Blade Fusion 480 Instruction Manual

Instruction Manual
Bedienungsanleitung
Manuel d’utilisation
Manuale di Istruzioni

EN

Safety Precautions and Warnings

• Always keep a safe distance in all directions around your model to avoid
collisions or injury. This model is controlled by a radio signal subject to
interference from many sources outside your control. Interference can cause
momentary loss of control.

• Always operate your model in open spaces away from full-size vehicles, traffi c
and people.

• Always carefully follow the directions and warnings for this and any optional
support equipment (chargers, rechargeable battery packs, etc.).

• Always keep all chemicals, small parts and anything electrical out of the reach
of children.

• Always avoid water exposure to all equipment not specifi cally designed and
protected for this purpose. Moisture causes damage to electronics.

• Never place any portion of the model in your mouth as it could cause serious
injury or even death.

• Never operate your model with low transmitter batteries.

• Always keep aircraft in sight and under control.

• Always activate throttle hold at rotor strike.

• Always use fully charged batteries.

• Always keep transmitter powered on while aircraft is powered.

• Always remove batteries before disassembly.

• Always keep moving parts clean.

• Always keep parts dry.

• Always let parts cool after use before touching.

• Always remove batteries after use.

• Never operate aircraft with damaged wiring.

• Never touch moving parts.

Age Recommendation: Not for children under 14 years. This is not a toy.

WARNING: This is a large model helicopter with carbon fi ber blades that spin at very high RPM. Always use extreme caution and common sense when

maintaining and operating this product. If you are unsure about ANY function or procedure described in this manual, DO NOT operate. Contact Horizon

Product Support for assistance.

WARNING: Always ensure you are operating the helicopter a safe distance, 45 feet (13 meters), away from yourself and others.

WARNING: Read the ENTIRE instruction manual to become familiar with the features of the product before operating. Failure to operate the product

correctly can result in damage to the product, personal property and cause serious injury.

This is a sophisticated hobby product. It must be operated with caution and common sense and requires some basic mechanical ability. Failure to operate this
Product in a safe and responsible manner could result in injury or damage to the product or other property. This product is not intended for use by children without
direct adult supervision. Do not use with incompatible components or alter this product in any way outside of the instructions provided by Horizon Hobby, LLC. This
manual contains instructions for safety, operation and maintenance. It is essential to read and follow all the instructions and warnings in the manual, prior to as­sembly, setup or use, in order to operate correctly and avoid damage or serious injury.

The following terms are used throughout the product literature to indicate various levels of potential harm when operating this product:
WARNING: Procedures, which if not properly followed, create the probability of property damage, collateral damage, and serious injury OR create a high probability
of superfi cial injury.

CAUTION: Procedures, which if not properly followed, create the probability of physical property damage AND a possibility of serious injury.
NOTICE: Procedures, which if not properly followed, create a possibility of physical property damage AND a little or no possibility of injury.

NOTICE

All instructions, warranties and other collateral documents are subject to change at the sole discretion of Horizon Hobby, LLC. For up-to-date product literature,
visit horizonhobby.com and click on the support tab for this product.

Meaning of Special Language

2

EN

To receive product updates, special offers and more, register your product at www.horizonhobby.com

Table of Contents

Length

38.6 in (980mm)

Main Rotor Diameter

43.1 in (1095mm)

Tail Rotor Diameter

9.1 in (232mm)

Components Needed to Complete ...................................................................... 3

Assembly Guide Legend ..................................................................................... 3

Tools Needed To Complete ................................................................................ 3

! BEFORE STARTING ASSEMBLY! ....................................................................... 4

Head Assembly ..................................................................................................4

Frame Assembly ................................................................................................5

Tail Assembly ................................................................................................... 11

Flight Controller Mounting ................................................................................15

Battery Installation ........................................................................................... 15

Helicopter Setup ..............................................................................................15

Main Rotor Alignment ......................................................................................16

Throttle Hold .................................................................................................... 16

Control Tests .................................................................................................... 16

Tail Rotor Blade Installation .............................................................................. 18

Main Rotor Blade Installation ...........................................................................18

Canopy Installation ..........................................................................................18

Flight Guidelines and Warnings ........................................................................ 19

Flying Your Fusion 480 ..................................................................................... 19

Blade Tracking ................................................................................................. 19

Post-Flight Inspection and Maintenance ...........................................................19

Troubleshooting Guide ..................................................................................... 20

Limited Warranty ............................................................................................. 20

Warranty and Service Contact Information .......................................................21

Exploded View ................................................................................................. 84

Parts List .........................................................................................................86

Recommended Components ............................................................................ 87

Optional Parts .................................................................................................. 87

Specifi cations

3

Recommended Component

Motor

Brushless Motor 4320-1300kV (BLH4953)

ESC

Talon 90-Amp 25V BL ESC W/20amp BEC (CSE010009700)

Battery

4400mAh 6S 22.2V 30C LiPo, 10AWG EC5 (EFLB44006S30)

Receiver

AR7210BX DSMX FBL Control System (SPMAR7210BX)

Swash Servos

H6050 Heli Cyclic Servo (SPMSH6050), metal gear servos required

Tail Servo

H6060 Heli Tail Servo (SPMSH6060), metal gear servo required

Charger

DC Li-Po Balancing Charger

Transmitter

DSM2

®

/DSMX® Compatible Transmitter

Components Needed to Complete Tools Needed To Complete

• Medium strength thread-locking compound

• High strength thread-locking compound

• 1.5mm, 2mm, 2.5mm, 3mm and 4mm hex drivers

• Ball link pliers

• Needle nose pliers

• Pitch gauge

• Metric ruler or calipers

Assembly Guide Legend

Apply NO Thread-locking Compound

Apply Medium Thread-locking Compound

Apply High Strength Thread-locking Compound

Loosely Tighten

Fully Tighten

EN

4

Head Assembly (H)

! BEFORE STARTING ASSEMBLY!

Many of the major sub-assemblies of the Blade Fusion 480 kit have been pre-assembled at the factory. These sub-assemblies
were not assembled with thread-locking compound. Prior to beginning assembly of the kit, loosen any pre-assembled
screws which are threaded into metal components and apply thread-locking compound. Use only enough thread-locking
compound to moisten the threads. Check all pre-assembled components to ensure all fasteners are tight.

1. Remove the spindle bolts from the blade grips.

2. Clean the spindle threads and the threads of the
4x12mm spindle bolts with isopropyl alcohol.

3. Apply high strength thread-locking compound and
re-install the spindle bolts. Ensure the thread-locking
compound does not contact the blade grip bearings.

WARNING: Failure to apply high strength

thread-locking compound to the spindle bolts
may allow the spindle bolts to work free during
operation, which could cause the rotor blades to fl y
off. Projectile rotor blades pose a serious risk of
property damage and may cause severe bodily injury.

4. Remove the linkage balls from the main grip arms
and re-install them using medium thread-locking
compound.

5. Install the main grip arms to the blade grips using
two 3x10mm socket head caps crews per arm and
medium thread-locking compound.

6. Remove the 2x5mm socket head cap screws one
at a time from the follower arms and re-install with
medium thread-locking compound.

7. Install the follower arms to the head block using one
3x20mm socket head cap screw and two washers
per arm and medium thread-locking compound.
Ensure the thread-locking compound does not
contact the bearings of the follower arms. Do not
fully tighten at this time.

1. Remove the seven linkage balls from the swashplate
assembly one at a time and re-install them with
medium thread-locking compound.

2. Fit the swashplate over the main shaft.

3. Insert the main shaft into the head block and secure
it with a 4x20mm bolt and locknut. Before tightening
the bolt pull on the head block to verify the bolt
passes through the hole in the main shaft. Do not

use thread-locking compound on the head bolt
and locknut.

4. Fully tighten the two follower arm 3x20 socket head
cap screws installed in step 7 above.

Step H2

Step H1

EN

55mm

68mm

5

Frame Assembly (F)

NOTICE: Always plan your servo wire routing prior to assembly. If servo wires will pass through or cross the frame plates, use sandpaper or a fi le to smooth the
edges of the frame plate to prevent wire chafi ng. Damage to servo wires may result in loss of control.

CAUTION: Sanding or fi ling carbon fi ber, such as frame plates, may produce carbon dust. Always wear appropriate Personal Protection Equipment (PPE)
such as a dust mask, when there is a danger of carbon dust.

1. Snap the follower arms onto two opposite linkage
balls on the upper swashplate.

2. Adjust the length of the rotor head linkages to 55mm
from center to center of the link openings.

3. Snap the rotor head linkages onto the main grip
linkage balls.

4. Snap the other end of the linkages to the remaining
linkage balls of the upper swashplate.

1. Adjust the length of the rotor head linkages to 68mm
from center to center of the link openings.

2. Snap one end of the servo control linkages onto the
linkage balls on the lower swashplate.

Attach two canopy posts to each frame plate using
a 3x10mm screw, a machined washer and medium
thread-locking compound for each post. Assemble both
a left and right frame side as shown in the illustration.

Step F1

Step H3

Step H4

EN

6

1. Attach the upper and lower bearing blocks to the
frame sides using 3x10mm screws, machined
washers and medium thread-locking compound.
The upper block has two threaded holes in the rear
of the block. Do not fully tighten the screws in the
bearing blocks at this time.

2. Slide the main shaft through both bearing blocks to
ensure the blocks are properly aligned with each
other.

3. Set the frame sides upright on a fl at surface, with
the bottom of both sides fully in contact with the
work surface.

4. Tighten all of the bearing block screws fully and
remove the main shaft from the bearing blocks.

5. Attach two landing gear mounts and two frame
posts to the frame sides using 3x10mm screws,
machined washers and medium thread-locking
compound.

Attach the landing gear to each side of the frame using
3x10mm screws, machined washers and medium
thread-locking compound.

Step F3

Step F2

EN

7

Frame side removed for clarity

1. Remove the 3x18mm socket head cap screws of
the tail belt guide assembly and re-install them
using medium thread-locking compound. Ensure
the thread-locking compound does not contact the
bearings of the tail guide assembly.

2. Install the tail belt guide between the frame sides
using 3x10mm screws and medium thread-locking
compound.

Thread the tail belt through the belt guide with the teeth
of the belt facing inward. Pull enough of the belt through
the guide to form a large loop, as shown.

Be careful to not crimp the belt.

Step F4

Step F5

EN

8

1. Pull the tail belt pulley off of the one-way bearing
sleave. Remove ten 2x4mm fl athead screws from
the tail drive pulley one at a time and re-install them
using medium thread-locking compound.

2. Remove fi ve 3x6mm fl athead screws one at a time
from the main gear and re-install them using medium
thread-locking compound. Re-install the tail belt pulley
on the one-way bearing sleave, ensuring the hole in the
pulley aligns with the holes in the sleave.

3. Slide the main gear assembly through the side of the
frame.

4. Place the tail belt around the upper gear as shown.

5. Slide the rotor head assembly down through both
bearing blocks and the main gear assembly.

6. Secure the main gear to the main shaft using a
4x20mm bolt and lock nut. Do not use thread-

locking compound on the bolt and lock nut.

7. Attach the anti-rotation bracket to the back of the
upper bearing block using two
M3x6mm button head screws
and medium thread-locking
compound. Ensure the anti­rotation pin is facing the rear
of the frame and is inserted in
the bracket before securing the
bracket to the bearing block.

8. Rotate the rotor head to ensure
it rotates freely.

1. Attach your chosen motor to the motor
mount using four 3x8mm screws and
medium thread-locking compound. The
motor leads should face toward the front
of the aircraft when installed.

2. Attach the pinion gear to the motor shaft
using two 4x4mm setscrews and high

strength thread-locking compound.

3. Prepare the motor leads for connecting
to the speed control. If using the
recommended speed control, solder the
large bullet connectors to the motor leads.

4. Attach the motor mount assembly
between the frame sides using
M3x10mm screws, machined frame
doublers and thread-locking compound.

Step F5

Step F6