minicopter Diabolo 2018, Manual

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Manual (Printable version):
Introduction: For the assembly of the Diabolo you need a set of good hex
drivers in the size 1,5-4mm and additional an open wrench of 5.5mm,
f.e.#707, nut wrenches in 4,5.5,7 and 8mm (we recommend the torque driver
#1720 and the tips #1721-1724). Also you need Loctite 243. It is recommended
to mount the frame screws until step 6 (both carbon frames, mainshaft unit,
first stage shaft unit, belt) still loose, then press them on a flat table
and tighten the screws adding Loctite on each screw. Then all additional
parts between the frames will be added. With this method you reach a high
grade of symmetry of the frame.
Use always on all not with lock nut secured screws Loctite 243. These screws
are marked in the graphics with an „L“.
Bag 1: Main shaft unit (Step 1-4)
1. We start with the mainrotor shaft unit 1 (bag 1). For this we prepare the
upper side frames D401 and D402. It is recommended to slightly sand down all
carbon frame edges with fine sandpaper (ca. 240 grain) or a small rasp
(preferably of high quality and unused), so that no wire or rubber ring can
be damaged on their sharp edges. Also the cable slot in plate D427 should be
removed carefully from all sharp edges. This step is not entirely necessary,
but increases, at least theoretically, operational safety. If you work with
sandpaper take care that you do not damage the nice carbon surface with
scratches. Work slowly and careful. Then the front lower corner of the long,
rectangular aileron servo cutout should be slightly worked over with a rasp,
so that this corner is square. This is necessary for correct perpendicular
installation of the main rotor shaft.
2. The initial assembling of the Diabolo is done on the side frame upper
right D402 and finally the upper left side frame D401 will be attached. The
best tactic is to mount the screws first a little bit loose and after adding
the left frame while pressing the whole unit on a flat table, then tighten
some screws provisorically and tighten each screw finally under add of
Loctite 243 and mark a "ready" screw with a felt pencil.
The lower ball bearing block main shaft D16 and the main bearing bracket D17
are attached to the side frame upper right D02 with five hex screws M3x8
D197. Additionally pay careful attention to the fact, that the ball
bearings, of these two bearing blocks, are flanged ball bearings. The side
of the flange with the larger diameter has always to be on the inside, i.e.
the flanges of the bearings of the main bearing block have to be positioned
below and those of the lower main rotor shaft bearing blocks (and later of
the lower gearing rack) at the top. Please therefore pay attention to the
correct positioning of the brackets in the following assembly pictures.
Insert the main rotor shaft D414 into the bearing blocks and check that he
shaft runs parallel to the front edge of the aileron servo cutout. If this
is not the case, the above described cutout corner has to be filed out some
more.
3. As the next step the hub main shaft D12 has to be bolted together with
the main gearwheel D13 by using 6 hex screws M3x8 D197 and 6 washers M3 002.
It is essential that the side with the short collar (diameter 26mm) is
pushed into the gear wheel while the bolt threads are aligned. Fasten the
screws in star fashion to avoid tension. Take attention that the side of the
wheel with the "X" is showing to the flange.
4. Hint: First assemble the blocks on the right frame as shown but do not
tighten the screws yet and wait for assembling the left frame. Then add on
each screw Loctite and tighten them piece after piece while pressing the
assembled mechanic on a flat table with mainshaft vertical to get a perfect
rectangularity.
The assembled unit will now be inserted, with the distance bush D15, between
the main rotor shaft blocks. The tightness should be such, that when holding
it sideways nothing falls out, but no tighter. If it is too loose, please
add a shim washer 10x16x0.1 048 or 0.2 033 between the hub and spacer. Then
insert main rotor shaft D14 from top and fix to main gear hub jesus bolt D77