Black Horse Model Edge 540-V3 Owner's manual

Instruction Manual book
SPECIFICATION
MadeinVietnam.
 
 
 Wingspan : 1,610 mm. 63.39 in.
 
 
 Length : 1,290 mm. 50.79 in.
 
 
 Weight : 2.9kg. 6.38 lbs.
 
 
 Radio : 4 channels.
 
 
 Servo : 5 servos.
 
 
 Engine : 55 2 stroke.
72 4 stroke.
 
 
 Electric Motor: EMAX 2832.


Battery:4 Cells-Li-Poly-14.8V-4,000 mAh.
EP & Glow Engine

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
2
This instruction manual is designed to help you build a great flying aeroplane. Please read this
manual thoroughly before starting assembly of your EDGE 540-V3.Use the parts listing below to
identify all parts.
WARNING.
Please be aware that this aeroplane is not a toy and if assembled or used incorrectly it is
capable of causing injury to people or property. WHEN YOU FLY THIS AEROPLANE YOU
ASSUME ALL RISK & RESPONSIBILITY.
IfyouareinexperiencedwithbasicR/CflightwestronglyrecommendyoucontactyourR/Csupplier
and join your local R/C Model Flying Club. R/C Model Flying Clubs offer a variety of training
proceduresdesignedtohelpthenew pilotonhiswaytosuccessfulR/C flight.Theywillalso beable
to 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.
Modellingknife.
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.
HARDWAREPACK
COWLING.
Landinggear.....
To avoidscratching yournew airplane,do not
unwrap the pieces until they are needed for
assembly. Cover your workbench with an old
towel or brown paper, both to protect the air-
craftand toprotect thetable.Keepacoupleof
jars or bowls handy to hold the small parts af-
ter you open the bag.
Pleasetrialfitalltheparts. Makesureyouhave
the correct parts and that they fit and are
alignedproperly beforegluing!Thiswillassure
proper assembly.EDGE 540-V3 ARF is hand
made from natural materials, every plane is
unique and minor adjustments may have to
be made. However, you should find the fit su-
perior and assembly simple.
The painted and plastic parts used in this kit
are fuel proof. However, they are not tolerant
of many harsh chemicals including the follow-
ing:paintthinner,C/Aglueaccelerator,C/Aglue
debonderandacetone. Donotletthesechemi-
cals come in contact with the colors on the
covering and the plastic parts.
PARTS LISTING.
FUSELAGE ASSEMBLY
(1) Fuselage.
WING ASSEMBLY
(1) Right wing half with pre-installed
aileron.
(1) Left wing half with pre-installed
aileron.
Tail section assembly
(1) Vertical stabilizer with pre-
installedrudder.
(1) Horizontal stabilizer with pre-
installedelevator halves.
SUGGESTION.
NOTE.

EDGE 540-V3- ITEM CODE: BH91. INSTRUCTION MANUAL
3
Caution: this model is not a toy!
If you are a beginner to this type of powered
model,please askan experiencedmodelflyer
forhelp andsupport.Ifyouattempttooperate
themodel withoutknowingwhat youaredoing
you could easily injure yourself or somebody
else. Please keep your safety and well-being
in mind at all times.
Important: before you start construction
Evenifyou havealready built alarge number
ofRC modelspleaseread rightthrough these
instructions and check all the kit components
against the parts list. We have taken great
trouble to keep construction as simple as
possible, without making any compromises
in the area of safety.
Note regarding the film covering
Minor creases or bubbles may develop in the
film covering due to major fluctuations in
weather conditions (temperature, humidity
etc.); in rare cases you may even find a slight
warp in a component. These minor faults are
in the nature of film-covered built-up wooden
structures, and can easily be corrected using
a heat gun, as commonly used for modelling.
Creases: Blowwarm airoverthearea
and rub down with a soft
cloth.
Wing warp: Hold the panel twisted
gently in the opposite
direction to the warp, and
apply warm air to remove
the creases from the
covering.
+ This is not a toy
+ Be sure that no other flyers are using your
radio frequency.
+ Do not smoke near fuel
+ Store fuel in a cool, dry place, away from
children and pets.
+ Wear safety glasses.
+Theglowplug clipmustbesecurely attached
to the glow plug.
+ Do not flip the propeller with your fingers.
+ Keep loose clothing and wires away from
thepropeller.
+ Do not start the engine if people are near.
Donot standinlinewiththesideof thepropel-
ler.
+Make engine adjustments from behind the
propeller only.Do not reach around the spin-
ningpropeller.
SAFETY PRECAUTION.
Caution! do not heat the film more than is
absolutely necessary. If the air or the iron is
too hot, the film may melt and holes may be
formed.
This model is highly pre-fabricated and can
bebuilt inaveryshorttime. However,the work
which you have to carry out is important and
must be done carefully. The model will only
be strong and fly well if you complete your
taskscompetently -so pleaseworkslowlyand
accurately.
When self-tapping screws have to be
screwed into wood, apply a little white glue
to prevent them shaking loose: just squirt
white glue into the hole and fit the screw.
REPLACEMENT LARGE PARTS
A.
B.
D.
F.
B.
C.
E.
G.

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
4
2. Wheels.
3. Wheel pant.
1. Aluminium landing gear.
4. Plastic parts for landing gear.
7.Plastic partsforelevator andrudderpushrod.
6. Rudder plastic light.
B. Wing panel.
C. Fuselage.
A.Cowling.
D . Horizon stabilizer.
F. Aluminium wing dihedral brace.
E. Vertical stabilizer
REPLACEMENT SMALL PARTS
 1. Install the rubber grommets and brass
eyelets onto the aileron servo.
INSTALLING THE AILERON SERVOS.
C/Aglue
Bottom side
Bottom side
Aileron
5. Plastic part for tail gear.
7.
1.
6.
1.
2.
3.
5.
3.
4.
G. Decal sheet.

EDGE 540-V3- ITEM CODE: BH91. INSTRUCTION MANUAL
5
 3. Drill 1,5mm pilot holes through the block
of wood for each of the four mounting screws
provided with the servo. Install servo into ai-
leron servo tray as same as picture below.
 4. Using the thread as a guide and using
masking tape, tape the servo lead to the end
of the thread: carefully pull the thread out.
When you have pulled the servo lead out, re-
move the masking tape and the servo lead
from the thread.
Secure
 5. Instal servo tray with aileron servo into
the wing as same as picture below.
C/Aglue
Bottom side
C/Aglue
Bottom side
C/Aglue
 2. Usingamodeling knife,remove the cov-
ering servo tray.
Thread
Electricwire
Remove covering
Servo tray

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
6
Repeat the procedure for the other wing
half.
Secure.
2x10mm.
Aileroncontrolhorn
3mm x 30mm.
Nilon control clasp.
M3 lock nut.
2.INSTALLING THE AILERON CONTROL HORN.
Aileron
control horn.
Repeat the procedure for the other wing
half.
Installing the aileron linkages as pictures
below.
INSTALLING THE AILERON
LINKAGES.
M2
M2 lock nut
68mm

EDGE 540-V3- ITEM CODE: BH91. INSTRUCTION MANUAL
7
Repeat the procedure for the other wing
half.
THERE ARE TWO OPTIONS:
1. ELECTRIC MOTOR
2. ENGINE MOUNT.
1. OPTION 1: ELECTRIC MOTOR
INSTALLING ELECTRIC MOTOR.
Drill a hole
5mmdiameter.
40mm
Cut.
40mm
Secure.
200 mm
4 x 60 mm

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
8
Rotor sharft.
Battery.
secure.
4 x 60 mm
Frontview.
Motor.
3 x 12 mm
 1) Slide the cowl over the motor and line
up the back edge of the cowl with the marks
you made on the fuselage.
COWLING.
3) Slide the cowl back over the motor.
2) While keeping the back edge of the
cowl flush with the marks, align the front of
thecowlwith thecrankshaftofthe motor. The
front of the cowl should be positioned so the
crankshaft is in nearly the middle of the cowl
opening. Hold the cowl firmly in place using
pieces of masking tape.

EDGE 540-V3- ITEM CODE: BH91. INSTRUCTION MANUAL
9
INSTALLING THE ENGINE MOUNT.
See pictures below:
2. OPTION 2: ENGINE MOUNT.
Secure.
Secure.
4x 30mm
3x 20mm
Drilla hole
5mmdiameter.

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
10
 8. Feed three lines through the fuel tank
compartment and through the pre-drilled hole
in the firewall. Pull the lines out from behind
the engine, while guiding the fuel tank into
place. Push the fuel tank as far forward as
possible,the frontofthetankshould justabout
touch the back of the firewall.
Blow through one of the lines to ensure the
fuel lines have not become kinked inside the
fueltankcompartment.Air shouldflowthrough
easily.
 6. When satisfied with the alignment of the
stopper assembly tighten the 3mm x 20mm
machine screw until the rubber stopper ex-
pandsand sealsthetank opening.Do notover
tighten the assembly as this could cause the
tank to split.
 7. Using a modeling knife, cut 3 lengths of
fuel line 150mm long. Connect 2 lines to the 2
vent tubes and 1 line to the fuel pickup tube in
the stopper.
INSTALLING THE STOPPER ASSEMBLY
FUEL TANK.
 1. The stopper has been pre-assembled at
the factory.
 2. Usinga modelingknife, cutone lengthof
siliconfuelline (thelength ofsilicon fuellineis
calculated by how the weighted clunk should
restabout 8mmaway fromtherearofthetank
andmove freelyinside thetank). Connectone
end of the line to the weighted clunk and the
otherend tothenylonpickuptubein thestop-
per.
 4. Carefullybend thethirdnylon tubedown
ata 45degreeangle (usingacigarettelighter).
This tubewill bevent tubeto thefuelingvalve.
 3. Carefullybend thesecondnylon tubeup
ata 45degreeangle (usingacigarettelighter).
This tube will be the vent tube to the muffler.
When the stopper assembly is installed
in the tank, the top of the vent tube should
rest just below the top surface of the tank.
It should not touch the top of the tank.
 5. Test fit the stopper assembly into the
tank. It may be necessary to remove some of
the flashing around the tank opening using
amodeling knife. Ifflashing is present, make
sure none of it falls into the tank.
Vent tube
Fuelfilltube
Fuel pick- up tube
( not included)
Silicon tube.

EDGE 540-V3- ITEM CODE: BH91. INSTRUCTION MANUAL
11
Locate the long piece of wire used for the
throttlepushrod. Oneendofthewire hasbeen
pre-bend in to a “Z” bend at the factory. This
“Z” bend should be inserted into the throttle
armofthe enginewhentheengine isfittedonto
theengine mount.Fittheengineto theengine
mount using the screws provided.
Do not secure the tank into place perma-
nently until after balancing the airplane.
You may need to remove the tank to mount
the battery in the fuel tank compartment.
 9. To secure the fuel tank in place, apply a
bead of silicon sealer to the forward area of
thetank, whereit exitsthefuselage behindthe
enginemountingbox andtotherearofthetank
at the forward bulkhead.
Fueltank
INSTALLING THE ENGINE.
Secure
C/Aglue
Fuel tank tray.
100mm
Markpoin.

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
12
 1) Slide the fiberglass cowl over the en-
gineand lineup thebackedgeofthe cowlwith
the marks you made on the fuselage.
COWLING.
Top side.
Right side
Drill a hole
2mm diameter.
3 x 20mm
Pushrod wire.
Pushrod wire
Right side.
Left side.
Secure

EDGE 540-V3- ITEM CODE: BH91. INSTRUCTION MANUAL
13
3) Slide the cowl back over the engine
andsecure itin placeusing fourwood screws.
See picture below.
2) While keeping the back edge of the
cowl flush with the marks, align the front of
thecowlwiththecrankshaftoftheengine. The
front of the cowl should be positioned so the
crankshaft is in nearly the middle of the cowl
opening. Hold the cowl firmly in place using
pieces of masking tape.
4) Installthe mufflerandmufflerextension
onto the engine and make the cutout in the
cowl for muffler clearance. Connect the fuel
and pressure lines to the carburetor, muffler
andfuel fillervalve.
Bottom side
Right side
Trim and cut
Bottom side
3 x 15mm
Top side
Left side
Machinescrew
Frontview.

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
14
Cut.
Throttle servo
PARTSREQUIRED
1)Assembleand mountingthewheel pants
as shown in the following pictures.
INSTALLINGTHEMAINLANDINGGEAR.
4 x 20 mm
Secure.
INSTALLING THE SPINNER.
Installthe spinnerbackplate,propellerand
spinner cone. The spinner cone is held in
place using two 3mm x 12mm wood screws.
3 x 15mm
 1. Install one adjustable metal connector
through the third hole out from the center of
one servo arm, enlarge the hole in the servo
arm using a 2mm drill bit to accommodate the
servo connector. Remove the excess mate-
rial from the arm.
INSTALLING THE THROTTLE PUSHROD.
After installing the adjustable metal con-
nector apply a small drop of thin C/A to
the bottom nut. This will prevent the con-
nector from loosening during flight.
Throttle servo
Throttle pushrod.
Servo arm.
Connector.
Connector.
Secure

EDGE 540-V3- ITEM CODE: BH91. INSTRUCTION MANUAL
15
Bottom side
Landing gear
2) Using the hardware provided, mount
the main landing gear to the fuselage.
Secure.
4 x 20 mm
Markline.
Cut
3) A drop of C/A glue on the wheel collar
screws will help keep them from coming lose
duringoperation.
Remove
covering
Epoxyglue

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
16
Drill 5mm
hole.
5mm.
C/Aglue.
Repeat the process for the other wheel.
Bottom side.
Secure
Secure

EDGE 540-V3- ITEM CODE: BH91. INSTRUCTION MANUAL
17
C/Aglue
Elevator servo
C/Aglue
C/Aglue
 2. Mount the servo to the tray using the
mountingscrews providedwithyourradiosys-
tem.
 1. Install the rubber grommets and brass
colletsintothe elevatorservo.Testfit theservo
into the servo tray.
See pictures below:
HORIZONTAL STABILIZER.
ELEVATOR INSTALLATION.
SERVO INSTALLATION.
C/Aglue
C/Aglue
C/Aglue

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
18
Check to mark sure the wing and stabi-
lizer are paralell. If they are not, lightly sand
theopening inthefuselageforthe stabilizer
until the stabilizer is paralell to the wing.
Epoxyglue
 3. Mark theshape oftheverticalontheleft
and right sides onto the horizontal stabilizer
using a left-tip pen.
 4. Remove the stabilizer. Using the lines
youjustdrew asa guide,carefully removethe
coveringfrom betweenthem usingamodeling
knife.
 1. Draw a center line onto the horizontal
stabilizer. Then slide the horizontal into the
fuselage.
 2 Using a modeling knife, cut away the
covering from the fuselage for the stabilizer
and remove it.
Centerline
Markline
Bottomside.
Remove
covering
When cutting through the covering to
remove it, cut with only enough pressure
to only cut through the covering it’s self.
Cutting into the balsa structure may
weaken it. This could lead to possible fail-
ure during flight.

EDGE 540-V3- ITEM CODE: BH91. INSTRUCTION MANUAL
19
C/Aglue
Elevator control horn install as same as the
way of aileron control horn. Please see pic-
tures below.
ELEVATOR CONTROL HORN
INSTALLATION.
epoxy cures. Remove any excess epoxy us-
inga papertoweland rubbingalcoholand hold
the stabilizer in place with T-pins or masking
tape.
 5. When you are sure that everything is
aligned correctly, mix up a generous amount
of 30 minute epoxy. Apply a thin layer to the
topand bottomofthestabilizermountingarea
and to the stabilizer mounting platform sides
inthefuselage.Slidethestabilizerinplaceand
re-align. Double check all of your measure-
ments one more time before the
Epoxyglue
C/Aglue
 6. Afterthe epoxy has fully cured, remov
the masking tape or T-pins used to hold the
stabilizer in place and carefully inspect the
glue joints. Use more epoxy to fill in any
gaps that were not filled previously and
clean up the excess using a paper towel and
rubbingalcohol.
C/Aglue
3mm x 40mm.
Nilon control clasp.
M3 lock nut.

EDGE 540-V3- ITEM CODE: BH91. Instruction Manual
20
Secure
Cut.
Elevatorandrudderpushrodinstall assame
as the way of aileron pushrod.
ELEVATOR PUSHROD INSTALLATION.
Elevator
control horn.
M2 M2 lock nut.
Secure
Elevatorservo
Elevator
pushrod Elevator
pushrod