Assembly Check List

Print this Sheet, laminate and keep with Field Box

Date:_________________________________

Performed By:_________________________

Machine:______________________________

Place a check next to item when completed:

Assembly
• _____Use of threadlock compound on all set screws and non-locking type screws. (Loctite Blue)
• _____No substitution of SAE hardware where metric is specified.
• _____All servo arm screws tight in servo output shafts.
• _____Wooden frame members fuel proofed.
• _____Servo tray(s) secure (check by twisting by hand).
• _____Servos secure in trays with clearance all around servo bodies.
• _____Servo grommets and brass spacers tight but not crushed.
• _____All ball links properly set on balls, and all balls secure.
• _____Flybar unit hardware secure.
• _____Mixing Arms secure and moving freely.
• _____SeeSaw moves smoothly without play or binding.
• _____Struts properly attached and skids secure in struts.
• _____Clutch bell secure to pinion drive gear.
• _____Rotor blades properly finished, exposed wood fuel proofed.
• _____Tail blades properly finished, exposed wood fuel proofed.
• _____All rods a minimum of 5mm threaded in ball links.
• _____Main drive gear and tail drive gear clearances as per instructions.



Engine


• _____Inspected for debris inside if new, clear of dirt if crashed.
• _____All engine fasteners torqued.
• _____Engine Mounts secure.
• _____Muffler secure.
• _____Fan Housing Secure.
• _____Starter Cone Secure or belt attached (do not use thread lock)
• _____Approximate mixture settings dialed-in. (2 turns High, factory low)
• _____Drive train alignment checked.
• _____Remove glow plug and turn over manually to check for binding.
• _____Confirm low throttle low trim will kill engine.
• _____Confirm half throttle stick gives slightly more than half throttle.
• _____Remote glow plug wiring tested (if installed).



Fuel System


• _____Tank securely mounted without chaffing.
• _____Fuel lines in good condition and routed properly.
• _____Clunk not touching rear of tank.
• _____Vent Line not touching top of tank.
• _____Muffler Pressure connected.
• _____Fuel filter installed, clean and tight.
• _____Pressure test system with squeeze method if possible.
• _____Fuel Shutoff clips installed



Radio Installation


• _____1000+ma receiver pack charged to capacity.
• _____Batteries in trans. and receiver, cycled and recharged, tested with ESV.
• _____Gyro Battery (if separate)
• _____Switches mounted. Up or forward for ON, down or rearward for OFF.
• _____All leads securely inserted in receiver, all connectors mated securely.
• _____Wire leads checked for nicks or cuts.
• _____All spliced wires soldered and insulated properly.
• _____Wires bundled or stowed neatly.
• _____Receiver, battery and gyro amplifier foam wrapped and secured on radio tray(s).
• _____Gyro double sided taped to frame.
• _____Antenna routed to clear mechanics and other electrical wires.
• _____Antenna strain relief provided.
• _____Antenna secured at rear of helicopter to prevent catching rotors.
• _____Whip antenna tip secured and connector mated (if installed)
• _____Range check transmitter 360 degrees with gyro on. Max range _______ft/m.
• _____Servos quiet in operation, no jittering within range.
• Servos operating in the correct direction on each channel.
• Pitch_____Throttle______Tail Rotor_____Aileron_____Elevator _____
• _____Gyro ON-OFF (if seperate switch).
• _____Gyro working in the proper sense, gain adjusted.



Complete Radio Setup Checklist


Mechanical Installation


• _____All rods removed at servos and checked for free movement.
• _____Main rotor blade bolts set for proper tension if swinging blades.
• _____Main rotor blades balanced.
• _____FlyBar weights installed and balanced.
• _____Control paddles epoxied or ca'd to Flybar and in line.
• _____Rotor Head balanced (high point if avail.)
• _____Main rotor secured to mast.
• _____Tail blade bolts set to proper tension so blades will find centers.
• _____Tail rotor head with blades balanced.
• _____Swashplate level at center trim.
• _____Washout unit travel checked.
• _____Control paddles parallel to swashplate at level position.
• _____Center of gravity meets specs.(on main shaft or slightly in front.



Lubrication
Upon initial construction or after rebuilding, these points are lubricated as follows (see legend below)


• _____Collective pitch mechanism.(L)
• _____Main Mast Bearings.(G)
• _____Engine Shaft Starter Cone Bearings.(G)
• _____Tail Drive Pickup Gear Support Bearings (G)
• _____Tail Drive wire / tube.(G)
• _____Tail rotor pitch change rod bearing or sleeve.(H)
• _____Tail blade thrust bearings.(G)
• _____Main blade thrust bearings.(G)
• _____AutoRotation One-Way bearing. (L)
• _____Swash Plate.(G)
• _____All Rotor Head bearings, including flybar.(L)
• (L) Light oil, TriFlow synthetic, Slick50 One-Lube (NOT WD-40)
• (H) Heavy Oil such as 70 weight gear lube.
• (G) Teflon Grease during assembly.
• Plastic drive gears are not oiled. Synthetics are preferred because they attract less dirt.

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