minicopter mini-Joker User manual

Dipl.Ing. Gerd Guzicki
Rheinstahlring 47
34246 Vellmar/Germany
www.minicopter.de / [email protected]
Fon: [phone] Fax: [phone] Version 5
Date: july 12th 2007
manual
Ord.-No. 4000

minicopter
Rheinstahlring 47
34246 Vellmar
Fon.: [phone]
Fax.: [phone]
e-mail: i[email protected]
www.minicopter.de
Congratulations on the purchase of your mini-Joker -helicopter.
The small brother of our popular Joker-series has got some new features to increase
its range of use. From beginners training to use in scale bodies, as a photo helicopter
to extreme 3D flight; all of them are achieved without modifications.
New items include a completely new designe of mainframe, which gives better
protection for the Lipobattery and offers a greater range of possible battery
dimensions, a new tail rotor with single-piece CNC housing and double sided slider-
linkage and last but not least a completely redesigned MFS-rotorhead. As always you
can excpect an excellent quality of all parts and a 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 to 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 mm
Hexagon wrenches for 2/2.5/3 mm bolts
Hexagon wrench 4 mm a.f. (2 recommended for the feathering spindle)
Thin nosed pliers with 45° cranked head
Phillips screwdriver small
Screw lock Loctite 243 blue
Special Tools:
Special open wrench 5,5mm for restricted access to the nuts part-no. 707
Ball joint pliers 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
Swash-plate servos: Futaba S9202, S9252, S9255 or similar
Gyro: Futaba GY 401 with servo S9254
If you have problems when building your model please contact us. We will help you!
And now: Much fun by building your mini-Joker !

Safety rules:
Radio controlled helicopters are not toys. Incorrect use of such models can cause
accidents with serious injuries. Therefore please bear the following rules in mind:
-Before performing an engine test run on your workbench, remove the
complete mainrotor-head including all rods and the tail-rotor blades. Make
certain that nothing can come into contact with the tail-rotor.
-As soon as the battery packs are connected, in an electric helicopter, there
is the possible danger of sudden unexpected start so please make sure that
the areas around the main and tail rotors are kept free of any obstructions.
-Don´t switch the controller off and on rapidly when spooling up. Wait a few
seconds before retrying.
-In hovering flight please keep at least 5 metres from the helicopter.
-When other people or animals are in the vicinity please keep the helicopter
at least 20 metres away from them.
-Don´t engage in forward flight when your battery is nearly empty unless you
can auto-rotate in any circumstances. 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 on the
packs.
-If using Lipos fit the Lipo battery just before the flight and remove it just
after the flight and then always keep the battery packs in a special metal
case.
-Don´t empty the battery completely when hovering, otherwise the battery
can be damaged.
-For the first flight get a partner to inform you of the flight time at 30 second
intervals so that you get a feeling for electric flight. With some experience
you can sense an empty battery by giving full pitch for a moment if the rotor
speed collapses then you should find a landing spot immediately.
-Practise auto-rotations with running engine as soon as possible.
-When you see that a crash is unavoidable try to stop the engine before
hitting the ground.
Liability exclusion:
As we have no control over your assembly, adjustments or use we cannot accept
any liability nor give any guarantees.
Vellmar, June 2006


1
843
902
(4x)
(2x)
182
15
94
(4x)
8
(4x)
26(4x)
L742
= use Loctite
L
manual
(bore Ø1.8mm)
(pair)


2a
26(2x)
(4x)
14
994
934
(6x)
L
(2x)
25
(2x)
15
8(4x)
972
(2x)
26 = hex countersunk screw M3 x 10
15 = hex screw M3 x 10
manual
= use Loctite
L
14 = hex screw M3 x 8
8 = lock nut M3
25 = hex countersunk screw M3 x 8


(4x)
2b
8
26(4x)
8 = lock nut M3
26 = hex countersunk screw M3 x 8
manual
Fix the nuts first after Step 10!


8
3
18
914(2x)
912
913
924
911
position of locknut M3:
wrong! correct!
8 = lock nut M3
18 = hex screw M3 x20
manual
Attention: Part 913 is WITH threads!


910
4
975(4x)
(4x)
908
975 = countersunk screw M3 x 4
manual

27 = washer 14x20x0.2
59 = snap ring 14

59
5
27
840
246
manual


14(4x)
6a
4(4x)
907
L
14 = hex screw M3 x 8
4 = washer M3 large
manual
= use Loctite
L
Chamfer downsides!


921(2x)
6b
442(2x)
944
920
33
8
88
19
(2x)
33
8 = locknut M3
33 = washer 10 x 16 x 0,2
19 = hex screw M3 x 25
88 = hex screw M3 x 23 special = use Loctite
L
manual


6c
18(4x) L
4(4x)
(4x)
975
907
(4 (4x) + 18 (4x) + 975 (4x))
Conversion set: Ord.-No.: 842
Optional: Stationairy tailrotor during AR
Tip: Insert mainshaft temporarilly to ensure concentric mounting
18 = hex screw M3 x 20
4 = washer M3 large
manual
= use Loctite
L


921(2x)
6d
442(2x)
35
918
920
33
8
88
L
919
(2x)
(2x)
88 = hex screw M3 x 23 special
35 = grub screw M4 x 5
33 = shim 10 x 16 x 0.2
8 = lock nut M3
manual
= use Loctite
L
(4 (4x) + 18 (4x) + 975 (4x))
Conversion kit: Ord.-No.: 842
Optional: Stationairy tailrotor during AR


17
(3x)
7a
51
925
926
64
14
(2x)
(2x)
L
L
996
(4x)16(4x)2
(4x)8
756 7
16 = hex screw M3 x 12
8 = lock nut M3
7 = lock nut M2
2 = washer M3
14 = hex screw M3 x 8
17 = hex screw M3 x 16
51 = shim 3 x 6 x 1
manual
= use Loctite
L


(2x)
7b
17
L
51
64
925
926
2
8
756
(2x)
14 L
997
7
(3x) (4x)
(4x)
16(4x)
51 = shim 3 x 6 x 1
17 = hex screw M3 x 16
14 = hex screw M3 x 8
2 = washer M3
7 = lock nut M2
8 = lock nut M3
16 = hex screw M3 x 12
manual
= use Loctite
L


915
14
8a
2(4x)
968
35(2x)
964
25
(4x)
actro 24-3
LL
903
L
(4x)
L
(4x)
14
actro 24-4
manual
= do not use Loctite
= use Loctite
L
L
14 = hex screw M3 x 8
25 = hex countersunk screw M3 x 8
35 = grub screw M4 x 5
2 = washer M3
16 teeth = 966 (optional) 1 : 9.48
15 teeth = 965 (optional) 1 : 10.11
14 teeth = 964 (kit cont.) 1 : 10.83
13 teeth = 993 (optional) 1 : 11.67
12 teeth = 992 (optional) 1 : 12.64


915
14
8b
2(4x)
968
35(2x)
964
975
(2x)
orbit 30-12
LL
903
L
(4x)
L
(4x)
14
orbit 30-10
orbit 25-12
orbit 25-10
0.5mm tief
2 = washer M3
35 = grub screw M4 x 5
975 = hex countersunk screw M3 x 6
14 = hex screw M3 x 8
manual
= use Loctite
L
12 teeth = 992 (optional) 1 : 12.64
13 teeth = 993 (optional) 1 : 11.67
14 teeth = 964 (kit cont.) 1 : 10.83
15 teeth = 965 (optional) 1 : 10.11
16 teeth = 966 (optional) 1 : 9.48
Important: Plane on hardened shaft is necessary!
For grinding this plane use Dremel and small grinding shim.
Grind careful, plane should be really flat!


915
14
8c
2(4x)
968
35(2x)
964
975
(2x)
Tango 45-08
LL
903
L
(4x)
L
(4x)
14
0.5 mm deep
Grind careful, plane should be really flat!
For grinding this plane use Dremel and small grinding shim.
Important: Plane on hardened shaft is necessary!
12 teeth = 992 (optional) 1 : 12.64
13 teeth = 993 (optional) 1 : 11.67
14 teeth = 964 (kit cont.) 1 : 10.83
15 teeth = 965 (optional) 1 : 10.11
16 teeth = 966 (optional) 1 : 9.48
2 = washer M3
14 = hex screw M3 x 8
35 = grub screw M4 x 5
975 = hex countersunk screw M3 x 6
manual
= use Loctite
L


943
9
923
970
928
953
984
14
709
(3x)
(28x)
(2x)
(3x)8
986(2x)
922
8 = lock nut M3
14 = hex screw M3 x 8
709 = hex screw M3 x 45
correct before mounting the frames.
Make sure that both belts are placed
Threads
manual


10a
995
(8x)
25 L
25 = hex countersunk screw M3 x 8 = do not use Loctite
L
manual