minicopter Diabolo Black, Manual

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Bag 8: Swashplate and linkage (Step 22-26)
22. Now the control unit (bag 8) is assembled. The roll servos have their
wires threaded through the lower main rotor shaft bearing block and exit
into the long gap between the two U-profiles. Each roll servo is screwed on
with 4 hex bolts M3x12 D119 and 4 washers M3 002.
23. The distance blocks D420 will be attached with x4 bolts M3x10 D328 to
the elevator servo. With very thick sevo grommets eventually M3x12 D119
screws cam be necessary. But it is important that the remaing hole depth of
the distance blocks is at least 5mm. Then the distance block will be fitted
with x4 bolts M3x6 D196 on the upper right frame D482. The servo cable is
pushed into the frame hole below the servo and the rubber grommet for servo
D80 is put onto the servo cable and inserted into the hole on the side
frame.
The best way to bend the servo cable around the corner is with the help of a
small wrench and a long screwdriver, so that it is drawn through the same
slot as the roll servos. The three servo cables are secured with a cable tie
at the base of the vertical U-profile, preferably positioned on the far
left. Do not cut the end of the cable tie short as per usual, but leave a
2cm length, so the cable cannot slide out to the front.
24. The installation of the tail rotor servo is slightly unusual. First the
two L-shaped tail servo holders D23s are screwed onto the rubber grommet
with x4 hex bolts M3x12 D119 and x4 M3 washers 002. If you are using a servo
with 2.5mm grommet bushes please replace them thru optional bushes D153. Now
the two threaded blocks D23a will be attached to the inside of the body with
x2 hex bolts M3x8 D119, note the front block lies vertically and the rear
block lies horizontally.
For installation the tail servo is tilted into the cut-out, beginning with
the cable outlet, and screwed on with x2 hex bolts M3x16 D329 and a lot of
Loctite. Please take care to attach the tail servo holders as vertically as
possible.
The tailservo unit can also used as "revision door" f.e. to place cables in
the area around the tailboom behind the tailservo slot.
25. Next step the linkages between the servos and the swash plate will be
assembled. For this you push the black swash leveller D289 onto the main
rotor shaft D220 and thread on the swash plate D226. X6 ball joints D72 will
be screwed onto x3 push rods for swash-servo linkage D54 with the help of
the milled wrench D73 and the included 4" monkey-wrench D120. The final
length of the push rods varies, depending on the servo type used. With
Futaba BLS 471SV the length of the roll servo push rods is 102.5mm overall
length, measured after sanding down the injection flash on the ball links.
The elevator servo push rod is 101mm long. The servo arms need drilling
holes of 2.7mm (7/64”) diameter, drilled out very slowly. With the 3mm thick
Futaba T-arms (which two of their arms carefully removed) the outer hole
will be used, which has an arm-lever distance of 18.5mm.
Now the ball joints are attached to the servo arms from the inside with x3
hex lens bolts M3x16 494 and washers M3 002. Because of the servo arm is
drilled to 2.7mm (7/64”) the bolt cuts a thread automatically into the servo
arm. On the rear side of each arm you secure the bolt with an M3 washer 002
and an M3 lock nut 008s. Caution: with the elevator servo push rod the ball
joint is attached on the other side.
26. The prepared push rod units are pushed onto the servo output shaft. The
final assembly of these will be done later, since first the neutral position
of the servos, by the flybarless system, has to be found. Now the roll servo
push rods are screwed onto the arms of the swash-outer ring provisionally,
with no Loctite as yet, using x2 hex lens bolts M3x18 D104 and 2 swash
conical spacer bushes D58. The rear elevator push rod is fitted with a hex
screw M3x30 D337, the anti-rotation device bush (brass) D55 and from the
opposite side, as done with the roll servos, a swash conical spacer bush D58
will be pushed on and provisionally screwed onto the rear swash hole. Now
while the push rods are virtually vertical the correct length of the push
rods will be checked (servo arms horizontal and square) and readjusted if
necessary.
If everything is ok, all three push rods will be detached again, the swashplate
holder D33 pushed onto the brass distance bush D55 of the elevator push rod and
each pair of threads will be lubricated with an abundance of Loctite 243 and