Align T-REX 450SA ARF User manual

Specifications
Length: 25.6 in (650mm)
Height: 9.0 in (228mm)
Main Rotor Diameter: 27.6 in (700mm)
Tail Rotor Diameter: 5.9 in (150mm)
Flying Weight: 22–24 oz (620–680 g)
Main Drive Gear: 150T
Motor Pinion Gears: 11T/13T/15T
Main Gear Ratios: 13.6:1/11.5:1/10:1
Main Tail Drive Gear: 106T
Tail Drive Gear: 25T
Tail Gear Ratio: 4.2:1

Table of Contents
2
Introduction...............................................................................................3
Electronics Required to Complete ..........................................................................4
T-REX 450SA ARF Contents .................................................................................4
Recommended Radio Systems and Setups ..................................................................5
Additional Items and Tools Required for Assembly ..........................................................7
Note on Lithium Polymer Batteries .........................................................................8
Using the Manual ..........................................................................................8
Limited Warranty Period....................................................................................8
Limited Warranty & Limits of Liability .......................................................................8
Warning...................................................................................................8
Limited Warranty & Limits of Liability .......................................................................9
Safety Precautions .........................................................................................9
Questions, Assistance, and Repairs..........................................................................9
Questions or Assistance ....................................................................................9
Inspection or Repairs.......................................................................................9
Warranty Inspection and Repairs ..........................................................................10
Non-Warranty Repairs.....................................................................................10
Safety, Precautions, and Warnings .........................................................................10
1.0 Swashplate Servo Installation .....................................................................11
2.0 Tail Servo Installation .............................................................................16
3.0 Gyro Installation ..................................................................................17
4.0 Receiver Installationand Connection ..............................................................19
5.0 Preparing the Motor and Electronic Speed Control for Installation ..................................24
6.0 Motor Installation.................................................................................25
7.0 Electronic Speed Control Installation ..............................................................27
8.0 Initial Transmitter Setup and Adjustment ..........................................................29
9.0 Servo Arm Setup and Installation..................................................................30
10.0 Control Linkage Assembly, Installation and Adjustment ............................................34
11.0 Additional Transmitter Setup and Adjustment .....................................................37
12.0 Control Tests......................................................................................38
13.0 Throttle and Pitch Curve Settings and Adjustments ................................................43
14.0 Canopy and Windshield Assembly and Installation .................................................46
15.0 Battery Mounting and Center of Gravity Check.....................................................47
16.0 Setting Tail Rotor Drive Belt Tension ...............................................................49
17.0 Motor Connection and Test .......................................................................50
18.0 Main Rotor Blade Balancing .......................................................................51
19.0 Before the First Flight .............................................................................53
20.0 Main Rotor Blade Tracking ........................................................................54
21.0 Recommended Maintenance......................................................................55
22.0 After Crash Inspection ............................................................................55
Main Rotor Head Assembly Parts Listing ...................................................................56
Main Rotor Head Assembly Exploded View.................................................................57
Washout, Swashplate and Main Drive Gear Assemblies Parts Listing ........................................58
Washout, Swashplate and Main Drive Gear Assemblies Exploded View ......................................59
Main Frame Assembly Parts Listing ........................................................................60
Main Frame Assembly Exploded View......................................................................61
Tail Boom, Tail Rotor and Landing Gear Assemblies Parts Listing ............................................62
Tail Boom, Tail Rotor and Landing Gear Assemblies Exploded View..........................................63
Replacement Parts Listing .................................................................................64
Optional Parts Listing .....................................................................................67
2006 Official AMA National Model Aircraft Safety Code .....................................................69
Building Notes ............................................................................................70
Flying Notes ..............................................................................................71

Welcome to the world of high-performance, electric powered mini helicopters, and thank you for choosing
the T-REX 450SA ARF.
The T-REX 450SA ARF is based on the proven design and performance of T-REX 450XL and 450SE helicopter
models. And through its use of tough, lightweight aluminum and updated composite parts, it offers an
excellent blend of performance, durability and reliability of both.
For intermediate and advanced pilots, the T-REX 450SA ARF offers performance that rivals even the most
capable 90-size glow powered helicopters. Its rapid cyclic response and incredible power loading (when
using the recommended power systems) allow it to perform even the most aggressive 3D aerobatics, as well
as basic sport and aerobatic flying, with ease. And because the T-REX 450SA ARF is a high-performance, 3D
capable model, it is not intended for first- or low-time helicopter pilots.
Although the T-REX 450SA ARF arrives 95% factory assembled, please take the time to read through
this manual completely before beginning assembly of your model. By carefully following all of the steps
outlined here, you can have your 450SA ready to fly in just one or two evenings.
Introduction
3

T-REX 450SA ARF Contents
4
• 6-channel (or greater) transmitter with helicopter and 120-degree CCPM programming
• 6-channel (or greater) FM, PCM or Spektrum® DSM® (for use with Spektrum transmitters only)
equipped micro receiver
• Three sub-micro servos (with at least 17 oz/in of torque) for swashplate (CCPM) control
• One sub-micro, micro or mini servo (with a .12 sec/60° or faster transit speed) for tail control
• Heading/Tail Lock gyro
• 430-class 3150–3550Kv brushless motor
• 25-amp (or greater) brushless ESC
• 3-cell (11.1V) 2000-2200mAh Li-Po battery pack, capable of 12C (for sport flying only) to 15C
(minimum for 3D flying) or greater discharge rates
• 3-cell Li-Po battery charger
Electronics Required to Complete
Before beginning assembly of your T-REX 450SA ARF, carefully remove the airframe, canopy, windshield,
decal sheet and bags from the box for inspection. Closely inspect the airframe and parts. If you find any
damaged or missing parts, now or during assembly of your model, please contact the place of purchase,
email [e-mail], or call 1-877-504-0233 toll free to speak to a product support
representative.
*Actual contents may vary slightly from photos shown
T-REX 450SA Airframe Decal Sheet Cable/Zip Tie and Canopy Mounting
Grommet Parts Bag
Motor Pinion Gear Parts Bag Motor Mounting Hardware Parts Bag
Servo Mounting Hardware Parts Bag
Linkage Parts Bag
Spare Hardware Parts Bag Hex Wrench and Screw Driver Tool Bag Threadlock and Battery Strap Bag
Canopy and Windshield

5
Recommended Radio Systems
Spektrum DX6 DSM 6-Channel 2.4GHz Park Flyer System (SPM2460: includes Spektrum AR6000 DSM
6-channel micro receiver and four S75 sub-micro servos)
JR® 7202 Synthesized 7-Channel PCM Micro/Mini Heli System (JRP7642: includes JR 790 Synthesized
7-channel PCM micro receiver and three 285 digital sub-micro servos)
Recommended Radio Systems and Setups

6
E-flite/Spektrum 7.5 Gram
Sub-Micro S75 Servo
(EFLRS75; four required)
Align 500X Head Lock Gyro
(AGNRG500X)
Align 430L Brushless Motor,
3150Kv
(AGNM4360)
Align 25-Amp Brushless ESC
w/5V BEC
(AGNE25G)
Align 2100mAh 3S 11.1V Li-Po Battery Pack
AGNB21003S)
E-flite/Spektrum 7.5 Gram
Sub-Micro S75 Servo
(EFLRS75; four required)
Align 500X Head Lock Gyro
(AGNRG500X)
Align 430L Brushless Motor,
3550Kv
(AGNM4365)
Align 35-Amp Brushless ESC
w/5V BEC
(AGNE35G)
Align 2100mAh 3S 11.1V Li-Po Battery Pack
(AGNB21003S)
Recommended Setup for Sport and Mild 3D Flying (Longest Durations)
Recommended Setup for Sport and 3D Flying

Additional Items and Tools Required for Assembly
77
• Adhesive-Backed Hook and Loop Tape (EFL2135)
• Double-Sided Servo Tape (EFL2135)
• Clear tape (Optional)
• Lightweight Oil (TRI4026)
• Isopropyl alcohol
• Hobby Knife (EXL16001)
• Scissors (DYN2511)
• Metric Ruler (MPTH710)
• Metric calipers (Optional)
• Drill and 1/16” drill bit (Optional)
JR 285 Digital Sub-Micro
Servo
(JRPS285: Three Required)
JR 3400G Digital Mini Gyro
Servo
(JRPS3400G)
Align 430L Brushless Motor,
3550Kv
(AGNM4365)
Align 35-Amp Brushless ESC
w/5V BEC
(AGNE35G)
or 6V BEC
(AGNE35X)
Align 2100mAh 3S 11.1V Li-Po Battery Pack
(AGNB21003S)
Recommended Setup for Precision and Aggressive 3D Flying
• #1 Phillips Screwdriver (Optional; EFLA258)
• #0 Phillips Screwdriver (Optional; EFLA257)
• Vise grips (Optional)
• Needle-Nose Pliers (EXL55560)
• Ball Link Pliers (Optional; KSJ673)
• Ball Link Sizing Tool (Optional; JRP960219)
• Soldering Iron (Optional; WELSP40L)
• Solder (Optional; WSD2020)
• Pitch Gauge (AGNH1000)
• Blade Balancer (KSJ1470)
• 1.5, 2.0 and 2.5mm Hardened Tip Hex Wrenches (Optional; DYN2904)
JR G500T Tail Lock Ring Gyro
(JRPG500T)

Note on Lithium Polymer Batteries
Using the Manual
Limited Warranty Period
Limited Warranty & Limits of Liability
8
An RC aircraft is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only
in open areas, preferably at AMA (Academy of Model Aeronautics) approved flying sites, following all
instructions included with your radio.
Keep loose items that can get entangled in the rotor blades away for the main and tail blades, including
loose clothing, or other objects such as pencils and screwdrivers. Especially keep your hands away from
the rotor blades.
Lithium Polymer batteries are significantly more volatile than alkaline or Ni-Cd/Ni-MH batteries
used in RC applications. All manufacturer’s instructions and warnings must be followed closely.
Mishandling of Li-Po batteries can result in fire. Always follow the manufacturer’s instructions
when disposing of Lithium Polymer batteries.
This manual is divided into sections to help make final assembly and preparing for flight easier to
understand, and to provide breaks between each major section.
Remember to take your time and follow all directions.
Horizon Hobby, Inc. guarantees this product to be free from defects in both material and workmanship at
the date of purchase.
Pursuant to this Limited Warranty, Horizon Hobby, Inc. will, at its option, (i) repair or (ii) replace, any
product determined by Horizon Hobby, Inc. to be defective. In the event of a defect, these are your
exclusive remedies.
This warranty does not cover cosmetic damage or damage due to acts of God, accident, misuse, abuse,
negligence, commercial use, or modification of or to any part of the product. This warranty does not cover
damage due to improper installation, operation, maintenance, or attempted repair by anyone other than
an authorized Horizon Hobby, Inc. service center. This warranty is limited to the original purchaser and is
not transferable. In no case shall Horizon Hobby’s liability exceed the original cost of the purchased product
and will not cover consequential, incidental or collateral damage. Horizon Hobby, Inc. reserves the right
to inspect any and all equipment involved in a warranty claim. Repair or replacement decisions are at the
sole discretion of Horizon Hobby, Inc. Further, Horizon Hobby reserves the right to change or modify this
warranty without notice.
REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE
CONSUMER. HORIZON HOBBY, INC. SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
As Horizon Hobby, Inc. has no control over use, setup, final assembly, modification or misuse, no liability
shall be assumed nor accepted for any resulting damage or injury. By the act of use, setup or assembly, the
user accepts all resulting liability.
Warning

Safety Precautions
Questions, Assistance, and Repairs
Questions or Assistance
Inspection or Repairs
9
If you as the purchaser or user are not prepared to accept the liability associated with the use of this
product, you are advised to return this product immediately in new and unused condition to the
place of purchase.
This is a sophisticated hobby product and not a toy. It must be operated with caution and common sense
and requires some basic mechanical ability. Failure to operate this product in a safe and responsible manner
could result in injury or damage to the product or other property. This product is not intended for use by
children without direct adult supervision.
The product manual contains instructions for safety, operation and maintenance. It is essential to read and
follow all the instructions and warnings in the manual, prior to assembly, setup or use, in order to operate
correctly and avoid damage or injury.
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 Hobby, Inc. 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 [e-mail], or call 1-877-
504-0233 toll free to speak to a product support representative.
If your product needs to be inspected or repaired, pack the product securely using a shipping carton. Please
note that original boxes may be included, but are not designed to withstand the rigors of shipping without
additional protection. Ship via a carrier that provides tracking and insurance for lost or damaged parcels, as
Horizon Hobby, Inc. is not responsible for merchandise until it arrives and is accepted at our facility. Include
your complete name, address, phone number where you can be reached during business days, , and a brief
summary of the problem. Be sure your name and address are clearly written on the shipping carton.
Products requiring inspection or repair should be shipped to the following address (freight prepaid):
Horizon Product Support
4105 Fieldstone Road
Champaign, Illinois 61822
Limited Warranty & Limits of Liability

Non-Warranty Repairs
Safety, Precautions, and Warnings
10
To receive warranty service, you must include your original sales receipt verifying the proof-of-purchase
date. Providing warranty conditions have been met, your product will be repaired or replaced free of charge.
Repair or replacement decisions are at the sole discretion of Horizon Hobby.
Should your repair not be covered by warranty and the expense exceeds 50% of the retail purchase
cost, you will be provided with an estimate advising you of your options. You will be billed for any
return freight for non-warranty repairs. Please advise us of your preferred method of payment. Horizon
Hobby accepts money orders and cashiers checks, as well as Visa, MasterCard, American Express, and
Discover cards. If you choose to pay by credit card, please include your credit card number and
expiration date. Any repair left unpaid or unclaimed after 90 days will be considered abandoned and
will be disposed of accordingly.
As the user of this product, you are solely responsible for operating it in a manner that does not endanger
yourself and others or result in damage to the product or the property of others.
This model is controlled by a radio signal that is subject to interference from many sources outside your
control. This interference can cause momentary loss of control so it is advisable to always keep a safe
distance in all directions around your model, as this margin will help to avoid collisions or injury.
• Never operate your model with low transmitter batteries.
• Always operate your model in an open area away from cars, traffic, or people.
• Avoid operating your model in the street where injury or damage can occur.
• Never operate the model out into the street or populated areas for any reason.
• Carefully follow the directions and warnings for this and any optional support equipment
(chargers, rechargeable battery packs, etc.) that you use.
• Keep all chemicals, small parts and anything electrical out of the reach of children.
• Moisture causes damage to electronics. Avoid water exposure to all equipment not specifically
designed and protected for this purpose.
• Never lick or place any portion of your model in your mouth as it could cause serious injury
or even death
Warranty Inspection and Repairs

11
Three sub-micro servos (with at least 17 oz/in of torque) are required for swashplate (CCPM) control.
1.1 Using a 1.5mm hex wrench, remove the aluminum frame joiner located just above the forward servo
mount holes as shown. This will allow the pitch and aileron servo to be installed more easily.
1.2 Remove the servo arm and screw from each servo and set them aside.
1.3 Install the pitch servo inside the lower forward hole in the right-hand frame as shown. Note that the
output shaft of the servo must be oriented toward the rear of the helicopter.
1.0 Swashplate Servo Installation

12
1.4 Using the hardware included in the Servo Mounting Hardware Parts Bag, fasten the servo in place
with two screws and two servo mounting plates. Note that the servo mounting plates have an
extended portion on one side. When using JR servos, the extended portion of the servo mounting
plate fits inside the servo’s mounting tab to help precisely center the servo in the frame. When using
other types of servos, the flat side of the servo mounting plate rests against the servo mounting tab.

13
1.5 Next, install the aileron servo inside the upper forward hole in the left-hand frame as shown. Note
that the output shaft of the servo must be oriented toward the rear of the helicopter. Use two screws
and two servo mounting plates to fasten the aileron servo in place.
1.6 The elevator servo mounts outside of the rear hole in the left-hand frame. The output shaft must be
facing inside the frame, oriented toward the rear of the helicopter. Note that the elevator servo’s lead
must pass though the frame, in the notch provided just below the servo, before the servo is installed.

14
1.7 Use two screws and two servo mounting plates to fasten the elevator servo in place. The screws
are installed from inside the frame, with the servo mounting plate on the outside of the servo
mounting tab.

15
1.8 Reinstall the aluminum frame joiner using the green colored R48 threadlock provided.
1.9 Carefully route the servo wire leads down the inside of the upper right main frame and out the rear
of the model just ahead of the tail boom mount. Secure them to the frame using cable/zip ties and
the slots found just behind the pitch servo and ahead of the tail boom mount.

16
One sub-micro, micro or mini servo (with a .12 sec/60° or faster transit speed) is required for tail control.
2.1 Install the tail rotor servo on the tail boom servo mounts using two of the remaining servo mounting
screws. If you are installing the JR 3400G servo, be sure to also use two of the blue anodized
aluminum cap washers from the Spare Hardware Parts Bag. Note that the output shaft of the servo
must be oriented toward the rear of the helicopter.
2.2 Leave the tail boom servo mounts loose on the boom at this time, as the servo and mount positions
will be adjusted later on.
2.0 Tail Servo Installation

17
A heading/tail lock gyro is required for the best possible tail holding performance.
We recommend that the gyro be mounted on the main frame base plate, just ahead of the motor mounting
area and below the battery mounting plate. This position offers good crash protection for the gyro, and
helps to better balance the helicopter.
Note: If you are using the Align 500X gyro, a short (approximately 3-6”) servo extension
may be required when connecting the tail servo to the gyro in this location.
3.0 Gyro Installation

18
Another option for mounting the gyro is to secure the gyro on top of the tail boom holder, near the rear of
the upper main frame.
3.1 Thoroughly clean the base of the gyro and the area that the gyro will be mounted on
with isopropyl alcohol.
3.2 Using the double-sided tape provided with the gyro, or servo tape, mount the gyro in your
chosen position.

19
A 6-channel (or greater) micro receiver is required.
We recommend the use of a PCM receiver (like the JR 790) if using a 72MHz transmitter. However, for
the ultimate in glitch-free performance, we strongly recommend the use of a DSM (Digital Spectrum
Modulation) equipped receiver (like the Spektrum AR6000) and transmitter on 2.4GHz.
The Spektrum DX6 transmitter and AR6000 receiver system has become a favorite among T-REX 450 pilots
due to its robust and reliable RF link that makes glitching and range impairment from motor, ESC, servo and
mechanical RF “noise” a thing of the past. It also eliminates any issues related to operating on 72MHz, as you
will no longer need to worry about securing an open channel, or having someone accidentally“turn on” on
your channel while flying, potentially causing loss of control and a crash.
4.0 Receiver Installation
and Connection

20
4.1 Mount the receiver on top of the main frame base plate, near the rear of the lower main frames. Use
double-sided tape and a cable/zip tie to fasten it in position.