Hangar 9 Taylorcraft 20cc ARF Assembly Manual Download Page 2

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Table of Contents

Contents of Kit and Parts Layout............................................2

Included Hardware.................................................................3

Using the Manual....................................................................4

UltraCote Covering Colors......................................................4

Before StartingAssembly........................................................4

Workspace Preparation..........................................................4

Radio System Requirements..................................................4

Recommended Power Setups................................................4

Important Information Regarding Warranty.........................4

Required Tools and Equipment......................................5

RequiredAdhesives................................................................5

Other Required Items.............................................................5

Product Registration...............................................................5

Rudder and Elevator Servo Installation..................................6

Tail Installation........................................................................7

Elevator Pushrod and Rudder Pull-Pull Cable Installation....9

Tailwheel Installation.............................................................14

Tail Brace Installation............................................................16

Landing Gear Installation......................................................19

Gas Engine Installation.........................................................21

Ignition and Engine Installation.............................................25

Throttle Servo, Linkage & Carburetor Installation................27

Cowling Installation...............................................................30

Fuel System Connections.....................................................33

Aileron Servo Installation......................................................34

Wing StrutAssembly.............................................................38

Radio Installation..................................................................41

Ignition Battery Installation....................................................43

Windshield and Landing Gear Cuff Installation....................44

FinalAssembly......................................................................45

Center of Gravity...................................................................48

Control Throws.....................................................................49

Flight Preparations................................................................49

Maintaining Your Model........................................................50

Safety Do’s and Don’ts for Pilots..........................................51

Dual Rate..............................................................................51

Age Requirements................................................................51

Daily Flight Checks...............................................................51

Safety, Precautions and Warnings.......................................52

Warranty Information............................................................52

2009 Official Academy of

ModelAeronautics Safety Code............................55

Hangar 9 Taylorcraft 20cc Assembly Manual

Contents of Kit and Parts Layout

Replacement Parts

1. HAN4907

Cowl

2. HAN4901

Fuselage with Top Hatch

3. HAN4906

Windshield

4. HAN4913

Fin and Rudder

5. HAN4905

Stabilizer

6. HAN4903

Left Wing Panel

7. HAN4904

Right Wing panel

8. HAN4909

Stabilizer Strut Parts

9. HAN4917

Pushrods

10. HAN4911

Wing Strut Assembly LR

11. HAN4910

Wing Tube

12. HAN4912

Wheel Pants

13. HAN4908

Landing Gear

14. HAN4566

Pilot

15. HAN4902

Top Window

16. HAN4915

Seat and Mounting Panel

Not Illustrated

HAN4914

Engine Standoffs for G20EI

HAN4916

Small Parts Bag

Summary of Contents for Taylorcraft 20cc ARF

Page 1: ...y Manual Specifications Wingspan 80 5 in 2045 5mm Length 63 7 in 1618mm Wing Area 1152 73 sq in 74 4 sq dm Weight 13 14 5 lb 5 90 6 58 kg Radio 4 channel w 6 servos Engine 1 00 1 60 2 stroke 1 20 1 80 4 stroke 20 26cc gas Power110 ...

Page 2: ...Radio Installation 41 Ignition Battery Installation 43 Windshield and Landing Gear Cuff Installation 44 FinalAssembly 45 Center of Gravity 48 Control Throws 49 Flight Preparations 49 Maintaining Your Model 50 Safety Do s and Don ts for Pilots 51 Dual Rate 51 Age Requirements 51 Daily Flight Checks 51 Safety Precautions and Warnings 52 Warranty Information 52 2009 Official Academy of ModelAeronauti...

Page 3: ...ut 4 8 steel washers 8 Aluminum engine mount 2 4 40 x 1 2 inch button head Allen screw 4 4 steel washer 4 Tailwheel Bag Tailwheel assembly with wheel 1 Springs 2 Tiller arm 1 2 x 5 8 inch self tapping screws 2 4 x 3 4 inch socket head wood screws 2 4 steel washers 2 Tail Flying Wire Bag Bottom strut supports 4 Top flying wire 2 4 40 steel rod end 2 4 40 hex nut 2 4 40 x 1 4 inch button head Allen ...

Page 4: ...ing foam or a thick bath towel will work well and help protect the model from damage during assembly A flat area measuring at least 24 x 72 inches is required to work on the model sub assemblies comfortably The completed and assembled model requires a space of 72 x 90 inches Ensure you have adequate lighting and a place to set aside parts that have been completed Radio System Requirements Spektrum...

Page 5: ...ew option parts or accessories or updates available for your product Register your product today at http www hangar 9 com Register Optional Accessory Setting up servos is a whole lot easier with a JR MatchMaker It lets you accurately center servos evaluate endpoints and cycle servos at varying speeds without ever having to switch on a transmitter It allows the precise digital centering of up to 2 ...

Page 6: ...door is held closed with magnets the handle does not need to be turned Step 2 Insert the rubber grommets into the servos Step 3 Insert the brass bushings in the servos Note that the flange is located on the lower side of the servo Step 4 Use a 1 Phillips screwdriver to install a servo screw in each of the pre drilled holes in the servo tray Step 5 Remove the servo screw and apply a drop of thin CA...

Page 7: ...tput shaft towards the tail the rudder servo mounts in the center with the output shaft forward Step 7 This shows the rudder and elevator servos installed Step 8 Route the servo leads forward into the radio compartment through the holes in the bulkhead Tail Installation Required Parts Fuselage Fin with rudder Stabilizer with elevators Required Tools Threadlock 3 32 inch hex wrench Step 1 Engage th...

Page 8: ... stabilizer joiner rods through the holes in the base of the fin and slide the stabilizer halves against each side of the fin Step 5 Locate the four 6 32 x 1 inch button head hex bolts Place a drop of threadlock on the end of the threads Step 6 Use a 3 32 inch hex wrench to install the four stabilizer bolts Use care to not tighten the bolts excessively and crush the stabilizer structure ...

Page 9: ...ecutters Crimping pliers 3 16 inch wrench Step 1 Prepare the elevator pushrods by threading a 4 40 hex nut and 4 40 clevis onto one end Step 2 Insert the elevator pushrod into the pushrod housing opening in the rear of the fuselage side Step 3 Use a 3 32 inch drill bit in a pin vise to enlarge the outer hole in a standard 180 degree servo arm Step 4 Use a 5 64 inch hex driver and 1 4 inch wrench t...

Page 10: ...e a ruler to check the alignment of the elevator with the stabilizer as the clevis is being adjusted Step 9 Locate the coil of coated steel pull pull cable Uncoil the cable and fold it against itself to find the center Use sidecutters to cut the cable into two equal lengths Step 10 Use a hobby knife with a 11 blade to debur the inside of each end of the copper crimp This will make it easier to dou...

Page 11: ...m the crimp Step 14 Use crimping pliers or sidecutters on the copper crimp to secure the cable end Use care not to cut completely through the cable Step 15 Thread a 4 40 ball link assembly onto the rigging coupler Use pliers to grip the coupler while threading the ball link on Step 16 Use a 3 32 inch drill bit in a pin vise to enlarge the outer hole in each end of a JR heavy duty servo arm Step 17...

Page 12: ...screwdriver to secure the arm to the servo Step 20 Invert the fuselage on the work table Install a 4 40 hex nut and clevis on a rigging coupler so that about three threads protrude from the barrel of the clevis Attach the clevis to the middle hole in the rudder horn Step 21 Slide a copper crimp onto the pull pull cable Step 22 Insert the free end of the pull pull cable through the hole in the end ...

Page 13: ...er servo arm and rudder are centered then use crimping pliers or sidecutters to secure the copper crimp to the pull pull cables Step 26 Use sidecutters to trim the excess cable protruding from the crimp Step 26 Place a drop of threadlock on the threads of the rigging coupler between the clevis and the hex nut Step 27 Use a 3 16 inch open end wrench to tighten the hex nut against the clevis Step 28...

Page 14: ... tiller arm on the bottom of the rudder with its edge aligned with the forward edge of the rudder Mark the mounting holes with a felt tipped pen Step 2 Use a 1 32 inch drill in a pin vise to drill the mounting holes for the tiller arm screws Step 3 Place 3 4 drops of thin CA in each of the holes to strengthen the wood around the holes Do not use accelerator as the CA needs to fully penetrate the w...

Page 15: ...ts bag Step 8 Place the aluminum tab on the tailwheel assembly over the rear hole Use a 3 32 in hex wrench to install the second mounting screw and washer Step 9 Use needle nose pliers to bend a loop in each end of the tailwheel steering springs and attach them to each end of the steering tiller on the rudder and tailwheel assembly Step 10 The springs should be under slight tension when installed ...

Page 16: ...r Step 8 Attach the inboard end of the rear strut to the top of the aluminum tab with a 4 40 x 1 4 inch button head machine screw and 4 40 nylon locknut Step 9 Use a 5 64 inch hex wrench and 1 4 inch open end wrench to tighten the rear strut to the aluminum tab Step 10 Thread a 4 40 rod end onto the threaded section of the upper brace wire and adjust it until the hole is aligned with the hole in t...

Page 17: ... tab of the upper wire brace and into the rear hole in the fin Whether the bolt head is on the left or right side is not critical Step 2 On the opposite side of the fin place the other wire brace over the protruding screw then a 4 washer and 4 40 nylon lock nut Step 3 Use a 5 64 inch hex wrench and 1 4 inch open end wrench to tighten the upper brace wires against the fin Only a snug fit is necessa...

Page 18: ...orward strut over the screw and thread on a 4 40 nylon locknut Step 14 Use a 5 64 inch hex wrench and 1 4 inch wrench to tighten the forward strut against the stabilizer lower surface Step 15 Place a drop of threadlock on a 4 40 x 5 8 inch button head machine screw Step 16 Use a 5 64 inch hex wrench to install the forward strut end to the bottom of the fuselage Step 17 Repeat steps 5 through 16 fo...

Page 19: ...f the landing gear leg The cutout in the cuff is located rearwards and outboard on the landing gear leg Note that the landing gear will angle forward on the airplane Step 2 Slide the cuff halfway up the gear leg and tape it in place with low tack tape Step 3 Locate the axle and slide its threaded end into the large hole in the landing gear The axle will face outward Thread the nut onto the axle Us...

Page 20: ... 2 5mm hex wrench Check that the wheel rotates freely adjust the wheel collar location if necessary A small drop of lightweight oil can be applied to help the wheel move easily Step 9 Slide one of the wheel pants over the wheel and into place against the landing gear leg Note that there is a left and right wheel pant Slide a 4 washer onto each of the 4 40 x 1 2 inch button head machine screws Appl...

Page 21: ...nylon lock nut Use a 3 32 inch hex wrench and 5 16 inch wrench to secure the strut to the landing gear leg Step 14 Repeat steps 1 through 13 for the opposite side Gas Engine Installation Firewall Preparation Parts Required Fuselage Ignition unit 8 washer 28mm aluminum standoff 8 32 blind nut 4 Fuel tank 64 rubber bands Gas compatible fuel line 8 32 x 1 1 2 inch socket head cap screw Small cable ti...

Page 22: ... located outside the outline of the ignition unit placement Step 4 Use a ruler to measure 1 inch below the lower hole drilled in Step 3 and mark the location with a pencil Step 5 Use a 1 4 inch drill bit to drill two holes next to each other Clean out the extra wood between the holes with a hobby knife or file forming a slot measuring 1 4 x 1 2 inches Step 6 Check that the battery lead from the ig...

Page 23: ...hten the screw against the standoff and draw the blind nuts into the mounting holes Check the back of the firewall and make sure that the blind nut flanges are fully seated against the firewall Step 11 Use a 1 Phillips screwdriver to loosen the screw in the fuel tank stopper Remove the stopper assembly from the fuel tank Note the orientation of the vent line when removing the stopper assembly Step...

Page 24: ... stopper towards the top of the tank Step 16 Slide the tank forward until the stopper cap engages in the hole in the firewall Step 17 Use two 64 rubber bands to secure the tank in the fuselage Hook the rubber bands around the tabs in the bulkhead on the left and right of the tank Step 18 Cut two lengths of fuel tubing one 5 inches long the other 8 inches Connect the 5 inch piece to the tubing on t...

Page 25: ...e in a medium cable tie Step 2 Insert the cable tie into the lower ignition mount hole and guide it out the upper hole Step 3 Cut a piece of 1 4 inch foam rubber the size of the ignition unit Place the ignition unit and foam against the firewall and use a second cable connected to the first tie to secure it Step 5 Use a 3mm hex wrench to remove the carburetor isolator block from the engine Step 6 ...

Page 26: ...ch Step 9 Feed the ignition battery lead through the hole in the lower firewall It will get connected at a later time Step 10 Connect the signal lead from the igntion unit to the lead from the engine Step 11 Route the spark plug lead from the ignition unit over the lower right standoff behind the engine and connect the cap to the spark plug The cap requires a firm push to make complete connection ...

Page 27: ...hrottle pushrod housing to a length of 7 1 2 inches with a hobby knife Use medium grit sandpaper to scuff 1 inch of one end Step 2 Insert the housing into the pushrod hole in the firewall with the scuffed end forward Guide it through the slot in the bulkhead at the front of the radio compartment Step 3 Leave 1 4 inch of the housing protruding from the firewall and glue it in place with medium CA S...

Page 28: ...rill bit in a pin vise to enlarge the outer hole of the remaining servo arm Step 9 Use your radio or a JR MatchMaker to center the throttle servo Use a 1 Phillips screwdrive to install the servo arm Step 10 Place the 2 56 ball link in the throttle arm in the position shown and apply a drop of threadlock to the screw threads Use a 1 5mm hex wrench and 3 16 inch wrench to install the 2 56 nut on the...

Page 29: ...o 4mmx 40mm mounting bolts Use a 4mm hex wrench to install the carburetor on the engine Step 15 Reattach the ball link connector to the throttle arm Step 16 The carburetor has a spring return that assists in returning the throttle to idle Verify that the throttle is completely closed by pulling the pushrod rearwards Use a felt tipped pen to mark the position of the centered servo arm on the pushro...

Page 30: ...rs 4 4mm x 50mm socket head cap screws 2 4 40 x 1 2 inch socket head cap screws 4 Tools Required Rotary tool 5 64 inch hex wrench Pencil Felt tipped pen Ruler Scissors 4mm hex wrench Hobby knife with 11 blade Three openings are required in the cowling to clear the spark plug cap intake funnel and exhaust Step 1 Use a rotary tool fitted with a sanding drum to make an opening in the lower surface of...

Page 31: ...nel to complete marking the circle on the template Step 7 Use a hobby knife with 11 blade to cut out the marked section of the template Use a pencil to mark which is the inside of the template so that it can t be installed incorrectly Step 8 Align the screw holes in the template over the mount ing holes on the right side of the cowling and tape it in place with low tack tape Use a felt tipped pen ...

Page 32: ...er the exhaust and tape it in place on the fuselage with low tack tape Step 13 Remove the muffler then use a 5 64 inch hex wrench to install the cowling with four 4 40 x 1 2 inch button head machine screws Make sure that the cowling is installed under the exhaust cutout template Use a felt tipped pen to mark the location of the exhaust cutout on the cowling Note Because the cowling does not fit fl...

Page 33: ...l System Connections Required Parts Fuselage Cowling Fuel dot Fuel tubing Small cable tie Required Tools Ruler Tapered reamer Felt tipped pen Sidecutters Step 1 Remove the cowling Use sidecutters to remove an approximately 1 1 2 inch length from the end of the fuel feed line and insert a tee fitting Step 2 Connect the fuel feed line to the carburetor inlet Attach an 8 inch length of fuel tubing to...

Page 34: ... Step 7 Mark a similar location on the lower cowl on the opposite side of the scoop Use a tapered reamer to make a suitably sized hole for the vent line from the fuel tank Aileron Servo Installation Parts Required Wing panels Aileron servos 4 40 clevis 4 4 40 hex nut 4 Aileron pushrods 2 12 inch servo extension 2 2 x 1 4 inch self tapping screws 8 20 x 20 x 10mm hardwood block 2 Tools Required Pen...

Page 35: ...ng and place the servo on the inside of the hatch Align the servo arm with the edge of the hatch Step 4 Center the servo arm within the length of the opening Step 5 Use a pencil to mark the servo location on the inside of the hatch Step 6 Mix a small amount of 12 minute epoxy and glue the 20 x 20 x 10mm servo mounting blocks to the hatch on the outside of the markings for the servo Note that the g...

Page 36: ... Step 9 Use a 1 Phillips screwdriver to thread a servo mounting screw into each of the mounting holes Step 10 Remove the screws and apply 1 2 drops of thin CA to each of the mounting holes to strengthen the wood Step 11 Use a 1 Phillips screwdriver to install the servo to the hatch with four servo mounting screws Step 12 Attach a 12 inch servo extension lead to the aileron servo and secure it with...

Page 37: ... Apply a drop or two of thin CA to each of the pre drilled servo mounting holes in the wing panel Step 16 Use a 1 Phillips screwdriver to install the aileron hatch in the wing panel with four 4 x 1 4 inch self tapping screws Step 17 Place a 4 40 hex nut and 4 40 clevis on each end of a 4 5 16 inch aileron pushrod Step 18 Use a piece of low tack tape to hold the aileron in the neutral position Wrap...

Page 38: ...to install the aileron servo and linkage in the opposite wing panel Wing Strut Assembly Parts Required Wing panels Wing Strut 4 Jury strut 6 Strut fitting wing 4 4 washer 4 Strut fitting fuselage 2 5mm hex nut 4 4 40 nylon lock nut 8 Strut end 4 Jury strut fitting 4 6 washer 4 4 40 x 3 8 inch button head machine screw 8 4 40 x 1 2 inch button head machine screw 4 4 40 x 5 8 inch socket head cap sc...

Page 39: ...ittings with a 4 40 x 3 8 inch button head machine screw 4 washer and 4 40 nylon lock nut Tighten the strut to the fitting with a 5 64 inch hex wrench and 1 4 inch open ended wrench Note All the jury struts are the same Step 5 Locate the wing struts Each of the four struts is different the forward strut measures 20 1 2 inches long the rear 21 1 8 inches and the attach bracket on the strut faces th...

Page 40: ...hex wrench and 1 4 inch open end wrench to secure the struts Step 9 Thread a 5mm hex nut and strut end onto the end of the wing struts Step 10 Slide a 6 washer onto a 6 32 x 1 2 inch button head machine screw Step 11 Use a 3 32 inch hex wrench to attach the strut fitting to the fuselage bottom with the two 6 32 x 1 2 inch machine screws Step 12 Repeat steps 1 through 11 to complete the strut assem...

Page 41: ...screws provided with the switch Step 2 Use scissors to cut an 8 inch length of hook and loop strap and loop it through the slots on the right hand side of the radio compartment Step 3 Attach the recevier battery to the radio compartment floor with double sided tape then fasten the hook and loop tape over the battery Step 4 Connect the battery lead to the chargeswitch and secure the connection with...

Page 42: ...eceiver Step 8 Connect the power lead from the chargeswitch to the receiver battery port Step 9 Plug the rudder and two elevator servo leads into the receiver Step 10 Plug the throttle servo lead into the receiver Step 11 Plug two 12 inch servo extension leads into the re ceiver for the ailerons Route the leads to each side of the fuselage and up through the unused switch port ...

Page 43: ...floor Ignition Battery Installation Required for Gas Engine Parts Required Fuselage Chargeswitch Ignition battery Tools Required Dental floss 0 Phillips screwdriver Double sided adhesive tape Step 1 Install a chargeswitch in the cutout on the right hand side of the radio compartment Use a 0 Phillips screwdriver and the self tapping screws provided with the switch Step 2 Feed the male lead from the...

Page 44: ...opy glue Ruler Step 1 Slide the landing gear cuff up the gear leg against the fuselage Apply a small bead of canopy glue around the intersection of the gear leg and the cuff Tape the cuff to the fuselage with low tack tape if necessary to hold it in position Gluing the cuff to the gear leg only will allow the landing gear to be removed in the future if required Step 2 Measure 1 3 4 inches behind t...

Page 45: ...t Wing tube Strut pin 4 Keeper 4 Pilot figure Propeller Cowling Cable tie small 4 washer 4 Silicone pin spacer 4 4 40 x 1 2 inch button head machine screw 4 4 x 1 4 inch self tapping screw 12 1 4 20 x 1 1 2 inch nylon wing bolt 2 Tools Required Thin CA 1 Phillips screwdriver Threadlock 9 32 inch open end wrench 5 64 inch hex wrench Step 1 Apply 1 2 drops of thin CA to each of the radio cover mount...

Page 46: ... tapping screws The window is shaped such that it will only fit one way Step 6 Slide the 21 3 4 x 3 4 inch aluminum wing tube into the fuselage Step 7 Slide the wing onto the wing tube Pass the aileron lead through the slot behind the wing tube and insert the alignment tube into its hole in the fuselage as the wing is pushed on completely Step 8 Install the 1 4 20 x 1 1 2 inch nylon wing retaining...

Page 47: ... Insert the strut pins and spacers Step 12 Insert the keepers in the strut pins Step 13 Apply a drop of threadlock to the threads at the end of the strut fitting Step 14 Use a 9 32 inch open end wrench to tighten the hex nut against the strut end fitting Repeat steps 7 through 14 for the opposite side Step 15 Install the pilot figure shown here with helmet and life jacket removed The boots have al...

Page 48: ...raft for flight is properly balancing the model Caution Do not inadvertently skip this step The recommended Center of Gravity CG location for your model is 3 3 4 inch 95mm behind the leading edge of the wing 25 chord Mark the location for the Center of Gravity on a piece of low tack tape on the bottom of the wing next to the fuselage as shown When balancing your model support the plane upright at ...

Page 49: ...ferred style of flying Note Travel Adjust Sub Trim and Dual Rates are not listed and should be adjusted according to each individual model and preference Flight Preparations Flight preparations should be performed each time you travel to the flying field Because your model will encounter a variety of situations it is best to keep an eye on the various components of your model to keep it in the bes...

Page 50: ...of wear or is broken replace it with a new clevis Also check the nylon connectors at the servo for any wear or damage If they look worn or in bad shape replace them as well Checking the Control Horns Inspect the control horns to make sure they have not crushed the wood of the control surface If so remove the control horn screws to remove the control horn Place 2 3 drops of thin CA into each of the...

Page 51: ...to help maintain heading as the model transitions from flying speed to taxi speeds Elevator and Aileron dual rates should be adjusted for personal feel and also if there are any unusual wind conditions Age Requirements Age Recommendation 14 years or over This is not a toy This product is not intended for use by children without direct adult supervision Daily Flight Checks Step 1 Check the battery ...

Page 52: ...defects in materials and workmanship at the date of purchase by the Purchaser LIMITED WARRANTY a This warranty is limited to the original Purchaser Purchaser and is not transferable REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER This warranty covers only those Products purchased from an authorized Horizon dealer Third party transactions are not cover...

Page 53: ...S 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 directly This will enable Horizon to better answer your questions and service you in the event that you may need any assistance For questions or assistance please direct your email to productsupport horizonhobby com or call ...

Page 54: ... 504 0233 or e mail us at productsupport horizonhobby com with any questions or concerns regarding this product or warranty United Kingdom Electronics and engines requiring inspection or repair should be shipped to the following address Horizon Hobby UK Units 1 4 Ployters Rd Staple Tye Harlow Essex CM18 7NS United Kingdom Please call 44 0 1279 641 097 or e mail us at sales horizonhobby co uk with ...

Page 55: ...truction 12 When and where required by rule helmets must be properly worn and fastened They must be OSHA DOT ANSI SNELL or NOCSAE approved or comply with comparable standards RADIO CONTROL 1 All model flying shall be conducted in a manner to avoid over flight of unprotected people 2 I will have completed a successful radio equipment ground range check before the first flight of a new or repaired m...

Page 56: ... 2009 Horizon Hobby Inc 4105 Fieldstone Road Champaign Illinois 61822 USA 877 504 0233 horizonhobby com Hangar 9 com 15660 Printed 07 09 ...

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