Pilot Communications COLUMBIA 400, Assembly Manual

Page 1: ...Assembly Manual For C l bi 400 Columbia 400 Wingspan 88 in Wingarea 1479 8 sp in il il Length 78 8 in Engine 50CC www pilot www pilot rc com rc com ...

Page 2: ...formence both the design and manufacturing have been taken care with the highest quality from any hardware covering wood and glue in the construction as well By optimal weight and reliable construction you will find this plane is really ideal for plane is really ideal for relaxing So we hope every effort and service we offer will make you feel easy and have a wonderful ti i th l f fl i time in the...

Page 3: ...i not responsible for any damage occurring during the use of a radio controlled model It is impossible to determine for certain whether crash damage was the result of a radio systerm failure or pilot error even improper installation of our products Model airplane owner is using it on his own responsibility In no event should Pilot RC accept the liability exceeds the original cost of the airframe n...

Page 4: ...perienced person or airplane model clubs in assembly operation and maintenance to ensure quick and successful learning q g Fly only in proven model airfield that AMA Academy of Model Areonautics approved Pilot RC has the right to change to this plane i t ti d li it d t ith t ti instruction and limited warranty without notice If you have any problems and questions please contact pilot RC Email pilo...

Page 5: ...evator Servo Assembly Engine Unit Firewall Assembly Engine Assembly 15 21 27 32 34 23 Engine Assembly Throttle Servo Assembly Ignition Module Hatch And Fuel Tank Final Assembly Unit Cowl Assembly Canister Assembly Light system Assembly 34 36 34 39 38 41 37 Light system Assembly Handrail Assembly Canopy lock Assembly Footplate Assembly Accessories Assembly CG And Control Throws Fli h P i 41 43 46 4...

Page 6: ...Front Landing Gear Installation Landing Gear Assembly Front Landing Gear Installation 5 ...

Page 7: ...re 6 holes in the bottom of the engine box which are for the front landing gear 3 Inside view of mounting front landing gear 2 Mount the front landing gear to the fuselage with 6 bolts 4 Outside view of mounting front landing gear 6 ...

Page 8: ...ake the front wheel in the middle place gear Put the servo to the servo bay which is on the back of the firewall 6 Put the fiber glass arm on the top of the front landing gear put the plastic washer on the top of the arm Then install the circlips 8 Finished view Then install the circlips 7 ...

Page 9: ...Landing Gear Assembly 9 Take off this bolt 10 Take off the bottom part of the landing gear 11 Install the tire into the front landing gear with the circlips outside 8 ...

Page 10: ...pants 2 Put the pants into the front landing gear Note the front wheel pants are different shape from the rear wheel pants 1 There is a hole on the top of the front wheel pants 3 Screw two side bolt to fit the wheel pants front wheel pants pants 9 ...

Page 11: ...anding gear Note The front landing gear covering only install after you install the cowl 3 Screw two bolts in front of the landing gear covering 2 Glue two pieces of wood inside the 3 Screw other bolts on the back of 2 Glue two pieces of wood inside the cowl 3 Screw other bolts on the back of the landing gear covering 10 ...

Page 12: ...Finished front Landing Gear covering Finished front Landing Gear covering 11 ...

Page 13: ...Rear Landing Gear Installation Landing Gear Assembly Rear Landing Gear Installation 12 ...

Page 14: ...t the covering Put the landing gear into the slot 3 Install the aluminum connecting angle between two side landing gear as shown 2 Screw two bolts in the landing gear 4 Install the landing gear axles with lock nut but do not tighten Note Must use washer between the landing gear and bolt 13 ...

Page 15: ...st the landing gear strut 7 Drill the holes for the mounting bolts and install the blind nuts 6 Install the collars and wheel in order with a drop of Blue Loctite on the collar set screw and ensure the 8 Finish the wheel pants mounting with the bolts the collar set screw and ensure the wheel is free to rotate 14 ...

Page 16: ...ervo as shown Then mark and drill holes with 2mm bit 15 kg cm Metal Gear 1 Turn on your transmitter and plug the servo into receiver Ensure 3 Mounting screws and nuts Pre fasten the arm with drops of fast cured gule on edge plug the servo into receiver Ensure every channel is neutral A drop of fast 15 A drop of fast cured gule here ...

Page 17: ...race around the locking plate with kinfe and cut off the cover below Then the pre cut slots appear 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 Then clean up the surface p 16 ...

Page 18: ... for horn and coat the horn with epoxy as shown Servo Installation 5 Slide the horn into slot slightly and Mount the locking plate in place Wipe away excess epoxy 1 Cut out the cover for servo location carefully as shown place Wipe away excess epoxy with rubbing alcohol 17 ...

Page 19: ...r with the provided safety clip against vibration and loosened tension as shown 3 Cut out the cover for servo location carefully Tape the lead to pull string tightly In order to ensure the servo wire can be pulled out 5 Find four sets of servo mounting plate the servo wire can be pulled out without hanging up inside wing 18 ...

Page 20: ...f wood to the 6 Glue two piece of wood to the servo mounting plate as shown Note Be sure to glue it strong enough 7 Use 1mm bit to drill the mounting holes Then screw four bolts to fix the servo to the servo mounting 8 Install servo arm 19 ...

Page 21: ...Repeat all the step above for the Wing Servo Assembly 6 Install the servo arms facing toward the wing edge and adjust pushrod in proper length to keep the aileron panel on the neutral position 7 Repeat all the step above for the flap 20 ...

Page 22: ...e locking plate with kinfe and cut off the cover below Then the pre cut slots appear 1 Tear off the cover on the horns and locking plates 3 Scuff the middle of horns with a piece of sand paper for good glue bond Then clean up the surface bond Then clean up the surface 21 ...

Page 23: ...he pre cut slot and coat the horn with epoxy as shown Make sure the horn line up with ground and align the both side before epoxy has cured 5 Slid the horn into slot slightly mount the locking plates in place Wipe away excess glue with rubbing alcohol 22 ...

Page 24: ...Servo 15 kg cm Metal Gear 1 Turn on your radio device according the Wing Servo Installation Keep the tray holes on d h li d i h 3 Mounting screws and nuts center and the arm aligned with brand as shown Then tape tightly A drop of fast cured gule here Or pre fasten the arm with drops of fast 23 p cured gule on edge ...

Page 25: ...stalled boll link to the rudder arm without 3 Attach the pre installed boll link to the rudder horn and not tighten the locking nut locking nut Put two brass tube through the cable and thread through the coupler hole Ensure the cables are straight 2 Tape the rudder panel to top of th ti l fi i th t l iti the vertical fin in the neutral position to make it straight NOTICE The coupler is best to thr...

Page 26: ...rimping pliers 7 Thread the coupler in 2 4 mm according the bolt holes center Ensure the same length of cables and tension 2 4mm 6 C t bl 8 Shrink the heat shrinking tube on 6 Cut away excess cable 8 Shrink the heat shrinking tube on the brass tube 25 ...

Page 27: ...all links with bolts and nuts 10 Turn off the radio now Reinstall the ball link Don t pull strongly to hurt the rudder or back to step 7 for readjustment you can find a helper and do that at certain deflection with and do that at certain deflection with supporting the bottom of the rudder 26 ...

Page 28: ...s with 2mm bit 180 in zo Metal Gear Digital Servo Arm Installation 1 Turn on your transmitter and plug the servo into receiver Ensure 3 Mounting screws and nuts Pre fasten the arm with drops of fast cured gule on edge plug the servo into receiver Ensure every channel is neutral A drop of fast dry 27 A drop of fast dry gule here ...

Page 29: ...2 Trace around the locking plate with kinfe and cut off the cover below Then the pre cut slots appear 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 Then clean up the surface p 28 ...

Page 30: ...s and coat the horn with epoxy as shown Servo Installation 5 Slide the horns into slots slightly and Mount the locking plate in place Align the right and left sides before epoxy has cured Wipe away 1 Cut off the cover on the pre cut slot before epoxy has cured Wipe away excess epoxy with rubbing alcohol 29 ...

Page 31: ...Face the brand toward the rear of fuse provided safety clip against vibration and loosened tension as shown 5 Then put the extention lead through fuselarge 3 Install the servo arm with mounting screw and make it vertical with ground Adjust pushrod in proper length to keep the aileron panel on the t l iti neutral position 30 ...

Page 32: ...7 Repeat all the step above for the Elevator Servo Assembly 6 Install the stab with mounting 7 Repeat all the step above for the other stabilizer 6 Install the stab with mounting bolts and washers 31 ...

Page 33: ...st The center of the engine axle will be in the exact center of the cowl 1 Measure the length of the engine from the firewall to the prop thrust washer the cowl and the engine box for the proper distance allowing 1 4 to 1 2 from the edge of the Note There are both right thrust line and down thrust line marked on the 1 4 to 1 2 from the edge of the cowl Then mark the location and down thrust line m...

Page 34: ...aser holes for DA 100 Otherwise measure your engine s mounting location 3 Drill the screw mounting holes aligning the line you have drawn both side as shown with the firewall taped Note Epoxy the triangular hardwood supports for reinforce 100cc firewall needs to cut off the center hole for air side as shown with the firewall taped or glued slightly in place 3mm bit needs to cut off the center hole...

Page 35: ...Engine Assembly Engine Installation Throttle servo Installation Not Include Remember Use Bue Loctite on all engine mounting screws 1 Install the engine throttle arm witn a little Blue Loctite 34 ...

Page 36: ...xtra wire Then bend to a sharp of z as shown Mount the throttle pushrod to engine A d f f t 3 Determine where the throttle servo mounting tray is going to be mounted on the engine box to get the straight d i h l li k i A drop of fast cured gule 5 Finish the servo installation with mounting screws and precise throttle linkage connection then make a mark 35 ...

Page 37: ... the engine box to allow the spark plug leads to connect the engine without excess tension Drill for Nylon tie 1 Tape foam rubber on bottom of ignition and attach to safety cover surplied as shown 3 Lock the connectors with the provided safety clip against vibration and loosened tension as shown p 36 ...

Page 38: ...and Dot Hatch And Fule Tank Engine Box Hatch Fule Tank and Dot Fule Fill Line Fule line Epoxy the hatch in place and secure with self tapping screws Fule tank and fule dot have been installed Just tighten the velcro ties 37 ...

Page 39: ...a round sander 1 Make a pattern of the exhaust with a paper to hold its shape Trial fit to make sure there is a minimum of 3 8 around the engine cooling 3 Ensue all the corner are rounded and not sharp 90 degrees against splitting under vibration Trial fit till the cowl is right of 3 8 around the engine cooling the cowl is right 38 ...

Page 40: ...Canister Assembly Canister Assembly 3 Install the headers y 1 Put the canister to the mounting 2 Glue the mounting to the canister room 39 ...

Page 41: ...Canister Assembly Canister Assembly y 4 Cut the covering on the canister room cover This is very important because it will cool the engine 40 ...

Page 42: ...Light system Assembly 1 All light already pre install in the factory You only need to 1 All light already pre install in the factory You only need to connect the wire to the flashing controller 41 ...

Page 43: ...Light system Assembly 2 There is a wood cover near the light on the wing front edge You can cut the Ultracote Oracover Open it and check the light if the light has problem 42 ...

Page 44: ...ear the back window on the fuselage as shown 3 Cut the covering on the hole Put some glue into the hole Then put the handrail into the hole 2 Find the reinforce wood for handrail which is inside of the handrail which is inside of the fuselage There are two holes for handrail to install 43 ...

Page 45: ...Accessories Assembly Canopy Lock Assembly Footplate Assembly Drill a 1mm diameter hole Then screw the bolt to fix the canopy screw the bolt to fix the canopy lock 44 ...

Page 46: ...ssories Assembly p y 1 Find the hole for footstep Cut the covering 3 Put the footstep into the hole Screw the bolt into the blind nut 2 There is a blind nut for the footstep inside the fuselage footstep inside the fuselage 45 ...

Page 47: ...accessories Assembly 1 Find the hole on the wing and aileron as shown Wing and aileron antenna Assembly 2 Put some glue on the black tip of the antennas Then insert the antennas into the hole antennas into the hole Note keep the white tip on the out side 46 ...

Page 48: ... stabilizer and elevator as shown Stabilizer and elevator antenna Assembly 2 Put some glue on the black tip of the antennas Then insert the antennas into the hole 2 Put some glue on the black tip of the antennas Then insert the antennas into the hole antennas into the hole Note keep the white tip on the out side antennas into the hole Note keep the white tip on the out side 47 ...

Page 49: ...ssembly Fuselage bottom 1 Find the place on the bottom of the fuselage for antenna as shown Cut the covering Fuselage bottom antenna Assembly 2 Glue the accessories on the bottom of the fuselage Cut the covering 48 ...

Page 50: ...s Assembly Fuselage top 1 Find the place on the bottom of the fuselage for antenna as shown Cut the covering Fuselage top accessories Assembly 2 Glue the accessories on the top of the fuselage Cut the covering 49 ...

Page 51: ... Degrees on Low rate Rudder 40 Degrees on High rate 30 Degrees on Low rate Your balance at the CG will determine batteries final mounting l ti After you set the given control throws up and have a few flights under you belt you can change the amounts as well as moving the CG as you like location Learn to use exponential of about 40 percent on your elevator to make great landings and not over contro...

Page 52: ...if you made a bad landing you first time Have an experienced pilot fly it for you the first time if you have any doubts in your mind about the maiden flight Take a break after you first flight and let the adrenaline y g burned off by bragging to your fellow members how good it flies Fly low and at a medium speed on your first few flight Listen to your engine run and have an observer with you to re...

Page 53: ...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 ...

Page 54: ...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 ...

Page 55: ...Install your horns Make sure to clean off any epoxy that comes out from under the plate with a paper towel and alcohol ...

Page 56: ...lation 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 ...

Page 57: ...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 ...

Page 58: ...y drilled servo screw holes and if need ed 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 ...

Page 59: ...o 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 ...

Page 60: ...The Tail wheel bracket will lock it in to place Make sure it overhangs the slot when you install the TW bracket ...

Page 61: ... 8 5inch Columbia 400 128 136mm 5 35inch Columbia 400 150 141mm 5 6inch EXTRA 300 330 73 154mm 6 06inch 170 6 7i h EXTRA 260 73 140mm 5 51 inch EXTRA 260 87 170mm 6 7inch EXTRA 260 106 202mm 7 95inch EXTRA 260 122 248mm 9 8inch YAK 54 73 156 mm 6 1inch YAK 54 87 183 mm 7 2inch YAK 54 107 225 mm 8 9inch YAK 54 121 266 mm 10 5inch YAK 54 129 273 mm 10 7inch YAK 54 148 314 mm 12 4inch YAK 54 180 401 ...