MS: SEA 84 ASSEMBLY MANUAL - RIKU386063,SEA84 MANUAL.pdf · EDGE 540. Instruction Manual 2...

Made in Vietnam.

Kit features.

• Ready-made—minimal assembly & finishing required.• Ready-covered covering.• Photo-illustrated step-by-step Assembly Manual.

SpecificationsWingspan-------------------------------------66.9 in------------------------------- 170cm.Wing area------------------------------------764.6 sq.in-------------------- 49.3 sq.dm.Approximate flying weight----------------10.4 lbs--------------------------------4.7kg.Length----------------------------------------- 60.4in------------------------------153.3cm.Recommended engine size------------ .1.2 cu.in-------------------------- 2-stroke.Radio System required 4 channels with 6 digital 6 kg/cm servos Flying skill level Intermediate/advanced.

“Graphics and specfications may change without notice”.

ASSEMBLY MANUALMS: SEA 84

The Edge 540 size 120 (SEA-84) is designed for sport flying andaerobatic flying only.If you are looking for 3D performanceairplane,please choose our Edge 540 size 61-91 (Sea-54) or Edge 540size120-160 (SEA-26A&SEA-26B).Thank you for your interested in ourEdge 540 airplane.

EDGE 540. Instruction Manual

2

INTRODUCTION.

Thank you for choosing the EDGE 540 ARTF by SEAGULL MODELS. The EDGE 540 wasdesigned with the intermediate/advanced sport scale in mind. It is a semi scale airplane which iseasy to fly and quick to assemble. The airframe is conventionally built using balsa, plywood to makeit stronger than the average ARTF , yet the design allows the aeroplane to be kept light. You will findthat most of the work has been done for you already. The motor mount has been fitted and the hingesare pre-installed . Flying the EDGE 540 is simply a joy. This instruction manual is designed to help you build a great flying aeroplane. Please read thismanual thoroughly before starting assembly of your EDGE 540. Use the parts listing below to identifyall parts.

WARNING.

Please be aware that this aeroplane is not a toy and if assembled or used incorrectly itis capable 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/Csupplier and 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.

ADDITIONAL ITEMS REQUIRED.

.1.2 cu.in 2-stroke engine4 - 6 digital 6 kg/cm servos

Glow plug to suit enginePropeller to suit engineProtective foam rubber for radiosystemSilicone fuel line

TOOLS & SUPPLIES NEEDED.

Thick cyanoacrylate glue30 minute epoxy5 minute epoxyHand or electric drillAssorted drill bitsModelling knifeStraight edge ruler2mm ball driverPhillips head screwdriver220 grit sandpaper90° square or builder’s triangleWire cuttersMasking tape & T-pinsThread-lockPaper towels

PARTS LISTING.

FUSELAGE ASSEMBLY(1) Fuselage(1) Canopy hatch

WING ASSEMBLY

(1) Right wing half/ aileron(1) Left wing half with/ aileron(1) Aluminium dihedral brace

Tail section assembly

(1) Horizontal stabilizer/ elevatorhalves.

(1) Rudder halves.

Some more parts.

HARDWARE PACK

COWLINGLanding gear.....

www.seagullmodels.com

3

1) Carefully remove the aileron from oneof the wing panels. Note the position of thehinges.

2) Remove each hinge from the wing paneland aileron and place a T-pin in the center ofeach hinge. Slide each hinge into the wingpanel until the T-pin is snug against the wingpanel. This will help ensure an equal amountof hinge is on either side of the hinge line whenthe aileron is mounted to the aileron.

3) Slide the wing panel on the aileron untilthere is only a slight gap. The hinge is nowcentered on the wing panel and aileron.Remove the T-pins and snug the aileronagainst the wing panel. A gap of 1/64” or lessshould be maintained between the wing paneland aileron.

The control surfaces, including theailerons, elevators, and rudder, areprehinged with hinges installed, but thehinges are not glued in place. It isimperative that you properly adhere thehinges in place per the steps that followusing a high-quality thin C/A glue.

Note:

4)Deflect the aileron and completelysaturate each hinge with thin C/A glue. Theailerons front surface should lightly contact thewing during this procedure. Ideally, when thehinges are glued in place, a 1/64” gap or lesswill be maintained throughout the lengh of theaileron to the wing panel hinge line.

Note: The hinge is constructed of a specialmaterial that allows the C/A to wick orpenetrate and distribute throughout thehinge, securely bonding it to the woodstructure of the wing panel and aileron.

To avoid scratching your new aero-plane we suggest that you cover your work-bench with an old towel. Keep a couple of jarsor bowls handy to hold the small parts after youopen the bags.Please trial fit all parts. Make sure you have thecorrect parts and that they fit and are alignedproperly before gluing! This will ensure properassembly as the EDGE 540 is made fromnatural materials and minor adjustments mayhave to be made. The paint and plastic partsused in this kit are fuel proof. However, they arenot tolerant of many harsh chemicals includ-ing the following: paint thinner, cyano-acrylateglue accelerator, cyanoacrylate glue de-bonderand acetone. Do not let these chemicals comein contact with the colours on the covering andthe plastic parts.

NOTE:

HINGING THE AILERONS.

5) Turn the wing panel over and deflect theaileron in the opposite direction from theopposite side. Apply thin C/A glue to eachhinge, making sure that the C/A penetrates intoboth the aileron and wing panel.

6) Using C/A remover/debonder and apaper towel, remove any excess C/A glue thatmay have accumulated on the wing or in theaileron hinge area.

C/A glue.Hinge.

Hinge.T- pin.

Hinge.

T- pin.


4

HINGING THE ELEVATOR.

8) After both ailerons are securely hinged,firmly grasp the wing panel and aileron tomake sure the hinges are securely glued andcannot be pulled out. Do this by carefullyapplying medium pressure, trying to separatethe aileron from the wing panel. Use cautionnot to crush the wing structure.

7) Repeat this process with the other wingpanel, securely hinging the aileron in place.

HINGING THE RUDDER.

Glue the elevator hinges in place using thesame tectniques used to hinge the ailerons.

Glue the rudder hinges in place using thesame tectniques used to hinge the ailerons.

Work the aileron up and down severaltimes to “work in” the hinges and checkfor proper movement.

Note:

Aileron control horn: See pictures below.

AILERON CONTROL HORN

M3 LOCK NUT.

ALUMINUM WASHER.

ALUMINUM WASHER.

CONTRONL HORN M3 SCREW.

16mm.

Epoxy.

Wing

Epoxy.

Wing

Hinge.

2 sets.

3x45mm.


5

Aluminum Washer.

CONTRONL HORN M3

M3 LOCK NUT.

Epoxy.

Aluminum Washer.

ELEVATOR CONTROL HORN.

Install the elevator control horn using thesame method as with the aileron controlhorns.

2 sets.

3x45mm.

Rudder control horn:Using the same tectniques used aileron controlhorn. See picture below.

16mm.

2 sets.

3x45mm.

EPOXY.

CONTRONL HORN

M3 SCREW.

ALUMINUM WASHER.

ALUMINUM WASHER.

M3 LOCK NUT.

EPOXY.

Rudder control horn.

16mm.

Epoxy.

RUDDER CONTROL HORN.

Horizontal Stabilizer.

Fuselage. Rudder.

Elevator control horn.


6

2) Using a modeling knife, cut one lengthof silicon fuel line. Connect one end of the lineto the weighted fuel pick up and the other endto the nylon pick up tube.(The silicon tube isnot included).

3) Carefully bend the second nylon tubeup at a 45º angle. This tube is the vent tube.

1) Using a modeling knife, carefully cutoff the rear portion of one of the 3 nylon tubesleaving 1/2” protruding from the rear of thestopper. This will be the fuel pick up tube.

INSTALLING THE STOPPER ASSEMBLY.

Thread locker glue.

See pictures below.Make yourself thetemplate of your engine on paper.

ENGINE MOUNT INSTALLATION.

Mark and drill 4 holes for engine mount. Insert 4 blind nuts to firewall.

4x30mm.

Diameter =5.5mm.


7

Vent tube. Fuel pick up tube.

Fuel fill tube.

4) Test fit the stopper assembly into thetank. It may be necessary to remove some ofthe flashing around the tank opening using amodeling knife. If flashing is present, makesure none falls into the tank.

5) With the stopper assembly in place,the weighted pick-up should rest away fromthe rear of the tank and move freely inside thetank. The top of the vent tube should rest justbelow the top of the tank. It should not touchthe top of the tank.

Important: When the stopper assembly is in-stalled in the tank, the top of the vent tubeshould rest just below the top surface of thetank. It should not touch the top of the tank.

Carefully use a lighter or heat gun topermenently set the angle of the vent tube.

6) When satisfied with the alignment ofthe stopper assembly tighten the 3 x 20mmmachine screw until the rubber stopper ex-pands and seals the tank opening. Do notovertighten the assembly as this could causethe tank to split.

FUEL TANK INSTALLATION.

You should mark which tube is the ventand which is the fuel pickup when you

attach fuel tubing to the tubes in the stopper.Once the tank is installed inside the fuselage,it may be difficult to determine which is which.

Rubber band. Fuel tank.

Blow through one of the lines to ensurethe fuel lines have not become kinked in-

side the fuel tank compartment. Air shouldflow through easily.

Fuel pick-up tube.

Fuel fill tube.

Vent tube.

INSTALLING THE BATTERY.

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

WHEEL AND WHEEL PANTSINSTALLATION.

Battery.

Tie Wrap.


8

2) Follow diagram below for wheel pantinstallation:

1) The blind nuts for securing the landinggear are already mounted inside the fuselage.

2) Using the hardware provided, mountthe main landing gear to the fuselage.

INSTALLING THE MAIN LANDING GEAR.

3) A drop of C/A glue on the wheel collarscrews will help keep them from coming loseduring operation.

Repeat the process for the other wheel.

wheel collar.

wheel.

Lite-Plywood block.

Axle.Washer.

M3.M3.

wheel Pant.

wheel.

M3.M3.

wheel collar.

Lite-Plywood block.

nut. Axle.

Washer.

Landing Gear.

4x20mm.

14mm.7mm.

wheel Pant.

Locker glue.

Locker glue.


9

1) Install the pushrod housing through thepredrilled hole in the firewall and into the servocompartment. The pushrod housing shouldprotrude 1/4" out past the front of the firewall. Make a Z-Bend 1/4" from one end of the plainwire pushrod.

MOUNTING THE ENGINE.

6) Attach the Z-Bend in the pushrod wire tothe throttle arm on the carburetor.

5) Bolt the engine to the engine mount usingthe four machine screws. Double check thatall the screws are tight before proceeding.

4) Remove the engine. Using an drill bit,drill the mounting holes through the enginemount at the four locations marked.

2) Place your engine onto the enginemount. Adjust the engine is centered of theedges of the engine case.

3) When you are satisfied with the align-ment, mark the locations of the enginemounting.

155mm.

4.2 mm diameter.

Machine Screw 4x30mm.

COWLING INSTALLATION.1) Slide the fiberglass cowl over the en-

gine and line up the back edge of the cowl withthe marks you made on the fuselage then trimand cut.

Pushrod wire.

Because of the size of the cowl, it may be nec-essary to use a needle valve extension for thehigh speed needle valve. Make this out of suf-ficient length 1.5mm wire and install it into theend of the needle valve. Secure the wire inplace by tightening the set screw in the side ofthe needle valve.

Trim and cut.

Trim and cut.

2) While keeping the back edge of thecowl flush with the marks, align the front ofthe cowl with the crankshaft of the engine. Thefront of the cowl should be positioned so thecrankshaft is in nearly the middle of the cowlopening. Use the spinner backplate as a guide.Hold the cowl firmly in place using pieces ofmasking tape.


10

3) Install the muffler and muffler extensiononto the engine and make the cut out in thecowl for muffler clearance. Connect the fueland pressure lines to the carburetor, mufflerand fuel filler valve. Secure the cowl to fuse-lage using the 3x10mm screws (4).

Install the spinner backplate, propeller andspinner cone.

The propeller should not touch any partof the spinner cone. If it does, use a

sharp modeling knife and carefully trim awaythe spinner cone where the propeller comesin contact with it.

INSTALLING THE SWITCH.

Install the switch into the precut hole in theside of fuselage.

Machine Screw 3x10mm.

1.5mm were(needle valve).

Switch.

SPINNER INSTALLATION.


11

THROTTLE SERVO ARM INSTALLATION.

Install adjustable servo connector in the servoarm .

2) Secure the servos with the screws pro-vided with your radio system.

INSTALLING THE FUSELAGE SERVO.

1) Install the rubber grommets and brasscollets onto the throttle servo. Test fit the servointo the aileron servo mount.

Because the size of servos differ, youmay need to adjust the size of the precut open-ing in the mount. The notch in the sides of themount allow the servo lead to pass through.

Throttle servo .

Elevator servo .

Elevator servo .

Rudder servo .

Throttle servo arm.

Elevator servo .

Elevator servo .

Rudder servo .

VERTICAL STABILIZER INSTALLATION.

Remove the covering as picture shownbelow.

Masking tape.

Remove covering.

Fill epoxy.

Remove the covering.

Adjustable Servoconnector.

Servo arm.

Loctite secure.

1 PCS.

Remove the covering.


12

Hinge slot.

Epoxy.

C/A glue.

Hinge.

Hinge.

INSTALLING HORIZONTAL FIN.

1) Remove the covering as same aspictures shown below. 2) Sand the aluminium tube usingsandpaper. This will improve the bond of theepoxy to the cardboard horizontal fin. Coat both sides of one half of the aluminiumtube with 30 minute epoxy. Next, pour someepoxy into the cardboard horizontal fin. Useenough epoxy to fill any gaps.

Epoxy.

3) Insert aluminium tube into the cardboardof fuselage.

Epoxy.

Epoxy.

4) Slide the two horizontal fin halves to-gether and carefully align them at the possitionon the fuselage. Wipe away any excess epoxyusing paper towels.

Aluminium tube.335mm.

Covering strip.

Covering strip.


13

Epoxy. Epoxy.

INSTALLING THE AILERON SERVOS.

String.Small weight.

Servos. Small weight.

Thread.

Installing the aileron servo in place using thesame techniques used to flap servo.

Electric wire.

AileronServo.

Attach the string to the servo lead and carefully thread it though the wing.

String.Small Weight.

Wing. Wing rib.

String.

Small Weight.


14

Aileron.

Wing.

Wing.Aileron.

AILERON PUSHROD HORN INSTALLATIONWing.

Aileron.

ELEVATOR - RUDDER PUSHROD HORNINSTALLATION.

Repeat the procedure for the other wing.

Elevator control horn.

Rudder control horn.

Wing. Aileron.

M2 lock nut.

1) Elevator and rudder pushrods assemblyfollow pictures below.

M2 Lock nut.M2 clevis.

Attach to servo arm in fuselage. Attach to elevator - rudder control horn.

M2 lock nut.M2 clevis.

75mm.

110mm.


15

Rudder pushrod.

Control horn.Elevator Pushrod.

Metal clevis.

Elevator pushrod.

M2 lock nut.

Elevator.

Elevator.

Rudder.

Throttle.

2) Install servos arm to servos. Notice theposition of the servo arms on the servos. Seepicture below.

Elevator.

Rudder.

Throttle.

3x25mm.

MOUNTING THE TAIL WHEEL.

See picture below.

3x30mm.


16

Tail landing gear.

Spring.

3x25 mm.

3x30 mm.

1) Plug the six servo leads and the switchlead into the receiver. Plug the battery packlead into the switch also.

2) Wrap the receiver and battery pack inthe protective foam rubber to protect themfrom vibration.

3) Route the antenna in the antenna tubeinside the fuselage and secure it to the bot-tom of fuselage using a plastic tape.

INSTALLING THE BATTERY-RECEIVER.

Antenna.

Receiver.

ATTACHMENT WING-FUSELAGE.

Attach the aluminium tube into fuselage.

Insert two wing panels as pictures below.

Wing tube.

3x30 mm.


17

Wing bolt.

1) It is critical that your airplane be bal-anced correctly. Improper balance will causeyour plane to lose control and crash. The cen-ter of gravity is locate 6.5-7.5cm back fromthe leading edge of the wing, measured at wingtip.

BALANCING.

2) If the nose of the plane falls, the planeis nose heavy. To correct this first move thebattery pack further back in the fuselage. Ifthis is not possible or does not correct it, sticksmall amounts of lead weight on the fuselagesides under the horizontal stabilizer. If the tailof the plane falls, the plane is tail heavy.

To correct this, move the battery and receiverforward orif this is not possible, stick weightonto the firewall.When balanced correctly, theairplane should sit level or slightly nose downwhen you lift it up with your fingers.

1) We highly recommend setting up theEDGE 540 using the control throws listed atright. We have listed control throws for bothLow Rate (initial test flying/sport flying) andHigh Rate (aerobatic flying).

CONTROL THROWS.

6.5-7.5cm.

4x15mm.

3) When the elevator, rudder and aileroncontrol surfaces are centered, use a ruler andcheck the amount of the control throw in eachsurface. The control throws should bemeasured at the widest point of each sur-face!

2) Turn on the radio system, and with thetrim tabs on the transmitter in neutral, centerthe control surfaces by making adjustmentsto the clevises or adjustable servo connectors.The servo arms should be centered also.


18

E) Check the throttle. Moving the throttlestick forward should open the carburetor bar-rel. If it does not, flip the servo reversing switchon your transmitter to change the direction.

PREFLIGHT CHECK.

D) Check the rudder. Looking from be-hind the airplane, move the rudder stick to theright. The rudder should move to the right. If itdoes not, flip the servo reversing switch onyour transmitter to change the direction.

4) By moving the position of the adjust-able control horn out from the control surface,you will decrease the amount of throw of thatcontrol surface. Moving the adjustable con-trol horn toward the control surface will in-crease the amount of throw.

FLIGHT PREPARATION.

A) Check the operation and direction ofthe elevator, rudder, ailerons and throttle.

C) Check the elevator first. Pull back onthe elevator stick. The elevator halves shouldmove up. If it they do not, flip the servo re-versing switch on your transmitter to changethe direction.

F) From behind the airplane, look at theaileron on the right wing half. Move the aileronstick to the right. The right aileron should moveup and the other aileron should move down. Ifit does not, flip the servo reversing switch onyour transmitter to change the direction.

INITIAL FLYING

AEROBATIC FLYING

Do not use the aerobatic settings forinitial test flying or sport flying.

1) Completely charge your transmitterand receiver batteries before your first day offlying.

B) Plug in your radio system per themanufacturer's instructions and turn every-thing on.


19

5) If your radio transmitter is equippedwith dual rate switches double check that theyare on the low rate setting for your first fewflights.

6) Check to ensure the control surfacesare moving the proper amount for both lowand high rate settings.

8) Properly balance the propeller. An outof balance propeller will cause excessive vi-bration which could lead to engine and/or air-frame failure.

We wish you many safe and enjoyable flights with your EDGE 540 .

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

2) Check every bolt and every glue jointin the EDGE 540 to ensure that everything istight and well bonded.

3) Double check the balance of the air-plane. Do this with the fuel tank empty.

4) Check the control surfaces. All shouldmove in the correct direction and not bind inany way.

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