minicopter Maxi-Joker 2 Installation and user guide

manual
Ord.-No.: 2600
Dipl.Ing. Gerd Guzicki
Rheinstahlring 47
34246 Vellmar
Fon: [phone] Fax: [phone]
www.minicopter.de / [email protected] Date: july 4th 2007
Version 3

minicopter
Rheinstahlring 47
34246 Vellmar
Fon.: [phone]
Fax.: [phone]
e-mail: i[email protected]
www.minicopter.de
Congratulations on the purchase of your Maxi-Joker 2 -helicopter.
The successor of our popular Joker-series has got some new features to increase its
span of usage. From beginners training over usage in scale bodies, as photo
helicopter to 3D extrem flight is everything possible without modifications.
New items are a toothed belt in the first gear reduction, a better servo linkage to the
swash plate, a simpler and more efficient construction and a better protection of the
flight battery. Our classic MFS rotorhead is standard like before and also the quality
of all parts and the long life expectancy of the model. So flying and servicing will give
you a great deal of fun for a long time.
The manual contains many detailed graphics so that you should have no problems
when building the helicopter. Please take a little time to study the manual before
beginning. Then you get an overview of the building process.
The kit contains some hexagon wrenches. Additionally you need the following tools:
Tools:
Thin walled socket wrenches to fit 5,5 and 7 mm nuts.
Open wrench 4,5/5,5 mm
Hexagon wrenches for 2/2,5/3 mm bolts
Hexagon wrench 4 mm a.f. (2 required for the feathering spindle)
Sharp tongs with 45° cranked head
Phillips screwdriver small
Screwdriver flat
Screw lock Loctite 243 blue
Special Tools:
Special open wrench 5,5mm for restricted access to the nuts Ord.-No. 707
Ball joint tongs e.g. Robbe S 1360
Pitch gauge e.g. Robbe S1366
Paddle gauge e.g. Robbe S1368
Lubricants:
Axial bearings: normal machine lubricant (from tool suppliers)
Autorotation coupling: grease or synthetic motor oil
The gear wheels and the belt drives don’t use lubricant.
Recommended RC-equpiment:
Receiver: Dual conversion PCM-system
RC-battery: 4 cells Sanyo KR 1700AU or cells with similar capacity
Swash-plate servos: Futaba S9252, S9206, S9202 or similar
Gyro: Futaba GY 401 with servo S9253/4 or GY 601 with servo S9251
If you have problems when building your model please contact us. We will help you!
And now: Much fun by building your Maxi-Joker 2 !

Safety rules:
Radio controlled helicopters are no toys. A wrong use of such models can cause
accidents with heavy injuries.
Therefore please bear following rules in your mind:
-For engine running tests on your workbench remove the complete mainrotor
including all rods and the tailrotor blades. Consider that nothing can come in
the tailrotor.
-You can´t assess by an electric helicopter the danger of a suddenly starting
engine. So remove the dangerous areas of main-and tailrotor after
connecting the battery packs.
-Don´t switch the controller suddenly off and on by running up. Wait some
seconds if retrying.
-In hovering flight please keep a distance of at least 5 metres to the
helicopter.
-Don´t aim in flight persons or other creatures and keep a security distance
of at least 20 metres.
-Don´t fly your battery in forward flight empty, if you can´t autorotate in all
situations. For landing calculate a security reserve of at least 30 seconds or
better one minute. Empty the battery while hovering. For safety rules for
Lipo batteries please follow the rules added to the packs.
-If using Lipos add the Lipo battery just before the flight and remove it just
after the flight to contain the battery always in a special metal case.
-Don´t empty the battery with the last force in hovering, otherwise the
battery can be damaged.
-For the first flight a partner should say you the flown time in intervals of 30
seconds so that you get a feeling for electric flight. After some time you feel
an empty battery by giving full pitch for a moment. When the rotorspeed
shuts down then you should search the ground for landing.
-Train autorotations with running engine as soon as possible.
-When you see that a crash is unavoidable try to stop the engine before
having ground contact.
Liability exclusion:
We can´t observe a correct mounting, justation, maintanence and usage.
So no guarantee is possible.
Vellmar, in september 2004


1
741
745
(4x)
(2x)
(2x)
187.5
55
94
(4x)
8
(4x)
26(4x)
(bore Ø1.8mm) L
= use Loctite
L
742
manual


2a
731
(8x) 740(2x)
(8x)
729
730
(2x) 8
14
(2x)24
L
14 = hexagon socket screw M3 x 8
8 = lock nut M3 = use Loctite
L
manual


2b
771
8
(4x)
(2x)
772(2x)
732(2x)
471
(2x)
471 = hexagon flat head screw M3 x 16
8 = lock nut M3
771 = hexagon flat head screw M3 x 25 = use Loctite
L
manual


3
14
(14x)
(16x)8
275
123
753
122
16(2x)
manual
= use Loctite
L
Tighten pos. 16 later!
16 = hexagon socket screw M3 x 12
14 = hexagon socket screw M3 x 8
8 = lock nut M3


4
442
421
(4x)15
15 = hexagon socket screw M3 x 10 = use Loctite
L
manual
Do not tighten Part.-No. 15 yet!


5
216
738
69
423
747
751
748
752
488
72
746
446
manual


6
425
409
8
16 = Inbusschraube M3 x 12
4 = U-Scheibe M3 groß
8 = Stopmutter M3
(4x)
(5x)
72
757
470
16
89
4(4x)
72 = Flanschkugellager 10x19x7
414
Erst Welle in Getriebe-
block einfügen!
105
15 = Inbusschraube M3 x 10
Bauanleitung
103
101
(feststehend) 18.0x10.2
(drehend) 17.8x10.0
Vertiefung nach unten!


7a
19
76
448
429
428
63
51
18
449
430
411
427
385
469
8(2x)
(2x)
(4x)
(5x)
L
L
51
469 = hexagon socket screw M2.5 x 12
76 = joint bolt M3 x 4
63 = ball bearing with flange F3 x 8 x 4
18 = hexagon socket screw M3 x 20
41 = ball joint 2.5
8 = lock nut M3
19 = hexagon socket screw M3 x 25
51 = shim 3 x 6 x 1
= use Loctite
L
manual


7b
412
18
17
63
430
51
76
449
8
(2x)
(2x)
462
716
472 L
L
14(2x) L
475
(6x)
778
(3x)
Bearing carrier should be tightened up after the belt is
fitted! Use shims 3x6x0.1 for the right distance to the belt!
Distance between bearing and belt about 0.2-0.3mm!
Bearing may NOT run with the belt during normal usage!!
51 = shim 3 x 6 x 1
17 = hexagon socket screw M3 x 16
8 = lock nut M3
18 = hexagon socket screw M3 x 20
14 = hexagon socket screw M3 x 8
63 = ball bearing F3 x 8 x 4
76 = joint bolt M3 x 4
manual
= use Loctite
L


8a
726
796
797
754(2x)
(2x)
35
14
(4x)
16
(4x)
18
(2x)
(4x)8
2
(4x)
1616 actro 24-5 heli
764 14Z i=11,6:1
765 15Z i=10,8:1
L
L
L
16 = hexagon socket screw M3 x 12
14 = hexagon socket screw M3 x 8
18 = hexagon socket screw M3 x 20
35 = grub screw M4 x 5
2 = washer M3
8 = Lock nut M3
manual
= use Loctite
L
1618 actro 32-4 heli


8b
16
(4x)
760
L(4x)
L(2x)18
726
798
1620 HP 370/40/A2S
796
L
(2x)
(2x)
35
754
768 18Z i= 9,0:1
2
8
(4x)
(4x)
35 = grub screw M4 x 5
18 = hexagon socket screw M3 x 20
16 = hexagon socket screw M3 x 12
14 = hexagon socket screw M3 x 8
8 = Lock nut M3
2 = washer M3
= use Loctite
L
760 = hexagon lense screw M4 x 8
manual


9
489
426
(2x)
21(15x)
8(16x)
(2x)
499
467
709
419
709 = hexagon socket screw M3 x 45
21 = hexagon socket screw M3 x 35
8 = lock nut M3
manual
Mainshaft may not have any endplay!
Justate with collar ring!
No screw in this hole!
in bag 8!


8(4x)
10
(2x)
132
(2x)
15
(2x)
457
(2x)454
490
279
L
nacharbeiten.
749
26
(2x)
8 = lock nut M3
15 = hexagon socket screw M3 x 10
26 = hexagon flat head screw M3 x 10
manual
= use Loctite
L
file fillet rectangular!
After mounting of upper and lower frame
remove screws from bearing plate 421 and
check concentricity of holes in lower frame to
threads holes in bearing plate, eventually file
holes in frame a little bit.


41
(4x) 11a
8
(4x)
(2x)
7
(2x)
756
156
(2x)
(4x)
16
2(4x)
ca.77.5
41 = ball joint 2.5
2 = washer M3
7 = lock nut M2
16 = hexagon socket screw M3 x 12
8 = lock nut M3
manual
46 mm long


(2x)17
11b
8(4x)
2(4x)
7(2x)
(2x)
756
41(4x)
(2x)524
ca 58.5
(2x)
494
8 = lock nut M3
16 = hexagon socket screw M3 x 12
7 = lock nut M2
2 = washer M3
41 = ball joint 2.5
494 = hexagon lense screw M3 x 16
manual
26 mm long


(2x)17
11c
8(4x)
2(4x)
7(2x)
(2x)
756
41(4x)
(2x)524
ca. 57
494(2x)
712
(4x)
manual
494 = hexagon lense screw M3 x 16
41 = ball joint 2.5
2 = washer M3
7 = lock nut M2
16 = hexagon socket screw M3 x 12
8 = lock nut M3
26 mm long


12a
2 1
:1 1 :
355
(2x)
1210
L86
356
L
359
76
(3x)
77
480(2x) L
= use Loctite
L
77 = joint bolt M 3 x 6
76 = joint bolt M 3 x 4
78 = joint bolt M 3 x 9
120°-mode (recommended) 140°-mode
51 = washer 3 x 6 x 1
Screw the jount balls 480
with care!
manual