Cobra Helicopter Goblin 500 User manual

Goblin 500 Manual
Release 1.0 - February 2013
SAB HELI DIVISION S.R.L.
Via San Crispino, 47
47030 San Mauro Pascoli (FC) - ITALY
Copyright@2013 - SAB Heli Division - All rights reserved

Chapter 07 – Tail assembly
Chapter 08 – Installation of the servos
Chapter 09 – Assembling the modules
Chapter 10 – Gear Ratios
Chapter 11 – Installation of the ESC and Bec
Chapter 12 – Motor Belt
Chapter 01 – Serial number/Specifications
Chapter 02 – Important notes
Chapter 03 – In the Box
Chapter 04 – Carbon frame assembly
Chapter 05 – Trasmission assembly
Chapter 06 – Head assembly
INDEX
Very Impotant:
Inside Box 4, you will find Bag 9 with a red label. This bag contains your serial number
tag. Please take a moment to register your kit online via our web site at:
http://www.goblin-helicopter.com/
It is extremely important that you take a moment to register your helicopter with us.
This is the only way to ensure that you are properly informed about changes to your
kit, such as upgrades, retrofits and other important developments. SAB Heli Division
cannot be held responsible for issues arising with your model and will not provide
support unless you register your serial number.
To mount the serial number tag on your helicopter, please refer to page 26.
Thank you for your purchase, we hope you enjoy your new Goblin helicopter!
SAB Heli Division
Chapter 13 – Installation of the FBL System
Chapter 14 – Boom Assembly
Chapter 15 – Battery / Canopy
Chapter
16 – In Flight
Chapter 17 – Maintenance
Chapter 18 – Exploded views
Chapter 19 – Spare parts
- Main rotor diameter: 1138mm (with 500mm blades)
- Main blade length: 500mm
- Tail rotor diameter: 226mm
- Tail blade length: 80mm
- Weight including standard electronics: 1900g (excluding batteries).
- Maximum motor size: diameter 52mm, height 53mm
- Battery compartment: 52x53x180mm.
SPECIFICATIONS
980mm
310mm
158mm
1138mm
The Goblin is a high performance radio controlled helicopter.
The design is original, moving away from traditional schemes, searching rationality for simplicity.
Our goal was to create a simple, high performance helicopter, with a minimum of mechanical components,
and simple maintenance.
Please read this user manual carefully, it contains instructions for the correct assembly of the model.
Please refer to the web site www.goblin-helicopter.com for updates and other important information.
Copyright@2013 - SAB Heli Division - All rights reserved
Page 1
Chapter 1, Serial Number

Use grease
(eg Tri-Flow
Synthetic Grease)
IMPORTANT NOTES
*This radio controlled helicopter is not a toy.
*This radio controlled helicopter can be very dangerous.
*This radio controlled helicopter is a technically complex device which has to be built and handled very carefully.
*This radio controlled helicopter must be built following these instructions. This manual provides the necessary
information to correctly assemble the model. It is necessary to carefully follow all the instructions.
*Inexperienced pilots must be monitored by expert pilots.
*All operators must wear safety glasses and take appropriate safety precautions.
*A radio controlled helicopter must only be used in open spaces without obstacles, and far enough from people to
minimize the possibility of accidents or of injury to property or persons.
*A radio controlled helicopter can behave in an unexpected manner, causing loss of control of the model, making it very
dangerous.
*Lack of care with assembly or maintenance can result in an unreliable and dangerous model.
* Neither SAB Heli Division nor its agents have any control over the assembly, maintenance and use of this product.
Therefore, no responsibility can be traced back to the manufacturer. You hereby agree to release SAB Heli Division
from any responsibility or liability arising from the use of this product.
SAFETY GUIDELINES
*Fly only in areas dedicated to the use of model helicopters.
*Follow all control procedures for the radio frequency system.
*It is necessary that you know your radio system well. Check all functions of the transmitter before every flight.
*The blades of the model rotate at a very high speed; be aware of the danger they pose and the damage they may cause.
*Never fly in the vicinity of other people.
Indicates that for this
assembly phase you need
materials that are in
bag xx, tray xx.
NOTES FOR ASSEMBLY
Please refer to this manual for assembly instructions.
Follow the assembly order shown here, the instructions are divided into chapters, the chapters are structured in a logical
sequence as each step is based on work done during the previous step. Changing the order of assembly may result in
additional or unnecessary steps.
Use thread lockers and retaining compounds as indicated. In general, each bolt or screw that engages with a metal part
requires thread lock.
It is necessary to pay attention to the symbols listed below:
Use grease
(eg Vaseline Grease)
Important
Use retaining
compound
(eg Loctite 648) Use CA Glue
Use retaining
compound
(eg Loctite 243)
Copyright@2013 - SAB Heli Division - All rights reserved
Page 2
Chapter 2, Important Notes

ADDITIONAL COMPONENTS REQUIRED
*Electric Motor: 6S – 900 / 1400Kv
maximum diameter 52mm,
maximum height 53mm, pinion shaft diameter 5 - 6mm
*Speed controller:
minimum 80A, recommended 100A
*Batteries: 6S - 3300-45000mAh
*1 flybarless 3 axis control unit
*Radio power system, if not integrated with the ESC
*3 cyclic servos
*1 tail rotor servo
*6 channel radio control system on 2.4 GHz
(See configuration examples on page 19)
The assembly process is described in the following chapters.
Each chapter provides you with the box, bag and/or foam
tray numbers you will need for that chapter. The information
is printed in a red box in the upper right hand corner of the
page at the beginning of every chapter.
TOOLS, LUBRICANTS, ADHESIVES
*Generic pliers
*Hexagonal driver, size 1.5, 2, 2.5, 3,4 mm
*4mm T-Wrench
*5.5mm Socket wrench (for M3 nuts)
*7mm Hex fork wrench (for M4 nuts)
*Medium threadlocker (eg. Loctite 243)
*Strong retaining compound (eg. Loctite 270)
*Spray lubricant (eg. Try-Flow Oil)
*Synthetic grease (eg. Tri-Flow Synthetic Grease)
*Grease (eg. Vaseline Grease)
*Cyanoacrylate adhesive
*Pitch Gauge (for set-up)
*Soldering equipment (for motor wiring)
Inside The Box:
Box 1: Canopy, Main Frames, Plastic Parts and
Blade Holder.
Box2: Optional Combo Components
Box 3: Mechanical Parts in 3 trays:
Tray 1: Head parts
Tray 2: Main structure
Tray 3: Transmission parts
Box 4: Bags
Box 5: Blades, Tail Blades, Boom, Carbon Rod
Inside the box:
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Page 3
Chapter 3, In The Box

4-Carbon Frame
The manufacturing process of the carbon parts
often leaves micro-burrs and sharp edges. We
recommend de-burring the edges to minimize
the risks of electrical wire cuts, etc.
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Page 4
Chapter 4, Carbon Frame

Main Frame
(H0240-S)
......x8
Socket Head Cap Screw
M2.5x8mm
......x1
Button Head Cap Screw
M2x5mm
Battery Block
(H0256-S)
Button Head Cap Screw
M2x5mm
(HC005-S)
Battery Support Dx
(H0259-S)
Battery Support Sx
(H0258-S)
Spacer 54mm
(H0239-S)
Right Main Frame
Assembly
Main Frame
(H0240-S)
Battery Support
Assembly
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Finishing Washer M2.5
(H0255-S)
Finishing Washer M2.5
(H0255-S)
Finishing Washer M2.5
......x8
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Detail A
Battery Block
(H0256-S)
A
NOTE:
We recommend drilling 4 holes (approximately 2.5 - 3 mm) to
facilitate the installation of the ESC ( See page 20 ).
Do not install these bolts yet
Main Frame Assembly
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Page 5
Chapter 4, Carbon Frame

......x2
Seft Tapping Hex Socket
Screw M3x10mm
......x2
Seft Tapping Hex Socket
Screw M3x10mm
Finishing Washer M3
......x2
Finishing Washer M3
......x2
Seft Tapping Hex Socket
Screw M3x10mm
(HC136-S)
Finishing Washer M3
(H0007-S)
Seft Tapping Hex Socket Screw
M3x10mm
(HC136-S)
Landing Gear Support
(H0262-S)
CF Red Landing Gear (H0285-S)
CF Yellow Landing Gear (H0241-S)
Seft Tapping Hex Socket
Screw M3x10mm
(HC136-S)
Finishing Washer M3
(H0007-S)
CF Landing Gear
Assembly
Landing Gear Support
(H0262-S)
Detail A
Frame Grommet
(HA021-S)
A
Copyright@2013 - SAB Heli Division - All rights reserved
Page 6
Chapter 4, Carbon Frame

5-Transmission Assembly
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Page 7
Chapter 5, Transmission Assembly

Socket Head Cap
Screw M2.5x15mm
(HC028-S)
Bearing
8x 16x5mm
(HC419-S)
Servo Support
(H0208-S)
Column
(H0263-S)
Bearing
10x 19x5mm
(HC422-S)
Bearing
8x 16x5mm
(HC419-S)
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Main Structure
(H0212-S)
Bearing
10x 19x5mm
(HC422-S)
Bearing Support
(H0207-S)
Bearing Support Assembly
Servo Support Assembly
Bearing Support
Assembly
Socket Head Cap
Screw M3x10mm
(HC056-S)
Washer
10x 16x0.1mm
(HC234-S)
(Use additional shims to
remove any axial play)
Spacer
10x 16x14.6mm
(H0223-S)
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Servo Support
Assembly
Washer
8x 14x0.2mm
(HC228-S)
(Use additional shims to
remove any axial play)
Socket Head Cap Screw
Shouldered M3x22mm
(HC083-S)
Metric Hex Nylon
Nut M3H4
(HC206-S)
Metric Hex Nylon
Nut M2.5H3.5
(HC200-S)
Secondary Shaft
(H0221-S)
62T Main Gear
(H0209-S)
Main Shaft
(H0222-S)
18T Pinion
(H0210-S)
Socket Head Cap Screw M3x10mm
Socket Head Cap Screw M2.5x15mm
Socket Head Cap Screw M2.5x8mm
Socket Head Cap Screw Shouldered M3x22mm
Metric Hex Nylon Nut M3 H4
Metric Hex Nylon Nut M2.5H3.5
.....x8
.....x3
.....x1
.....x1
.....x1
.....x1
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Copyright@2013 - SAB Heli Division - All rights reserved
Page 8
Chapter 5, Transmission Assembly

Socket Head Cap
Screw M2.5x15mm
(HC028-S)
Socket Head Cap Screw
M2.5x6mm
(HC018-S)
Socket Head Cap Screw M2.5x15mm
Socket Head Cap Screw M2.5x6mm
Finishing C Washer M2.5
48T Pulley
(H0214-S)
Flanged Bearing
8x 12x3.5mm
(HC418-S)
One Way Bearing
8x 12x12mm
(HC440-S)
48T Pulley Assembly
.....x1
.....x1
.....x2
48T Pulley
Assembly
28T Pulley
(H0218-S)
Sensor Support
(H0224-S)
Metric Hex Nylon
Nut M8 H6.5
(HC224-S)
Nylon Screw
M8x14mm
(HC164-S)
Block Nut
(H0267-S)
Finishing C Washer
M2.5
(H0255-S)
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Swashplate Anti-Rotation Guide
(H0244-S)
Socket Head Cap Screw M2.5x8mm
.....x1
Note: Small Diameter Facing UP
Copyright@2013 - SAB Heli Division - All rights reserved
Page 9
Chapter 5, Transmission Assembly

5mm
5mm
Set Screw
M4x4mm
(HC152-S)
Flat Head Cap Screw
M3x5mm
(HC132-S)
18T Pulley
(H0215-18-S)
(See page 19 for additional
pulleys available)
Set Screw M4x15mm
Socket Head Cap Screw
M2.5x8mm
(HC020-S)
Washer 4.3x 11x1mm
(HC184-S)
Metric Hex Nylon Nut M4H5
(HC212-S)
Spring de 5 / df 0.3 / LL6
(HC316-S)
Washer
4.3x 11x1mm
Socket Head Cap Screw M2.5x8mm
Finishing Washer M2.5
Metric Hex Nylon Nut M4 H5
Note:
To maximize space for the batteries, it is advisable
to shorten the motor shaft.
Follow the dimensions given in this drawing.
For the cut, you can use an electric tool like a
“Dremel” with a cut-off disc.
Additionally, ensure the motor shaft has an
appropriate 'flat' for one of the set screws.
Motor Support
(H0211-S)
Set Screw M4x15mm
(HC154-S)
Finishing Washer
M2.5
(H0255-S)
Set Screw M4x4mm
Flat Head Cap Screw M3x5mm
....x2
....x4
....x2
....x2
....x2
....x2
....x2
Bushing
5x 6x18mm
(H0266-S)
(Needed with 5 mm motor shaft)
23mm
Socket Head Cap Screw
M2.5x8mm
(HC020-S)
Spring
de 3 / df 0.53 / LL35
(HC311-S)
Note:
Recommended
motor wiring
orientation
Copyright@2013 - SAB Heli Division - All rights reserved
Page 10
Chapter 5, Motor Assembly

6-Main Rotor
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Page 11
Chapter 6, Head

Center Hub
(H0206-S)
Main Blade Grip
Assembly
(H0202-S)
Note : Smaller ID
Uniball M3x4
5H3
(H0065-S)
...x2
...x2
...x2
...x2
Note:
Please add thread
locker to the M6x10 Screws
Spindle
(H0213-S)
Uniball Radius Arm ... x 2
Assembly
Main Blade Grip Assembl y ....x2
Note : Larger ID
Button Head Cap Screw
M6x10mm
(HC122-S)
Spacer
8x 12.5x0.75mm
(H0225-S)
Oring
(HC330-S)
Washer
6x 12 x1mm
(HC193-S)
Thrust Bearing
8x 14x4mm
(HC437-S)
Washer
2.5x4x0.3mm
(HC172-S)
Linkage Rod A Assemly . . . . .x2
Center Hub Assembly
Radius Arm
(H0204-S)
Uniball Radius Arm
(H0205-S)
Flanged Bearing
2.5x 6x2.5mm
(HC400-S)
Flanged Bearing
2.5x 6x2.5mm
(HC400-S)
Spacer Arm
2.5x4x6.3mm
(H0253)
Spacer Arm
3x5x2.7mm
(H0134)
Main Blade Grip
Assembly
Bearing
8x 14x4mm
(HC417-S)
Radius Arm ... x 2
Assembly
Linkage Rod
M2.5x33mm
(H0237-S)
Approx. 62mm
Radius Arm
Assembly
(H0204-S)
Oring
(HC330-S)
Socket Head Cap
Screw M2.5x18mm
(HC032-S)
Main Blade Arm
(H0203-S)
Socket Head Cap
Screw M3x8mm
(HC050-S)
Spacer 11x 13.8x0.5mm
(H0226-S)
Socket Head Cap
Screw M2.5x15mm
(HC028-S)
Linkage Rod A
Assemly
Linkage Ball Link
(H0066-S)
(Initial length for the rods from the swashplate
to the blade grip.)
Left Thread
Right Thread
Bearing
8x 14x4mm
(HC417-S)
Button Head Cap Screw M6x10mm
Socket Head Cap Screw M3x8mm
Socket Head Cap Screw M2.5x15mm
Socket Head Cap Screw M2.5x18mm
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Page 12
Chapter 6, Head

Bearing
4x 9x2.5mm
(HC403-S)
Spacer
4x 7.5x0.5mm
(H0219-S)
Spacer
7x 9x0.5mm
(H0062-S)
Bearing
4x 9x2.5mm
(HC403-S)
Tail Shaft
(H0227-S)
Spindle Shaft
(H0220-S)
Socket Head Cap Screw M3x6mm
Tail Pitch Slider Link
(H0261-S)
Tail Blade Grip
H0236-S)
Oring
(HC334-S)
Tail Pitch Slider 03
(H0233-S)
Socket Head Cap Screw M2x6mm
Tail Rotor Hub Assembly
Note : Larger ID
Spacer
4x 7.5x0.5mm
(H0219-S)
Socket Head Cap Screw M3x6mm
(HC044-S)
Tail Blade Grip
Assembly
Tail Rotor Hub
Assembly
Tail Pitch Slider Assembly
Socket Head Cap
Screw M2x6mm
(HC004-S)
Flanged Bearing
7x 11x3mm
(HC416-S)
......
x2
Spacer
2x 3x3mm
(H0076-S)
Note : Smaller ID
Thrust Bearing
4x 9x4mm
(HC434-S)
Uniball M2.5x
5H6
(H0064-S)
Socket Head Cap
Screw M2x6mm
(HC004-S)
......
x4
Tail Pitch Slider Link Assembly
Tail Pitch Slider 01
(H0233-S)
Tail Pitch Slider 02
(H0233-S)
Tail Pitch Slider
Assembly
Note:
It is a normal for the tail to feel a bit tight after initial
assembly as the tail spindle preload is ussually high when
the helicopter is brand new. The preload will loosen up
after 2-5 flights allowing the system to become smooth.
Note: S >> Left Side
Note: S >> Right Side
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Page 14
Chapter 7, Tail

......
x1
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Socket Head Cap Screw
M2.5x18mm
Socket Head Cap
Screw M2.5x6mm
(HC018-S)
Tail Case Spacer
(H0216-S)
Set Screw M3x8
Bell Crank Support
(H0229-S)
Tail Pin
(H0264-S)
Flanged Bearing
5x 13x4mm
(HC412-S)
Tail Side Plate Assembly
Tail Belt
1530-HTD-4.5
(HC342-S)
Socket Head Cap Screw M2.5x8mm
Tail Side Plate
(H0243-S)
Flanged Bearing
2.5x 6x2.5mm
(HC400-S)
Spacer Arm
2.5x 4x6.3mm
(H0253-S)
Uniball
M3x 4 H5
(H0279-S)
Bell Crank Lever
(H0234-S)
Bell Crank Lever Assembly
Socket Head Cap Screw M2.5x6mm
......
x2
......
x3
Socket Head Cap
Screw M2.5x6mm
(HC018-S)
Set Screw M3x8mm
(HC148-S)
Socket Head Cap Screw
M2.5x18mm
(HC032-S)
Flanged Bearing
5x 13x4mm
(HC412-S)
Bell Crank Lever
Assembly
Tail Side Plate
Assembly
Yellow Vertical Fin (H0242-S)
Red Vertical Fin (H0281-S)
Tail System Assembly
Socket Head Cap Screw
M2.5x6mm
......
x3
......
x1
21T Pulley
(H0230-S)
A
DETAIL A
H0230
HC148
H0227
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Page 15
Chapter 7, Tail

Servo Spacer
(H0075-S)
Socket Head Cap
Screw M2x6mm
(HC004-S)
Tail Servo Assembly
......
x4
Socket Head Cap Screw
M2.5x12mm
......
x1
Socket Head Cap Screw M2x6mm
......
x1
Uniball M2 5H6
15-17mm
The distance between the
center of the horn and the ball
should be between 15-17 mm.
Uniball M2
5H6
(H0064-S) Tail Servo
Socket Head Cap
Screw M2.5x12mm
(HC026-S)
Tail Servo
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Finishing C Washer M2.5
(H0255-S)
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Canopy Positioner
(H0217-S)
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Finishing C Washer M2.5
(H0255-S)
Socket Head Cap Screw M2.5x8mm
......
x8
Finishing C Washer M2.5
......
x6
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Page 16
Chapter 8, Installation Of Tail Servo

34mm 36mm
120°
120°
18.5
Servo 1
Servo Support
Servo 2 Servo 3
Installation Of The Swashplate Servos
The distance between the center of the horn and the ball should be between 16-18 mm (Figure 1) .
Select the carbon fiber servo mount that is suitable for the size of servos to be used (Figrure 2) .
Choose the support of servo more suitable for servos you
want to use.
Servo Support H0245 for servo 36mm
Servo Support H0246 for servo 34mm
H0245 H0246
Assembly of the Ball on the Horn.
The rods going from the servos to the swashplate must
be as vertical as possible. Not all servos are equal so
to better align them you can choose to use the
supplied spacer H0031.?????
Servo 2
Servo 3
Servo 1
Front
H0064-S
H0031-S
HC008-S
H0251-S
H0245-S
SERVO
HC022-S
H0064-S
HC008-S
H0251-S
SERVO
H0245-S
HC022-S
H0031-S
HC008-S
H0064-S
HC008-S
H0064-S
HC022-S
H0251-S
SERVO
H0245-S
HC022-S
H0251-S
SERVO
H0245-S
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Socket Head Cap Screw
M2.5x8mm
....x6
Servo Mounting
The servo linkages must be aligned correctly. In order to do this, you must chose from one of the options shown here.
Figure 3 shows the installation of the servos at 120 degrees. Note that the distance between the carbon fiber servo mount and the center of
the ball should be 18.5mm.
Figure 4 shows 4 different mounting options, the distance “X” should be as close as possible to 18.5mm.
X
X
X
X
Final Servo Assembly
Servo Mounting Options
Note:
Chamfer Outside In Carbon Parts
16-18mm
Note:
Chamfer Outside In Carbon Parts
Note:
Chamfer Outside In Carbon Parts
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Page 17
Chapter 8, Servos

Swashplate Assembly
Uniball
M3x4 5H18
(H063-S)
Uniball M3x4
5H3
(H065-S)
Set Screw M2.5x15mm
(HC146-S)
Linkage Rod B Assembly . . . . .x3
(Initial length for the rods from the servos to the swash plate.)
(Initial length for the rods from the swash plate to the Blade Grip.)
Linkage Rod A Assembly . . . .x2
Approx. 62mm
Linkage Rod M2.5x33mm
(H0237-S)
Plastic Ball
Link
(H0066-S)
Linkage Rod B
Assembly
Linkage Rod A
Assembly
Socket Head Cap Screw
Shouldered M3x20mm
(HC082-S)
Socket Head Cap
Screw M2.5x12mm
(HC026-S)
Metric Hex Nylon
Nut M3
(HC206-S)
Approx. 44.5mm
Swashplate
Assemly
Plastic Ball Link
(H0066-S)
Swashplate
Assemly
(H0201-S)
53mm
Preliminary Head Setup
Adjust the linkages as shown. You can change the tracking
without disconnecting the plastic ball links by inserting a small
tool through the rod hole and turning it.
Left Thread
Right Thread
Metric Hex Nylon Nut M3
Socket Head Cap Screw M2.5x12mm
Socket Head Cap Screw Shouldered M3x20mm
....x1
....x2
....x1
Socket Head Cap
Screw M2.5x12mm
(HC026-S)
Approx. 35.5mm
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Page 18
Chapter 9, Assembling The Modules