Hangar 9 Alpha 40 User manual

Wingspan.......................................63.0 in (160 cm)
Length w/Spinner...........................52.5 in (133 cm)
Wing Area ............................710 sq in (45.8 sq dm)
Flying Weight........... 5.25 - 5.75 lb (2.40 - 2.60 kg)
ASSEMBLY MANUAL
Alpha 40 with Spektrum™DX5e
Engine Size .............................. .45 cu in (included)
Radio...............................Spektrum DX5e (included)
Servos........................................4 servos (included)
Specifications
The Spektrum trademark is used with
permission of Bachmann Industries, Inc. US
patent 7,391,320. Other patents pending.
12843.1_HAN_Alpha40_SpektrumManual.indd 1 6/4/10 10:17:48 AM

2
NOTICE: All instructions, warranties and other collateral documents are subject to change at the sole discretion of
Horizon Hobby, Inc. For up-to-date product literature, visit http://www.horizonhobby.com and click on the support
tab for this product.
Meaning of Special Language:
The following terms are used throughout the product literature to indicate various levels of potential harm when
operating this product:
NOTICE: Procedures, which if not properly followed, create a possibility of physical property damage AND little or
no possibility of injury.
CAUTION: Procedures, which if not properly followed, create the probability of physical property damage AND a
possibility of serious injury.
WARNING: Procedures, which if not properly followed, create the probability of property damage, collateral damage,
and serious injury OR create a high probability of superficial injury.
WARNING: Read the ENTIRE instruction manual to become familiar with the features of the product before
operating. Failure to operate the product correctly can result in damage to the product, personal property and cause
serious injury.
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.
Do not attempt disassembly, use with incompatible components or augment product in any way without the approval of
Horizon Hobby, Inc. This 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 serious injury.
Table of Contents
Using the Manual .........................................................................3
Required Items ...........................................................................3
Optional Parts and Accessories ..............................................................4
Required Tools and Adhesives ...............................................................4
EasyCote Covering Colors ..................................................................4
Before Starting Assembly ...................................................................4
Phoenix RC..............................................................................5
Safety, Precautions, and Warnings ............................................................5
Contents of Kit ...........................................................................6
Section 1: Landing Gear Installation ...........................................................7
Section 2: Fin and Stabilizer Installation........................................................9
Section 3: Propeller and Spinner Installation ...................................................12
Section 4: Wing Dowel Installation ...........................................................14
Section 5: Wing Assembly .................................................................15
Section 5b: Optional: Gluing the Wing Halves ..................................................16
Section 6: Centering the Control Surfaces .....................................................19
12843.1_HAN_Alpha40_SpektrumManual.indd 2 6/4/10 10:17:49 AM

3
Section 7: Wing Installation ................................................................20
Section 8: Your Spektrum DX5e Radio System..................................................21
Section 9: Battery Installation ...............................................................21
Section 10: Digital Trims...................................................................22
Section 11: Low Battery Alarm ..............................................................22
Section 12: Trainer .......................................................................22
Section 13: Binding ......................................................................23
Section 14: Checking the Control Surface Movement.............................................26
Section 15: Hi/Lo Rate ....................................................................30
Section 16: Setting the Control Throws .......................................................31
Section 17: Checking the Throttle Operation....................................................32
Section 18: Balancing Your Alpha RTF ........................................................34
Section 19: Flight Preparations..............................................................35
Section 20: How to Range Test the DX5e ......................................................36
Section 21: Starting and Adjusting the Evolution Engine ..........................................37
Section 22: Maintaining Your Alpha 40 RTF....................................................38
Safety Do’s and Don’ts for Pilots.............................................................40
Daily Flight Checks.......................................................................40
Glossary of Terms ........................................................................41
Building and Flying Notes .................................................................42
2008 Official AMA National Model Aircraft Safety Code...........................................43
Warranty Information .....................................................................45
FCC Information .........................................................................46
Compliance Information for the European Union ................................................47
Declaration of Conformity..................................................................47
Instructions for Disposal of WEEE by Users in the European Union..................................47
Using the Manual
This manual is divided into sections to help make assembly easier to understand, and to provide breaks between each
major section. In addition, check boxes have been placed next to each step to keep track of each step completed. Steps
with a single box () are performed once, while steps with two boxes () indicate that the step will require
repeating, such as for a right or left wing panel, two servos, etc. Remember to take your time and follow the directions.
Required Items
• Fuel (10%–15% nitro content) • Glow Plug Wrench (HAN2510)
• Glow Plug Igniter with Charger (HAN7101) • Glow Plug (EVOGP1)
• Manual Fuel Pump (HAN118)
or
• Start-Up Field Pack (HANSTART)
12843.1_HAN_Alpha40_SpektrumManual.indd 3 6/4/10 10:17:49 AM

4
Optional Parts and Accessories
• Fieldmate Prebuilt Field Box (HAN117) • MOSFET Power Panel (HAN106)
• Metered Glow Driver w/Ni-Cd and Charger (HAN7101) • PowerPro™ 12V Starter (HAN161)
• Manual Fuel Pump (HAN118) • Double Vision™Fast Field Charger (HAN114)
• Aluminum Transmitter Case for Single Tx (HAN124) • Digital Variable Load Voltmeter (HAN171)
• Long Reach Glow Plug Wrench (HAN2510) • Super Glow Plug (EVOGP1)
• Transmitter Stand (HAN2525) • Angle Pro Throw/Incidence Meter (HAN192)
• Hangar 9 Straw Hat (HANP303) • Sealing Iron ( HAN101)
• Sealing Iron Sock (HAN141) • Heat Gun (HAN100)
• Covering Glove (HAN150) • Trainer Power System Propeller (EVOE100P)
Required Tools and Adhesives
• #64 Rubber Bands (ARC064) • 4-Way Wrench (DUB810)
• Felt-tipped pen • Adjustable wrench
• 30-minute Epoxy (HAN8002) • Hobby knife
• Phillips screwdriver: #2 • Paper towels
• Rubbing alcohol • Masking tape
• Ruler • Hobby scissors
• Thin CA (MEUM5T1OZ) • Epoxy brush
EasyCote™Covering Colors
• White (HANU70000) • Black (HANU70800)
• Orange (HANU70700) • Silver (HANU70900)
Before Starting Assembly
Before beginning the assembly of the Alpha RTF with DSM, remove each part from its bag for inspection. Closely inspect
the fuselage, wing panels, rudder, and stabilizer for damage. If you find any damaged or missing parts, contact the
place of purchase.
If you find any wrinkles in the covering, use a heat gun or sealing iron to remove them. Use caution while working around
areas where the colors overlap to prevent separating the colors.
HAN100 – Heat Gun
HAN150 – Covering Glove
HAN101 – Sealing Iron
HAN141 – Sealing Iron
Sock
12843.1_HAN_Alpha40_SpektrumManual.indd 4 6/4/10 10:17:50 AM

5
Phoenix R/C
Get ready to fly like you’ve never flown before. PhoenixRC’s flight sim is the only simulator with a genuine Spektrum™
DX5e 2.4GHz DSM2™transmitter you can use on screen or at the field. This sim features advanced heli and aircraft
training modes, as well as more than 100 aircraft from Horizon Hobby brands you know
and love. Brands like JR®Heli, E-flite®and Hangar 9®. You can even fly with other pilots
around the world via an internet multiplayer mode.
Once you’ve mastered flying on your computer, you can use your DX5e to fly the real
planes and helis you’ve been practicing with. And you can do it all with state-of-the-art
technology. The DX5e’s 2.4GHz DSM®technology is so advanced you’ll fly without any
interference or frequency conflicts. And for pilots who already have a transmitter, the
simulator comes in a version without one.
PhoenixRC and the PhoenixRC logo are registered trademarks of Runtime Games Ltd.
Safety, Precautions, and Warnings
Age Recommendation: 14 years or over. This is not a toy. This product is not intended for use by children without direct
adult supervision. 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.
• Consult local laws and ordinances before choosing a location to fly your aircraft.
• 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 into the street or populated areas for any reason.
• Never operate your model with low transmitter batteries.
• 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.
RTM2500
12843.1_HAN_Alpha40_SpektrumManual.indd 5 6/4/10 10:17:51 AM

6
A. HAN4401 Wing Set w/Wing Tube
B. HAN4402 Fuselage
C. HAN4403 Tail Set
D. HAN4404 Aluminum Wing Tube
E. HAN4405 Decal Sheet
F. HAN2454 Landing Gear Set
(does not include wheels)
HAN304 2.5-inch Wheels (2)
HAN305 2.75-inch Wheels (2)
G. EVOE200S Evolution Power System
Orange Spinner
H. EVOE100P Evolution Power System Propeller
I. EVOE100 Evolution Trainer Power System
Contents of Kit
A
B
C
F
F
H
G
D
I
12843.1_HAN_Alpha40_SpektrumManual.indd 6 6/4/10 10:17:52 AM

7
Required Parts
• Fuselage • Landing gear strap (2)
• Main landing gear assembly (2)
• 3mm x 12mm sheet metal screw (4)
Required Tools and Adhesives
• Phillips screwdriver: #2
o Step 1
Locate one of the landing gear assemblies. Insert the end
of the wire into the hole in the fuselage.
o Step 2
Press the landing gear into the notch on the bottom of the
fuselage so it is flush with the bottom of the fuselage.
Step 3
Repeat Steps 1 and 2 to install the remaining landing
gear assembly.
 Step 4
Locate one of the landing gear straps. The strap will be
used to secure the main gear to the fuselage. Holes have
been pre-drilled for the screws that secure the landing
gear strap in position.
Note: Before installing the screws, apply
2–3 drops of thin CA into each of the holes
to harden the surrounding wood. This will
allow the screws to be more secure and will
help in preventing them from vibrating loose.
Section 1: Landing Gear Installation
12843.1_HAN_Alpha40_SpektrumManual.indd 7 6/4/10 10:17:54 AM

8
 Step 5
Use a #2 Phillips screwdriver and two 3mm x 12mm
sheet metal screws to secure one of the straps to the
bottom of the fuselage.
Step 6
Repeat Steps 4 and 5 to secure the remaining landing gear
strap to the bottom of the fuselage.
Section 1: Landing Gear Installation
12843.1_HAN_Alpha40_SpektrumManual.indd 8 6/4/10 10:17:55 AM

9
Required Parts
• Fin/Rudder assembly • #4 washer (4)
• Stabilizer/Elevator assembly • Wing nut (2)
• 3mm x 10mm machine screw (2)
Required Tools and Adhesives
• Threadlock • Scissors
• Phillips screwdriver: #2
Step 1
Locate the fin and stabilizer assemblies. The threaded rods
from the fin will fit into the holes that are pre-drilled in the
stabilizer as shown.
Step 2
Slide the two #4 washers onto the threaded rods from the
bottom of the stabilizer.
Step 3
Use scissors to cut the end of the tube of threadlock. Cut
only the corner so the application of the threadlock can be
controlled easier than if the whole end were cut off.
Step 4
Apply a drop of threadlock onto each of the threaded rods.
Section 2: Fin and Stabilizer Installation
12843.1_HAN_Alpha40_SpektrumManual.indd 9 6/4/10 10:17:57 AM

10
Step 5
Thread the two wing nuts onto the threaded rods to secure
the fin to the stabilizer. Don't over-tighten the wing nut and
damage the underlying wood.
Step 6
Slide the fin into position. Make sure the control rod
for the rudder is on the top side of the stabilizer when
installing the tail assembly.
o Step 7
Locate a #4 washer and 3mm x 10mm machine screw.
Slide the washer onto the screw, then apply a small
amount of threadlock on the screw.
o Step 8
Insert the screw into the hole in the fuselage and
through the stabilizer to the pre-installed blind nut on
the top of the stabilizer. Use a #2 Phillips screwdriver
to tighten the screw.
Section 2: Fin and Stabilizer Installation
12843.1_HAN_Alpha40_SpektrumManual.indd 10 6/4/10 10:17:59 AM

11
Step 9
Repeat Steps 7 and 8 to install the second screw.
Step 10
Connect the clevis to the center hole of the elevator
control horn. The alignment of the elevator will be
covered later in this manual.
Step 11
Connect the clevis to the center hole of the rudder
control horn. The alignment of the rudder will be
covered later in this manual.
Attach clevis
to center hole
Section 2: Fin and Stabilizer Installation
12843.1_HAN_Alpha40_SpektrumManual.indd 11 6/4/10 10:18:01 AM

12
Required Parts
• Fuselage assembly • Spinner assembly
• Propeller
Required Tools and Adhesives
• Adjustable wrench • Hex wrench: 2.5mm
Step 1
Remove the plastic shipping saver, nut and washer from
the engine crankshaft.
Step 2
Check that the flywheel is fully installed on the engine. It
will fit closely to the engine when it is positioned correctly.
Slide the spinner backplate onto the engine crankshaft so
it is tight against the flywheel.
Step 3
Slide the propeller onto the engine crankshaft. The
blades of the propeller will be positioned against the
bosses for the spinner screws of the spinner backplate
as shown below.
Step 4
Slide the propeller washer onto the engine crankshaft.
Section 3: Propeller and Spinner Installation
12843.1_HAN_Alpha40_SpektrumManual.indd 12 6/4/10 10:18:03 AM

13
Step 5
Thread the propeller nut onto the engine crankshaft.
Step 6
Use an adjustable wrench to tighten the propeller nut,
securing the propeller and spinner backplate onto the
engine crankshaft.
Important: When tightening the propeller
nut, always use an adjustable wrench, box
end wrench or 3/8-inch drive socket. Using
pliers will not allow you to place enough
grip to properly tighten the propeller nut.
Note: Make sure the propeller has not
moved from its position as described back
in Step 3. If it has, the spinner cone will not
be able to be installed in the following steps.
Step 7
Slide the spinner cone over the propeller. It will fit into the
grooves in the spinner backplate when installed.
 Step 8
Use the three 3mm x 10mm sheet metal screws supplied
with the spinner to secure the spinner cone to the spinner
backplate. A #1 Phillips screwdriver will be required to
tighten the screws.
Section 3: Propeller and Spinner Installation
12843.1_HAN_Alpha40_SpektrumManual.indd 13 6/4/10 10:18:05 AM

14
Required Parts
• Fuselage assembly • Wing dowel (2)
Required Tools and Adhesives
• Thin CA
Step 1
Slide the wing dowel into the pre-drilled holes in the front
of the fuselage. Center the dowel so it extends equally
from both sides of the fuselage.
Step 2
Slide the second wing dowel into the pre-drilled holes in
the rear of the fuselage. Center the dowel so it extends
equally from both sides of the fuselage.
Step 3
Use the following photo to confirm the location of the
wing dowel installation in the fuselage.
Step 4
Apply thin CA into the joint between the dowel and
fuselage to keep it from moving.
Section 4: Wing Dowel Installation
12843.1_HAN_Alpha40_SpektrumManual.indd 14 6/4/10 10:18:07 AM

15
Required Parts
• Wing panel (left and right) • Wing tube
• Clear tape
Note: The following covers the assembly of
the wing without the use of glue. The wing,
when joined in this method, is very strong
and does not need to be glued together. You
will want to purchase additional clear tape
if you plan on breaking the wing down into
two pieces for transportation purposes.
Step 1
Slide the wing tube into the wing panel as shown. The
wing tube will only slide in halfway, so do not force it in
any further than it will slide easily.
Step 2
Slide the remaining wing panel onto the wing tube.
Step 3
As you slide the wing panels together, make sure the
aluminum pin at the back (trailing edge) of the wing
slides into the hole of the receiving wing panel. Slide
the two wing panels tightly together so there is no gap
between the two.
Step 4
Use the supplied clear tape to secure the joint between the
two wing panels. Make sure to apply the tape to both the
top and bottom of the joint.
Section 5: Wing Assembly
12843.1_HAN_Alpha40_SpektrumManual.indd 15 6/4/10 10:18:09 AM

16
Step 5
Connect the clevises from the aileron pushrods to the
aileron control horns. The alignment of the ailerons will be
checked later in this manual.
Required Parts
• Wing panel (left and right) • Wing tube
• Covering (white) • Covering (orange)
Required Tools and Adhesives
• 30-minute epoxy • Mixing cup
• Mixing stick • Epoxy brush
• Rubbing alcohol • Paper towel
• Painter's tape • Covering iron
Note: It is not necessary to glue the wing
panels together on your model. This section
has been provided in case you opt to do
so. Make sure your vehicle has enough
room to transport the joined wing before
joining the wing panels using this method.
Step 1
Slide the wing tube into the wing panel as shown. The
wing tube will only slide in halfway, so do not force it in
any further than it will slide easily.
Section 5: Wing Assembly
Section 5b: Optional: Gluing the Wing Halves
12843.1_HAN_Alpha40_SpektrumManual.indd 16 6/4/10 10:18:10 AM

17
Step 2
Mix 1/2-ounce total (15ML) of 30-minute epoxy. Use an
epoxy brush to apply a thin layer of epoxy to each of the
wing roots as shown.
Step 3
Slide the remaining wing panel onto the wing tube.
Step 4
As you slide the wing panels together, make sure the pin
at the back (trailing edge) of the wing slides into the hole
of the receiving wing panel. Slide the two wing panels
tightly together so there is no gap between the two.
Step 5
Use a paper towel and rubbing alcohol to remove any
epoxy that seeps from the joint between the two wing
panels.
Section 5b: Gluing the Wing Halves
12843.1_HAN_Alpha40_SpektrumManual.indd 17 6/4/10 10:18:13 AM

18
Step 6
Use tape (painter's tape suggested) to keep the two wing
panels tight against each other until the epoxy is fully
cured.
Step 7
After the epoxy has fully cured, use a covering iron
to apply the covering to the joint of the wing. Use the
orange covering on the bottom of the wing, and the white
covering on the top of the wing.
Step 8
Connect the clevises from the aileron pushrods to the
aileron control horns. The alignment of the ailerons will be
checked later in this manual.
Section 5b: Optional: Gluing the Wing Halves
12843.1_HAN_Alpha40_SpektrumManual.indd 18 6/4/10 10:18:14 AM

19
Required Parts
• Assembled airframe
Required Tools and Adhesives
• Ruler
Checking the Elevator
Center the elevator stick and trim. If necessary, detach the
clevis from the control horn and thread the clevis in or out
on the elevator pushrod until the elevator is aligned with
the stabilizer as shown. Remember to attach the clevis
back in the center hole as described earlier in the manual.
Checking the Rudder
Center the rudder stick and trim. If necessary, detach the
clevis from the control horn and thread the clevis in or out
on the rudder pushrod until the rudder is aligned with the
fin as shown. Remember to attach the clevis back in the
center hole as described earlier in the manual.
Checking the Ailerons
Center the aileron stick and trim. If necessary, detach the
clevis from the control horn and thread the clevis in or out
on each aileron pushrod until the ailerons are aligned with
the wing as shown. Don't forget to align both ailerons at
this time. Remember to attach the clevis back as described
earlier in the manual.
Section 6: Centering the Control Surfaces
12843.1_HAN_Alpha40_SpektrumManual.indd 19 6/4/10 10:18:16 AM

20
Required Parts
• Wing assembly • Fuselage assembly
• Rubber band (10)
Step 1
Locate the aileron extension that is inside the fuselage.
Align the colors from the aileron servo lead with the
extension so they match, then plug them together.
Step 2
Start securing the wing to the fuselage by installing two of
the rubber bands.
Hint: Always start with the cross rubber
bands. This will keep the wing from
twisting on the fuselage when installing
the remaining rubber bands.
Step 3
Install a second set of rubber bands on the wing
as shown.
Step 4
Continue installing a total of six or more of the rubber
bands, alternating the direction of each set until they have
all been installed.
Hint: Always end the rubber band installation
by installing the cross rubber bands last.
They will help in keeping all the other rubber
bands in position on the wing dowels.
Hint: After flying, store your rubber bands in
a bag with a small amount of baby powder.
This will soak up the fuel that is on the
rubber bands, making them last longer.
Section 7: Wing Installation
12843.1_HAN_Alpha40_SpektrumManual.indd 20 6/4/10 10:18:18 AM