JR Voyager E Assembly Instructions Manual

Electric-powered radio control helicopter

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VOYAGER E SPECIFICATIONS

Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33"

Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Main Rotor Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Tail Rotor Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7"

Gear Ratio

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.92:1:1.5

Speed Controller . . . . . . . NEA-300H High Frequency (included)

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . NHM-540ST (included)

Battery . . . . . . . . . . . . . . . 8.4V 2000mAh NiCad (not Included)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.0 oz– 54.7 oz

(weight will vary based on the servos used)

ASSEMBLY INSTRUCTIONS

The JR Voyager E is the first electric helicopter to utilize the

JR 120-CCPM swashplate control system. This new system

features a lower parts count and also reduces weight for

increased precision and improve performance. The Voyager's

lightweight, yet highly rigid frame design enables the

Voyager E to fly with power and control authority never

before seen in an electric helicopter.

* Gyro not Included.

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Summary of Contents for JR Voyager E

Page 1 ASSEMBLY INSTRUCTIONS ASSEMBLY INSTRUCTIONS The JR Voyager E is the first electric helicopter to utilize the VOYAGER E SPECIFICATIONS JR 120-CCPM swashplate control system. This new system Overall Length ........33"...
Page 2: Table Of Contents
Servo Arm Preparation and Installation ..34 Voyager E Features ....... 4 CCPM Servo Centering with the Sub-Trim Function .
Page 3: Introduction
PREASSEMBLY INFORMATION tric motor, it should be assembled and operated with the same care as its When first opening your Voyager E kit, you will notice that all of the larger glow engine counterparts. When operating your Voyager E, please parts are packaged and numbered to coordinate with the assembly step exercise caution and safety.
Page 4: Voyager E Features
Reduces assembly time and eliminates the need for paintings. ADDITIONAL ITEMS REQUIRED TO COMPLETE THE JR VOYAGER E 1. RADIO SYSTEM REQUIREMENTS (NOT INCLUDED): 6-channel or greater R/C helicopter system with 120° CCPM function (see list below), 4 standard or 4 mini servos, and gyro.
Page 5 3. BUILDING SUPPLIES (NOT INCLUDED): The following items are needed to complete the assembly of the JR Voyager: Nylon Wire Ties to Heavy-Duty Servo Arms (3 pcs) Whip Antenna (optional) Double-Sided Servo secure radio wires w/Screws Mounting Tape (JRPA215 or equivalent) 4.
Page 6: Hardware Identification
HARDWARE IDENTIFICATION There are various sizes and shapes of hardware included in this kit. Prior All of the hardware, screws, nuts, etc. contained in the Voyager kit are to assembly, please be careful to identify each screw by matching it to the described in the following A, B, C manner: full-size screw outlines included in each step.
Page 7: Anatomy Of The Voyager E
ANATOMY OF THE VOYAGER E Tail Case Flybar Control Arms Washout Assembly Anti-Rotation Plate Canopy 120 CCPM Swashplate Assembly Main Rotor Shaft Main Drive Gear Main Frame Pinion Gear Tail Boom Intermediate Gear Tail Rotor Blade NEH-300H Special RS540 Motor...
Page 8: Preassembled Main Frame Components
Preassembled Main Frame Components Note: Please familiarize yourself with Upper Main Shaft Bearing Block the components in this assembly Lower Main Shaft Bearing Block before proceeding to the next step. Upper Intermediate Gear Bearing Block Intermediate Gear Front Tail Rotor Drive Pulley Body Mount Attachment Attach the body mounts to the frame as shown.
Page 9: Mini Servo Mounting Plate Installation
Mini Servo Mounting Plate Installation 1 - A If you are using standard size servo, please proceed to Step 1-3........16 pcs 2.6 x 12 mm Self Tapping Screw When installing mini servos,it is necessary to install the mini servo adapters prior to com- pleting the frame assembly.
Page 10: Landing Gear Assembly
Landing Gear Assembly ....4 pcs Do not over tighten the 3 x 4 mm Set Screw four 3 x 4 mm set screws as it can damage the landing struts. Refer to the diagram below for 3 x 4 mm Set Screw (4) proper positioning when assem- bling the landing gear assembly.
Page 11: Main Drive Gear Assembly Installation
Main Drive Gear Assembly Installation If it is difficult to insert the main drive gear assembly, loosen the 4 screws in the lower ......... 2 pcs Short main shaft bearing block and push the 3 x 3 mm Set Screw block down slightly.
Page 12: Rotor Head Installation
3 mm Lock Nut ........2 pcs paddle as shown in the diagram. When correctly installed, the words “JR Propo” should face upward. 3 mm Lock Nut It is very important to insure that the 2 flybar pad- Flybar Paddles (2) dles are parallel to each other, as well as to the flybar control arm assembly.
Page 13: Flybar Adjustment
B and C. Please check to insure the correct direction of the universal links as shown in the diagram, so that the letters “JR PROPO” face the correct direction as shown. Next, install the control rods as shown so that the letters “JR PROPO”...
Page 14: Motor Installation
Motor Installation Pinion Gear 15T ....2 pcs Use Threadlock 3 x 18 mm Socket Head Bolt 3 x 8 mm Socket Head Bolt ......2 pcs 3 mm Flat Washer 3 mm Flat Washer ......1 pc 3 mm Set Screw 3 x 3 mm Set Screw Adjust the gear backlash before securing the 3 x 3 mm...
Page 15: Tail Gear Case Assembly
Tail Gear Case Assembly Be sure to note the correct orientation of the ........2 pcs tail boom so the slotted side is toward the tail gear case. Insert the tail boom fully into the 2.6 x 8 mm Self Taping Screw tail gear case before tightening.
Page 16: Tail Rotor Assembly Installation
Tail Rotor Assembly Installation Make sure that the 3 x 3 mm ......2 pcs set screws engage into the 2 x 4 mm Set Screw two flat spots on the tail output shaft....2 pcs 2 x 10 mm Socket Head Bolt 2 x 10 mm Socket Head Bolt (2) Use Threadlock on both bolts.
Page 17: Tail Boom Assembly Installation
Tail Boom Assembly Installation Slide the tail boom through the tail boom carrier and engage the tail drive ..4 pcs belt over the front pulley. Next, set the belt tension as shown below. 2.6 x 32 mm Phillips Head Bolt ..........
Page 18: Tail Rotor Blade Installation
Tail Rotor Blade Installation ... 2 pcs Tail Rotor Blade (2) 2.6 x 12 mm Socket Head Bolt Be careful not to over tighten the 2.6 x 12 mm socket head ......2 pcs bolts when attaching the tail Tailblade Movement 2.6 mm Lock Nut rotor blades.
Page 19: Servo Installation And Linkage Suggestions
Servo Installation and Linkage Suggestions • Use caution not to overtighten the servo mounting screws. The servos • Check to insure that all control rods have been adjusted to the proper should be able to be moved slightly within the grommets so that they lengths as shown in the manual.
Page 20: 4-A Aileron/Elevator Servo Installation (Mini Servo) . 20 4-B Pitch/Rudder Servo Installation (Mini Servo)
Aileron/Elevator Servo Installation (Mini Servo) ........8 pcs 2.6 x 10 mm Self Tapping Screw ............ 8 pcs 2.6 mm Flat Washer 2.6 mm Flat Washer (8) 2.6 x 10 mm Self Tapping Screw (8) Pitch/Rudder Servo Installation (Mini Servo) ........
Page 21: Tail Pitch Control Rod Assembly
Tail Control Rod (478 mm) Tail Control Rod Bushing (2) Tail Control Rod (478 mm) JR PROPO 9 mm 9 mm Universal Ball Link Tail Control Rod Installation...
Page 22: Receiver/Gyro/Speed Controller Installationn
Receiver/Gyro/Speed Controller Installation Servo Mounting Tape Receiver Double-Sided Servo Mounting Tape NEA-300H Speed Controller To protect the receiver, gyro, and speed controller from vibration, use thick servo tape when attaching. Gyro If you choose to wrap the receiver in foam rubber, be sure to wrap it in sponge of moderate thickness so as not to come in contact with canopy when the body is installed.
Page 23: Understanding Swashplate Control Systems
For JR radio owners, please refer to the radio information contained at the front of this manual or on the following page to determine if your radio system has the CCPM function. For other brands of radio systems, please contact the radio manufacturer for CCPM information. Please note...
Page 24: How Jr 120 Ccpm Works
HOW JR 120 CCPM WORKS The JR 120° three servo CCPM relies on the radio’s special CCPM swashplate mixing, rather than a conventional mechanical mixer that is utilized to achieve the same results. The radio’s 120° 3-servo CCPM function automatically mixes the three servos to provide the correct mixing inputs for aileron (roll), elevator (pitch) and collective.
Page 25: Ccpm Software Activation And Initial Adjustment
6-channel or greater R/C helicopter system with 120° CCPM function 5 servos Gyro CCPM-Ready JR Radio Systems Most current JR heli radio systems (XP652, XP8103 w/digital trims, 10X, as well as older 10 series systems) are equipped with 120° CCPM electronics for use with the Ergo CCPM machines.
Page 26 1. JR XP652 SYSTEMS The following activation and setup procedure should be used for all JR XP652 systems. Please note that the XF622 and XP642 6 channel systems do not have the required CCPM software, and therefore cannot be activated by the Horizon Service Center.
Page 27 -120 Note: The travel values shown for the rudder function are for use with Piezo gyros, like the JR NEJ-400, or NEJ-450 type gyros. If a conventional mechanical type gyro is used (JR 120, 130, etc.), then the travel values of the rudder will need to be changed to approximately 100%.
Page 28 2. JR XP8103/XP8103DT SYSTEMS The following activation and setup procedure should be used for all JR XP8103 and XP8103DT (digital trim) systems. Note: Some early XP8103 systems will require the activation of the CCPM software through the Horizon service center. It’s easy to identify if your system has the CCPM function activated by identifying if the “SWASH TYP”...
Page 29 U 100% Note: The travel values shown for the rudder function are for use with Piezo type gyros, like the JR NEJ-400 or NEJ-450 type gyros. If a conventional mechanical type gyro is used (JR 120, 130, etc), then the travel values of the rudder channel will need to be reduced to...
Page 30: Ccpm Software Activation And Initial Adjustment
– Note: The travel values shown for the rudder function are for use with Piezo type gyros, like the JR NEJ-400, or NEJ-450 type gyros. If a conventional mechanical type gyro is used (JR 120, 130 etc.), then the travel value of the rudder channel will need to be reduced to...
Page 31: Important Ccpm Programming Dos And Don'ts
Minor travel value adjustments are necessary due to slight variations in servo travel and centering. Although the three servos may appear to travel at the same amounts in each direction, in reality the servos can vary slightly. This variation is more common in analog type servos. If JR’s new digital servos are used, the travel adjustment values will generally not need to be altered.
Page 32: Important Ccpm Programming Dos And Don'ts
Elevator Servo: We will refer to this servo as the “Front” servo. The channel number for this servo when using a JR radio is CH3. Aux 1 (Pitch) Servo: We will refer to this servo as the “Right” servo. The channel number for this servo when using a JR radio is CH6.
Page 33: Speed Controller Setup
SPEED CONTROLLER SETUP Please refer to the instructions below for proper speed controller adjustment. Important: Prior to connecting the NiCad batteries, please check to insure that the motor pinion gear does not engage the intermediate gear. Once the speed controller valves have been set, connect the motor leads to the speed controller.
Page 34: Servo Arm Preparation And Installation
2 x 10 mm Flat Head Screw fitted to the servo to insure that the arms will attach to the servo as indicated. Since the JR servo ..3 pcs arm spline uses an odd number of teeth, it is sometimes possible to rotate the servo arm 180°...
Page 35: Ccpm Servo Centering With The Sub-Trim Function
3. JR PCM10, 10S, 10SX, 10SXII, 10X SYSTEMS 1) Enter the sub-trim function (code 15). 2) Adjust the left (aileron), right (Aux 1) and front (elevator) servos as needed until the servo arm is exactly parallel to the servo as shown when the collective stick is in the center position.
Page 36: Ccpm Linkage Connection
Please also note the direction of the ball links as shown by the “JR Propo” name imprinted on each ball link. The “JR Propo” name is imprinted on the front of each ball link.
Page 37: Checking The Swashplate For Level
Checking the Swashplate for Level After the three control linkages have been attached to the swashplate, it will be necessary to check the swashplate to insure that it is level. To do this, turn on the radio system and place the collective stick in the center position as before. Next, check to make sure that all trim levers and knobs are also in their center position.
Page 38: Pitch-To-Aileron Mixing Adjustment With Travel Adjust
This condition is generally more common when stan- dard type servos are used. If JR digital servos are used, the adjustment required is generally very small, if any. These variations in travel can be corrected by altering the travel value of each servo slightly through the travel adjustment function.
Page 39: Pitch-To-Elevator Mixing Adjustment With Travel Adjust
Pitch-to-Elevator Mixing Adjustment with Travel Adjust The total travel of each servo can vary slightly, which can also cause the swashplate to be tilted fore and aft when the col- lective is moved to the extreme high and low pitch positions. This situation can also be corrected if necessary through the use of the travel adjustment function.
Page 40: Tail Rotor Linkage Connection/Adjustment
Tail Rotor Linkage Connection/Adjustment Install the servo arm so that the linkage rod and the servo arm are at 90 degrees. (Refer to the ....1 pc diagram shown below.) If the desired angle cannot be achieved, use the sub-trim function of your 2 x 7 mm Flat Head Screw radio for fine tuning.
Page 41: Trimming The Body/Canopy
Trimming the Body/Canopy Body Canopy It will be necessary to remove the shaded areas shown Trim away the shaded portion of the canopy area on the body using an X•Acto knife or rotary tool. using scissors (Lexan ® scissors preferred). Canopy Attachment Test fit the canopy to the body before drilling the mounting holes by taping the canopy to the body.
Page 42: Body Mounting/Decel Attachment
Body Mounting/Decal Attachment ........6 pcs Body Mounting Grommets (4) 2.3 x 8 mm Self Tapping Screw Body It is suggested that the body decals be applied at this time. Use rubbing 2.3 x 8 mm Self Tapping Screws (6) alcohol to clean oil Canopy from the body...
Page 43: Decal Placement
DECAL PLACEMENT...
Page 44: Main Rotor Blade Balancing
Main Rotor Blade Balancing Main Rotor Blades Spanwise C.G. Balancing Final Static Balancing Place each rotor blade on a sharp edge of a table as To static balance the main rotor blades, either attach each blade to shown and adjust so each rotor blade “teeters” on the a “seesaw”...
Page 45: Motor Connection/Battery Installation
MOTOR CONNECTION/BATTERY INSTALLATION Install the battery and connect it to the motor at this time. During this procedure, check to insure that the throttle stick is in the low position. Connect the motor connectors at this time. When connecting, please make sure that you connect the red to red and black to black.
Page 46: Final Servo Adjustment And Radio Setup
FINAL SERVO ADJUSTMENT AND RADIO SETUP Now that the radio system is completely installed into the helicopter, it is Pitch Range Settings necessary to check and adjust the following: Flight Application Low Pitch Hovering Pitch High Pitch 1. SERVO DIRECTION (SERVO REVERSING) Mode (Low Stick) (Half Stick)
Page 47 FINAL SERVO ADJUSTMENT AND RADIO SETUP (CONTINUED) It will now be necessary to establish the maximum pitch value B. THROTTLE CURVE SETTINGS required for your application prior to adjustment. For example, if you are Below are several examples of possible throttle curves during vari- a beginning pilot, then your maximum negative pitch will be -5, and your ous flight conditions.
Page 48: Final Servo Adjustment And Radio Setup
“Right.” To do this, turn the radio system on and suspend the helicopter by GYRO GAIN ADJUSTMENT FOR JR G400 GYRO the main rotor head. Next, move the rudder stick to the right and watch the direction that the tail rotor servo arm travels.
Page 49: Radio System Operation/Helicopter Control Movements
RADIO SYSTEM OPERATION/HELICOPTER CONTROL MOVEMENTS Following is a brief explanation about the relation of radio's stick operation to helicopter movements. It is suggested that this basic operation be first understood prior to flying. ELEVATOR When the elevator stick is moved forward, When the elevator stick is pulled back, the helicopter will move and tilt forward.
Page 50: Radio System Operation/Helicopter Control Movements
RADIO SYSTEM OPERATION/HELICOPTER CONTROL MOVEMENTS (CONTINUED) PITCH / THROTTLE When the throttle stick is moved up, the helicopter will increase power and rise. When the throttle stick is moved down, the helicopter will decrease power and desend. MULTI VOLTAGE DATA INDICATOR DISPLAY Throttle/Rudder Stick...
Page 51: Final Preflight Check
FINAL PREFLIGHT CHECK Once all assemblies have been completed, please review the follow- Correct Main/Tail Rotation direction ing suggestions before attempting initial flights. • Review the instruction book and confirm that all assembly steps have been completed thoroughly. • Check to verify that the tail rotor assembly rotates in the correct direc- tion (see the diagram below).
Page 52: General Maintenance
GENERAL MAINTENANCE TAIL ROTOR BELT BATTERY MAINTENANCE Periodically check the tension on the tail drive belt (as shown in Step 3-5, Check that your batteries are properly mounted and charged. The most fre- page 17) to insure that it has sufficient tension for proper engagement. It is quent cause of crashes (aside from pilot error) is battery failure or discon- especially important to check this after initial test flights.
Page 53: Preassembled Components
PREASSEMBLED COMPONENTS The following parts included in this kit are preassembled. When repair or maintenance is necessary, refer to the diagrams below for disassembly or reassembly. INTERMEDIATE GEAR ASSEMBLY Intermediate Gear Make sure that the Intermediate Gear screw engages the Bearing block flat spot of the shaft.
Page 54 PREASSEMBLED COMPONENTS (CONTINUED) ROTOR HEAD ASSEMBLY 2 x 10 mm Flat Head Screw 2.6 x 8 mm Self Tapping Screw Blade Holder Spacer (Inner) Blade Holder Spacer (Outer) Long side is toward Main Blade Holder the Holder. Dampener Blade Holder Bearings, 3 mm Flat Washer 4 x 10 x 4 mm 3 mm Lock Nut...
Page 55: Xp652 Heli Data Sheet Voyager E Ccpm Initial Setup
XP652 HELI DATA SHEET VOYAGER E CCPM INITIAL SETUP Modulation S-PCM • Z-PCM • PPM (FM) Model Number ___________________ Voyager E CCPM Initial Setup Model Name ________________________ CHANNEL THR (1) AIL (2) ELE (3) RUD (4) GER (5) PITCH (6)
Page 56: Xp8103 Heli Data Sheet Voyager E Ccpm Initial Setup
XP8103 HELI DATA SHEET VOYAGER E CCPM INITIAL SETUP Modulation S-PCM • Z-PCM • PPM (FM) Model Number ___________________ Voyager E CCPM Initial Setup Model Name ________________________ INH • ACT AILE ELEV RUDD AUTO INH • ACT (POS. 1) DUAL-RATE Adjust as needed INH •...
Page 57: 10X Heli Data Sheet Voyager E Ccpm Initial Setup
10X HELI DATA SHEET VOYAGER E CCPM INITIAL SETUP Modulation S-PCM • Z-PCM • PPM (FM) Model Number ___________________ Voyager E CCPM Initial Setup Model Name ________________________ THRO AILE ELEV RUDD GEAR PITCH AUX2 AUX3 AUX4 AUX5 REVERSE SW TRAVEL ADJUST...
Page 58: X Heli Data Sheet Voyager E Ccpm Initial Setup
10X HELI DATA SHEET VOYAGER E CCPM INITIAL SETUP (CONTINUED) • —— —— HOV.SEL THRO • CURVE 100% 100% 100% 100% 100% 100% 100% (18) • TH,TRIM=SLOW HOV.T=CENTER • • -3°Pitch 7–8°Pitch 12°Pitch • —— —— HOV.SEL • PITCH -5°Pitch 5–6°Pitch...
Page 59: Body Set/Landing Gear/Servo Plate Assembly Parts
BODY SET / LANDING GEAR / SERVO PLATE ASSEMBLY 982150 982152 960072 980025 960036 980001 960631 960632 960633 982151 980147...
Page 60: Main Rotor Head/Swashplate/Washout Unit/Main Gear
MAIN ROTOR HEAD / SWASHPLATE / WASHOUT UNIT / MAIN GEAR ASSEMBLY 960635 970274 960636 960637 970006 960638 980001 980009 980039 970273 80035 980142 970246 980018 970004 960640 970247 960639 970098 970246 980121 980041 960641 981015 970273 983057 970010 960642 960634 980060 980044...
Page 61: Tail Rotor Assembly Parts
TAIL ROTOR ASSEMBLY 980131 980129 980009 980001 970252 981041 960648 960649 970253 960650 970254 970255 980073 960647 960652 980026 960651 960653 970272 960646 980024 980024 983059 980035 980027 983058 970256 960661 960654 980144 980129...
Page 62: Main Frame/Motor/Intermediate Gear Assembly Parts
MAIN FRAME / MOTOR / INTERMEDIATE GEAR ASSEMBLY 981042 960667 970258 960655 960656 960657 981042 960667 970261 960658 980026 980067 980013 980036 970257 980026 980148 980145 960660 960659 960626...
Page 63: Motor/Miscellaneous Assembly Parts
ASSEMBLY INSTRUCTIONS 958014 960664 The JR Voyager E is the first electric helicopter to utilize the VOYAGER E SPECIFICATIONS JR 120-CCPM swashplate control system. This new system Overall Length ........33"...
Page 64: Voyager Parts Listing
VOYAGER E PARTS LISTING Part # Description Quantity 958010 Motor Brush A Motor Brush 2 pc 958011 Armature 1 pc For NHM-540ST 958012 Endbell Set For NHM-540ST Endbell 1 pc Brush A 2 pc 958013 Brush Spring Brush Spring 2 pc...
Page 65 VOYAGER E PARTS LISTING (CONTINUED) Part # Description Quantity 960638 Hiller Control Lever Hiller Control Lever 1 pc Set Screw, 3 x 4 mm 2 pc 960639 Seesaw Assembly Seesaw Assembly 1 pc Seesaw Installation Bolt 2 pc 960640 Seesaw Arm...
Page 66 VOYAGER E PARTS LISTING (CONTINUED) Part # Description Quantity 960652 Horizontal & Vertical Fin Set Vertical Fin 1 pc Horizontal Fin 1 pc Self Tapping Screw, 2.6 x 12 mm 2 pc Flat Washer, 2.6mm 2 pc 960653 Tail Pitch Control Lever...
Page 67 VOYAGER E PARTS LISTING (CONTINUED) Part # Description Quantity 960665 Linkages Set K Swashplate to Rotor Head Thread Screw, 2.3 x 20 mm 2 pc Thread Screw, 2.3 x 25 mm 2 pc Universal Link 4 pc Universal Link S...
Page 68 VOYAGER E PARTS LISTING (CONTINUED) Part # Description Quantity 970251 Autorotation Collar Autorotation Collar 1 pc 970252 Tail PC Link Tail PCLink 1 pc 970253 Tail Slide Ring Sleep Tail Slide Ring Sleep 1 pc 970254 Tail Output Shaft Tail Output Shaft...
Page 69 VOYAGER E PARTS LISTING (CONTINUED) Part # Description Quantity 980024 Self-Tapping Screw, 2 x 8 mm Self-Tapping Screw, 2 x 8 mm 10 pc 980025 Self-Tapping Screw, 2.3 x 08 mm Self-Tapping Screw, 2.3 x 8 mm 10 pc 980026 Self-Tapping Screw, 2.6 x 8 mm...
Page 70 VOYAGER E PARTS LISTING (CONTINUED) Part # Description Quantity 981019 Shielded Bearing, 04 x 10 x 4 Shielded Bearing, 04 x 10 x 4 2 pc 981040 Plastic Bearing Case A (1680ZZ) Plastic Bearing Case A (1680ZZ) 1 pc Self Tapping Screw, 2.6 x 8 mm...
Page 71 NOTES...

JR Voyager E Assembly Instructions Manual

Section Description

1 Mini Servo Mounting Plate Installation

4 A Aileron/Elevator Servo Installation (Mini Servo) . 20 4-B Pitch/Rudder Servo Installation (Mini Servo)

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