SAB Heli Division Goblin 630 COMPETITION User manual

Goblin 630 Competition Manual
Release 1.0 - Octorber 2013
SAB HELI DIVISION S.R.L.
Via San Crispino, 47
47030 San Mauro Pascoli (FC) - ITALY

7 – Assembling The Modules
8 – Installation of Swashplate Servos
9 – Installation of The ESC
10 – Installation of Flybarless Unit and RX
11 – Installation of The Motor
12 – Tail Assembly
1 – Serial Number
2 – Important Notes
3 – Components and Box
4 – Carbon frame Assembly
5 – Trasmission Assembly
6 – Main rotor
INDEX
13 – Installation of the Boom, Canopy
14 – Battery
15 – In flight
16 – Maintenance
17 – Exploded Views
18 – Spare Parts
//www.goblin-helicopter.com
http:
1428mm
1290mm
380mm
224mm
Main rotor diameter: 1428mm (with 630mm blades)
Main blade length: 600 to 630mm
Tail rotor diameter: 285mm
Tail blade length: 105mm
Main shaft diameter: 12mm
Tail shaft diameter: 6mm
Spindle diameter: 10mm
Weight including standard electronics: 3220g (excluding batteries).
Motor size: Maximum 64mm diameter, maximum height 64mm
Battery compartment: 60x58x350mm (adaptable to 64x58x350mm)
SPECIFICATIONS
It is extremely important that you take a moment to register your helicopter with us. This is the only way to ensure that you are
properly informed about changes to your kit, such as upgrades, retrofits and other important developments. SAB Heli Division cannot
be held responsible for issues arising with your model and will not provide support unless you register your serial number.
To mount the serial number tag on your helicopter, please refer to page 32.
Thank you for your purchase, we hope you enjoy your new Goblin helicopter!
SAB Heli Division
VERY IMPORTANT
Inside Box 5, you will find Bag 21. This bag contains your serial number tag. Please take a moment to register your kit online via
our web site at:
The Goblin Competition is the result of all the feedback and experienced gained with the original Goblin.
All the changes incorporated into the Goblin Competition create a model even more reliable and efficient than ever before.
New colors, new composite materials and many upgrades are included in this kit making it the best Goblin ever.
Please read this user manual carefully, it contains instructions for the correct assembly of the model.
Please refer to the web site www.goblin-helicopter.com for updates and other important information.
Copyright@2013 - SAB Heli Division - All rights reserved
Page 1
Chapter 1, Serial Number

Use grease
(eg Tri-Flow
Synthetic Grease)
IMPORTANT NOTES
*This radio controlled helicopter is not a toy.
*This radio controlled helicopter can be very dangerous.
*This radio controlled helicopter is a technically complex device which has to be built and handled very carefully.
*This radio controlled helicopter must be built following these instructions. This manual provides the necessary information
to correctly assemble the model. It is necessary to carefully follow all the instructions.
*Inexperienced pilots must be monitored by expert pilots.
*All operators must wear safety glasses and take appropriate safety precautions.
*A radio controlled helicopter must only be used in open spaces without obstacles, and far enough from people to minimize
the possibility of accidents or of injury to property or persons.
*A radio controlled helicopter can behave in an unexpected manner, causing loss of control of the model, making it very
dangerous.
*Lack of care with assembly or maintenance can result in an unreliable and dangerous model.
* Neither SAB Heli Division nor its agents have any control over the assembly, maintenance and use of this product.
Therefore, no responsibility can be traced back to the manufacturer. You hereby agree to release SAB Heli Division from
any responsibility or liability arising from the use of this product.
SAFETY GUIDELINES
*Fly only in areas dedicated to the use of model helicopters.
*Follow all control procedures for the radio frequency system.
*It is necessary that you know your radio system well. Check all functions of the transmitter before every flight.
*The blades of the model rotate at a very high speed; be aware of the danger they pose and the damage they may cause.
*Never fly in the vicinity of other people.
Indicates that for this
assembly phase you need
materials that are in
box xx, bag xx, tray xx.
NOTES FOR ASSEMBLY
P
lease refer to this manual for assembly instructions for this model.
Follow the order of assembly indicated. The instructions are divided into chapters, which are structured in a way that
each step is based on the work done in the previous step. Changing the order of assembly may result in additional or
unnecessary steps.
Use thread lockers and retaining compounds as indicated. In general, each bolt or screw that engages with a metal part
requires thread lock.
It is necessary to pay attention to the symbols listed below:
Important
Use CA Glue
Use retaining
compound
(eg Loctite 648)
Use retaining
compound
(eg Loctite 243)
Use grease
(eg Vaseline Grease)
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Page 2
Chapter 2, Important Notes

ADDITIONAL COMPONENTS REQUIRED
*Electric Motor: 10 - 12S – 480/650Kv
Maximum diameter 64mm,
Maximum height 64mm,
Pinion shaft diameter 6mm
*Speed controller: minimum 100A to be safe.
*Batteries: 10 - 12S - 3700/4500mAh
*1 flybarless 3 axis control unit
*Radio power system, if not integrated with the ESC
*3 cyclic servos
*1 tail rotor servo
*6 channel radio control system on 2.4 GHz
(See configuration examples on page 21)
The assembly process is described in the following chapters.
Each chapter provides you with the box, bag and/or foam
tray numbers you will need for that chapter. The information
is printed in a red box in the upper right hand corner of the
page at the beginning of every chapter.
TOOLS, LUBRICANTS, ADHESIVES
*Generic pliers
*Hexagonal driver, size 1.5,2,2.5,3,4mm
*4mm T-Wrench
*5.5mm Socket wrench (for M3 nuts)
*8mm Hex fork wrench (for M5 nuts)
*Medium threadlocker (eg. Loctite 243)
*Strong retaining compound (eg. Loctite 648)
*Spray lubricant (eg. Try-Flow Oil)
*Synthetic grease (eg. Tri-Flow Synthetic Grease)
*Grease ( eg. Vaseline grease )
*Cyanoacrylate adhesive
*Pitch Gauge (for set-up)
*Soldering equipment (for motor wiring)
Inside the main box:
Box 2: Canopy, Blade Holder.
Box 3: Boom, Blades, Tail blades, Carbon rod.
Box 4: Mechanical parts in 4 trays:
Tray 1: Main rotor
Tray 2: Carbon frame and tail rotor
Tray 3: Transmission
Tray 4: Main structure
Box 5: Bags
Box 6: Carbon parts
Box 7: Carbon parts
Inside the main box there are:
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Page 3
Chapter 3, Components and Box

4-Carbon Frame
The manufacturing process of the carbon parts
often leaves micro-burrs and sharp edges. We
recommend de-burring the edges to minimize
the risks of electrical wire cuts, etc. Very
important in red line zone.
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Page 4
Chapter 4, Carbon Frame

Frame Spacer
(H0003-S)
......x6
Flat Head Cap Screw M2.5x5mm
Flat Head Cap Screw M2.5x5mm
(HC128-S)
Flat Head Cap Screw
M2.5x5mm
(HC128-S)
Flat Head Cap Screw
M2.5x5mm
(HC128-S)
Socket Head Cap Screw
M2.5x8mm
(HC020-S)
Flat Head Cap Screw M2.5x5mm
Socket Head Cap Screw M2.5x8mm
Stop Battery Plate
(H0150-S)
Flat Head Cap Screw
M2.5x5mm
(HC128-S)
Battery Support
(H0153-S)
Battery Tray
(H0002-S)
... x4
Battery Tray Assembly 1
Battery Tray Assembly 1
Battery Tray Assembly
... x2
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Page 5
Chapter 4, Carbon Frame

Flat Head Cap Screw
M2.5x5mm
(HC128-S)
Frame Spacer
(H0003-S)
Socket Head Cap
Screw M3x10mm
(HC056-S)
Finishing Washer M3
(H0007-S)
ESC Support
Assembly
Main Frame
(H0362-S)
......x4
Flat Head Cap Screw
M2.5x5mm
......x4
Socket Head Cap Screw
M3x10mm
Finishing Washer M3
......x4
Flat Head Cap Screw
M2.5x5mm
(HC128-S)
Frame Spacer
(H0003-S)
ESC Support
(H0088-S)
Finishing
Washer M3
(H0007-S)
Cable Pass
(HA010-S)
Canopy
Positioners
(H0159-S)
ESC Support
Assembly
ESC Support Assembly
Landing Gear Support
(H0005-S)
Note:
Landing Gear Support
(H0005-S)
Note:
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Page 6
Chapter 4, Carbon Frame

Socket Head Cap
Screw M3x10mm
(HC056-S)
Finishing
Washer M3
(H0007-S)
Finishing Washer M3
(H0007-S)
Battery Support
Assembly
Finishing
Washer M3
(H0007-S)
Finishing
Washer M3
(H0007-S)
Finishing
Washer M3
(H0007-S)
Socket Head Cap
Screw M3x8mm
(HC056-S)
Socket Head Cap
Screw M3x10mm
(HC056-S)
Finishing Washer M3
Socket Head Cap Screw M3x10mm
..... x3
..... x3
Finishing Washer M3
..... x7
Socket Head Cap Screw M3x10mm
Battery support position
..... x7
Top holes: Standard position.
Canopy Positioners
(H0159-S)
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Page 7
Chapter 4, Carbon Frame

Socket Head Cap Screw
M2.5x6mm
Button Head Cap Screw M4x10mm
(HC100-S)
Landing Gear Struts
(H0074-S)
Button Head Cap Screw M4x6mm
(HC096-S)
Button Head Cap Screw
M4x6mm
......
x4
Socket Head Cap Screw
M2.5x6mm
(HC018-S)
Carbon Fibel Landing Gear - Yellow
(H0106-S)
Sliding Landing Gear
(H0039-S)
Sliding Landing Gear
(H0039-S)
Landing Gear 2
Assembly
Socket Head Cap Screw
M2.5x6mm
(HC018-S)
Socket Head Cap
Screw M2.5x6mm
(HC018-S)
Socket Head Cap Screw
M2.5x6mm
(HC018-S)
Landing Gear Struts
(H0074-S)
Button Head Cap
Screw M4x10mm
(HC100-S)
Button Head Cap
Screw M4x6mm
(HC096-S)
Landing Gear 1
Assembly
Button Head Cap Screw
M4x10mm
......
x4
.....x4
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Page 8
Chapter 4, Carbon Frame

5 - Transmission Assembly
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Page 9
Chapter 5, Transmission Assembly

Bearing 10x 19x5mm
(HC422-S)
Socket Head Cap
Screw M3x10mm
(HC056-S)
......
x1
Finishing Washer M3
(H0007-S)
Bearing 10x 19x5mm
......
x1
Servo Support
(H0010-S)
Bearing 12x 24x6mm
(HC426-S)
Bearing 12x 24x6mm
(HC426-S)
Socket Head Cap Screw
M3x10mm
......
x2
......
x1
......
x3
Swash plate Anti-Rotation Guide
(H0017-S)
Button Head Cap Screw
M3x4mm
(HC038-S)
Antenna Guide
(H0050-S)
Main Structure
(H0009-S)
Bearing Support Assembly
(H0024-S)
......
x1
......
x4
Button Head Cap Screw
M3x4mm
......
x1
Flat Head Cap Screw
M2.5x5mm
(HC128-S)
Socket Head Cap Screw
M3x8mm
Socket Head Cap
Screw M3x8mm
(HC050-S)
Bearing
12x 24x6mm
......
x3
Socket Head Cap
Screw M3x10mm
(HC056-S)
Column
(H0018-S)
Bearing 10x 19x5mm
Bearing
12x 24x6mm
Socket Head Cap Screw
M3x10mm
Flat Head Cap Screw
M2.5x5mm
Bearing
10x 19x5mm
(HC422-S)
Note:
Socket Head Cap
Screw M3x10mm
(HC056-S)
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Page 10
Chapter 5, Transmission Assembly

......
x2
19T Drive Pinion
(H0156-S)
Metric Hex Nylon Nut M3
(HC206-S)
68T Main Gear
(H0012-S)
Metric Hex Nylon Nut M2.5
(HC200-S)
Front Tail Pulley Low Assembly
(H0101-S)
M4 Locking Collar
(H0121-S)
Secondary Shaft
(H0157-S)
37T Pulley
(H0172-S)
Socket Head Cap Screw
M2x8mm
......
x3
Bearing
10x 15x4mm
(HC420-S)
Check the axial play
See Note 1.
Washer
10x 16x0.2mm
(HC232-S)
One Way Bearing
10x 14x12mm
(HC442-S)
60T Pulley Assembly
(H0104-S)
Bearing
10x 15x4mm
(HC420-S)
Socket Head Cap Screw Shouldered
M2.5x19mm
(HC033-S)
Note 1:
When you tighten the collar ( H0121-S ) on
the main shaft, ensure there is no axial play. Push
down the main shaft while pulling up the locking
collar. Tighten the screw M4x22 at this time.
Note 2:
The pinion and gear are designed to have zero
backlash. This leads to initial “rough” rotation.
After some run in flights ( 3-5 flights ) it will begin
to rotate freely, ensuring perfect contact and
the ability to transmit maximum power.
It is advisable to lubricate these two elements
with a lubricant ( Tri-Flow Synthetic grease).
Use this Hole
Main Shaft
(H0122-S)
Main Structure
Assembly 1
Metric Hex Nylon Nut M2.5
Socket Head Cap Screw M4x22mm
......
x1
Socket Head Cap Screw
Shouldered M4x24mm
(HC111-S)
Socket Head Cap Screw Shouldered
M2.5x19mm
Socket Head Cap Screw Shouldered M4x24mm
......
x1
......
x2
Metric Hex
Nylon Nut M4
(HC212-S)
Metric Hex Nylon
Nut M4
(HC212-S)
Socket Head Cap Screw
M4x22mm
(HC104-S)
Socket Head Cap
Screw Shouldered
M3x18mm
(HC079-S)
60T Pulley
(H0104-1)
60T Pulley Assembly
(H0104-S)
Metric Hex Nylon Nut M4
......
x2
Socket Head Cap
Screw M2x12mm
(HC014-S)
Front Tail Pulley Assembly
(H0101-S)
Bush One Way
(H0110-S)
Note:
Put a small amount of grease
every 30/40 flights on the main
gear (for example Tri- flow
Synthetic grease)
Note 2
The perfect play is 0.5mm
add or remove shim for this
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Page 11
Chapter 5, Transmission Assembly

Spring
de 8 / df0.5 / LL8
(HC315-S)
Flanged Bearing
5x 9x3mm
(HC410-S)
Flanged Bearing
3x 7x3mm
(HC402-S)
......
x1
......
x1
Flanged Bearing 5x 9x3mm
......
x2
Flanged Bearing 3x 7x3mm
......
x2
Tail Belt Idler
Washer
3x 4x0.5mm
......
x1
Washer 3.2x 6x0.5mm
(HC180-S)
Belt Tensioner Arm
......
x1
Washer 3x 4x0.5mm
(HC176-S)
Button Head Cap Screw M3x4mm
Belt Tensioner Support
(H0070-S)
Socket Head Cap Screw M3x12mm
Socket Head Cap Screw M3x50mm
Socket Head Cap
Screw M3x12mm
(HC062-S)
Tail Belt Idler Assembly
(H0070-S)
Belt Tensioner Arm
Assembly
(H0070-S)
Washer
3.2x 6x0.5mm
(HC180-S)
Socket Head Cap
Screw M3x50mm
(HC092-S)
Main Structure
Assembly 3
Tail Belt Idler Assembly
(H0070-S)
Button Head Cap Screw
M3x4mm
(HC038-S)
Belt Tensioner Arm Assembly
(H0070-S)
Note:
Position without preload.
Insert the screw in the
hole through the
aluminum support as in the
picture.
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Page 12
Chapter 5, Transmission Assembly

Motor
Motor Support
(H0143-S)
Button Head Cap Screw M4x8mm
.....x2
Set Screw M5x20mm
(HC158-S)
Set Screw M4x4mm
.....x1
Finishing Washer
M3
(H0007-S)
.....x2
.....x2
.....x2
.....x4
Set Screw M5x20mm
Socket Head Cap
Screw M3x10mm
(HC056-S)
Socket Head Cap
Screw M3x10mm
(HC056-S)
Finishing Washer
M3
(H0007-S)
34mm
21mm
6mm
7mm
Set Screw
M4x4mm
(HC152-S)
Button Head Cap
Screw M4x8mm
(HC098-S)
21T Pulley
(H0015-21-S)
(see page 21 for optional pulley
selection)
Spring
HC314
(HC315-S)
Washer
5.3x 15x1mm
(HC188-S)
Metric Hex Nylon
Nut M5
(HC218-S)
Spring
HC310
(HC315-S)
Washer
5.3x 15x1mm
Socket Head Cap Screw M3x10mm
Finishing Washer M3
Note for 6mm motor shaft
To maximize space for the batteries, it
is advisable to shorten the motor shaft.
Follow the dimensions given in this
drawing. For the cut, you can use an
electric tool like a “Dremel” with a cut-
off disc.
Additionally, ensure the motor shaft
has an appropriate 'flat' for one of the
set screws.
Bushing
6x 8x18mm
(H0176-S)
Use with 6mm
motor shaft.
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Page 13
Chapter 5, Transmission Assembly

6 - Main Rotor
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Page 14
Chapter 6, Head

Center Hub
(H0130-S)
Main Blade Grip
(H0086-S)
Bearing
10x 19x5mm
(HC422-S)
HC232-S
Socket Head Cap Screw M3x10mm
(HC056-S)
Plastic Ball Link
(H0066-S)
Plastic Ball Link
(H0066-S)
Uniball
M3x4
5H3
(H0065-S)
Left Thread Right Thread
Note : Smaller ID
Blade Grip Arm
(H0131-S)
Uniball Radius
Arm Assembly
Linkage Rod Assembly
Damper Derlin
(H0144-S)
Damper Derlin
(H0144-S)
H0346-S
Spindle
(H0097-S)
Uniball Radius Arm... x2
Assembly
Main Blade Grip Assembly...x2
Note : Larger ID
Washer
10x 16x1mm
(HC230-S)
Oring
(HA024)
Washer 6x 14 x1.5mm
(HC194-S)
Washer
10x 16x1mm
(HC230-S)
Thrust Bearing
10x 18x5.5mm
(HC438-S)
Socket Head Cap
Screw M2.5x18mm
(HC032-S)
Socket Head Cap
Screw M3x16mm
(HC068-S)
Washer
3x4x0.5mm
(HC176-S)
Swashplate Assemly
Center Hub Assembly
Radius Arm
(H0132-S)
Uniball Radius Arm
H0205 (H0132-S)
Flanged Bearing
3x 7x3mm
(HC402-S)
Flanged Bearing
2.5x 6x2.5mm
(HC400-S)
Spacer Arm
2.5x 4x6.3mm
H0253 (H0132-S)
Spacer Arm 3x5x2.7mm
H0134 (H0132-S)
Main Blade Grip
Assembly
Bearing
10x 19x5mm
(HC422-S)
Approx. 75mm
Radius Arm ... x2
Assembly
Uniball
M3x4
5H3
(H0065-S)
Uniball
M3x4
5H18
(H0063-S)
Swashplate
Assemly
(H0023-S)
Uniball
M3x4 5H3
(H0065-S)
Linkage Rod A Assembly ...x2
Radius Arm
Assembly
The HPS head should be assembled with one, 1mm shim
(HC230) and one, 0.2mm shim (HC232) on each side. If the
blade grips are too tight, you can remove the 0.2mm shim
(HC232) from each side. After approximately 10/20 flights,
please check preload, you can add one or two 0.2mm shim
(HC232) if preload has changed.
(Initial length for the rods from the swash plate
to the Blade Grip.)
Button Head Cap Screw
M6x10mm
(HC122-S)
Oring
(HA024)
Note:
The main rotor is assembled provisionally
without loctile. Need to add Loctile 243 in the
screws M4x10 and M6x10
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Page 15
Chapter 6, Head

Flat Head Cap
Screw M3x8mm
(HC134-S)
Flat Head Cap
Screw M3x8mm
(HC134-S)
Finishing Washer
M3
(H0007-S)
Socket Head Cap Screw M4x24mm
......
x6
......
x1
......
x6
......
x2
Socket Head Cap Screw M3x12mm
Socket Head Cap Screw M3x8mm
Finishing Washer M3
Metric Hex Nylon Nut M4
Socket Head Cap Screw
M3x8mm
(HC050-S)
Socket Head Cap Screw M3x12mm
(HC062-S)
Carbon Frame
Assembly
Canopy Mount Base
(H0319-S)
Head HPS
Assembly
Central Group
Assembly
Socket Head Cap Screw
M3x8mm
(HC050-S)
Metric Hex
Nylon Nut M4
(HC212-S)
Socket Head Cap Shoudered
M4x24mm
(HC111-S)
Finishing
Washer M3
(H0007-S)
......
x1
Swashplate
Assembly
Socket Head Cap Screw M3x12mm
(HC062-S)
Canopy Mount Base
(H0319-S)
Copyright@2012 - SAB Heli Division - All rights reserved
Page 16
Chapter 7, Assembling The Modules

ASSEMBLY OF THE BALL ON THE HORN.
The rods going from the servos to the swash plate must be as vertical
as possible. Not all servos are equal, so to better align them you can
choose to use the supplied spacer H0031. Figure 4 illustrates this.
INSTALLATION OF SWASHPLATE SERVOS
The linkage ball must be positioned between 17-19 mm out on the servo arm ( figure 1 ). The 120° placement of the servos inside Goblin means
the arms are difficult to access. For this reason it is advisable to ensure alignment of the servo arms (and sub trim set) before installation of
the servos in the model ( figure 2 ). Proceed with installation following the instructions below. Figure 3 shows a completed installation.
Uniball M2 5H6
(H0064-S)
Socket Head Cap Screw M2x8mm
(HC008-S)
or
Socket Head Cap Screw M2x6mm
(HC004-S) without Uniball Spacer
..... x3
Socket Head Cap Screw
M2.5x8mm
Servo 2
SERVO ASSEMBLY 1, 2, 3
Servo 1
Uniball Spacer
(H0064-S)
Socket Head Cap
Screw M2.5x12mm
(HC026-S)
..... x9
Socket Head Cap Screw
M2.5x12mm
Socket Head Cap Screw
M3x6mm
(HC044-S)
Socket Head Cap
Screw M2.5x8mm
(HC020-S)
Servo 1
Servo 3
Servo Spacer
(H0075-S)
Servo 2
Servo 3
17-19mm
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Page 17
Chapter 8, Installation Of Swashplate Servos

Plastic ball link
(H0066-S)
Plastic ball link
(H0066-S)
Plastic ball link
(H0066-S)
40mm 66 mm
Approx 75mm
Left Thread Right Thread
Initial length for the rods from the servos to the swash plate.
Approx. 49 mm
Plastic ball link
(H0066-S)
Initial length for the rods from the swashplate to the blade grips.
Set Screw M2.5x18mm
(HC140-S)
Linkade Rod B
Aseembly
Head HPS Version Preliminary Setup
Adjust the linkage as shown. The linkage Rod A has thead right/left.
Turning, you can change the tracking without disconnecting the
plastic ball link.
If it is necessary to tighten
then horn screws,use the
included hexagonal wrench
(HA002)
The wire for the front servo must be positioned here
Linkade Rod A
Aseembly
Approx Approx
Linkage Rod B Assembly ... x3
Linkage Rod A Assembly ... x2
(H0346-S)
Tool HA002
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Page 18
Chapter 8, Installation Of Swashplate Servos