GRAUPNER JODEL ROBIN DR 400/180 User manual

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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11/2011
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Re: Order No. 9370
9370.M
Instructions
JODEL ROBIN DR 400/180
For internal combustion motors up to 58 cm³
Requires a HoTT radio control system with 5 functions

GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
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Specification
Wingspan about 2500 mm
Fuselage length without spinner about 1910 mm
Wing area about 98 dm²
Tailplane area about 10 dm²
Total surface area about 108 dm²
All-up weight depending on equipment about 11000 g
EWD 0-0.5 degree
Centre of gravity about 140 -150 mm behind the leading
edge
Caution: This model is not a toy!
If you do not have experience with such motorised models, please ask experienced
model flyers for help. If the model is operated without the proper knowledge, injuries
can result. Think of your health and safety!
Important! Before you start the assembly!
Even if you have already built lots of RC models, read these instructions through
carefully and check the parts in the kit for completeness. A lot of effort was made to
keep things as simple as possible without neglecting safety.
Note on the covering sheet
Because of strong changes in the weather (temperature, humidity, et cetera), small
creases can appear in the covering sheet. In rare cases, the components can even
be warped. This lies in the nature of wood construction with covering sheet. This can
be corrected as follows using a hair dryer like those available to model builders.
Creases: Blow hot air over the area and rub with a soft cloth.
Warped area: Gently twist the area against the direction of warping and smooth
it out again using hot air.
Caution! Never use more heat than is absolutely necessary. If the iron is too hot, the
covering sheet will melt and holes will form.
The extensively pre-fabricated model can be built in a very short time. However, the
remaining steps are important and have to be carried out with care. Doing this work
properly determines whether the model will have the prescribed rigidity and flight
characteristics; so please work slowly and precisely!
When putting screws into wood, apply a little casein glue to keep them from
loosening: Squirt casein glue into the drill hole and screw in the screw.

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Tips on building the model
•Before assembling the model, it is essential to read the construction diagram and
the instructions all the way through. When using tools, be aware of the possible
dangers.
•Use only suitable cables that are adequate for the electrical currents that occur
during operation.
•Set up the receiver aerial as far as possible away from the cables carrying the
operating current (at least 3 cm).
•Clean residual grease from all connections that are to be glued. This could be
done, for example, through sanding and using a non-relubricating cleaning
solution. The same goes for the surfaces to be painted, in order to make sure that
the paint sticks. Before gluing parts, always roughen the corresponding surfaces
(especially for GFR fuselages) carefully with fine sandpaper and de-grease them
thoroughly, for example with acetone. Otherwise, adequate adhesion is not
assured.
Other required accessories
Internal combustion motor and accessories
Motor
Order No. Capacity cm³ Silencer Order No. Exhaust manifold
Order
No.
Propeller
Order No. Teflon hose
Order No.
Spring
clamps
Order
No.
OS GT 55
2760 55
2760.34
2760.51
56x25 cm
2960.56.25
6861.25
6865
2
required
Radio control system
It must have at least 5 control functions and 10 servos. Furthermore, the
transmitter must be capable of reversing the direction of servo rotation.
Particularly recommended: Computer systems MC-22s to MC-24. Servos with
standard dimensions can be installed.
As receiver battery, we recommend: two GRAUPNER 5N-5000 NiMH Order No.
98903.5, which must always be serviced well before and after flight operations,
meaning that the battery has to be charged and discharged again multiple times until
the specified capacity has been reached.

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Connecting the two ailerons and the landing flap servos to the receiver requires four
spark suppression filters, Order No. 1040 or one folding ferrite ring, Order No.
98516.1 with four extension cables Order No. 3935.32.
The two aileron servo cables must each be extended with an extension cable Order
No. 3935.65; the two landing flap servo cables with Order No. 3935.11; the two
elevator servos with Order No. 3935.105. For the servos for throttle coupling, nose
landing gear, aero-tow coupling, et cetera, seven extension cables Order No.
3935.32 are needed. Connecting the telemetry sensors requires one cable Order No.
33700.2.
Two Order No. 7907.2 are used as servo control arms.
Receiver and battery: Store in foam material.
Any servo of standard size and an adjusting power of about 50 Ncm can be installed.
Adhesives
Epoxy glue, such as "UHU plus schnellfest," Order No. 962
Epoxy glue, such as "UHU plus endfest 300," Order No. 950.43
"UHU Holzleim express" casein glue, Order No. 958.60
"UHU hart" glue, Order No. 534.35
Fast-setting (cyano-acrylate) glue, such as Order No. 5821
Fast-setting glue, such as Order No. 5821
Thread lock fluid, such as Order No. 952
Heat-shrink tubing, Order No. 3391.8
Accessories for operation (not included)
Fuel, depending on the motor petrol/oil mixture (see instructions for the motor used)
Fuel tubing, petrol, such as Order No. 1325.2
Manual fuel pump, such as Order No. 6870
Ignition battery, Order No. 8716.5
OS Super-Filter Order No. 1646.1
Required tools (not included)
Various (Philips) screwdrivers, needle-nose pliers, flat-nose pliers, wire cutter, balsa
knife or razor blade, various drills, pencil, felt marker, soldering iron with fine tip.
Assembling the JODEL ROBIN DR 400/180
Wings with undercarriage and tailplane
Do not begin the assembly until you have familiarised yourself with the components
and the individual construction stages. If you are not satisfied with any component,
report it to your retailer before you start the construction process.

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Using sandpaper or sanding block, sand the control horns on the surfaces to be
glued in order to achieve an adequate connection when gluing.
As seen in the photos, remove the covering from the slots for the GRP control horns,
put a dab of glue into the slot, and push the control horn in until it stops.
Wipe off any excess glue.
Until the glue hardens, the servos
are installed in the corresponding mounts and fastened into the wing or tailplane.

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Extend the servo cables using the corresponding extension cable and make sure
they can not come loose, for example with a piece of heat-shrink tubing or a drop of
fast-setting glue. Using the RC system, bring the servos into centre position and
install the servo levers.
Fasten the servo to the attachment block using the screws included with the servos.
To do so, insert the rubber grommets with the brass hollow rivets, collar downward,
into the servo flange. For drilling Ø 1.5 mm holes for the screws, the hollow rivets can
be used as a drilling template. To make it easier to push them in,
the hollow rivets can be placed onto a screwdriver of the proper size.
Now the servo cables are pulled into the wing halves and tailplane halves using a
thread. Just behind the connector, tie the thread to the cable and pull it in so that it
comes out the wing root.
With servo and rudder in neutral position, screw together the lengths of the rods for
the ailerons, landing flaps, and elevators, adjust them; then use thread lock fluid
(such as UHU schraubensicher) and lock nuts to secure them against loosening.

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As shown in the photo, secure the hinges for the landing flaps using heat-shrink
tubing.
On the underside of the wings, there are markings indicating where the flap hinges
can be screwed in. Make sure that the axes of rotation of the hinges are all the same
distance from the trailing edge of the wing.
As shown in the photo at the left, use one screw to
fix the hinges in place; then use an engineer's square or geometric protractor for
alignment with the trailing edge, and fasten the hinges with two more screws. Now
push the landing flaps up against the wings and tape them in place temporarily; align
them, and fasten them with screws.
Screw the pushrods together as shown in the following photos.

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In the next step, use your fingers to feel for the slot for the landing gear wire, and
melt it free with a hot soldering iron.
Now place the leg of the undercarriage into the slot to mark the attachment points of
the two tabs and the wheel fairing support block.
Drill pilot-holes in the wings for the retaining screws; then screw the tabs and the
wheel fairing support block to the wing.

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For the wire undercarriage units you will need to file away the inside of the two
fairings a bit. When installing the fairings, make sure that the wheel covers face
outwards. The wheels can now be attached to the axles using collets and
grubscrews. Apply UHU thread-lock fluid to the grubscrews to prevent them working
loose. Loosen the grubscrew at the front of the shock absorbing strut, loosen, and
push the wheel axle to the other side. Re-tighten the grubscrew.
The wheels and wheel fairings must be aligned exactly parallel with the fuselage
centreline.
The final work on the wing is to install the landing searchlight.
As shown in the following photographs, fit the two LEDs in the white plastic holder
and secure them with a little UHU Power all-purpose adhesive.
Trim the outside edges of the plastic holder so that it fits in the recess in the wing.
Route the connecting leads of the two diodes to the root rib using a piece of thread,
and run they out of the drilled access hole. The plastic holder can now be glued in

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using UHU Power all-purpose adhesive. Fix the glazing to the wing using clear
adhesive tape.
Fuselage with tailplane, vertical stabiliser, and nose gear
The vertical stabiliser can either be glued permanently to the fuselage or fastened
removably using four screws.
Only the fastening of the vertical stabiliser using screws is described.
Before putting in the screws, the two extension cables for the two elevator servos
must be pulled into the fuselage.
Use the Ø 12 mm aluminium tube to put the horizontal stabiliser onto the fuselage to
test the fit; the two extension cables must be routed through the openings of the
horizontal stabiliser on the right and left.

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The two halves of the tailplane must be attached to the fuselage using the Ø 12 mm
aluminium tube and four M3x16 Allen screws each.
Now the rudder is fastened to the horizontal stabiliser using steel wire. Assemble the
pull cables as shown in the photo.
Then attach the rudder servo to the servo plate at the front of the fuselage.
As shown in the photo, install the pull cables to the servo lever and adjust them so
that the rudder is in the centre position when the servo is in the centre position.
As shown in the photo, fix the fairing support block to the nose gear using an M4
Allen screw and nut.

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Fix the nose gear in the brackets by tightening the screw in the collet. Assemble the
pull cables as shown in the photo.
Here too, make sure that the nose gear is exactly in the neutral position when the
servo is in the centre position. Later the nose gear steering servo and the rudder
servo can be connected to the same receiver socket either using a Y-lead or via a
mixer at the transmitter.
As shown in the photos, the wheel fairing is attached to the support block using four
self-tapping screws.
The nosewheel can now be fitted onto the axle and secured using two collets, as
already described for the main undercarriage.
As with the ailerons and landing flaps, each of the rudder pushrods consists of two
M3 clevises and nuts and one threaded rod. The length of the two rods must be
adjusted so that the elevators are at the centre position when the servo is in centre
position. Before screwing in the two elevator servos, the connecting cables must be
extended using suitable extension cables.
Screw the aero-tow mechanism into the hole just behind the canopy, and apply UHU
thread-lock fluid to prevent the coupling and nut from working loose.
The aluminium part must be shortened enough so that the clevis can move freely;
adjust the rods accordingly.

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It is best to operate the aero-tow release mechanism using a momentary switch
mounted on the joystick. The servo travel must be set accordingly.
Installing the tank and motor
Assembling and installing the fuel tank
Slip a piece of plastic tubing (about 160 mm long) onto the fuel tank clunk pick-up.
Push the free end of the fuel tubing onto one of the tubes in the fuel tank stopper so
that the pick-up will be able to move freely inside the tank later on without binding or
jamming when the stopper is in place. Use a heat-gun or lighter to gently heat the free
plastic tubes so that they can be bent easily. One tube should face down and will be
used later to fill the tank; the other one points upward and will serve later as the
overflow when the tank is filled. Extend each of the two tubes with a piece of fuel
tubing so that they extend to the top and bottom of the tank, respectively.
Now push the tank stopper over the throat of the fuel tank, and tighten the Philips-head
screw to fasten the stopper in place. It is important to tighten the screw so that the tank
is completely sealed. This can be checked by holding the tank under water. Hold it
under water and blow air into it. If the tank is sealed, there will be no air bubbles.
Connect a further length of fuel tubing to each stub tube projecting from the fuel tank.
Mark the silicone tubes with a felt marker to show which of them runs to the motor, the
overflow, and the filler.

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Once the tank is pre-assembled in this way, it is fastened to the attachment block as
shown in the photo.
Push the fuel tank into the fuselage so that the three silicone tubes stick out through
the drill hole in the bulkhead.
The tube from the clunk is then connected to the carburettor, while the overflow is run
downward. The fuel filler tube can later be routed out through a drill hole in the motor
bonnet. After filling, it should be sealed with a plug.
The attachment block is fastened with two screws.
The throttle servo must be installed using the bracket as shown in the photo.
Depending on the motor used, the servo is installed to right or left of the tank.
Installing the motor
This section describes the installation of the OS MAX GT 55, but the procedure is the
same for other engines.
Four holes for the rubber damping elements have to be drilled into the firewall to
match the particular engine.

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The centre of the motor is marked on the firewall. Drill Ø 10 mm holes to match the
attachment holes for the engine.
Now push the rubber dampers into the four holes, and attach the engine using four
Allen screws, stud bolts, washers, and nuts. Tighten the Allen screws only to the
point that there is still a damping effect.
The throttle rod is adjusted so that the carburettor is half open when the servo is in
centre position. The servo travel must be adjusted so that the engine stops when the
throttle stick and trim are at the full back position.
The silencer is attached using the brass strips supplied, which are bent and drilled
according to the dimensions shown in the photo.
Attach the silencer to the motor using the manifold, the Teflon hose, and the spring
clamps. With these parts in place, the attachment points for the two aluminium
brackets can be marked on the fuselage by screwing the two attachment brackets to
the silencer; drill the Ø 4.2 mm holes and attach the brackets to the fuselage using
M4 Allen bolts and captive nuts.
Now, the silencer can be attached to the

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aluminium brackets, and, together with the manifold, can be bolted to the engine; a
drop of UHU thread-lock fluid should be applied to each bolt and nut to prevent them
working loose.
To fit the motor used, it is necessary to cut or file out openings in the engine bonnet
for the silencer exhaust pipe, spark plug, et cetera. Position the engine bonnet on the
fuselage in such a way that the clearance is about 2 mm between the spinner base
plate and the front edge of the bonnet.
To attach the engine bonnet to the fuselage, the four attachment points also have to
be marked on the engine bonnet. To do so, cut four strips of scrap wood and drill a Ø
3 mm hole in each one as shown in the photo.

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Now each strip is fastened to the fuselage using an M3 Allen screw and taped in
place as shown in the photo.
Unscrew the Allen screws, then push up the engine bonnet so that it moves under
the strips and the spinner base plate is about 1.5-2 mm from the engine bonnet. In
this position, mark the four attachment points on the engine bonnet.

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The engine bonnet is attached with four Allen screws as shown in the photos.
Cockpit canopy
Glue the seat backs and pilot figure in the proper positions as shown in the following
photos.
The parts should be affixed using double-sided tape, such as Order No. 2904.

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The cockpit canopy is attached to the frame using small pan-head self-tapping
screws. A strip of tape all around has proven to be a good way to ensure that the
cockpit canopy fits the frame uniformly.
The final work on the model consists of fitting and gluing the navigation lights, hatch
covers, and aerials and affixing the decals and lettering.
Balancing the Jodel ROBIN DR 400/180
The completely equipped model, with the fuel tank empty, should balance level when
supported at a point about 140 - 150 mm aft of the leading edge of the wing, ideally
in inverted flight position. If the centre of gravity is correct, the model should balance
out horizontally or with the nose pointing slightly downward. If necessary, adjust the
centre of gravity by shifting the position of the receiver batteries or screwing on trim
weights. Before flying the aircraft, set the transmitter trims to centre and ensure that
all the control surfaces are also exactly centred (in neutral position).
Rudder deflection for normal flying
Ailerons 30 mm up and 10 mm down
Elevators 25 mm up and down
Rudder 45 mm left and right
Landing flaps Take-off 15 mm down
Landing 60 mm down
We recommend that you set exponential values of 30% at the transmitter.
Assembling the Jodel Robin 400/180
Attach the two halves of the tailplane to the fuselage using the aluminium tube.
Connect the servo cables to the extension cables coming from the fuselage; secure
with Order No. 3506. Push the halves of the tailplane all the way onto the fuselage
and fasten each with four Allen screws.
Use the aluminium tubes to place the wing halves onto the fuselage. Stick the servo
connector cable together with the extension cable from the receiver and secure with
Order No. 35060. Slide the wing halves completely onto the fuselage and connect

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each to the fuselage using two plastic screws. Only tighten the screws enough to
bring the two wing halves together with the root rib.
Important:
When assembling the rods, always take care to ensure that they move freely and can
move through their entire controllable path - including trim travel - and are not
mechanically impeded.
When the joystick moves to the right, the rudder and nose gear must turn to the right
(left stick/left rudder). When the elevator stick is pulled back, toward your stomach,
the elevators must deflect upward (stick forward = elevators down). If the aileron stick
is moved to the right, the right aileron should move upward; the left aileron
downward. When the throttle stick is pushed forward, the motor must run at full
power; if the throttle stick and trim are moved back to their end-points, the engine
must stop. If the trim travel is moved all the way back, the motor must stop. The
landing flaps are best activated via a three-position switch.
All that remains is to wish you many hours of happy flying your JODEL ROBIN DR
400/180.
Your Team !