Instruction Manual book - Pichler Modellbau

SPECIFICATION Wingspan : 1,550 mm 61.02 in. Length : 1,250 mm 49.2 in. Weight : 2.4 kg 5.28 Lbs. Radio : 04 channels. Servo : 05 servos. Engine : 40 - 46 2 stroke

52 4 stroke

Instruction Manual book

Made in Vietnam.

TRAVEL AIR. Instruction Manual

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This instruction manual is designed to help you build a great flying aeroplane. Please read thismanual thoroughly before starting assembly of your TRAVEL AIR. Use the parts listing below toidentify all parts.

WARNING.

Please be aware that this aeroplane is not a toy and if assembled or used incorrectly it iscapable of causing injury to people or property. WHEN YOU FLY THIS AEROPLANE YOUASSUME ALL RISK & RESPONSIBILITY.If you are inexperienced with basic R/C flight we strongly recommend you contact your R/C supplierand join your local R/C Model Flying Club. R/C Model Flying Clubs offer a variety of trainingprocedures designed to help the new pilot on his way to successful R/C flight. They will also be ableto advise on any insurance and safety regulations that may apply.

TOOLS & SUPPLIES NEEDED.

Thick cyanoacrylate glue.30 minute epoxy.5 minute epoxy.Hand or electric drill.Assorted drill bits.Modelling knife.Straight edge ruler.2mm ball driver.Phillips head screwdriver.220 grit sandpaper.90° square or builder’s triangle.Wire cutters.Masking tape & T-pins.Thread-lock.Paper towels.

Some more parts.

HARDWARE PACK

Landing gear.....

To avoid scratching your new airplane, do notunwrap the pieces until they are needed forassembly. Cover your workbench with an oldtowel or brown paper, both to protect theaircraft and to protect the table. Keep a coupleof jars or bowls handy to hold the small partsafter you open the bag.

Please trial fit all the parts. Make sure you havethe correct parts and that they fit and arealigned properly before gluing! This will assureproper assembly. TRAVEL AIR ARF is handmade from natural materials, every plane isunique and minor adjustments may have tobe made. However, you should find the fitsuperior and assembly simple.The painted and plastic parts used in this kitare fuel proof. However, they are not tolerantof many harsh chemicals including thefollowing: paint thinner, C/A glue accelerator,C/A glue debonder and acetone. Do not letthese chemicals come in contact with thecolors on the covering and the plastic parts.

PARTS LISTING.

FUSELAGE ASSEMBLY(1) Fuselage.

WING ASSEMBLY

(1) Right wing half with pre-installedaileron.(1) Left wing half with pre-installedaileron.

Tail section assembly

(1) Vertical stabilizer with pre-installed rudder.(1) Horizontal stabilizer with pre-installed elevator halves.

SUGGESTION.

NOTE.

TRAVEL AIR. INSTRUCTION MANUAL

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+ This is not a toy + Be sure that no other flyers are using yourradio frequency. + Do not smoke near fuel + Store fuel in a cool, dry place, away fromchildren and pets. + Wear safety glasses. +The glow plug clip must be securely attachedto the glow plug. + Do not flip the propeller with your fingers. + Keep loose clothing and wires away fromthe propeller. + Do not start the engine if people are near.Do not stand in line with the side of thepropeller. + Make engine adjustments from behind thepropeller only. Do not reach around thespinning propeller.

SAFETY PRECAUTION.

1. Install the rubber grommets and brasseyelets onto the aileron servo.

3. Drill 1,5mm pilot holes through the blockof wood for each of the four mounting screwsprovided with the servo. Install servo into aileronservo tray as same as picture below.

4. Using the thread as a guide and usingmasking tape, tape the servo lead to the endof the thread: carefully pull the thread out.When you have pulled the servo lead out,remove the masking tape and the servo leadfrom the thread.

2. Using a modeling knife, remove thecovering servo tray.

INSTALLING THE AILERON SERVOS.

Servo tray.


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5. Instal servo tray with aileron servo intothe wing as same as picture below.

Repeat the procedure for the other winghalf.

Electric wire.

Servo tray.

1. Using a ruler & pen to draw a straightline as below picture.

INSTALLING THE AILERON CONTROL HORN.

3x40mm.

Nilon control clasp.

M3 lock nut.

Wing.

2x10mm.


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2. Drill through 6mm (diameter) the aileronusing the control horn as a guide and screwthe control horn in place.

3. Install aileron control horn as same aspicture below.

Bottom side.


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C/A glue

C/A glue

INSTALLING THE AILERONLINKAGES.

1. Working with the aileron linkage fornow, thread one clevis onto one of thethreaded wires. 2. Attach the clevis to the outer hole in the

control horn. Install a silicone tube on theclevis.

3. Plug the aileron servo into the receiverand center the servo. Install the servo arm ontothe servo. The servo arm should beperpendicular to the servo and point towardthe middle of the wing.


Control horn.

finishing.

4. Locate one nylon servo arm, and usingwire cutters,remove all but one of the arms.Using a 2mm drill bit, enlarge the third holeout from the center of the arm to accommodatethe aileron pushrod wire.

5. Using pliers, carefully make a 90 degreebend down at the mark made. Cut off theexcess wire, leaving about 4mm beyond thebend.

6. Insert the 90 degree bend down through the hole in the servo arm. Install one nylon snap keeper over the wire to secure it to the arm. Install the servo arm retaining screw and remove the masking tape from the aileron.

M2 clevis.

Snap keeper.


Bend and cut after.


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JOINING THE WING HALVES.

1. Locate the aluminium wing dihedralbrace.

2. Using a modeling knife, remove thecovering wing.

3. Test fit the dihedral brace into each winghalf. The brace should slide in easily. If not,use 220 grit sandpaper with a sanding blockand sand down the edges and ends of thebrace until it fits properly.

Top side.

Remove covering.

Masking tape.

Apply masking tape.

Masking tape.

Epoxy glue.


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When the stopper assembly is installedin the tank, the top of the vent tube shouldrest just below the top surface of the tank.It should not touch the top of the tank.

8. Feed three lines through the fuel tankcompartment and through the pre-drilled holein the firewall. Pull the lines out from behindthe engine, while guiding the fuel tank intoplace. Push the fuel tank as far forward aspossible, the front of the tank should just abouttouch the back of the firewall.

INSTALLING THE STOPPER ASSEMBLY

1. The stopper has been pre-assembled at the factory.

2. Using a modeling knife, cut one length ofsilicon fuel line (the length of silicon fuel line iscalculated by how the weighted clunk shouldrest about 8mm away from the rear of the tankand move freely inside the tank). Connect oneend of the line to the weighted clunk and theother end to the nylon pick up tube in thestopper.

3. Carefully bend the second nylon tube upat a 45 degree angle (using a cigarette lighter).This tube will be the vent tube to the muffler.

4. Carefully bend the third nylon tube downat a 45 degree angle (using a cigarette lighter).This tube will be vent tube to the fueling valve.

FUEL TANK.

5. Test fit the stopper assembly into thetank. It may be necessary to remove some ofthe flashing around the tank opening usinga modeling knife. If flashing is present, makesure none of it falls into the tank.

6. When satisfied with the alignment of thestopper assembly tighten the 3mm x 20mmmachine screw until the rubber stopperexpands and seals the tank opening. Do notover tighten the assembly as this could causethe tank to split.

7. Using a modeling knife, cut 3 lengths offuel line 150mm long. Connect 2 lines to the 2vent tubes and 1 line to the fuel pickup tube inthe stopper.

INSTALLING THE ENGINE MOUNT.


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Blow through one of the lines to ensurethe fuel lines have not become kinked insidethe fuel tank compartment. Air should flowthrough easily.

9. To secure the fuel tank in place, apply abead of silicon sealer to the forward area ofthe tank, where it exits the fuselage behind theengine mounting box and to the rear of the tankat the forward bulkhead.

Do not secure the tank into placepermanently until after balancing theairplane. You may need to remove the tankto mount the battery in the fuel tankcompartment.

Locate the long piece of wire used for thethrottle pushrod. One end of the wire has beenpre-bend in to a “Z” bend at the factory. This“Z” bend should be inserted into the throttlearm of the engine when the engine is fitted ontothe engine mount. Fit the engine to the enginemount using the screws provided.

INSTALLING THE ENGINE.

Fuel tank.


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INSTALLING THE SPINNER.

Install the spinner backplate, propeller andspinner cone. The spinner cone is held inplace using two 3mm x 12mm wood screws.

Pushrod wire


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1. Install the rubber grommets and brasscollets into the elevator servo. Test fit the servointo the servo tray.

2. Mount the servo to the tray using themounting screws provided with your radiosystem.

3. Mark the shape of the vertical on the leftand right sides onto the horizontal stabilizerusing a felt-tip pen 4. Remove the stabilizer. Using the lines

you just drew as a guide, carefully remove thecovering from between them using a modelingknife.

When cutting through the covering toremove it, cut with only enough pressureto only cut through the covering it’s self.Cutting into the balsa structure mayweaken it. This could lead to possiblefailure during flight

Center line.

Elevator servo.

ELEVATOR INSTALLATION.

SERVO INSTALLATION.

Remove covering.

HORIZONTAL STABILIZERINSTALLATION.

1. Using a modeling knife, cut away the covering from the fuselage for the stabilizer and remove it. 2 . Draw a center line onto the horizontal

stabilizer. Then slide the horizontal into thefuselage.


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6. After the epoxy has fully cured, re-move

the masking tape or T-pins used to hold thestabilizer in place and carefully inspect theglue joints. Use more epoxy to fill in anygaps that were not filled previously andclean up the excess using a paper towel andrubbing alcohol.

in the fuselage. Slide the stabilizer in place andre-align. Double check all of yourmeasurements one more time before theepoxy cures. Remove any excess epoxy usinga paper towel and rubbing alcohol and holdthe stabilizer in place with T-pins or maskingtape.

5. When you are sure that everything isaligned correctly, mix up a generous amountof 30 minute epoxy. Apply a thin layer to thetop and bottom of the stabilizer mounting areaand to the stabilizer mounting platform sides

Pen.

Removecovering.

C/A glue

Elevator control horn install as same as theway of aileron control horn. Please see picturesbelow.

3mm x 40mm.

M3 lock nut.Niloncontrol clasp.

Control horn of elevator.

ELEVATOR CONTROL HORNINSTALLATION.


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ELEVATOR PUSHROD INSTALLATION.

Elevator pushrod install as same as the wayof aileron pushrod. Please see pictures below.

Drill 1 hole with 6 mm diameter.

C/A glue


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Elevatorpushrod.

Cut.

Secure.

Secure.

Ben and cut.

Elevator servo.Elevator pushrod.


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3. Mark the shape of the vertical on the leftand right side on the rudder using a felt-tippen.

4. Now, remove the rudder and using amodeling knife, carefully cut just inside themarked lines and remove the film of the rud-der. Just as you did with the horizontal stabi-lizer, make sure you only press hard enoughto cut the film, not the balsa rudder.

5. Put the vertical stabilizer back inplace. Using a triangle, check to ensurethat the vertical stabilizer is aligned 90 de-gree to the horizontal stabilizer.

VERTICAL INSTALLATION.

Control clasp.

Hinge.

2. Slide the rudder into the fuselage assame as picture below.

Removecovering.

Hinge slot.

1) Using a modeling knife, remove thecovering from the top of the fuselage and thecovering from over the precut hinge slot cutinto the lower rear portion of the fuselage Thisslot accepts the lower vertical.

Pen.

Remove covering.

90º

VerticalStabilizer.Horizontal

Stabilizer.


16

Control horn of Rudder.

Drill 6mm diameter a hole of the mountingrudder control horn on to the rudder .

Mark point.

Pen.

3mm x 40mm.

M3 lock nut.Niloncontrol clasp.

and re-align. Double check all of your meas-urements once more before the epoxy cures.Remove any excess epoxy using a papertowel and rubbing alcohol and hold the stabi-lizer in place with T-pins or masking tape. Al-low the epoxy to fully cure before proceeding.

RUDDER CONTROL HORNINSTALLATION.

Rudder control horn install as same as theway of aileron control horn. Please see pic-tures below.

Epoxy glue.

Epoxy glue.

C/A glue

6) When you are sure that everything is aaligned correctly, mix up a generous amountof 30 minute epoxy. Apply a thin layer to theslot in the mounting platform and to the verti-cal stabilizer mounting area. Apply epoxy tothe lower rudder hinge. Set the stabilizer inplace


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C/A glue

C/A glue

Ruddercontrol horn.

RUDDER PUSHROD INSTALLATION.

Rudder pushrod install as same as the wayof aileron pushrod.

Rudder pushrod.

Bend andcut after

Snap keeper.

Elevator pushrod.

Rudder pushrod.

Rudderpushrod.

Elevatorpushrod.

Elevatorpushrod.


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Throttle Servo.

1. Cut out the switch hole using a modelingknife. Use a 2mm drill bit and drill out the twomounting holes through the fuselage side.

2. Secure the switch in place using thetwo machine screws provided with the radiosystem.

INSTALLING THE SWITCH. INSTALLING THE THROTTLE PUSHROD.

1. Install one adjustable metal connectorthrough the third hole out from the center ofone servo arm, enlarge the hole in the servoarm using a 2mm drill bit to accommodate theservo connector. Remove the excess materialfrom the arm.

After installing the adjustable metalconnector apply a small drop of thin C/Ato the bottom nut. This will prevent theconnector from loosening during flight.

Servo arm.

Connector.

Throttle servo.

Cut.

Throttle pushrod.


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Tie wrap.

Tie wrap.

Battery.

1) Assemble and mounting the wheel pantsas shown in the following pictures.

MAIN GEAR INSTALATION.PARTS REQUIRED

Receiver.

INSTALLING THE RECEIVER AND BATTERY.

1. Plug the servo leads and the switchlead into the receiver. You may want to plugan aileron extension into the receiver to makeplugging in the aileron servo lead easierwhen you are installing the wing . Plug thebattery pack lead into the switch.

2. Wrap the receiver and battery pack inthe protective foam to protect them fromvibration. Use a rubber band or masking tapeto hold the foam in place.

3. Position the battery pack and receiverbehind the fuel tank. Use sing to two tie wrapsto hold the battery and receiver securely inplace as picture below. Do not permanently secure the receiver andbattery until after balancing the model.

4. Using a 2mm drill bit, drill a hole throughthe side of the fuselage, near the receiver, forthe antenna to exit.


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2) Using the hardware provided, mount themain landing gear to the fuselage.

Repeat the process for the other wheel.

1. Set the tail wheel assembly in placeon the plywood plate. The pivot point of thetail wheel wire should be even with the rud-der hinge line and the tail wheel bracket shouldbe centered on the plywood plate.

MOUNTING THE TAIL WHEELBRACKET.

Secure.

3x12mm.


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WING ATTACHMENT.

2. Using a pen, mark the locations of thetwo mounting screws. Remove the tail wheelbracket and drill 1mm pilot holes at the loca-tions marked.

3. Secure the tail wheel bracket in placeusing three 3mm x 12mm wood screws. Becareful not to overtighten the screws.

See pictures below:

Wing attach to fuselage.

Wing bolt.

Top side.

Mark point.

Bottom side.


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CG100 MM

*If possible, first attempt to balance the modelby changing the position of the receiverbattery and receiver. If you are unable to obtaingood balance by doing so, then it will benecessary to add weight to the nose or tail toachieve the proper balance point.

With the wing attached to the fuselage, allparts of the model installed ( ready to fly), andempty fuel tanks, hold the model at themarked balance point with the stabilizer level.

Lift the model. If the tail drops when youlift, the model is “tail heavy” and you must addweigh* to the nose. If the nose drops, it is “noseheavy” and you must add weight* to the tail tobalance.

3. Turn the airplane upside down. Placeyour fingers on the masking tape and carefullylift the plane .

BALANCING. 1) It is critical that your airplane be balanced

correctly. Improper balance will cause yourplane to lose control and crash.THE CENTER OF GRAVITY IS LOCATED100mm BACK FROM THE LEADING EDGEOF THE WING.

2) Mount the wing to the fuselage. Using acouple of pieces of masking tape, place themon the top side of the wing 100 mm back fromthe leading edge, at the fuselage sides.

Accurately mark the balance point on the topof the wing on both sides of the fuselage. Thebalance point is located 100mm back from theleading edge. This is the balance point at whichyour model should balance for your first flights.Later, you may wish to experiment by shiftingthe balance up to 10mm forward or back tochange the flying characteristics. Moving thebalance forward may improve thesmoothness and arrow- like tracking, but it maythen require more speed for take off and makeit more difficult to slow down for landing.Moving the balance aft makes the model moreagile with a lighter and snappier ”feel”. In anycase, please start at the location werecommend .

Finishing.


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1. Completely charge your transmitter andreceiver batteries before your first day of flying.

2. Check every bolt and every glue joint inyour plane to ensure that everything is tightand well bonded.

3. Double check the balance of theairplane.

4. Check the control surface.

5. Check the receiver antenna . It shouldbe fully extended and not coiled up inside thefuselage.

6. Properly balance the propeller.

We wish you enjoy.

PRE-FLIGHT CHECK.

Ailerons : 10mm up 10mm down Elevator : 10mm up 10mm down Rudder : 25mm right 25mm left

1. We highly recommend setting up a planeusing the control throws listed.

2. The control throws should be measuredat the widest point of each control surface.

3. Check to be sure the control surfacesmove in the correct directions.

CONTROL THROWS.

Aileron Control

1010

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Instruction Manual book - Pichler Modellbau

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