GRAUPNER Starlet 50 Instruction Manual
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GRAUPNER Starlet 50 Instruction Manual

GRAUPNER Starlet 50 Instruction Manual

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Starlet 50
Model helicopter
Order No. 4445 Kit
Order No. 4446 Complete kit including motor and silencer
Warning!
The contents of this kit can be assembled to produce a working model which is by no
means a harmless plaything. It is a complex flying machine, and if built incorrectly or
handled incompetently or carelessly it can cause serious injury to persons and damage
to property.
You alone are responsible for completing the model correctly and operating it safely.
Please be sure to read the sheets SHW3 and SHW7 which are supplied in the kit. They
include much important safety information, and represent an essential part of these
instructions.
GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY
Liability for printing errors excluded.
ID# 52068
5/04
We reserve the right to introduce modifications

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  • Page 1 Please be sure to read the sheets SHW3 and SHW7 which are supplied in the kit. They include much important safety information, and represent an essential part of these instructions. GRAUPNER GmbH & Co. KG D-73230 KIRCHHEIM/TECK GERMANY Liability for printing errors excluded. ID# 52068...
  • Page 2 .60 engine. The STARLET 50 therefore forms an ideal starting point for a helicopter system which extends from a small beginner’s machine to a model suitable for the expert or scale modeller.

  • Page 3: Warnings

    Starlet 50 Warnings • • • • The contents of this kit can be assembled to produce a working model helicopter, but the model is by no means a harmless plaything. If built incorrectly or handled incompetently or carelessly it can cause serious injury to persons and damage to property.
  • Page 4 Liability exclusion / Compensation As manufacturers, we at GRAUPNER are not in a position to influence the way you assemble your model, nor how you install, operate and maintain the radio control system components.

  • Page 5: Table Of Contents

    Starlet 50 Contents • Foreword ......... • Warnings ......... • Accessories, additional items required ....• 1. Assembling the main mechanics ...... • 2. Installing the radio control system ..... P.21 • 3. Assembling the main rotor head P.24 ......
  • Page 6 Starlet 50 Accessories Recommended motors and accessories for the Starlet 50 Motor Capacity Order Expansion silencer Exhaust (Tuned pipe) manifold silencer OS MAX 46 7,45 1893 1809.33 2259 1783A or FX-HG 1871.72 2272 OS MAX 50 8,17 1921 1809.33 2259...

  • Page 7: Assembling The Main Mechanics

    The type of construction used in the Starlet 50 is simply not subject to this kind of damage. Glass-filled nylon components therefore have many advantages, and the only drawbacks are...
  • Page 8 Starlet 50 1.1 Assembling the tail rotor drive system (bag UM-1A Please note that there must be no axial play at all in the quick-release coupling shaft 4618.57 when fitted in the bearings 4618.6. If the shaft does not seat securely enough in the bearings, fix it to the bearings using bearing retainer fluid 603, Order No.
  • Page 9 Starlet 50 Fit the top bearing support on the shaft loosely for the moment (note the correct orientation; the opening in this bearing support should face up), then fit the top bearing 4450.31, followed by a shim washer. Press the freewheel sleeve 4618.107 into the gear 4618.105, and fit this assembly on the shaft.
  • Page 10 Starlet 50 1.3 Preparing the main rotor shaft and bearings (bag UM-1C) Fix the swashplate guide 4618.113 to the dome bearing holder 4448.8 using two M2 x 12 cheesehead screws. Press one of the ballraces 4450.24 into the dome bearing holder, and one into the main rotor shaft bearing holder 4448.12;...
  • Page 11 Starlet 50 1.4 Assembling the main gearbox Fit the tail rotor drive unit, the layshaft assembly and the main rotor shaft bearing holders between the mechanics side frames 4450.9 and 4450.10, and fix them in place using M3 x 16 socket-head cap screws;...
  • Page 12 The mechanical assembly of this helicopter is designed for a motor with a long ground 8 mm Ø crankshaft, as specified for all Graupner / Heim model helicopters. However, other types of motor can also be installed at the modeller’s discretion; all you need is the optional plain bearing clutch, which is available separately.
  • Page 13 Starlet 50 Notes: Power transference between crankshaft and clutch is achieved exclusively by the clamping pressure of the taper collet on the ground crankshaft nose, and on the tapered socket in the clutch. To ensure that sufficient pressure is applied, it has proved good practice to start by installing the clutch alone - without the cooling fan - and tightening it fully;...
  • Page 14 Starlet 50 Fix the motor mounts 1291.18 to the top part of the mechanics using the two special M3 x 12 screws, working from the inside of the assembly. Attach the motor to the motor mounts using four M3 x 16 socket-head cap screws, fitting a washer 560.7 on each screw between the motor...
  • Page 15 Starlet 50 1.6 Assembling the cooling fan housing (bag UM-3) You may find that you have to open up the carburettor opening in the fan housing, depending on the type of carburettor you are using; the same applies to the hole for the cylinder head.
  • Page 16 Starlet 50 1.7 Assembling the sub-structure (bag UM-4) Assemble the sub-structure as shown in the illustration, using the side frames 4448.34, the bulkhead 4450.18, the spacers 4450.17, the RC box 4445.101 and the skid brackets 1291.21A, using the appropriate self-tapping screws, as shown in the drawing.
  • Page 17 Starlet 50 1.8 Mounting the mechanics on the sub-structure (bag UM-5) Fit the circular projections on the main gearbox (assembled in Section 1.6) between the side frames of the sub-structure, and allow them to engage in the moulded-in sockets. Fix the parts together using M3 x 16 socket-head cap screws and washers as shown.
  • Page 18 Starlet 50 1.9 Glowplug connector (bag UM-6) Fit the socket of the glowplug connector in the hole in the right-hand side frame 4448.34, and fit the solder tag, the washer and the nut on it on the inside to secure the socket. Tighten the nut.
  • Page 19 Starlet 50 1.10 Fueltank The fueltank is assembled as shown in the drawing. First install the pressure nipple in the small raised area at the highest point in the tank: cut a 5 mm Ø hole, slip the nipple through it from the inside, and secure it with the washer and nut on the outside.
  • Page 20 Starlet 50 1.12 Collective pitch compensator and swashplate (bag UM-8) The collective pitch compensator 4618.47A is assembled as shown in the drawing. First fit a circlip on each of the brass rods, and glue them in the holes in the collective pitch compensator hub 4618.46 using bearing retainer fluid, ensuring that the circlips engage fully in...

  • Page 21: Installing The Radio Control System

    Starlet 50 2. Installing the radio control system (bag UM-9) 2.1 Mounting the servos Attach brass linkage balls to the inside of the pitch-axis servo arm (1), and the output arms of the roll servos (2) + (3), using M2 x 10 screws, and secure them with M2 nuts on the outside.
  • Page 22 Starlet 50 The next stage is to link the swashplate servos to the swashplate using the pushrods already prepared, to form a 120° linkage. A four-point swashplate linkage is also possible; details of this alternative installation are left up to the builder. In this case one further servo is installed in the vacant servo aperture in the mechanics, and connected to the appropriate linkage point on the swashplate by means of a 2.5...
  • Page 23 Starlet 50 Connect the carburettor arm to the throttle servo output arm using this pushrod, as shown in the drawings: 2.2 Installing the remaining radio control system components To attach the gyro system to the gyro platform we recommend the use of double-sided foam tape, e.g.

  • Page 24: Assembling The Main Rotor Head

    Starlet 50 3. Assembling the main rotor head (bag UM-10) The main rotor head is assembled as shown in the illustrations. All ballraces must be greased. 3.1 Preparing the blade holders The first step is to glue the brass sleeves from 4618.32 to the M3 x 16 screws using thread-lock fluid.
  • Page 25 Starlet 50 3.2 Installing the blade holders Press the two O-rings 4607.28 into both sides of the rotor head hub 4682.26, grease the blade pivot shaft and slide it through the O-rings. Set it exactly central, i.e. projecting by an equal amount on both sides.
  • Page 26 Starlet 50 3.3 Assembling the Hiller rotor Assemble the rocker 4618.27 as shown in the drawing. Note that the hole in the pivot bar 4618.28 must line up with the through-hole in the rocker, to ensure that the flybar can be slid through later without jamming or binding.
  • Page 27 Starlet 50 Roughen the surface of the flybar at the point where the control bridge 4618.37 is to be clamped. Screw the control bridge to the flybar, applying thread-lock fluid between the bar and the control frame to prevent any danger of the flybar rotating in the control bridge during violent aerobatic manoeuvres.
  • Page 28 Starlet 50 3.4 Installing the main rotor head Fit the main rotor head on the main rotor shaft. Align the hole in the rotor head with the top cross-hole in the main rotor shaft, then fit the special screw 4618.87 to fix the parts together.

  • Page 29: Assembling The Tail Rotor Gearbox

    Starlet 50 4. Assembling the tail rotor gearbox (bag UM-11, 11A) Fit the bevel gear 4618.38 on the tail rotor shaft 1221 as shown in the drawing. Apply a drop of thread-lock fluid to the threaded holes in the bevel gear, then fit the M3 x 3 grubscrews. One of the two grubscrews must engage squarely on the machined flat in the tail rotor shaft.
  • Page 30 Starlet 50 meshing clearance between the bevel gears, as if under maximum load. Now check that the tail rotor gearbox runs smoothly, with just detectable meshing clearance in the bevel gears. If the play in the gears is too slight, i.e. the gears are stiff to move, you will need to remove the drive assembly again and remove the shim washer under the bevel gear.

  • Page 31: Assembling The Control Bridge

    Starlet 50 5. Assembling the control bridge (bag UM-11B) Press the ballrace 4607.137 into the control ring 4618.62 as far as it will go. Apply a little thread- lock fluid to the control sleeve 4618.61, taking care not to allow it to run between the control ring and the control sleeve.

  • Page 32: Assembling The Tail Rotor Head

    Starlet 50 6. Assembling the tail rotor head (bag UM-11C) Assemble the tail rotor head as shown in the drawing, greasing all bearings as you install them. Place the two O-rings in the hub 4448.22 and press them into the channels. Oil the O-rings, fit the tail rotor head on the tail rotor shaft, and line up the cross-hole in the shaft accurately with the hole in the hub, and press the pin 4448.22 into place to fix the parts together.

  • Page 33: Tail Boom

    Starlet 50 7. Tail boom (bag SR-0) 7.1 Assembling the tail boom braces (bag SR-1) Press the strut end-pieces 1292.11 into both ends of the aluminium tail boom braces 4445.8 as far as they will go, and set the eyes parallel to each other. Drill a 1.5 mm Ø pilot-hole through each brace and into each end-piece, and fit 2.2 x 6.5 mm self-tapping screws to secure them.
  • Page 34 Starlet 50 The front shaft coupling can now be prepared; you must work carefully here, as the coupling must engage automatically inside the tail boom without you being able to see what is happening, and without using tools. For this reason it is important that the brass coupling sleeve 4618.58 is an easy sliding fit over the coupling yoke 4618.57.
  • Page 35 Starlet 50 Alternatively you could re-position the tail rotor gearbox flange 1292.7 slightly further aft on the tail boom. Remove the tail boom from the mechanics again. 7.6 Connecting the tail boom to the mechanics Withdraw the tail rotor assembly from the tail boom to the point where the shaft coupling becomes accessible.

  • Page 36: Assembling The Skid Landing Gear

    Starlet 50 8. Assembling the skid landing gear (bag SR-4) Push the skid tubes 4447.7 through the skid bars 4447.6, and set the bars 207 mm apart (distance between retaining screws) by adjusting the position of the bars on the tubes.

  • Page 37: Cabin

    Starlet 50 The front end of the guide tube must not be supported against the tail boom, but should be left „floating“ freely on the wire pushrod; for this reason it must be left as long as possible, i.e. it should extend forward as close to the servo as possible.
  • Page 38 Starlet 50 11.2 Attaching the cabin Press two rubber grommets 3515.3 into the appropriate holes in the bulkhead 4445.17; you may like to apply a drop of cyano on one side to secure them. Fit the bulkhead, with the curved edge facing down, onto the stand-off pillars which are located on the front of the mechanics.

  • Page 39: Main Rotor Blades

    Starlet 50 12. Main rotor blades Epoxy the rotor blade bushes 4607.164 in the root holes in the rotor blades, unless your blades are supplied with these parts factory-fitted. Allow the epoxy to set hard, then sand the blades smooth overall using fine abrasive paper, Order No.

  • Page 40: The Set-Up Procedure

    Starlet 50 13. The set-up procedure 13.1 Setting up the cyclic control system The basic settings for the roll-axis and pitch-axis control systems should already be correct if you have installed the linkages exactly as described in the instructions. Since the instructions include the lever lengths (correct linkage holes), the final setting up is carried out using the electronic facilities on your transmitter.
  • Page 41 Starlet 50 If you have made up all the linkages exactly as described in the previous sections, no changes to the mechanical arrangements will be necessary. The following adjustments can all be carried out at the transmitter: 1. Servo direction Set the „sense"...
  • Page 42 The aim of the gyro adjustment process is to achieve as high a level of gyro stabilisation as possible, without the gyro causing the tail boom to oscillate. Notes regarding the use of the Graupner/JR „PIEZO 900 ... 5000" piezo gyro system in conjunction with a computer radio control system (e.g. mc-12 ... mc-24) The design of these gyro systems necessitates a different set-up process to the one described above.

  • Page 43: Final Pre-Flight Checks

    Starlet 50 14. Final pre-flight checks When you have completed the model, run through the final checks listed below before the first flight: • Study the manual again and ensure that all the stages of assembly have been completed correctly.

  • Page 44: Adjustments During The First Flight, Blade Tracking

    Starlet 50 15. Adjustments during the first flight 15.1 Blade tracking “Blade tracking" refers to the height of the two rotor blades when they are spinning. The adjustment procedure aims at fine-tuning the pitch of the main rotor blades to exactly the same value, so that the blades rotate at the same level.

  • Page 45: Adjusting The Motor

    Starlet 50 15.2 Adjusting the motor Please be sure to read the operating instructions supplied with your motor. The correct matching of collective pitch and throttle when the helicopter is hovering is of crucial importance to the model’s flying characteristics and performance. For example, if the pitch of the main rotor blades is too high, the motor may not reach the intended rotational speed, and this may cause you to think that the motor is not powerful enough for the job.

  • Page 46: General Safety Measures

    Starlet 50 16. General safety measures • Make sure you have adequate third-party insurance cover. • Wherever possible join the local model flying club. At the flying site: • Never fly your model above spectators. • Do not fly models close to buildings or vehicles.

  • Page 47: Some Basic Terms Used In Model Helicopter Flying

    Starlet 50 17. Some basic terms used in model helicopter flying The term „rotary wing machine" indicates that the helicopter’s lift is derived from rotating „wings" which take the form of rotor blades. As a result, a helicopter does not require a minimum forward speed in order to fly, i.e.
  • Page 48 Starlet 50 Auto-rotation This term refers to the flight of a helicopter without motor power. The rotational speed of the main rotor can be kept high by setting both blades to negative pitch, and the airflow through the rotor as it descends then keeps the blades turning. The rotational energy stored in the rotor by this means can be converted into upthrust when the helicopter is close to the ground, by the pilot applying positive collective pitch.

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