Black Horse Model Edge 540-V3 User manual

SPECIFICATION
MadeinVietnam.
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Wingspan : 2,286 mm 90.00 inches.
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Length : 1,806mm 71.10 inches.
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Weight : 7.9 kg 17.38 lbs.
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Radio : 8 channels.
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
Servo : 8 servos.
(JR DS: 8321-FUTABA: BLS252)
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
GlowEngine: OSGT-55cc gas.
Instruction Manual book

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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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.....
Toavoid scratching yournew airplane,donot
unwrap the pieces until they are needed for
assembly. Cover your workbench with an old
towel or brown paper, both to protect the
aircraftand toprotect thetable. Keepa couple
of jars or bowls handy to hold the small parts
after 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
following: paint thinner, C/A glue accelerator,
C/A glue debonder and acetone. Do not let
these chemicals 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: BH92. INSTRUCTION MANUAL
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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.
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, thework
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.
+ 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.
Do not stand in line with the side of the
propeller.
+ Make engine adjustments from behind the
propeller only. Do not reach around the
spinningpropeller.
SAFETY PRECAUTION.
A.
B.
D.
B.
E.
C.
F.
G.
C. Fuselage. D. Horizon stabilizer.
E. Vertical stabilizer.
B. Wing panel.A. Cowling. F. Aluminium wing dihedral brace.
G. Decal sheet .

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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REPLACEMENT SMALL PARTS
8. Wheels.
4. Wheel pant.
1. Aluminium landing gear.
3. Plastic parts for landing gear.
7. Plastic for rudder pushrod.
9. Rudder plastic light.
6. Fuel Tank.
5.Spinner.
 1. Install the rubber grommets and brass
eyelets onto the aileron servo.
INSTALLING THE AILERON SERVOS 1.
I. SERVO
 2.Usinga modelingknife,remove thecov-
ering servo tray.
Aileron.
2. Plastic for bottom fuselage.
10.Engine mount ply of wood .
Remove
covering
11.Tail gear set .
1
7
4
6 x 20 mm.
9
26
1
5
4
10
8
3
11

EDGE 540 - V3 - Item code: BH92. INSTRUCTION MANUAL
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3.Drill1,5mm pilotholes through theblock
of wood for each of the four mounting screws
providedwiththeservo.Installservointoaileron
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,
remove the masking tape and the servo lead
from the thread.
5. Instal servo tray with aileron servo into
the wing as same as picture below.
Bottom side.
Thread
Electricwire
2x12mm.
Secure.
Secure.
Repeat the procedure for the other wing
half.
M2locknut.
3 x 50mm.
Installaileron controlhornas sameas
picturebelow.
INSTALLING THEAILERON CONTROL HORN1
.
Servo tray.

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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INSTALLING THE AILERON
LINKAGES 1.
Repeat the procedure for the other wing
half.
85 mm
3x12 mm.
Installing the aileron linkages as pictures
below.
Attach the clevis to the outer hole in the con-
trol horn.
Secure.
Secure.
Secure.
C/Aglue
C/Aglue
Control
horn 1.

EDGE 540 - V3 - Item code: BH92. INSTRUCTION MANUAL
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C/Aglue
Aileron.
INSTALLING THE AILERON SERVOS 2.
2x12mm.
Bottom side.
Thread
Electric
wire
Secure.
INSTALLING THE AILERON CONTROL HORN 2.
3 x 50 mm. M2locknut.

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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Installing the aileron linkages as pictures
below.
INSTALLING THE AILERON 2
LINKAGES.
85 mm
3x12 mm.
C/Aglue.
Secure.
Secure.
C/Aglue.
C/A
glue.
Repeat the procedure for the other wing
half.
Bottom side
Aileron
INSTALLING THE ENGINE MOUNT.
See pictures below:
Control
horn 2.

EDGE 540 - V3 - Item code: BH92. INSTRUCTION MANUAL
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Drilla hole
4mmdiameter.
INSTALLING THE STOPPER ASSEMBLY
1) The stopper has been pre-assembled
at the factory.
2) Using a modeling knife, cut one length
ofsilicon fuelline(thelengthofsiliconfuel line
iscalculatedbyhowtheweightedclunkshould
restabout 8mmaway fromtherearofthetank
andmove freelyinside thetank). Connectone
FUEL TANK.
end of the line to the weighted clunk and the
otherend tothenylonpickuptubein thestop-
per.
3) Carefully bend the second nylon tube
up at a 45 degree angle (using a cigarette
lighter). This tube will be the vent tube to the
muffler.
4) Carefullybend thethirdnylon tubedown
ata 45degreeangle (usingacigarettelighter).
This tubewill bevent tubeto thefuelingvalve.
When the stopper assembly is installed in the
tank, the top of the vent tube should rest just
belowthe topsurfaceof thetank. Itshould not
touch the top of the tank.
Vent tube Fuel pick- up tube
Fuelfilltube
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.
6) When satisfied with the alignment of
thestopperassemblytightenthe3mmx20mm
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.
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 fuel tank compartment. Air should flow
througheasily.
(Silicon tube not included)

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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9) To securethe fuel tankin place,applya
bead of silicon sealer to the forward area of
thetank, whereit exitsthefuselage behindthe
enginemountingbox andtotherearofthetank
at the forward bulkhead.
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
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.
INSTALLING THE ENGINE-
THROTTLE.
Secure.
4 x 40 mm.
Fueltank.

EDGE 540 - V3 - Item code: BH92. INSTRUCTION MANUAL
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Secure. 3x12mm.
Secure.
Secure.
Right side
Left side.

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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Throttle servo
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.
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.
INSTALLING THE THROTTLE PUSHROD.
Secure.
Throttle
cable

EDGE 540 - V3 - Item code: BH92. INSTRUCTION MANUAL
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PARTSREQUIRED
MAIN GEAR INSTALATION.
1)Assembleand mountingthewheel pants
as shown in the following pictures.
Secure.
2) Using the hardware provided, mount
the main landing gear to the fuselage.
Cut.
Secure.
Landing
gear.
6x20mm.
6 x 20mm

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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Remove
covering.
Remove
covering
3) A drop of C/A glue on the wheel collar
screws will help keep them from coming lose
duringoperation.
Epoxy
glue.
C/Aglue.
Markline.
Bottom side .

EDGE 540 - V3 - Item code: BH92. INSTRUCTION MANUAL
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Drill 8mm
hole.
Markline.
Secure.

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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Secure.
Secure.
MOUNTING THE TAIL WHEEL
BRACKET.
Repeat the process for the other wheel.
3x12mm
3x15mm
3x12mm
Secure.
Secure.
Bottom side .

EDGE 540 - V3 - Item code: BH92. INSTRUCTION MANUAL
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4. Installthemufflerandmufflerextension
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.
1. Slide the fiberglass cowl over the en-
gineand lineup thebackedgeofthe cowlwith
the marks you made on the fuselage.
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.
3. Slide the cowl back over the engine
andsecure itin placeusing fourwood screws.
COWLING.
Top side
Trimandcut.
Bottom side

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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Secure.
Secure.
1. Install the rubber grommets and brass
collets into the elevator servo. Test fit the
servo into the servo tray.
2. Mount the servo to the tray using the
mounting screws provided with your radio
system.
INSTALLING THE ELEVATOR
SERVOS.
3 x 12mm.
INSTALLING THE SPINNER.
Installthe spinnerbackplate,propellerand
spinner cone. The spinner cone is held in
place using two 3mm x 12mm wood screws.
3 x 12mm
Front view
Bottom side
Machine screw.

EDGE 540 - V3 - Item code: BH92. INSTRUCTION MANUAL
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2 x 12 mm.
Secure.
HORIZONTAL STABILIZER.
.Draw a center line onto the horizontal sta-
bilizer. Then put the horizontal into the fuse
large.
Vertical stabilizer installation
See picture below.
VERTICAL INSTALLATION.
2. Markthe shapeoftheverticalontheleft
and right side of the rudder on to the horizon-
tal stabilizer using a felt-tip pen.
1.Put the rudderintothe fuselageassame
as picture below.
Center line.
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.

EDGE 540 - V3 - Item code: BH92.Instruction Manual
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Epoxy glue.
Remove
covering
5) When you are sure that everything is a
aligned correctly, mix up a generous amount
of 30 minute epoxy. Apply a thin layer to the
slot in the mounting platform and to the verti-
cal stabilizer mounting area. Apply epoxy to
the lower rudder hinge. Set the stabilizer in
place and re-align. Double check all of your
measurements once more before the epoxy
cures. Remove any excess epoxy using a
paper towel and rubbing alcohol and hold the
stabilizerinplacewithT-pinsor maskingtape.
Allow the epoxy to fully cure before proceed-
ing.
Epoxyglue.
Remove
covering
4. Now, remove the rudder and using a
modeling knife, carefully cut just inside the
marked lines and remove the film of the rud-
der. Just as you did with the horizontal stabi-
lizer, make sure you only press hard enough
to cut the film, not the balsa rudder.
Also carefully remove the covering from
below the lines as you drew as same picture
below.
Markline.
90º
Vertical
Stabilizer.
Horizontal
Stabilizer.
3. Put the vertical stabilizer back in
place. Using a triangle, check to ensure
that the vertical stabilizer is aligned 90 de-
gree to the horizontal stabilizer.