JR Robinson R22 User manual

.46–.50 ASSEMBLY INSTRUCTIONS
ERGO SPECIFICATIONS
Overall Length 46.25"
Overall Height 16.50"
Main Rotor Diameter 52.75"
Tail Rotor Diameter 9.17"
Gear Ratio 9.78:1 : 5.18
Gross Weight 7.0–7.5 lb
JRP9012.46 Robinson R22 Manual 10/6/00 5:05 PM Page 1

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Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Robinson R22 SS CCPM Features . . . . . . . . . . . . . . . . . . . . . . . 4
Additional Items Required to Complete
the Robinson R22 SS CCPM. . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-1 Clutch Bell/Start Shaft Assembly. . . . . . . . . . . . . . . . . 8
1-2 Tail Drive Pinion/Bearing Block Assembly . . . . . . . . . . 8
1-3 Elevator Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9
1-4 Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-1 Upper Main Frame Section Assembly . . . . . . . . . . . . 10
2-2 Upper Main Frame Clutch/Tail Pinion Installation . . . 11
2-3 Lower Main Frame Assembly . . . . . . . . . . . . . . . . . . 12
2-4 Fuel Tank Installation. . . . . . . . . . . . . . . . . . . . . . . . . 12
2-5 Front Radio Bed/Gyro Mounting Plate Installation. . . 13
2-6 Cooling Fan Shroud Installation. . . . . . . . . . . . . . . . . 13
2-7 Upper/Lower Main Frame Assembly Attachment . . . 14
3-1 Main Drive Gear/Autorotation Assembly . . . . . . . . . . 15
3-2 Main Drive Gear/Autorotation Assembly Installation . . 15
3-3 Landing Gear Assembly Installation . . . . . . . . . . . . . 16
3-4 Cooling Fan/Hub Installation . . . . . . . . . . . . . . . . . . . 16
3-5 Engine Mount Attachment. . . . . . . . . . . . . . . . . . . . . 17
3-6 Clutch Assembly Attachment (All). . . . . . . . . . . . . . . 17
3-7 Engine Installation (All) . . . . . . . . . . . . . . . . . . . . . . . 18
3-8 Installation of the Muffler . . . . . . . . . . . . . . . . . . . . . 18
4-1 Rotor Head Hub Assembly . . . . . . . . . . . . . . . . . . . . 19
4-2 Main Blade Holder Assembly. . . . . . . . . . . . . . . . . . . 19
4-3 Main Blade Holder/Seesaw Attachment. . . . . . . . . . . 20
4-4 Seesaw Mixing Arm Installation . . . . . . . . . . . . . . . . 20
4-5 Swashplate Adjustment. . . . . . . . . . . . . . . . . . . . . . . 21
4-6 Swashplate/Washout Assembly Installation . . . . . . . 21
4-7 Rotor Head Installation . . . . . . . . . . . . . . . . . . . . . . . 22
4-8 Flybar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-9 Flybar Paddle Attachment . . . . . . . . . . . . . . . . . . . . . 23
4-10 Rotor Head/Swashplate Control Rod Installation. . . . 23
5-1 Tail Output Shaft/Pulley Assembly. . . . . . . . . . . . . . . 24
5-2 Tail Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . 24
5-3 Tail Center Hub Assembly . . . . . . . . . . . . . . . . . . . . . 25
5-4 Tail Blade Holder Assembly . . . . . . . . . . . . . . . . . . . . 25
5-5 Tail Pitch Control Lever Installation . . . . . . . . . . . . . . 26
5-6 Tail Fin Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-7 Tail Boom Carrier Installation . . . . . . . . . . . . . . . . . . 27
5-8 Tail Boom Assembly Installation . . . . . . . . . . . . . . . . 27
5-9 Tail Boom Brace Assembly . . . . . . . . . . . . . . . . . . . . 28
5-10 Tail Brace/Body Mount Attachment . . . . . . . . . . . . . . 28
6-1 Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-2 Tail Control Rod Assembly . . . . . . . . . . . . . . . . . . . . 30
6-3 Tail Control Rod Installation . . . . . . . . . . . . . . . . . . . 30
6-4 Gyro/Receiver/Switch Harness/Battery Installation . . 31
7-1 Servo Arm Preparation and Installation. . . . . . . . . . . 32
7-2 CCPM Servo Centering with the Sub-Trim Function . 33
7-3 CCPM Linkage Connections . . . . . . . . . . . . . . . . . . . 34
7-4 Checking the Swashplate for Level . . . . . . . . . . . . . . 35
7-5 Pitch-to-Aileron Mixing Adjustment with Travel Adjust . . 36
7-6 Pitch-to-Elevator Mixing Adjustment with Travel Adjust. . 37
7-7 Tail Control Rod Servo Connection . . . . . . . . . . . . . . 38
7-8 Throttle Linkage Installation (All). . . . . . . . . . . . . . . . 39
8-1 Body Preparation and Trimming . . . . . . . . . . . . . . . . 40
8-2 Body Attachment/Final Fitting . . . . . . . . . . . . . . . . . . 41
Robinson R22 SS CCPM Decal Sheet . . . . . . . . . . . . 42
8-3 Main Rotor Blade Balancing . . . . . . . . . . . . . . . . . . . 43
8-4 Main Rotor Blade Attachment . . . . . . . . . . . . . . . . . . 43
Understanding Swashplate Control Systems . . . . . . . . . . . . . . 44
Radio System Requirements (not included) . . . . . . . . . . . . . . 45
CCPM Software Activation and Initial Adjustment . . . . . . . 46–48
Important CCPM Programming Dos and Don’ts . . . . . . . . . . . 49
Final Servo Adjustment and Radio Setup. . . . . . . . . . . . . . 50–52
Final Preflight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Data Sheet Robinson R22 SS CCPM Initial Setup
XP652 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
XP8103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
PCM10XII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57–58
10X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59–60
Parts List
Rotor Head Assembly . . . . . . . . . . . . . . . . . . . . . 61–62
Start Shaft/Clutch/Engine Assembly . . . . . . . . . . 63–64
Washout Unit/CCPM Control System . . . . . . . . . 65–66
Upper Main Frame/Body Set/Main Gear Assembly . . 67–68
Lower Main Frame/Landing Gear/Fuel Tank Assembly . . 69–70
Tail Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . 71–72
Tail Boom/Tail Boom Carrier Assembly . . . . . . . . 73–74
Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
TABLE OF CONTENTS
Section Description Page Section Description Page
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INTRODUCTION
Congratulations on your purchase of the JR Robinson R22 CCPM
helicopter kit. This kit has been both engineered and manufactured
by JR with help from some of Japan’s top R/C helicopter engineers
now employed by JR.
As you may well know, for years the name JR has been
synonymous with state-of-the-art, high-quality radio control
systems known the world over for their exceptional reliability
and engineering.
JR now brings this reputation and knowledge into the helicopter
market with the development and organization of the JR heli
division. Years in the making, the JR heli’s superior quality and
exceptional parts fit and finish create a new standard of quality
that was previously unavailable.
JR CCPM
To take JR heli designs to the next level, JR’s designers turned to
CCPM (Cyclic/Collective Pitch Mixing). CCPM is a unique control
system that mounts three servos below the swashplate with short,
straight linkages directly to the swashplate at 120-degree
intervals. With CCPM, complex collective and cyclic mixing is
accomplished electronically, rather than mechanically. As a result,
many parts are eliminated, along with excessive control system
play, not to mention quicker building and lower maintenance.
What’s more, you get more servo power from CCPM. That’s
because instead of one servo moving the collective, you now have
three. Instead of one servo moving the cyclic, you have two.
Before you begin the assembly of your Robinson R22 CCPM, we
suggest that you first review the entire instruction manual to
become familiar with the assembly sequences and parts layout.
WARNING
The radio-controlled model helicopter contained in this kit is not a
toy but a sophisticated piece of equipment. This product is not
recommended for use by children. Radio-controlled models such
as this are capable of causing both property damage and/or bodily
harm to both the operator/assembler and/or spectator if not
properly assembled and operated. Horizon Hobby assumes no
liability for damage that could occur from the assembly and/or
use/misuse of this product.
AMA INFORMATION
We strongly encourage all prospective and current R/C aircraft
pilots to join the Academy of Model Aeronautics. The AMA is a
non-profit organization that provides services to model aircraft
pilots. As an AMA member you will receive a monthly magazine
entitled Model Aviation, as well as a liability insurance plan to
cover against possible accident or injury. All AMA charter aircraft
clubs require individuals to hold a current AMA sporting license
prior to operation of their models. For further information, contact
the AMA.
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302
[phone]
PREASSEMBLY INFORMATION
When first opening your JR heli kit, you will notice that all of the
parts are packaged and numbered to coordinate with the assembly
step numbers of this instruction manual.
All small hardware (nuts, bolts, washers, etc.) for each step are
packaged separately within the main parts bags. When beginning a
section, you will need to open only the bag with the corresponding
number to the section you are about to start. It is suggested that
you place all of the hardware in an open container (e.g., coffee
can) during assembly so as not to lose any of the small parts. It
may also be helpful to familiarize yourself with the various sizes of
screws, bolts, nuts, etc., as illustrated in the appropriate assembly
section before you begin assembly. In most cases, at the end of
each assembly section there should be no parts remaining.
Great care has been taken in filling the bags with the correct
quantity of parts and hardware for each section. However,
occasionally mistakes do happen. In the event that you find a parts
shortage or are in need of technical assistance, please contact
your local JR heli division parts dealer or contact the Horizon
Service Center.
Horizon Service Center
4105 Fieldstone Road
Champaign, IL 61822
[phone] (9 a.m. to 5 p.m. CST)
www.horizonhobby.com
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ADDITIONAL ITEMS REQUIRED TO COMPLETE THE JR ROBINSON R22 SS CCPM
1. Radio System Requirements (not included):
6-Channel or greater R/C helicopter system with 120°CCPM function (see list below)
5 Servos
1000mAh receiver battery
Gyro
ROBINSON R22 SS CCPM FEATURES
CCPM (Cyclic/Collective Pitch Mixing)—
More Accurate: Control system play is totaly eliminated
Simpler: Fewer links to setup and maintain
More Powerful: Collective has three times the servo power,
cyclic has double
Heavy-Duty Aluminum Quad Frame System—
Provides excellent rigidity and vibration absorption
One-Way Hex Start Shaft System—
Provides positive starting, starter shaft utilizes a one-way bearing
that allows the shaft to stop after the engine is started
Wide Spread Tail Output Shaft Bearings—
Reduce vibration and improve control response
Belt-Driven Tail Rotor Design—
Provides easy adjustment and low maintenance, eliminates
the need for optional/expensive tube drive shafts
Precision Ball Bearings at All Critical Locations—
Provide low wear, high precision, and reduced maintenance
Self-Aligning One-Piece Steel Clutch System—
Offers easy installation and adjustment with exceptional reliability
Straight Blade Axle Rotor Head Design—
Provides high responsiveness and solid blade tracking
Low Drag Flybar Paddles—
Provide quick yet smooth cyclic response at all flight speeds
Heavy-Duty Main Blade Grips with 4 mm Blade Bolts—
Provide a solid and secure mounting surface to easily handle
blade stresses
Rearward-Facing Engine Design—
Provides easy access to the glow plug for starting, engine slips
easily through the main frame for trouble-free engine maintenance
Heavy-Duty Tail Boom Carrier—
Provides increased structural rigidity and improved tail
rotor precision
Prefinished Main Rotor Blades—
Provide easy assembly with excellent flight characteristics
Superior Parts Fit and Finish—
Make assembly trouble free and enjoyable
Durable Polyethelene Robinson R22 Body Set—
Provides a durable, semi-scale appearance, full decal set included,
no painting required
CCPM-Ready JR Radio Systems
Most current JR heli radio
systems (XP652, XP8103
w/digital trims, 10X, as well as
older 10 series systems) are
equipped with 120°CCPM
electronics for use with the
Robinson R22 SS CCPM
machines. Radios you may be
flying now, like the X347, X388S,
XP783, and XP8103* have CCPM
capability built in, but require
activation by the
Horizon Service Department.
Please call [phone]
for details.
*Please note that many XP8103 systems have the
CCPM function already activated. Please check
with the Horizon Service Center for details.
CURRENT RADIO SYSTEMS
JRP1656** PCM 10X, 5-8231 Servos (50/53/72 MHz)
JRP165TX PCM 10X, Transmitter Only (50/53/72 MHz)
JRP8622** XP8103FM, 5-517 Servos (50/53/72 MHz)
JRP8653** XP8103PCM, 5-531 Servos (50/53/72 MHz)
JRP6622** XP652 FM, 5-517 Servos (50/53/72 MHz)
12'' Aileron Extensions (2)450 Piezo GyroJR AirPac
JR XP652 JR 10X JR XP8103 DT
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Double-Sided Servo
Mounting Tape
Threadlock
(blue and red required)
Nylon Wire Ties
to secure radio wires
Heavy-Duty
Servo Arms (3)
Silicone Fuel Tubing Whip Antenna
Fuel Filter
Glow Plugs
2. Engine Requirements (not included):
3. Building Supplies (not included):
The following items are needed to complete the assembly of the JR Robinson R22:
A .46–.50 R/C helicopter engine
(MDS .48 heli engine shown)
(JRP960079 Ergo .46 muffler shown)
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Needle-Nose Pliers
Drill and Drill Bits
Allen Wrenches: 1.5, 2.0, 2.5,
3.0 mm
Ball Link Pliers Ball Link Sizing Tool
JRP960219
Blade Balancer
RVO1001
Small Hammer X-Acto Knife Metric Ruler
Scissors
12-Volt Electric Starter 12-Volt Starting Battery 1.5-Volt Glow Plug Battery Remote Glow Plug Adaptor
Helicopter Fuel, 15%–30%
Pitch Gauge
Fuel Pump
Training Gear (beginners only)
Hex Starting Shaft
Phillips Screwdriver Nut Drivers: 5 mm, 7 mm
4. Tools Needed To Assemble the JR Ergo (not included):
5. Field Equipment Required (not included):
or
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Socket Head Bolt Tapping Screw Flat Washer
.05 mm
Flat Head Screw Lock Nut
There are many various sizes and shapes of hardware
included in this kit. Prior to assembly, please be careful to identify
each screw by matching it to the full size screw outlines included
in each step.
All of the hardware, screws, nuts, etc., contained
in the Robinson R22 SS kit are described in the following
A, B, C manner:
CC
C
A
B
A
A
B
B
C
3 x 8 mm Socket Head Bolt
Set Screw
C
A
B
C
C
A
A
A
2 x 8 mm Flat Head Screw
2.6 x 10 mm Self Tapping Screw
AB
B
3 mm Flat Washer
AB
B
3 mm Lock Nut
Spring Washer
AB
B
3 mm Spring Washer
A
Hex Nut
AB
B
2 mm Hex Nut
C
4 x 4 mm Set Screw
HARDWARE IDENTIFICATION
A
B
Flat Head Cap Screw
AC
B
C
3 x 8 mm Flat Head Cap Screw
ABAB
ABAB
.05 mm
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1-1
3 x 4 mm Set Screw
3 x 4 mm Set Screw
* When installing the
start shaft bearing
block assembly, be
sure the bearing block
is positioned so the
small inside diameter
bearing faces upward
toward the starter hex
adaptor, with the large
inside diameter bearing
toward the clutchbell
assembly.
Starter Hex Adaptor
*Start Shaft
Bearing
Block with
Ball Bearing
Apply a very light coat of red Threadlock
before inserting pinion gear into the
start shaft bearing block.
Start Shaft
Complete Assembly
Clutch Bell Assembly
.......... 1 pc
3 x 6 mm Socket Head Bolt
..... 1 pc
3 mm Flat Washer
............. 1 pc
CLUTCH BELL/START SHAFT ASSEMBLY
1-2 TAIL DRIVE PINION/BEARING BLOCK ASSEMBLY
Install the lower bearing block so the
bearing face is toward the top.
Note: Be sure to allow a slight
amount of clearance between
the start hex adaptor and the
bearing block to prevent
binding.
Tail Drive Pinion
Bearing Blocks
Tail Drive Pinion
with Shaft
Front Tail Belt Pulley
(install flat side up)
3 mm Flat Washer
3 x 6 mm Socket Head Bolt
Complete Assembly
UP
UP
Bearing
Bearing Use red
Threadlock
Use blue & red Threadlock
Use red Threadlock
Install the upper bearing block so that
the bearing is toward the bottom.
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1-3 ELEVATOR ARM ASSEMBLY
Swashplate A Arm
JR Logo Direction
Elevator Arm
11 mm Long Ball Arm
3 mm Flat Washer
Swashplate A Arm
Edge of Work Bench
Elevator Arm
Tap in gently with
a small hammer.
Elevator Arm Pin 3 mm Lock Nut
Caution: Be sure to note the correct Swashplate A Arm
installation direction.
Elevator Arm
Marked Side Out
Swashplate
A Arm
1-4 FUEL TANK ASSEMBLY
3 mm Lock Nut
11 mm Long Ball Arm
Elevator Arm Pin
3 mm Flat Washer
...................... 1 pc
......... 1 pc
.................. 1 pc
.............................. 1 pc
7 mm Nut
........... 1 pc
7 x 12 x 1 mm Washer
........... 1 pc
Silicone Tube (small) —Use tubing
included in seperate package in kit.
Nipple
Medium Silicone Fuel
Tubing (not included) —
Connect to Engine Carburetor
1. Cut the small silicone fuel tubing (included)
to a length of 58 mm. Next, connect the fuel
tank clunk, nipple, and medium silicone fuel
tubing (not included) as shown above.
Fuel Tank Grommet
2. Insert the assembly into the fuel tank
opening so that the nipple is inside the tank.
Next, slide the fuel tank grommet over the
medium fuel tubing.
Make sure grommet is fully seated.
Pull out until nipple threads are exposed.
3. Inset the fuel tank grommet into
the fuel tank opening, making
sure that it is fully seated.
4. Pull the medium
fuel tubing out of
the fuel tank unit
the threads of the
fuel tank nipple
are exposed.
7 mm Nut
7 x 12 x 1 mm Washer Use two wrenches if necessary
to secure tank nipple.
5. Remove the medium silicone fuel tubing
from the nipple and secure the nipple to the
fuel tank using the 7 x 12 x 1 mm washer
and 7 mm nut supplied. Be sure to secure
this assembly firmly to avoid leakage.
6.Complete Assembly
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2-1 UPPER MAIN FRAME SECTION ASSEMBLY
Frame Supporter
3 x 8 mm
Socket Head
Bolt
Slot denotes left frame side
3 x 8 mm Socket Head Bolt
Bearing side must face
downward
3 X 8 mm Socket Head Bolt
Use Threadlock
Use Threadlock
Use Threadlock
Upper Main Frame, Left
Upper Main Frame, Right
Main Frame Standoff,
32 mm (3)
*Elevator Arm from Step 1-3
Elevator Arm
Bushing, 32 mm 5 mm Nylon
Washer (2)
Use blue Threadlock on all screws
UP
UP
Bearing Flush
with Flange
Bearing
Bearing
Bearing side must
face upward
*Note: Install elevator arm
assembly first!
Note: Be sure to note the left
and right upper main
frame positions.
Bearing Flush
with Flange
5 mm nylon washer
Main frame standoff, 32 mm
.................................. 16 pcs
.................................................... 2 pcs
...... 3 pcs
........ 1 pc
3 x 8 mm Socket Head Bolt
Elevator Arm Bushing, 32 mm
Use
Threadlock 3 x 8 mm Socket Head Bolt
Position so side of the
bearing block that has
the bearing flush with
the flange is upward.
Lower Main Shaft-Bearing Block
Position so side of
the bearing block
that has the bearing
flush with the flange
is downward.
Upper Main Shaft-Bearing Block
.............. 2 pcs
Body Mounting Standoff, 37 mm
Body Mounting Standoff, 37 mm (2)
3 x 8 mm
Socket Head Bolt
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