
216 mm/8.5inch
267 mm/10.5inch
287mm/11.3inch
YAK-54 53’’
YAK-54
YAK
54 73’’
73
YAK-54 87’’
YAK-54 107’’
YAK-54 121’’
YAK-54 129’’
YAK-54 148’’
YAK-54 180’’
EXTRA-300/330 73’’
EXTRA-300/330 88’’
EXTRA-300/330 107’’
EXTRA-300/330 122’’
Sbach 342
Sbach 342
Sbach 342
Sbach 342
Sbach 342
Sbach 342
53’’
73’’
87’’
107’’
122’’
122
148’’
126mm/5.0 inch
156 mm/6
mm/6.1inch
1inch
183 mm/7.2inch
225 mm/8.9inch
266 mm/10.5inch
273 mm/10.7inch
314 mm/12.4inch
401 mm/15.8inch
This recommendation balance point is for
your first flight.The CG can be moved
around to fit your personal taste.
Columbia 400 128’’
Columbia 400 150’’
Edge-540 73’’
Edge-540 87’’
Edge-540 107’’
Edge-540 122’’
EXTRA-260
EXTRA
260
EXTRA-260
EXTRA-260
EXTRA-260
73’’
73
87’’
106’’
122’’
136mm/5.35inch
141mm/5.6inch
116mm/4.5inch
136mm/5.35inch
141mm/5.6inch
166mm/6.5inch
140mm/5 51 inch
140mm/5.51
170mm/6.7inch
202mm/7.95inch
248mm/9.8inch
154mm/6.06inch
170
170mm/6.7inch
/6 7i h
211mm/8.3inch
236mm/9.3inch
132mm/5.2inch
145mm/5.7inch
173mm/6.8inch
234mm/9.2inch
269mm/10 6inch
269mm/10.6inch
305mm/12 inch
The location of CG has been
marked inside plane as show.
Usually it is near the wing tube.
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