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Henseleit Helicopters Three-Dee-Fun TDR-II User Manual

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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!

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Summary of Contents for Henseleit Helicopters 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 Index Safety Precautions page 3 - Description / Technical data and RC component recommendation page 4 - 5 Introduction: Important! General information to be read before building page 6 Chapter Main Rotor (Assembly Group 1) page 7 - 14 Chapter Main shaft unit (Assembly Group 4) page 15 - 18...

  • Page 3: Safety Precautions

    Safety Precautions: A remote controlled model helicopter is not a toy. Keep strictly out of reach for children. A model helicopter will only perform reliably if assembled properly and regularly maintained after each flight. Keep sufficient safety distance from the model. Always assume technical failure could happen at any given moment, which may cause the model to become out of control.
  • Page 4 h r e e - e e Fun After delivered the TDR-II, pilots came often to me, asking for another helicopter close to the TDR, but technically up to date. The TDR impresses by simpleness and was one of the most powerful and variable helicopters for years. It was important for me, to have a machine in range , which can be flown with less powerful and cheaper drive components, but with lots of fun.
  • Page 5 The adjustable damping was implemented - so adjustments can be done on the field in seconds. Technical Data: Name (Tree Dee Fun) Manufacturing and sales Henseleit Helicopters Main rotor diameter up to 1600 mm Rotor blades 680 - 720 mm...
  • Page 6 General information for the assembly (very important!) Before you start, you should try to get an overview of the assembly by scrolling through the manual. It is recommended to assemble the helicopter next to your computer. You can also print the manual. Please start at the beginning of the manual and keep with the sequence of the assembly instructions.
  • Page 7 Chapter – 1 M a i n R o t o r (Assembly group 1) A d j u s t a b l e f e a t h e r i n g s p i n d l e d a m p i n g 0140a Straining screw R-L-thread 0140b...
  • Page 8 F e a t h e r i n g s p i n d l e m o u n t 0102 O ring 14x3 - NBR80 0105 C-clip Seeger - JV-20 0109 O-ring inner bushing 0110 Feathering spindle 8x110 0120 Center hub 0140d...
  • Page 9 First, apply some lubricant onto the O-rings 0102 and the O-ring inner bushing 0109. You may use a viscose bearing grease or the enclosed “DRY FLUID GEAR” (Shake well before use). The inside of the center hub 0120 should also be greased at the O-ring seat.
  • Page 10 B l a d e h o l d e r 0107 Spacer washer 8x14x0,2 0113 Radial bearing 8x16x5 0114 Blade holder 0115 Axial bearing 8x16x5 0117 Spacer washer 5x10x1 Hex socket screw M5x10 – 12.9 0119 First assemble the blade holder with all bearings. Attention! To avoid any mistake it is important to follow a specific sequence.
  • Page 11 Finally slide both blade holders onto the feathering spindle. However, the spacer washers 0107 (8x14x0.2) need to be inserted before, between the O-ring inner bushing 0109 and the pre-assembled blade holder. In case the pre-assembled blade holders do not properly slide onto the feathering spindle, the predominant cause would be a displacement of spacer washer 0107.

  • Page 12: Table Of Contents

    P i t c h a r m s 0116 Pitch arm Threaded ball stud M3x4 – 6mm 0116a Blade bolt M4x30 – 10.9 0138a 0138b Spacer for rotor blade 4x20x1 0138c Adapter sleeve 5mm to 4mm Washer M4 Nyloc nut – M4 NS04 Nyloc nut –...
  • Page 13 Attention! Do not use an open-end wrench to tighten the ball stud. Use a socket wrench in order to not damage the external hex. The pitch arms 0116 has to be mounted in the grooves of the blade holder as shown in the picture. Look for the different screw length M3x8 or rather M3x12 (use Loctite).
  • Page 14 P u s h r o d f o r b l a d e c o n t r o l 0121a Spacer 30mm 0121b Ball link 15mm 0121c Stud bolt M2,5x 45 Mount the rod as shown in the picture above. Position the ball link in line to prevent damage. Attention! Screw both ball links 0121b...
  • Page 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 0400b Radial bearing 45x55x6 0400c Swash plate inner ring 0400d Ball shell 0400e...
  • Page 16 The bearing 0400b will be placed into the outer ring of the swashplate from above, without tilting. Slightly heating the ring will ease the insertion significantly. Secure the bearing with the three tapered grub screws M3x4 (see detail drawing below), placed in the lower radial hole of the outer ring (use Loctite at the thread of the hole).
  • Page 17 M a i n s h a f t g e a r (Assembly group 4) 0416 Main shaft gear 0416a Carbon spoke 0416b Spacer 3x8x4 0418 Main gear flange P2510 Phillips screw M2,5x10 Nut M2,5 flat M0312 Hex socket screw M3x12 WL03 Washer M3 large...
  • Page 18 To prevent the increase of the diameter of the main gear by heating even in case of hardest flying style, a special design measure was taken. The delrin gear ring 0416 is manufactured with a 0,5mm smaller diameter as it should be. The inner carbon spoke 0416a will not fit inside the gear in cold condition.
  • Page 19 Chapter – 3 S e r v o p r e p a r a t i o n (Assembly group 6) 0630NS Elevator servo mount 0630RS Aileron servo mount 0630HS Tail servo mount 0634 Servo pad Threaded ball link M2x5 – 3mm 0638 0640 Servo gear - 28 teeth...
  • Page 20 The following drawings show midi size servos with a housing width of 15mm. When using standard servos with a width of 20mm the blocks for the aileron servos are just 0,2mm wider on the side with the M3 thread. E l e v a t o r s e r v o – p r e p a r a t i o n The elevator servo will be screwed to the blocks 0630NS (three...
  • Page 21 Now mount a servo gear 0640 on each swash plate servo. To reach an optimum adjustment from mechanical point of view, you should follow the described procedure exactly. So much the better you work here the less corrections you have to do by electronics. In the ideal case you can keep all values in you FBL system without adjustment of the trims and can use your system perfectly.
  • Page 22 Chapter – 4 C h a s s i s (Assembly group 2) S e r v o m o u n t r i g h t c h a s s i s p l a t e The following three pictures show the installation of the right aileron servo and the elevator servo to the right upper chassis plate 0201...
  • Page 23 S e r v o m o u n t l e f t c h a s s i s p l a t e The following three pictures show the installation of the left aileron servo and the tail servo at the inner side of the left upper chassis plate 0201.
  • Page 24 B e a r i n g p l a t e p r e p a r a t i o n (Assembly group 2) 0221 Upper bearing plate 0222 Lower bearing plate 0223 Radial bearing 12x24x6 0206 Mounting block 0207 Carbon X stiffening front 0208...
  • Page 25 C h a s s i s m o u n t The two chassis plates will now be connected with the two bearing plates. Check with the drawing which screws will be placed in which holes. Use a M3x8 lens head screw at the front and a M3x8 Allen screw at the rear of the upper bearing plate.

  • Page 26: Washer M4

    T a i l b o o m m o u n t i n g f l a n g e (Assembly group 8) 0832 Boom clamping flange front 0833 Boom clamping flange rear 0837 Thread rod M3x72 M0308 Hex socket screw M3x8 NS03 Nyloc nut M3...

  • Page 27: Hex Socket Screw M3X14

    Chapter – 5 Swash plate linkage A i l e r o n s e r v o t o o t h r a c k (Assembly group 6) 0641 Support for roll toothed rack guide rod 0642 Toothed rack 0644 Toothed rack guiding rod 3x98 0646...
  • Page 28 View from the rear to the left chassis side View from the front to the mechanics First the two guide rods 0644 of the tooth racks will be fixed to the brackets 0646 of the guide rods for the aileron tooth racks.
  • Page 29 E l e v a t o r t o o t h e d r a c k (Assembly group 6) 0642 Toothed rack 0644 Guiding rod 3x98 0645 Support for elevator toothed rack guid rod 1 Threaded ball link M3x4 – 4mm long 0650b G0306 Grub screw M3x6...
  • Page 30 Chapter – 6 C h a s s i s l o w e r s e c t i o n L o w e r C h a s s i s (Assembly group 2) 0202 Lower carbon frame 0203 O ring 7x3 0238...
  • Page 31 C a n o p y m o u n t b a c k (Assembly group 3) 0305 Rubber grommet for canopy 0336 Canopy mount 0336a R-Clip L0308 Lense head screw M3x8 The two rear canopy fittings 0336 will be fixed by a lens head screw M3x8 respectively.
  • Page 32 S k i d s ( Assembly group 3) 0339 Skid plate 0340 Skid 0342 Skid plate holder 0345 Stud 6x62 M0420 Hex socket screwn M4x20 L0308 Lense head screw M3x8 NS03 Nyloc nut M3 WL03 Washer M3 large The skids 0340 will be screwed from outside with the lens head...
  • Page 33 Chapter – 7 Installation of rotor shaft unit M o u n t t h e m a i n s h a f t u n i t i n t o t h e c h a s s i s (Assembly group 4) 0410 Main shaft 12x171...
  • Page 34 Slide the spacer 0407 on the rotor shaft down to the upper bearing, but do not install the swashplate. Slide the rotor head on the rotor shaft temporary down until it stops at the bushing. Press the main gear in the mechanics upwards as far as possible.
  • Page 35 S w a s h p l a t e l i n k a g e (Assembly group 6) 0650a Ball link 19mm 0650c Stud bolt M2,5x33 Screw respectively 2 ball ends 0650a on the three thread rods 0650. The distances „X“...
  • Page 36 S w a s h p l a t e a n t i t w i s t g u i d e (Assembly group 4) 0420 Swash plate anti-twist guide L0308 Lense head screw M3x8 The swashplate guide 0420 will be positioned from above over the special...
  • Page 37 Chapter – 8 M o t o r p i n i o n u n i t + m o t o r M o t o r p i n i o n u n i t (Assembly group 7) 0706 Pinion shaft 0707...
  • Page 38 Attention! The pinion shaft 0706 has an accurately fitting dent with two spanner flats resulting in a form lock connection to the counter piece at the free wheel housing. A slippage is therefore not possible. Assemble these parts carefully to prevent a damage of the fit. The counter sunk screw M5x12 (use Loctite) connects the two parts.
  • Page 39 M o t o r m o u n t (Assembly group 7) 0718 Motor support 0717 Spacer 6x8x3,7mm SW061205 Spacer washern 6x12x0,5 SW061210 Spacer washern 6x12x1 The recommended PYRO 650 or PYRO 700 motors use a plane continuous 6mm diameter shaft. The fixing collar is exactly flushing with the motor flange. As the shaft is diving 16mm deep into the free wheel housing there will remain a gap of 4mm between the collar and the bearing.
  • Page 40 E S C p l a t e m o u n t (Assembly group 2) 0209 ESC plate 0210 Hinge axis 3x35 0212 ESC plate hinge 0213 ESC plate fastener SW030610 Spacer washer 3x6x1 M0310 Hex socket screw M3x10 NS03 Nyloc nut M3 L0308...
  • Page 41 I n s t a l l a t i o n o f t h e m o t o r u n i t t o t h e c h a s s i s M0312 Hex socket screw M3x12 Washer M3 Insert the motor unit from above into the frame of the lower bearing plate.
  • Page 42 Chapter – 9 T a i l g e a r (Assembly group 9) P r e p a r a t i o n o f t a i l g e a r h o u s i n g r i g h t 0900a Carbon tail gear housing and vertical stabilizer 0900b...
  • Page 43 Press the two bearings 0902b together with one of the spacers 0902c into the hole of the pulley 0902a. As you can see on the picture on the left the pulley will be mounted between the two vertical fin plates 0900a. Two other spacers 0902c will be added on...
  • Page 44 M o u n t i n g o f t h e v e r t i c a l f i n p l a t e s t o t h e t a i l b o o m 0800 Boom 25 x 850 0901...
  • Page 45 C o n n e c t i n g t h e t i p s o f t h e v e r t i c a l f i n 0900L Tip protection left 0900R Tip protection right M0308 Hex socket screw M3x8 Nut M3 - flat...
  • Page 46 T a i l p i t c h s l i d e r 0915a Tail pitch rod 0915b Pin for tail pitch rod 0915c C-clip 0916 Tail pitch slider The sleeve of the pitch slider is chamfered with both bearings. Therefore, this unit is only available complete, under the part order no.
  • Page 47 T a i l c e n t e r h u b w i t h t a i l b l a d e h o l d e r s 0911 Hex socket screw M3x6 - 10.9 0917 Spacer washer 3x6x1 0919...
  • Page 48 The assemblies of the tail blade grips are done in the following procedure: First push the radial bearing (5x10x4) 0919 into the blade holder 0927 until it stops. The bearing has to be pushed to the recess in the rear (expand the blade grip with heat if needed). It is followed by the largest of the three spacer washers (7x10x0.5) 0920a.
  • Page 49 Chapter – 10 T a i l b o o m (Assembly group 8) M o u n t i n g o f t h e t a i l b o o m t o t h e m e c h a n i c s Turn the core mechanic and tail boom upside down then pull the belt toward the front out of the tail boom and align it in such a manner, that it runs straight without being twisted.
  • Page 50 F i n i s h b e l t t e n s i o n e r m o u n t (Assembly group 8) 0824b Radial bearing 8x16x4 0824c Bearing support 0824e Lower belt tensioner flange SW0891405 Spacer washer 8x14x0,5 M0318 Hex socket screw M3x18...
  • Page 51 R u b b e r b a n d m o u n t (Assembly group 8) 0824d Rubber band 0824f Rubber band mount L0310 Lense head screw M3x10 WL03 Washer M3 - large G2505 Grub screw M2,5x5 The support of the rubber band 0824f will be fixed with both noses in the long hole on the inner side of the...
  • Page 52 A d j u s t m e n t o f t h e b e l t t e n s i o n a n d c l a m p i n g o f t h e t a i l b o o m Initially torque the lower screw of the rear plastic clamping flange a little bit, so the tail boom can still be turned and moved.
  • Page 53 B o o m s u p p o r t (Assembly group 8) 0802 Carbon boom support 5,5 x 580 0805 Boom support end 0807 Ball link 8mm 0807a Stud bolt M3,5 x 29 Mount the boom support ends on both sides of the tail struts (see image above). At first, attach the M3.5 threaded rod 0807a on one side using superglue, so that it still protrudes by 12mm (upper drawing).
  • Page 54 0808 Push rod guide front 0809 Stud clamp M0325 Hex socket screw M3x25 NS03 Nyloc nut M3 The clamp 0809 can be spread as much as allow to slide it on the tail boom. Fix the two struts with the M3x25 screw loosely.
  • Page 55 0831c Shrinking tube In advance of the assembly of the push rod the two 60mm long shrink tubes have to be shrinked on the push rod. You can find the positions in the picture above measured from the end of the push rod to the rear end of the shrink tubes. Grease the outside of the shrink tubes to ensure a good sliding in the guides.
  • Page 56 Chapter – 11 Installation of the remaining RC components M o u n t o f E S C 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.
  • Page 57 F B L s y s t e m a n d r e c e i v e r Ideal solution is a FBL system with integrated receiver as shown in the picture on the left. But also the installation of a separated receiver can be done without problems.
  • Page 58 F l i g h t b a t t e r i e s The picture above shows examples for the fixation of a 12S and a 6S battery to the respective battery trays. The batteries can be connected with Velcro fasteners. I suggest this only when you have several batteries and just one battery tray.
  • Page 59 Chapter – 12 Applying the decor on the canopy The canopy has the same shape as the one from the old TDR. You can also use the old decor foils. A video for applying this décor you can find on our homepage. The new modern TDF-design consists of a similar window which is a little bit slimmer and is tapering out longer to the rear.
  • Page 60 In order for you to identify the front and back side, I have marked the beginning of the text with a black marker line (at the location of the from Henseleit Helicopters Cut the two stickers between . You can identify this position when...
  • Page 61 Chapter – 13 Settings P i t c h Starting from the basic setting of the swash plate in the neutral position (on page 35), in which the blade holders are 0 °, the desired pitch maxium and minimum values are first set. Follow the instructions of your FBL system. In general, this is not different with the (Linear Drive System) as with conventional swash plate controll.
  • Page 62 That one cyclic servo rod moves downwards and the other upwards does not matter. As a result, only the swash plate remains at its predetermined height. However, you can not take the table values for this because, in the case of cyclic moves, the swash plate does not slide up and down parallel to the rotor shaft, but makes a pivoting movement about its center point.
  • Page 63 T a i l The setting of the neutral position has already been described on page 55, so that only the maximum deflections have to be limited. To do this, move the control stick to the maximum level, and adjust the percentages so that the control sleeve with the brass inner part touches the ball bearing in the right-hand side tail fin when the control stick is fully right.
  • Page 64 A d j u s t a b l e f e a t h e r i n g s p i n d l e d a m p i n g In the fully relaxed state, the damping is too soft. Therefore, take the 3mm pin out of the tool bag to make a basic setting for the first flights.
  • Page 65 Chapter – 14 First flight Before flying, you should put the helicopter on the table again and look at it calmly from all sides. In the head once again everything go through. All screws have been tightened, even those which have been solved in the later construction phase. If all cables are securely routed, neatly inserted and secured if necessary.
  • Page 66 Jan Henseleit...
  • Page 67 D i m e n s i o n s (TDF - equipped with 712mm long baldes)