Hangar 9 PULSE XT 40 ARF User manual

Wingspan................................. 60.7 in (1540.5mm)
Wing Area .............................. 667 sq in (43 sq dm)
Length............................................ 50 in (1270mm)
Assembly mAnuAl
Pulse XT 40 ARF
Weight................ Glow: 5.5–6.25 lb (2.5 kg–2.8 kg)
..... Electric w/o battery: 4.7–5lb (2.1–2.3 kg)
Specifications
5.


2
Table of Contents
UltraCoteCoveringColors...........................................................3
Radio and Power Systems Requirements ................................................3
Contents of Kit ....................................................................3
Required Items for Electric Installation ..................................................4
Field Equipment Required............................................................4
Optional Field Equipment ............................................................4
Required Tools and Adhesives ........................................................4
Limited Warranty & Limits of Liability ..................................................5
Safety Precautions .................................................................5
Questions, Assistance, and Repairs ....................................................5
Questions or Assistance .............................................................5
Inspection or Repairs ...............................................................6
Warranty Inspection and Repairs.......................................................6
Non-Warranty Repairs...............................................................6
Warranty Information ...............................................................7
Before Starting Assembly ............................................................7
Using the Manual ..................................................................7
Section 1: Aileron Installation.........................................................8
Section 2: Hinging the Stabilizer......................................................13
Section 3: Hinging the Rudder .......................................................15
Section 4: Landing Gear Installation ...................................................17
Section 5: Servo Installation .........................................................20
Section 6A: Tail Installation..........................................................23
Section 6B: Gluing the Tail (Optional)..................................................25
Section 7A: Electric Motor Installation .................................................26
Section 7B: Glow Engine Installation ..................................................29
Section 8: Final Assembly ..........................................................32
Control Throws ...................................................................34
Recommended Center of Gravity (CG) .................................................35
Pre-Flight.......................................................................35
Range Test Your Radio .............................................................35
Adjusting the Engine (Glow) .........................................................36
Maintaining Your Pulse XT ARF ......................................................36
Glossary of Terms .................................................................37
2006 Official AMA National Model Aircraft Safety Code....................................38

3
Radio and Power Systems Requirements
• 4-channel radio system (minimum) w/receiver
• 537 Standard Servo (JRPS537) (5) or equivalent
(4 required when building the electric version)
• 9” Servo Lead Extension (JRPA097) (2)
• 6” Y-Harness (JSP98020)
Recommended JR®Systems
• XP9303
• XP6102
• XP662
• XF631
• XF421EX
Recommended Power Systems
• .40–.48 2-stroke
• .40–.82 4-stroke
• Power 46 Brushless Outrunner
UltraCote®Covering Colors
• True Red HANU866 • White HANU870
• Silver HANU881
Contents of Kit
Replacement Parts
A. Fuselage HAN4101
B. Wing w/o Aluminum Tube HAN4102
C. Tail Set HAN4104
D. Canopy HAN4108
E. Landing Gear HAN4107
F. Painted Cowl HAN4105
G. Painted Wheel Pants HAN4106
Items not shown
Pushrod Set HAN4109
Decal Set HAN4112
Aluminum Wing Tube HAN4103
Wing Bolt Set HAN4110
EP Motor Mount HAN4111
A
BE
D
C
JR XP6102
JR XP9303
Evolution .46NT
EVOE0460
Saito .82 AAC
SAIE082A
Power 46 Brushless
Outrunner Motor,670KV
EFLM4046A
F
G

4
Required Items for Electric Installation
• Female Deans connector w/wire • Male Deans connector (3)
• Soldering iron • Solder
• Phoenix-60 Speed Control (CSEPHX60) • Electric Propeller,13 x 6.5E (APC13065E)
• Heat shrink tubing: 1/4" (6mm)
• 4200mAh 2S2P 7.4V Li-Po, 13GA (THP42002S2PPL) (2)
Field Equipment Required
• Propeller • Fuel
• Long Reach Glow Plug Wrench (HAN2510) • Metered Glow Driver w/Ni-Cd & Charger (HAN7101)
• 2-Cycle Sport Plug (HAN3001) • 2-Cycle Super Plug (HAN3006)
• 4-Cycle Super Plug (HAN3011) • Manual Fuel Pump (HAN118)
Optional Field Equipment
• Fieldmate™ Pre-built Flight Box (HAN117) • Cleaner & towels
• Blue Block After Run Oil (EVOX1000) • Power Panel (HAN106)
• 12V 7Ah Sealed Battery (HAN102) • PowerPro™ 12V Starter (HAN161)
Required Tools and Adhesives
Tools
• Adustable wrench • Drill
• Drill bit: 1/16" (1.5mm), 5/64" (2mm), 9/64" (3.5mm), 5/32" (4mm)
• Hobby knife • Masking tape
• Phillips screwdriver (large) • Phillips screwdriver (small)
• Ruler • Sandpaper
• Square • Straight edge
Adhesives
• 6-minute epoxy • 30-minute epoxy
• Thin CA (cyanoacrylate) glue • CA remover/debonder
• Pacer Z-42 Threadlock
Other Required Items
• Epoxy brushes • Felt-tipped pen or pencil
• Mixing sticks for epoxy • Paper towels
• Petroleum jelly • Rubbing alcohol
• Sandpaper • String
• T-pins

5
Limited Warranty & Limits of Liability
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.
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.
Safety Precautions
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.
Questions, Assistance, and Repairs
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.
Questions or Assistance
For questions or assistance, please direct your email to [e-mail], or call 877.504.0233 toll
free to speak to a service technician.

6
Inspection or Repairs
If your product needs to be inspected or repaired, please call for a Return Merchandise Authorization (RMA). 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, RMA
number, and a brief summary of the problem. Be sure your name, address, and RMA number are clearly written on the
shipping carton.
Warranty Inspection and Repairs
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. Horizon Hobby, Inc. guarantees this product to be free from defects
in both material and workmanship at the date of purchase.
Non-Warranty Repairs
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.
Electronics and engines requiring inspection or repair should be shipped to the following address (freight prepaid):
Horizon Service Center
4105 Fieldstone Road
Champaign, Illinois 61822
All other products requiring inspection or repair should be shipped to the following address (freight prepaid):
Horizon Product Support
4105 Fieldstone Road
Champaign, Illinois 61822

7
Warranty Information
Horizon Hobby, Inc. guarantees this kit to be free from defects in both material and workmanship at the date of purchase.
This warranty does not cover any parts damage by use or modification. In no case shall Horizon Hobby’s liability exceed
the original cost of the purchased kit. Further, Horizon Hobby reserves the right to change or modify this warranty without
notice. In that Horizon Hobby has no control over the final assembly or material used for the final assembly, no liability
shall be assumed nor accepted for any damage resulting from the use by the user of the final user-assembled product. By
the act of using the user-assembled product, the user accepts all resulting liability.
Once assembly of the model has been started, you must contact Horizon Hobby, Inc. directly regarding any warranty
question that you have. Please do not contact your local hobby shop regarding warranty issues, even if that is where you
purchased it. This will enable Horizon to better answer your questions and service you in the event that you may need any
assistance. If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is advised
to return this kit immediately in new and unused condition to the place of purchase.
Horizon Hobby
4105 Fieldstone Road
Champaign, Illinois 61822
[phone]
Before Starting Assembly
Before beginning the assembly of the Pulse XT, 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.
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.
HAN100 – Heat Gun
HAN150 – Covering Glove
HAN101 – Sealing Iron
HAN141 – Sealing Iron
Sock

8
Required Parts
• Wing panel (right and left) • Aileron (right and left)
• Servo w/hardware (2) • Clevis w/retainer (2)
• CA hinge (8)
• Servo extension, 6" (152mm)
• Aileron linkage, 4" (102mm) (2)
• Control horn w/backplate (2)
• 2mm x 16mm screw (4)
• 2mm x 12mm screw (2)
Required Tools and Adhesives
• Thin CA • Drill
• Hobby knife • Felt-tipped pen
• T-pins • Phillips screwdriver
• Drill bit: 1/16" (1.5mm), 5/64" (2mm)
Step 1
Locate four CA hinges. Place a T-pin in the center of each
of the four hinges.
Step 2
Use a 1/16" (1.5mm) drill bit to drill a hole in the center of
each hinge slot. Drill holes for both the wing and aileron.
Note: The hole will allow the CA to penetrate
the hinge farther into the surface, providing
a better bond between the hinge and wood.
Step 3
Slide the hinges into the aileron. The T-pins will rest
against the hinge line of the aileron.
Step 4
Slide the aileron onto the wing. Press the aileron
tightly against the wing, and then remove the T-pins
from the hinges.
Section 1: Aileron Installation

9
Step 5
Position the aileron so it can move freely and not
bind at the wing tip or wing root. Deflect the aileron
without changing the hinge gap, and apply thin CA to
each of the four hinges. Apply CA to both the top and
bottom of the hinges.
Note: Do not use CA accelerator
on the hinges; the CA must be
allowed to soak into the hinge.
Step 6
Once the CA has fully cured, gently pull on the aileron to
make sure the hinges are secure. Avoid too much pressure
which could cause damage to the wing and aileron.
Step 7
Flex the aileron up and down a number of times to break
in the hinges.
Step 8
Prepare an aileron servo by installing the grommets
and brass eyelets provided with the servo. Secure
a 6" (152mm) servo extension to the servo using a
commercially available connector or with string or
unwaxed dental floss.
Section 1: Aileron Installation

10
Step 9
Slide one of the longer pushrod wires into the wing.
Attach the servo extension to the “Z” bend of the
pushrod wire.
Step 10
Pull the servo lead through the wing using the pushrod
wire. The lead will exit the hole on the top of the wing.
Use a piece of tape to keep the extension from falling back
into the wing.
Step 11
Place the servo into the opening with the servo output
towards the trailing edge of the wing. Use a felt-tipped pen
to mark the locations for the four servo mounting screws.
Step 12
Remove the servo and drill the locations for the servo
mounting screws using a 1/16" (1.5mm) drill bit.
Apply a couple drops of thin CA to each hole to harden
the wood, which will help in preventing the screws from
damaging the wood.
Section 1: Aileron Installation

11
Step 13
Secure the servo using the screws provided with
the servo.
Step 14
Slide a clevis retainer onto a clevis. Thread the clevis
onto the 4" (102mm) aileron pushrod wire.
Step 15
Enlarge the outer hole of the servo arm using a 5/64"
(2mm) drill bit. Attach the “Z” bend to the servo arm.
Note: You may want to use tape at the
wing tip and wing root to hold the aileron
in position for the next few steps.
Step 16
Plug the aileron servo into the radio system. With the
radio on, center the aileron stick and trim. Position the
aileron servo arm parallel to the hinge line. Thread the
clevis so the pin in the clevis is aligned with the trailing
edge of the wing.
Step 17
Remove the backplate from a control horn using a hobby
knife. Attach the clevis to the center hole of the control
horn. Use a felt-tipped pen to mark the locations on the
aileron for the three aileron control horn screws.
Section 1: Aileron Installation

12
Step 18
Use a 5/64" (2mm) drill bit to drill the locations for the
control horn screws. Place a few drops of thin CA into
each hole to harden the underlying wood. This will help
in preventing the wood from crushing when tightening the
control horn screws.
Step 19
Attach the control horn using two 2mm x 16mm screws, a
2mm x 12mm screw and the control horn backplate. The
shorter screw goes towards the trailing edge of the aileron.
Step 20
Repeat Steps 1 through 19 for the remaining wing panel
and aileron.
Section 1: Aileron Installation

13
Required Parts
• Stabilizer
• Elevator (right and left)
• Elevator joiner wire
• Control horn w/backplate
• 2mm x 12mm screw (3)
Required Tools and Adhesives
• Thin CA • Drill
• Drill bit: 1/16" (1.5mm) • Straight edge
• 6-minute epoxy • Masking tape
• Sandpaper • Paper towel
• Rubbing alcohol • Mixing stick
• T-pins • Phillips screwdriver
Step 1
Locate the elevator joiner wire. Use sandpaper to roughen
the wire. Use a paper towel and rubbing alcohol to clean
the wire to remove any dirt or debris.
Step 2
Test fit the joiner wire into one of the elevator halves.
The wire must rest parallel or behind the hinge line
of the elevator. Make any adjustments to the elevator
to correct any offset.
Step 3
Mix up a small amount of 6-minute epoxy. Apply epoxy to
the hole and groove of the elevator. Also apply epoxy to
the joiner wire where it will contact the elevator half. Slide
the joiner wire into position and use masking tape to hold
it in position until the epoxy cures.
Step 4
Test fit the remaining elevator to the joiner wire.
There are two items to check: Make sure both elevators
rest flat on the work surface, and that the leading edge
of both elevators are parallel. Make adjustments to the
elevator and/or joiner wire to properly align the two
elevator halves.
Step 5
Use epoxy to glue the joiner into the remaining
elevator half.
Section 2: Hinging the Stabilizer

14
Step 6
Drill a 1/16" (1.5mm) hole in the center of each hinge slot
in both the elevators and stabilizer. Prepare six CA hinges
by placing a T-pin in the center of each hinge. Slide the
hinges into the elevators until the T-pins are resting on the
leading edge of the elevator.
Step 7
Slide the elevators onto the stabilizer. Remove the T-pins
and use thin CA to glue the hinges. Allow the CA to fully
cure before testing and breaking in the hinges using the
same technique as the aileron hinges.
Step 8
Since the holes are pre-drilled in the elevator, go
ahead and install the control horn using three
2mm x 12mm screws.
Section 2: Hinging the Stabilizer

15
Required Parts
• Rudder • Fin
• Tail wheel assembly • Tail wheel 1" (25mm)
• CA hinge (2)
• 2mm wheel collar w/setscrew
• Control horn w/backplate
• 2mm x 12mm screw (3)
Required Tools and Adhesives
• Thin CA • Drill
• Hobby knife • Felt-tipped pen
• 6-minute epoxy • Ruler
• Sandpaper • Paper towel
• Rubbing alcohol • Mixing stick
• T-pin • Hex wrench: 1.5mm
• Phillips screwdriver • Threadlock
• Drill bit: 1/16" (1.5mm), 5/64" (2mm)
Step 1
Locate the tail wheel assembly. Fit the nylon bushing into
the rudder post. Use a felt-tipped pen to mark the nylon
bearing where it protrudes from the rudder post.
Step 2
Use a hobby knife or side cutters to trim the nylon bearing
as shown. Drill three 5/64" (2mm) holes in the bearing to
give the epoxy something to grab on to when it gets glued
into the rudder post.
Step 3
Apply a thin coat of petroleum jelly to the wire and work
it onto the nylon bearing. This will help prevent the epoxy
from gluing the wire to the bearing.
Step 4
Use a small amount of 6-minute epoxy to glue the bearing
into the rudder post.
Step 5
Prepare the hinge slots in the rudder and fin by drilling
a 1/16" (1.5mm) hole in the center of each slot. Prepare
the last two CA hinges by placing a T-pin in the center
of each one.
Section 3: Hinging the Rudder

16
Step 6
Test fit the rudder and fin together. Make sure to insert the
tail gear wire into the rudder. When satisfied with the fit,
mix up a small amount of 6-minute epoxy and apply it to
the tail gear wire and the corresponding hole in the rudder.
Slide the rudder back into position against the fin.
Step 7
Position the rudder control horn 5/8" (16mm) up from the
bottom of the rudder. With the holes in the horn aligned
with the hinge line, mark the locations for the control horn
screws. Drill the locations using a 5/64" (2mm) drill bit.
After placing a few drops of thin CA into each hole, secure
the control horn using three 2mm x 12mm screws.
Note: The horn will be on the right side
of the plane from the pilot’s perspective.
Step 8
Attach the tail wheel using the 2mm wheel collar
and setscrew. Use threadlock on the setscrew to prevent it
from coming loose in flight due to vibration.
Section 3: Hinging the Rudder

17
Required Parts
• Fuselage • Landing gear
• 4mm nut (6) • 4mm locknut (2)
• 6-32 x 1/2" socket head screw (3)
• 4-40 blind nut (4) • #6 washer (3)
• 2 3/4" (70mm) wheel (2)
• Wheel pant (right and left)
• 4-40 x 3/8" socket head bolt (4)
• 4mm x 40mm socket head bolt (2)
Required Tools and Adhesives
• Hex wrench: 3/32", 7/64" • Drill
• Drill bit: 9/64" (3.5mm) • Threadlock
• Felt-tipped pen
Step 1
Attach the landing gear to the bottom of the fuselage using
three 6-32 x 1/2" socket head bolts and three #6 washers.
Put a little threadlock on the bolts to prevent them from
vibrating loose during flight.
Step 2
Slide a 4mm x 40mm socket head bolt into a wheel. Slide
a 4mm washer onto the bolt then thread a 4mm nut onto
the bolt. Leave the bolt loose enough that the wheel can
spin freely on the bolt. Use a drop of thin CA or threadlock
to keep the nut in position.
Step 3
Thread a second 4mm nut onto the bolt. Slide the bolt into
the landing gear. Place a second 4mm washer onto the
bolt, then start the 4mm locknut onto the bolt. The order
is: wheel, 4mm nut, 4mm washer, 4mm nut, landing gear,
4mm washer and 4mm locknut.
Section 4: Landing Gear Installation

18
Step 4
Position the inner 4mm nut so there is about 7/16"
(12mm) between the wheel nut and landing gear.
Tighten the 4mm locknut onto the screw. The
distance may require some adjustment once the
wheel pants have been installed.
Step 5
Repeat Steps 2 through 4 for the remaining wheel.
Step 6
Place the wheel pant over the wheel. Position the wheel
pant so it is parallel to the fuselage centerline. Mark the
location for the two screws from the back of the wheel
pant using a felt-tipped pen.
Section 4: Landing Gear Installation

19
Step 7
Use a 9/64" (3.5mm) drill bit to drill the two locations
for the screws.
Step 8
Install two 4-40 blind nuts inside the wheel pants through
the holes drilled in the previous step.
Step 9
Secure the wheel pant to the landing gear using two
4-40 x 3/8" socket head screws. Make sure to use
threadlock to prevent the screws from loosening
during flight.
Step 10
Check that the wheel can spin freely without rubbing on
the wheel pant. If it does, loosen the 4mm nut and 4mm
locknut and reposition the wheel so it can spin freely.
Step 11
Repeat Steps 6 through 10 to install the remaining
wheel pant.
Section 4: Landing Gear Installation

20
Required Parts
• Fuselage
• 23 3/8" (594mm) rudder pushrod
• 22 1/2" (572mm) elevator pushrod wire
• Clevis w/retainer
Required Tools and Adhesives
• Drill • Felt-tipped pen
• Switch harness • Standard servo (3)
• Phillips screwdriver
• Drill bit: 1/16" (1.5mm), 5/64" (2mm)
Note: The throttle servo is not required when
building the electric version of your Pulse XT.
Step 1
If you choose to use a glow engine, place the throttle
servo into the fuselage. Use a felt-tipped pen to mark
the locations for the four servo mounting screws on
the radio tray.
Step 2
Use a 1/16" (1.5mm) drill bit to drill the locations for the
screws. Place a drop of thin CA into each of the holes to
harden the surrounding wood.
Step 3
Secure the throttle servo using the hardware supplied with
the servo. Don’t forget to install the grommets and brass
eyelets before installing the servo.
Section 5: Servo Installation