minicopter Maxi-Joker User manual

Version 3
Date: 16.09.03
Ord.-No. 2100
Manual
www.minicopter.de
Fax:[phone]
34246 Vellmar
Rheinstahlring 47
Dipl.Ing. Gerd Guzicki
Fon:[phone]

minicopter
Dipl.Ing. Gerd Guzicki
Rheinstahlring 47
34246 Vellmar
Fon.: [phone]
Fax.: [phone]
e-mail: i[email protected]
www.minicopter.de
Congratulations for the purchase of your Joker -helicopter.
With this model you have a long-life product in your hands, which is maufactured to
the highest quality standards. 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 bulding 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. Additionaly you need the following tools:
Tools:
socket wreches with grip for nuts 5,5 and 7 mm with a thin outer diameter.
open wrench 4,5/5,5 mm
hexagon wrenches with axial grip 2/2,5/3 mm
hexagon wrench with cross grip 4 mm (2 parts for feathering spindle)
sharp tongs with 45° cranked head
Phillips screwdriver small
screwdriver flat
screw lock (for example Loctite 243 blue)
Special Tools:
ball joint tongs f.e.Robbe S 1360
pitch gauge f.e. Robbe S1366
paddle gauge f.e. Robbe S1368
Lubricants:
axial bearings: normal machine lubricant (from toolmarket)
autorotation coupling: synthetic motor oil
The gear wheels don´t use lubricant.
Recommended RC-equpiment:
receiver: PCM-system with 10bit and double superhet
RC-batttery: 4 cells Sanyo KR 1400AE
swash-plate servos:Futaba S9202 or better
gyro: Futaba GY 401 with servo S9253
interference elimination filter between receiver and controller
If you have problems when building your model please e-mail us. We help you!
And now: Much fun by building your Joker !

Safety rules:
Radio controlled helicopters are not toys. The wrong use of such models can cause
accidents with serious injuries.
Therefore please bear the following rules in mind:
-For engine running tests on your workbench remove the complete mainrotor
including all rods and the tailrotor blades. Make sure that nothing can come
in contact with the tailrotor assembly.
-With an electric helicopter there is a danger of sudden engine starts. So
remove the main-and tailrotor before connecting the battery packs.
-Don´t switch the controller off and on suddenly when running up. Wait some
seconds if retrying.
-In hovering flight please keep a distance of at least 5 metres from the
helicopter.
-When flighing DON’T aim at persons or other creatures and keep a safe
distance of at least 20 metres.
-Don´t fly in forward flight if your battery is nearly empty, if you can´t
autorotate in all situations. For landing calculate a safety reserve of at least
30 seconds or better one minute. Empty the battery while hovering.
-Don´t empty the battery absolutely completely in hovering, otherwise the
battery can be damaged.
-For the first flight a partner should tell you the flight 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.
-Practice autorotations with running engine as soon as possible.
-When you see that a crash is unavoidable try to stop the engine before
ground contact.
Liability exclusion:
We can´t check for correct building, adjustment, maintanence and usage.
So no guarantee is possible.
Vellmar, in november 2001


1
351
352
353
17
= Use Loctite
L
L
(4x)
(4x)
(2x)
(2x)
manual


2
303
129
14
49
8
(2x)
(2x)
(8x)
(4x) 28(2x)
354(2x)
28 = hexagon flat head screw M3 x 12
14 = hexagon socket screw M3 x 8
8 = nut with lock ring M3
49 = hexagon flat head screw M3 x 20
manual


3
328
8(7x)
122
123
255
275
(6x)14
15
16
16 = hexagon socket screw M3 x 12
15 = hexagon socket screw M3 x 10
14 = hexagon socket screw M3 x 8
8 = nut with lock ring M3
manual


4
15
8(11x)
303
14(10x)
328
16
16 = hexagon socket screw M3 x 12
14 = hexagon socket screw M3 x 8
8 = nut with lock ring M3
15 = hexagon socket screw M3 x 10
manual


4a
gyro
Tip: mount gyro in such position that you can use switches and potentiometers
manual


5
246
104
87
207
59
(2x)
1400
Lubricate the clutch only with synthetic motor oil, never with grease!
(open snap ring No.59 with pliers)
for other rotation sense turn bush No.246
manual


6
16
193
4
8
16 = hexagon socket screw M3 x 12
4 = washer M3 large
8 = nut with lock ring M3
(4x)
(4x)
(4x)
manual


7
268
72
249
250
262
37
8
88
35
(2x)
L263
bearing to eliminate end play!
Eventually use shims under upper
88 = hexagon socket screw M3 x 23 special
35 = headless screw M4 x 5
72 = ball bearing with flange 10 x 19
8 = nut with lock ring M3
37 = straight pin 2 x 8 hardened
= use Loctite
L
only after damage
separate hub and gearwheel
(concentricity)
manual


8
371
20Z
102
259
72 69
70
70
69
36
370 20Z
20Z
35 398
16
(3x)
(2x)
L
45(2x)
243
actro 32-4
13 L
1630
300
14 L
L
manual
35 = headless screw M4 x 5
16 = hexagon socket screw M3 x 12
36 = straight pin 2 x 16
69 = ball bearing w flange 5 x 16
70 = ball bearing w flange 6 x 15
72 = ball bearing w flange 10 x 19
= no Loctite
= use Loctite
L
L
shims if necessary 6x12x0,1
(no end play)
(2x)(2x)
14 = hexagon socket screw M3 x 8


8a
371
20Z
102
259
72 69
70
70
69
36
370 20Z
20Z
35 398
18
(3x)
(2x)
L
45(2x)
243
actro 24-5
13 L
1630
300
14 L
L
manual
72 = ball bearing w flange 10 x 19
70 = ball bearing w flange 6 x 15
69 = ball bearing w flange 5 x 16
= use Loctite
= no Loctite
L
L
14 = hexagon socket screw M3 x 8
36 = straight pin 2 x 16
16 = hexagon socket screw M3 x 12
35 = headless screw M4 x 5
shims if necessary 6x12x0,1
(no end play)


9
358
264
38
260
69
40
22
(2x)
(2x)
44
44 = shim 5 x 10 x 0.1
22 = headless screw M3 x 3
39 = rolled pin 2 x 14
40 = collar 5
69 = ball bearing with flange 5 x 16
alternativly
in autorotation (recommended)
tail rotor running
Atail rotor stationary
in autorotationB
manual

10
16
301
41
156
8
2
75
7
269
(8x)
(8x)
(8x)
(2x)
align rod vertical
2 = washer M2
7 = nut with lock ring M2
75 = joint bolt M2 x 6
41 = ball joint 2,5
8 = nut with lock ring M3
16 = hexagon socket screw M3 x 12

direction
view in flight
if necessary use
washers 2mm
to align rod vertical
manual

11
327
302
261
132
20
8
(2x)
(13x)
(13x)
329(2x)
294
198
286
8 = nut with lock ring M3
20 = hexagon socket screw M3 x 30
manual



78 = joint bolt M 3 x 9 = use Loctite
L
76 = joint bolt M 3 x 4
77 = joint bolt M 3 x 6
120°-mode
(preset) 140°-mode
2 1
:1 1
:
355
(2x)
1210
L86
356
L
359
76
(3x)
77
78(7x) L
12
manual

13
132
2
8
19
42
156
41
74
7
(2x)
(4x)
(4x)
(2x)
(2x)
(2x)
(2x)
(4x)
142(2x)
141
(2x)

74 = joint bolt M2 x 4
2 = washer M3
7 = nut with lock ring M2
8 = nut with lock ring M3
19 = hexagon socket screw M3 x 25
42 = pin 3 x 8
41 = ball joint 2,5
manual

14
279
198
132
8
326
325
(2x)
(6x)
(4x)

198 = distance bush 22,0
326 = distance bush 15,0
325 = distance bush 17,0
8 = nut with lock ring M3
manual

15
237
14
8
391
361
316
Epoxy
(2x)
(4x)
(4x)
(2x)
399
21

389
94
94
1mm
389 399
bore Ø 1.8!
10
Mit Epoxy füllen
Glue lthe full contact surfaces with Epoxy!
carefully! Remove oil and grease from bush!
Sand CfC-tube on the inner side
Tip: Pull belt thru tube with a cranked steel wire!
2 = washer M3
8 = nut with lock ring M3
14 = hexagon socket screw M3 x 8
21 = hexagon socket screw M3 x 35
manual
Use slow hardening Epoxy!