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Henseleit Helicopters Three-Dee-Fun TDR-II User Manual Download Page 15

15 

 

Chapter   

– 2 

M a i n  s h a f t  u n i t 

(Assembly group 4) 

 

S w a s h  p l a t e  

 
 

 

0400a 

Swash plate outer ring 

1 

 

 

 

 

0400b 

Radial bearing 45x55x6 

1 

 
 

0400c 

Swash plate inner ring 

1 

 
 

0400d 

Ball shell 

1 

 
 

0400e 

Ball 

1 

 
 

0400f 

Threaded ball stud M3x4 / 9mm 

2 

 
 

0400g 

Threaded ball stud M3x4 - 9mm (Special Elevator)  1 

 
 

0400h 

Threaded ball stud M3x4 / 6mm 

2 

 
 

G0304S

 

Grub screw M3x4 with tip 

3 

 
 

P2508 

Phillips screw M2,5x8 

4 

 
 

C2506

 

Countersunk head screw M2,5x6 

4 

 

 

 

 

 

 

 
 
 
The base body of the swash plate will generally be delivered finally assembled. In case of a  damage of the bearing the 
swashplate can be disassembled to all single parts. 
The proceeding of the assembly will be described in the following chapter. So in case of an exchange of the bearing you 
understand the proceeding and what to take care about. 

 

 

 

Summary of Contents for Three-Dee-Fun TDR-II

Page 1: ...Three Dee Fun M A N U A L Version 30 09 2017 Jan Henseleit C A U T I O N I M P O R T A N T Please read this manual before opening any bags ...

Page 2: ...roup 8 page 38 Motor mount Assembly Group 7 page 39 ESC plate mount Assembly Group 2 page 40 Installation of the motor unit to the chassis page 41 Quick exchange battery tray page 41 Chapter 9 Tail gear Prepatation of tail gear housing right Assembly Group 9 page 42 Mounting the deflection puller between the carbon housing Assembly Group 9 page 42 Assembly of the belt disc Assembly Group 9 page 43...

Page 3: ...thal injuries or property damage Therefore refrain from overflying pedestrians and vehicles by all means Safety is the highest commandment within the scope of your sole responsibility The particular hazards involved are explicitly mentioned here due to the fact that neither the manufacturer nor the seller of these kit products has any influence on their use and operation Henseleit Helicopter corpo...

Page 4: ...ifferent from usual constructions and follow new paths The result is the TDFun TDF is the new 700 size helicopter for all pilots which like a light weight agil 3D helicopter build up clear and simple but having all necessary features which are recommend in a high end helicopter A fun machine which impresses by its flying simplicity even without monster motor systems During development the weight w...

Page 5: ...Maximum motor PYRO 750 45 Competition for 12S Recommended ESC JIVE PRO 120 HV KOSMIK 160 HV depending on motor and flight syle recommended only for PYRO 750 motors Gear ratio main rotor to tail rotor 1 5 56 tail rotor is running during auto rotation Gear ratio motor to main rotor 9 27 1 Maximum flight pack size L x W x H 340 mm x 60 mm x 62 mm When using 6S or 7S the flight pack should be a weight...

Page 6: ...ed some modified parts Right rotation helicopters are mainly used worldwide The differences to left rotation are minimized due to the excellent flybarless systems Some parts of the helicopter are already pre assembled Nevertheless this manual contains detailed instructions for these parts These instructions may be helpful in case you have to disassemble or to change parts There is no need for you ...

Page 7: ...on is indispensable shake well before use Otherwise the threads will damage upon clamping under pressure Attention The nut 0140b with a single mark has a right hand thread The nut with two marks has a left hand thread There are no markings on the straining screw Find the matching threads by careful insertion Preferably start with nut 0140b right hand thread This will conclude the left hand turns o...

Page 8: ...n this position all O rings are relaxed The straining screw can be rotated with the 3mm pin in the tool bag through the slot on the top of the center hub 0120 The straining screw 0140a will push both thrust nuts outwards The O rings are squeezed axial and supported by the C clips 0105 of the center hub This will increase the tension onto the O ring inner busher 0109 and the damping gets harder Bot...

Page 9: ... from left and right all the way through the O rings until the stop Finally the feathering spindle 0110 is inserted and aligned roughly to the middle The shaft usually has a tight fit in the jacks Retain the averted opposite jack so that it will not be pushed out again while inserting the feathering spindle Now align the two grooves for the grub screws 0140d with their threads in the top of the ce...

Page 10: ...ork where the bore of the blade holder begins the rings are swiveled into rectangular position and pushed into the bore Make sure the rings do not swivel by 180 and carefully reassure that the grooves of the rings always point to the bearing balls This procedure can be simplified with the aid of a pin inserted from the other side onto which you may align the rings The first ring to be inserted has...

Page 11: ...dle without damaging it you would need a special shaft wrench If you do not have such a tool I recommend to remove the other blade holder with the attached feathering spindle from the center hub in order to access the second washer Avoid clamping nuts to slip away from the grub screws 0140d Do so by carefully pushing the feathering spindle out of the center hub with another 8mm shaft It will serve...

Page 12: ...d M3x4 6mm 2 0138a Blade bolt M4x30 10 9 2 0138b Spacer for rotor blade 4x20x1 4 0138c Adapter sleeve 5mm to 4mm 2 W04 Washer M4 4 NS04 Nyloc nut M4 2 NS03 Nyloc nut M3 2 M0308 Hex socket screw M3x8 2 M0312 Hex socket screw M3x12 2 M0314 Hex socket screw M3x14 2 ...

Page 13: ...t position until it fits Main rotor head is ready and can be lay beside Attention The bolts 0138 are of high grade steel fabric and may only be replaced by original spare parts Standard bolts bear the great danger of tearing The two plastic spacer 0138b are needed to fill the gap when using 12 mm blades in the 14 mm blade holder Do not use the usual Aluminum washers they will damage the blade hold...

Page 14: ...ion the ball link in line to prevent damage Attention Screw both ball links 0121b as far as it touches the spacer bush 0121a Then rotate backward until the lettering 2 5 is in 90 position to each other as shown on the picture Do not try to screw the ball links further if they are touching to the bush as the thread may be damaged and fixation is not longer guaranteed ...

Page 15: ...tor 1 0400h Threaded ball stud M3x4 6mm 2 G0304S Grub screw M3x4 with tip 3 P2508 Phillips screw M2 5x8 4 C2506 Countersunk head screw M2 5x6 4 The base body of the swash plate will generally be delivered finally assembled In case of a damage of the bearing the swashplate can be disassembled to all single parts The proceeding of the assembly will be described in the following chapter So in case of...

Page 16: ...etween inner and outer ring visible tilting you can decrease this play by stepwise tightening the three tapered grub screws Tighten all three screws at the same level This presses the outer bearing ring some hundredths mm to the inside putting a little bit pressure on the balls Attention Just tighten the grub screws so far that the bearing is still running smoothly With this method you can also co...

Page 17: ...t g e a r Assembly group 4 0416 Main shaft gear 1 0416a Carbon spoke 2 0416b Spacer 3x8x4 4 0418 Main gear flange 1 P2510 Phillips screw M2 5x10 8 N25 Nut M2 5 flat 8 M0312 Hex socket screw M3x12 4 WL03 Washer M3 large 4 ...

Page 18: ... to the ground of the 2mm step of the gear ring During cooling down the gear ring is shrinking on the carbon rip and will be fixed with screws All screws will be put from above to the holes and fixed with the M2 5 nuts from below use Loctite Now the nominal diameter of the gear is reached Even under highest loading during flight the diameter will not increase It just could increase when the temper...

Page 19: ...servos are identical and will be mounted with the thread orientated respectively to the right and the left side The blocks for the elevator servo are a little bit longer They can be distinguished from the other ones by the third hole between the holes for mounting the servos The blocks for the tail servo are much longer and therefore easily to identify Note All blocks are equipped with a larger ho...

Page 20: ...next assembly step on the inner side of the right chassis plate A i l e r o n s e r v o p r e p a r a t i o n Both aileron servos will be fixed similar to the elevator servo on the blocks 0630RS Take care of the positioning of the M3 thread holes at the front side which shall be facing to the left and the right outside These servos will be mounted later on in the inner side of the left and right c...

Page 21: ...he housing You can choose the right direction for the repositioning by checking the tendency if it getting better or worse To support the adjusting you can also compare the distances of the two teeth which are closed to the servo side wall This is easier to check with your eyes Prerequisite is a straight fitting servo gear and that you look exactly from above After finding the optimum position the...

Page 22: ...s use the long holes marked with yellow arrows A slight vertical offset doesn t matter Some of the midi servos e g MKS servos have the shaft located very close to the housing edge In this case the servo gear would be located too far upwards in the gear slot In this case use the long holes marked with the red arrows even when the servo gear is positioned 3mm below the center of the slot A lower pos...

Page 23: ...0201 View from the inner side of the chassis View from the outside of the chassis The left aileron servos will be mounted mirror inverted to the right aileron servo to the left chassis plate The tail servo will be installed according to the drawing using the horizontal aligned long holes It will be slided backwards as far as possible The M3x6 screws for the tail servos will be mounted without wash...

Page 24: ...come easier Three M3x6 lens head screws secure the bearings from sliding either upwards lower plate or downwards upper plate Attention The three M3 holes in the plates have a sunk on one side to allow the head of the screws resting on the plate in any case Take care to use the plates in the right direction and insert the security screws from this side The two fixation blocks 0206 used later on for...

Page 25: ...uring operation and will not get loose The rear higher X stiffener 0208 will be screwed at all four corners with M3x6 Allen screws directly to the upper and lower bearing plates picture left use some Loctite at this position The front shorter X stiffener 0207 will be screwed with two fitting blocks 0206 picture left below Take care to align the blocks parallel to each other Position the X stiffene...

Page 26: ...d rod The end of the thread rod should protrude about 0 5mm above the nut Secure the nut additionally with Loctite Keep in mind on which chassis side you positioned the additionally secured nuts Use a washer M3 for each nut The rear clamping flange 0833 will be positioned with two thread rods Just one thread rod will be used at the front clamping flange in the lower hole Screw a M3x8 Allen screw i...

Page 27: ...crew M3x14 2 M0306 Grub screw M3x6 4 Following the tooth racks of the two aileron servos will be mounted mirror inverted at the outer sides of the chassis see also additional views at the next page View to the left chassis side Attention Screw in the threaded ball link 0650b carefully into the tooth racks 0642 for not over torqueing the threads in the plastic material Therefore the tooth racks wil...

Page 28: ...acket 0641 in a horizontal position to allow the spring steel spindle moving in the long hole without jamming Tighten now the M3x14 screw use Loctite Hold the bracket with an even parallel collet to prevent the bracket from tilting if necessary The M3x6 grub screw will be screwed in the hole until touching the spring steel spindle slightly see red arrow in the right picture Tighten the grub screw ...

Page 29: ...two chassis plates Align the center tooth gap of the tooth rack 0642 with the marked tooth of the servo gear of the elevator servo yellow circle and the guide rod 0644 is inserted in the long hole of the lower bearing plate red arrow right picture Insert the grub screw M3x6 with a socket wrench through the hole in the chassis plate red arrow picture on the left and screw it into the lower bearing ...

Page 30: ...om the outside and will be connected with the bolts 0238 for better visualization the left upper chassis plate is shown transparent Attention The bolt without O rings will be mounted at the third position counted from the front The front spacer will be fixed with the two canopy holders 0253 Screw the threaded pin M3x12 by using Loctite about 5mm deep into the two canopy holders Ensure the Loctite ...

Page 31: ...336 Canopy mount 2 0336a R Clip 2 L0308 Lense head screw M3x8 2 The two rear canopy fittings 0336 will be fixed by a lens head screw M3x8 respectively Turn the fitting in a position so the hole for the safety splint is facing forward in longitudinal direction of the mechanics red arrow ...

Page 32: ...o the skid plates 0339 Slide the skid brackets 0342 in the area of the long hole onto the skid plate until the stop Check if the M4 screws can be put through Afterwards the brackets will be screwed to the 6x62 spacers 0345 Possibly the screws have to be torqued again after a while as the plastics can be set There is no need to use Loctite for these screws as they will not get loose due to the pre ...

Page 33: ... on each side of the rotor shaft have a different distance to the shafts end The side with the lower distance has to face downwards The shaft should go easy into all components Never hit the shaft with force through the bearings or into the flange The shaft is made of high strength aluminum and will fret easier as a steel shaft When the shaft is clamped put it in a drilling machine and polish it w...

Page 34: ...dismounting the rotor head each time you can put the shims between the spacer and the bearing from the side until you investigated the right total shim thickness After that you can remove the rotor head and the spacer and place the shims finally under the spacer Position the swash plate and the rotor head and tilt the shaft screw tight Use M4 lock nut and two M4 washers respectively Grease the spa...

Page 35: ...n by the swashplate guide see next page Center the three swashplate servos in neutral position center of the collective stick You can do in the same manner as for the mounting of the servo gear or you can connect the servos to your FBL system and adjust the servos to neutral position in e g the setup menu Adjust the length of the control rods until the swashplate is in a horizontal position and th...

Page 36: ...screws to the upper bearing plate use Loctite Attention The two additional holes are used as marking for the neutral position of the special ball pin If you look at the mechanics exactly from the rear and the special ball pin is on the same height as the two holes than the swashplate is in neutral position The references for the front ball pins are as described on the last page the two brackets of...

Page 37: ...it high loads Just when during a crash the rotor is suddenly blocked overloads can occur by the inertia of the rotating motor bell The hardened free wheel sleeve 0707 is generally pressed into the free wheel housing 0708 by us It is not possible to remove the sleeve So when a sleeve is worn the assembly sleeve and housing has to be exchanged The free wheel 0709 itself can be exchanged Therefore th...

Page 38: ...uild up a corrosion layer at the inner ring quickly T o o t h e d t a i l b e l t d i s c b e l t t e n s i o n e r Assembly group 8 0822 Toothed belt disc 21 T 1 0824a Upper belt tensioner flange 1 0824b Radial bearing 8x16x4 2 0824g Pin 2x8 2 SW081205 Spacer washer 8x14x0 5 2 G0405 Grub screw M4x5 1 The bearing 0824b will be pressed into the upper flange of the belt tensioner Press the two 2x8mm...

Page 39: ...lly move to the top outside the bearing seat To prevent this situation a brass spacer 0711 and some shim washers are added to the bag of assembly group 7 When using one of the recommended PYRO motors you just have to slide the 3 7mm high brass spacer on the motor shaft before mounting the motor to the motor support see picture on the left The motor base 0718 will be positioned with the flange into...

Page 40: ...e cutting into the plastics and have to be tightened carefully to prevent from over winding The hinge axle 0210 will be slipped in the cross hole of the motor mount Place a shim washer 3x6x1 a on each side followed by the ESC plate hinge 0212 Check the centered position of the axle The ECS plate will be pushed into the hinges and screwed tight with two M3x10 screws and two M3 nuts You can spread t...

Page 41: ...ws tight using some Loctite to fix the hooks properly and prevent them from twisting Loosen the bolt again and proceed in the same way with the next pair of hooks Finally the front hooks are mounted and the bolt remains mounted At this position the M3x12 lens head screws will secured with Loctite Insert the motor unit from above into the frame of the lower bearing plate Due to the support on the p...

Page 42: ...335 Hex socket screw M3x35 1 NS03 Nyloc nut M3 1 In the picture left you can see the preparation of the vertical fin plate which will be mounted later on the right side The plate is also used as a bearing seat for the tail shaft bearing 0900b which is already mounted by us by using Loctite Attention Take care the collar of the bearing is positioned at the inner side of the tail fin This secures th...

Page 43: ... twisting and keeps them aligned Before tightening the screws you can bend the two lower tips of the vertical fin plates together and check if they are aligned Lay the belt 0812 arround the belt disc 0903 and slide the disc from above between the two bearings in the vertical fin plates Take care not to tilt the disc In some cases it is necessary to spread the flexible plates a little bit at the to...

Page 44: ...m 0800 by using a long wire hook or a cord Position the fixation insert 0901 between the two strings of the belt and position it in the tail boom aligning the threated holes with the holes of the tail boom When sliding the tail unit on the tail boom position the two adapters 0905 on both sides The unit will be screwed with four M4x12 screws and four washers to the end of the tail boom Secure the s...

Page 45: ...fin plates act as a feathering ring and clamp the screw The double fin has the advantage compared to conventional fins of a high stability also with slim plates and is not breaking even during hard landings There will be no resonances at the whole RPM range and they participates to the vibration reduction in the helicopter Bend also the upper ends of the vertical fin plates together The easy solut...

Page 46: ...0939g will be pressed from above into the lower bell crank 0939e The axle 0939c will also be slide into the hole from above and fixed at the flat surface area with a M3x4 grub screw The shaft should look outside the bell crank by 1 5mm As shown in the right picture slide the axle from the lower side into the bell crank support Put in a shim washer 0939f between bearing and bell crank Attention Fir...

Page 47: ...9 Radial bearing 5x10x4 4 0920a Spacer washer 7x10x0 5 2 0920b Spacer washer 5x8x0 5 2 0921 Axial bearing 5x10x4 2 0923 Threaded ball link M3x4 4mm 2 0925a Hex socket screw shanked M3x21 2 0925b Spacer for tail blade 4 NS03 Nyloc nut M3 2 0925d Compensation weight 3x6x2 4 0927 Blade holder 2 0936 Center hub 1 G0404 Grub screw M4x4 1 ...

Page 48: ... tail blades 0925b If possible please do not use any other washers The screws 0925a for the purpose of fastening the tail blades are only tightened fast enough to keep blades swiveling lightly Only use this particular sized shaft screw Any other normal screw with a complete thread will cut its way through the thin sleeves of the bore Fasten the link ball 0923 to the blade holders with Loctite and ...

Page 49: ...f the tail rotor Look from the front to the tail boom Twist the belt 90 to the left counterclockwise see circular red arrow until the loop is in a horizontal position and no more vertical as shown in the picture Guide the belt through the two clamping flanges without twisting further until you can lay the belt over the belt disc At the same time slide also the tail boom into the two clamping flang...

Page 50: ... the shaft Put the other two bearings 0824b with a spacer washer 8x14x0 5 in between on the bearing bolt 0824c Slide this unit between the two belt tensioner flanges to the belt Align the holes of the two flanges and the bearing bolt and put in the M3x18 screw Apply some Loctite into the thread hole of the upper bearing flange and tighten the screw Attention After tightening the screw the belt ten...

Page 51: ... and then pull it over the front over the pin green arrow of the upper belt tensioner flange The grub screw M2 5x5 will be screwed with some Loctite into the small thread hole at the front of the motor mount Attention Tighten the grub screw very carefully until the stop Do not continue tightening after reaching the stop as the grub screw is pressing against the bearing even the thread is just 2mm ...

Page 52: ...bright pen see yellow arrow Now the belt will be pre tensioned and the tail boom clamped Take the tail boom with one hand and press with the thumb to the rear clamping flange Now the tail boom is slided backwards and the belt will be tensioned Attention Pull the tail boom backwards until the front edge of the upper belt tension flange is parallel to the front edge of the lower bearing plate in the...

Page 53: ...ower drawing Roughen the first 10mm of the carbon strut using some sandpaper and push the boom support end until it reaches the stop Only cover the carbon strut thin and use a larger amount of glue for the hole of the support end Immediately wipe off leaking superglue After the glue has dried the two ball links 0807 are attached with a gap of approx 1mm to the carbon boom and aligned such that the...

Page 54: ...ball end until it fits Then you can press the rod end onto the ball Now align the clamp that the guidance for the control rod is centered above the tail boom Tighten the screw to fix the clamp The front push rod guide 0808 will be fixed with thin double sided tape in a distance of 137mm to the rear clamping flange on the center of the tail boom Glue the thread rods 0831b with thin superglue into b...

Page 55: ...all pin of the tail servo Attention In case of chaffing of the control rod with the rear clamping flange yello cricle the tail servo is positioned too low in the mechanics This can be the case when you use servos with a large distance between fitting flanges and the upper side of the servo In this case mount shims between the servo brackets and the servo to raise the servo Turn the servo lever per...

Page 56: ...the half round hole of the FBL plate Stick the ESC with double sided tape as far as possible to the front of the ESC plate The front edge of the ESC should be aligned with the front end of the plate The capacitors can overlap at the front Attention AS the lens head screws of the ESC plate fixation are sticking out of the plate use thicker double sided tape beside the screw heads to prevent the ESC...

Page 57: ...r the servos should face to the rear to have good access The cables of the two aileron servos yellow X should be routed on the left side of the X stabilization to the rear The excess cable length can be folded in loops and fixed to the rear end of the left chassis plate The black arrows show a possible downward routing of the antennas with tubes As the canopy is made of GRP and not from carbon the...

Page 58: ...front or the rear but hangig in the same position as standing on the table with slight nose down By shifting the battery you can adjust the correct CG In the example shown above the 6S battery has a weight of 850g and the dimension X is 50mm A 6S or 7S battery should not weigh below 800g You will not get a correct CG without the battery touching the canopy The 12S battery shown in the example abov...

Page 59: ...pull it directly into the water with the adherent side so that sections of the adherent side do not come in contact and stick together The rest of the design consists of different sized arrows and a character styled similar as the arrows These segments have to be applied one by one This is easier to do as with one large sticker but the poisoning is hardly possible without reference points Therefor...

Page 60: ... to look exactly from the top on the area Take the stripe with both hands from the left and right side after removing the wax sheet Then close up to the tail boom Look exactly perpendicular on the helicopter lying on the side and take care the foil is positioned in the center and parallel on the tail boom Carefully set the label onto the tail boom and sweep it on Then remove the transparent rip of...

Page 61: ...f 2 4 In the table the corresponding pitch angles for adjusting the collective pitch are shown in steps of 0 5 mm The values are of course also in the other direction for the negative pitch range which is set just the same I recommend to set the maximum and minimum pitch values in the yellow range depending on the individual needs and the setup used More than 15 pitch are not recommended because e...

Page 62: ... the top to the right clockwise to check whether there is any tension on the linkage in any position Of course you can also make the whole setup with a classic pitch gauge taking care that the helicopter is standing stable and that the blades are really at 0 when the swashplate is at the neutral position This must be done in any case at the latest now if everything else is set so far anyway It is ...

Page 63: ...nces used revs of 1000 rpm to 1850 rpm are recommended Higher revs makes no sense with the light TDF since here no flying advantage is achieved but only unnecessary energy is wasted The system is only loud and restless and any midi servos that may be used will then reach their performance limits under unfavorable circumstances The tail rotor performance is also high enough at moderate speeds due t...

Page 64: ...rse axis during hovering it swings under the rotor A to hard setting may result in resonances between the main rotor and the fuselage at low head speeds This is particularly dangerous on the ground ground resonance since the helicopter can even tip over The critical speeds are usually between 600 and 900 rpm at the head Depending on the blades and weights your blades have a completely different re...

Page 65: ...t the blades are just clamped so tightly that they do not fold by their own weight while holding the helicopter in knif edge position If you shake the helicopter a bit they should do so Start the engine and run it up to Idle Up 1 Get familiarize with the helicopter If Idle Up 1 is a bit restless and does not yet run smoothly briefly switch to the next higher speed and then down again so that the b...

Page 66: ...66 Jan Henseleit ...

Page 67: ...67 D i m e n s i o n s TDF equipped with 712mm long baldes ...

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