minicopter Diabolo 600 User manual

minicopter
Manual
Diabolo 600
# 6000
minicopter
Rheinstahlring 47
34246 Vellmar
Germany
[phone]
[e-mail]
www.minicopter.de

Introduction:
Congratulations on your new Diabolo 600. This model closes the hole between the
smaller Diabolo 550 and the Diabolo 700/800. It is possible to y the model with a single
6s battery pack. Best results you will get with a 10s battery pack. Then you get an agile
and very precious ying model. Generally we had a main aspect on this model that it
becomes very light. With a frame weight of less than 1600 grams the Diabolo 600 is one
of the lightest helicopters available in that size. Alternatively the Diabolo 600 can also be
converted in an ultralight Diabolo 700 or on the other hand can be own with small 550
blades.
I wish you a lof of fun during assembly and ying of your Diabolo 600.
Gerd Guzicki
To this manual:
Following many wishes this manual was assimilated to the manual of the Heli-Baby NT
which was specially designed for beginners to help especially them with basic mounting
technics and to answer many questions reading the manual. So this manual contains
more than 200 pictures in different perspectives to keep no question unanswered. Also
recommended tools are shown. If you see a botttle of Loctite then it means you should
use Loctite in this step.
Independend if you have already assembled many helicopters or of it is your rst one:
Assemble the model careful and without any stress. Being concentrated on the work is the
precondition for a perfect result.

Maintenance and Security
A radio controlled model helicopter and a speed helicopter especially is not a toy. A mistake
can result in serious accidents and injuries.
Please keep the following rules always in your mind:
- During motor tests on the workbench, remove main and tailrotor blades and take care that
nothing touches the rotating rotor heads.
- On electric helicopters you cannot calculate the risk of a sudden starting motor. So move
quickly out of the range of main and tailrotor after you have connected the ight battery.
- If you adjust or program the ESC or FBL on the workbench, remove two of the three motor
cables to eliminate the risk of a sudden motor start.
- Keep a distance to the model of at least 5m (15ft.) to the model during hovering.
- Never aim helicopter towards a person or another living object with your model and keep a
distance to them of at least 20 metres (60ft).
- Remove all Lipo batteries from the model during stocking, and put them on a reproofed con-
tainer on a reresistant oor.
- Attention with kids and pets! Children are only seeing in the model helicopter a toy and do
not see the danger of the turning rotorblades. If you are ying and hear children then climb up
with the model over your head, inform the child, clear the situation and land on a safe place.
Similar rules apply to unroped dogs.
- In case of pending crash, activate throttle hold to turn off ESC.

Beutel1: Main rotor shaft unit
Parts overview
Attach the main gearwheel hub D604 with
the side, marked with a „X“ in the main
gearwheel D13 and check the screw holes
for corresponding together.
Add six washers M3 002 to six screws
M3x8 D197 and apply Loctite on the
threads.
Mount the screws, but still do not tighten
them. If all screws are attached then
tighten them crosswise.

Put the mainrotor shaft D605 into the
mainwheel hub, put a jesus bolt D77
through both and tighten the bolt well with
a lock nut M4 009. If the screw does not
easily t then turn the shaft in the hub 180
degree and try again.
Push the spacer bush D606 on the shaft.
Push the upper main shaft bearing plate
D607 on the mainshaft. The ange of the
ball bearing D71a must show to the spa-
cer bush.
Push the lower mainshaft bearing block
D608 on the lower end of the mainshaft.
The ange of the ball bearing D71a must
show to the main gearwheel D13.

View of the assembled unit ready to mount
in the frame. Note that the curved contour
in the lower ball bearing block D608 must
be on the left side (view in ight direction).
Attach the lower ball bearing block D608
on the upper right frame D602 with two
hex bolts M3x6 D196 using Loctite. Tigh-
ten the bolts rst if the screws of the upper
mainshaft bearing block D607 are also
mounted.
Attach the upper ball bearing block D607
with two hex bolts M3x6 D196 still without
Loctite and tighten it only a bit, because
later you must open the bearing block
again to insert the elevator servo in its
slot.
After tightening the four screws check the
mainshaft for easily turning without any
endplay.

Bag 2: First stage shaft
Parts overview
Push the freewheel hub D509 from the „X“
marked side in the rst stage gearwheel
D611 and check mounting holes for corre-
sponding.
Add four washers M3 002 on four hex
lense screws M3x8 D199 and attach
Loctite to the therads, screw them into the
holes and tighten the screws crosswise.
Push the belt wheel D610 on the pinion
shaft D609 upto the end. First add now
a grub screw M4x5 035 with Loctite on
the area of the shaft with the at spot and
tighten it. Then add a second grub screw
M4x5 035 in the second threaded hole
with Loctite and tighten it. Finally add a
washer shim 10x16x0,2 033.

Push the mounted freewheel unit on the
pinion shaft D609.
Add a washer shim 10x16x0,2 033.
Push the lower bearing block D612 with
the anged bearing D70 onto the shaft
showing with the anged side of the ball
bearing to the freewheel unit. Note the dif-
ferent inner contour of the bearing block.
The rounded side is the longer side that is
on the left side (view in ight direction).
Push the upper bearing block D613 (with
the cover plate) and the anged bearing
D70 onto the upper pin of the pinion shaft
showing the ange of the bearing to the
toothed gear wheel.

Overview over the mounted rst stage unit
ready to mount in the frame. Please note
that the bearing blocks are assymetric ,
the rounded contour is longer than the rec-
tangular contour and is placed on the left
side (view in ight direction).
Add the toothed belt 713 in the belt wheel
and position the unit as shown on the cor-
responding holes of the frame.
Mount the rst stage with four screws
M3x6 D196 using Loctite. First mount all
screws loose. If all screws are mounted
then tighten them. After that check the
gear mesh. There must a small play be
noticable. Is the mesh too small then open
all screws of mainshaft and rst stage
again, pull the mainshaft unit backwards
during tightening and the rst stage for-
ward and check the gear mesh again.
Bag 3: Belt tightener
Parts overview

Two ball bearings 3x10x4 064 are pushed
on a lense screw M3x12 982, followed
from a washer shim 3x6x1 051 and will be
attached with Loctite on the belt tightening
lever D614.
A hex bolt M3x22 D332 is pushed into the
longer dampening rubber ring holder D615
and mounted with Loctite on the rst hole
of the belt tightening lever. The other holes
are thought for personally experiments.
A hex bolt M3x30 D337 is pushed into the
shorter dampening rubber holder (longer
end of the holder outside).
Three ball bearings 3x10x4 and a washer
shim 3x6x0.2 455 are following.

A hex bolt M3x16 D329 ist pushed into the
belt tightening lever D614 and a washer
shim 3x6x0.2 455 will be added.
The xed roller is now screwed with Loc-
tite into the right hole of the lower mast be-
aring block (seen in ight direction). After
tightening the screw all bearings will be
checked for clearness.
The premounted belt tightening lever will
be screwed with Loctite into the left hole
of the lower mast bearing block (seen in
ight direction). Please check before that
the washer shim 3x6x0.2 455 is placed
between the upper bearing of the lever
and the lower mast bearing block. After
tightening check the lever for easy turning.
The dampening rubber ring D617 will be
placed on the two grooves of the rubber
ring holders.

Overview from the mounted unit.
Bag 4: Frame completion
Parts overview
Before starting the mount the shown
corners of the tailservo cutout should led
rectangular (radius removed). So later the
tailservo mounting blocks are sitting exact-
ly vertical.
Filing rectangular the front corner of
the tailservo cutout. For some certain
tailservo cables it would be good to round
additionally the area on the upper right
corner of the cutout a little bit.

Break the edges of the cable slots in the
gyro platform careful with a small needle
le.
The frame completion starts with attaching
the ve frame connectors D622. The four
connectors, that are xing later the left
cover plate D603 must be tightened very
careful with Loctite on the right frame to
avoid loosing during maintenance. For
locking the bolts during tightening use the
mounting wire D115 that must be placed in
the center bore of each connector.
Start with the upper front connector using
Loctite and a hex bolt M3x6 D196.
Then mount the front connector...
...followed from the upper rear connector...

... and nally the lower rear connector.
View of the mounted unit.
The front tailboom holder clamp D620 is
attached with two hex bolts M3x6 D196.
Apply Loctite only on the upper screw. On
the lower screw Loctite will be applied la-
ter after tightening the long tailboom tigh-
tening screws (long slot in the frame) and
as long it will be loose. The front holder is
not anodized to guarantee electric con-
duction between boom and frame. Check
if a 3mm thick aluminum spacer D620a is
placed under the long screw M3x35 D338.
The rear tailboom holder clamp D620s is
attached with two hex bolts M3x6 D196.
Here the upper bolt will be tightened with
Loctite too and the lower bolt is still kept
loose without Loctite.

Attach the rear canopy holder D618 with
a lense screw M3x8 024 on the upper
right frame D602 as shown. Now the gyro
platform D621 will be mounted using four
countersunk screws M3x6 974 and Loctite.
Put the vertical frame stiffener D623 into
the slot of the right frame and check for
clearness, eventually le the edges a bit.
Check the same on the slot of the upper
rear frame D601.
View of the mounted mechanic.
Attach the second rear canopy holder
D618 on the upper left frame D601 with a
lense screw M3x8 024 using Loctite.

Now place the upper right frame D601
on the unit and check all holes for correct
corresponding.
Add four hex bolts M3x6 D196 on the tail-
boom clamps with Loctite but still do not
tighten them.
Attach the upper front frame connector
using two hex bolts M3x6 D196 and Loc-
tite. Keep it still loose. Connect the frame
with the upper mainshaft bearing block
D607 using two hex bolts M3x6 D196
without Loctite and keep it also still loose.
Use no Loctite here because the upper
mainshaft bearing block will be loosed la-
ter again for mounting the elevator servo.
Add the cover plate D603 and check for
corresponding holes.

Mount the cover plate with the frame con-
nectors D622 using four hex bolts M3x8
D197 using Loctite and keep them still
loose.
Connect the cover plate with the rst stage
bearings blocks D612 and D613 using four
hex bolts M3x6 D196 and Loctite. Keep
them still loose.
Connect the cover plate with the lower
mainshaft bearing block D608 using two
hex bolts M3x6 D196 and Loctite. Keep
them still loose.
Now press the complete frame on a at
surface and tighten all screws on both
frame sides (except the two lower right tail
boom clamp screws).+---+

Bag 5: Lower frame
Parts overview
Attach the lower left side frame D624 on
the mechanics with ve delrin connector
rolls D626 and ve hex bolts M3x10 D328.
Start with the front connector. To avoid
turning of it during screwing use the moun-
ting wire D115.
Then add a hex bolt M3x8 D197 at the
rear end and tighten it with a lock nut M3
008s.
Check the gear mesh again and if neces-
sarry follow the procedure of the assembly
of bag 2. The mechanic should now stay
on the ground without any tilting. If not,
loose srews again and retighten them.

For the shown point use again a hex bolt
M3x8 D197 and a lock nut M3 008s ...
... and also this shown point will be con-
nected with a hex bolt M3x8 D197 and a
lock nut M3 008s. Attach the delrin con-
nectors D626 after that to make the tighte-
ning of the screws easy.
Add the remaining four delrin connectors
D626 with four hex bolts M3x10 D328. It
is recommended to tighten the connectors
at this point only as far as they can be still
turned a little bit. So the later mount of
controller and battery plate will be easier.
Attach the lower right frame D625 and
check all holes for corresponding.

Add at the rear end (as on the left side
too) a hex bolt M3x8 D197 and a lock nut
M3 008s and tighten it.
Add ve hex bolts M3x10 D328 to the con-
nectors D626 and keep them in position
with the mounting wire D115.
Attach the left canopy holder D619 with a
lense screw M3x10 989. Use no Loctite
here.
Tighten the holder with a 2mm allen key
and the mounting wire D115.