FUTABA 9z User Manual
CONTENT
UPDATE
OVER 80 PAGES OF
INFORMATION
THE UNOFFICIAL WORKSHOP
MANUAL
Version 3 Release 5
by QuinCross
July 2012
© 2012 jamesandtracy.co.uk
www.jamesandtracy.co.uk
V
THE UNOFFICIAL WORKSHOP MANUAL
FUTABA 9Z
INFORMATION ABOUT THIS DOCUMENT
Title FUTABA 9Z – The Unofficial Workshop Manual
Description Comprehensive workshop manual for the Futaba 9Z series of
transmitters (9Z, WCI and WCII), providing technical reference material
and servicing, repair and upgrade procedures.
Author QuinCross
Version and release Version 3 Release 5
(Version 2B was a restricted Beta release for subscribers only)
Date 01/08/2012
Download updates
from
Copyright information Copyright 2012 www.jamesandtracy.co.uk (All rights reserved)
Restrictions on Use Please refer to section 1 (Introduction) in this document, specifically
Feedback Please provide all feedback on this document using the “get in contact”
Acknowledgements
In addition to all who have contributed by proxy through posts on internet forums and personal
websites, the following individuals deserve specific mentions and huge thanks from me for their
contributions and comments to this or the previous version of the manual. Without these guys
giving up their time, effort and equipment, this version of the manual would never have been
completed to the current standard. If you meet them on the web, waves or sky say “Thanks!”
because we owe them!
Key Contributors
http://www.jamesandtracy.co.uk
sections 1.3 and 1.4.
links and forms that can be found at www.jamesandtracy.co.uk.
Nico Rossi, from Italy – for all the pointers, photos, new information
and part numbers. You went beyond the call of duty in helping to
update this version of the manual!
René Berger, from Germany - for improving this version by
pointing out the current “glitches”.
Crazy8’s from RCGroups who paved the way in replacing the 9Z’s
soft button covers.
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
www.jamesandtracy.co.uk
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FUTABA 9Z
Contents
Contents ............................................................................................................................ 3
List of Tables ..................................................................................................................... 7
1. Introduction ............................................................................................................... 8
1.1. Document Overview ........................................................................................... 8
1.2. Please help support this work ............................................................................. 8
1.3. Disclaimer & Warning! ........................................................................................ 8
1.4. Distribution and Use ........................................................................................... 9
1.5. How to Report Errors and Get the Most Recent Version .................................... 9
1.6. The Different Futaba 9Z Models ....................................................................... 10
2. How to use this Manual ........................................................................................... 13
2.1. Document Structure .......................................................................................... 13
2.2. Servicing and Upgrade Matrix .......................................................................... 14
2.3. Preparation and Tools ...................................................................................... 16
THE UNOFFICIAL WORKSHOP MANUAL
2.3.1. General Tools ............................................................................................ 16
2.3.2. Specific Tools ............................................................................................ 17
2.3.3. Working with Printed Circuit Boards (PCBs) ............................................. 18
2.3.4. Soldering ................................................................................................... 19
2.3.5. Working with Ribbon Cables ..................................................................... 19
2.3.6. Attitude ...................................................................................................... 19
3. Servicing the 9Z ...................................................................................................... 20
3.1. User Password ................................................................................................. 20
3.2. 9Z Transmitter Calibration ................................................................................ 20
3.3. Replacing Corner Switches .............................................................................. 20
3.4. Front face controls, gimbals, and POTs ........................................................... 21
3.4.1. Removing the Throttle Ratchet for Flying Helicopters ............................... 21
3.4.2. Replacing the Joysticks and Potentiometers (POTS) ................................ 23
3.5. Replacement of LCD button panels .................................................................. 28
3.6. 35MHz Aerial Replacement and Servicing ....................................................... 29
3.7. Backup (Lithium) Battery .................................................................................. 30
3.8. Cleaning the LCD Screen ................................................................................. 33
3.9. Replacing the LCD Screen ............................................................................... 34
3.10. Transmitter battery pack ............................................................................... 35
3.11. RF Module ..................................................................................................... 37
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
3.12. Hard Resetting the 9Z Back to Factory Settings ........................................... 38
4. Upgrading and Tailoring the 9Z ............................................................................... 40
4.1. Adding extra 3 position switches ...................................................................... 40
4.2. Tailoring the Reference Plane of Joysticks ....................................................... 40
4.3. Strengthening and Repairing the Joysticks ...................................................... 41
4.4. Backlit LCD Display .......................................................................................... 43
4.5. 9Z Mode and Version Change (e.g. ZAP to ZHP) ............................................ 44
4.6. Upgrading to 2.4GHz and Telemetry ................................................................ 45
4.6.1. IMPORTANT: Antenna positioning for maximum range ............................ 46
4.6.2. Upgrading to 2.4GHz using the FrSky DHT-U ........................................... 47
4.6.3. Upgrading to 2.4GHz using the Spektrum DM8 module ........................... 50
4.7. Cycling and Fast Charging the Transmitter Battery Pack ................................. 51
4.8. Building a DSC Cable for Direct Servo Control ................................................ 54
4.9. DIY CAMPAC’s and “backing up” model memory to a PC ............................... 54
THE UNOFFICIAL WORKSHOP MANUAL
4.10. Building a Training Cable for Buddy Boxing .................................................. 55
th
4.11. Futaba 10Z upgrade - Adding a 10
Channel to the 9Z ................................ 56
5. Disassembling and Reassembling the 9Z’s Case ................................................... 57
5.1. Stage 1 – Module and Battery .......................................................................... 59
5.2. Stage 2 – Case Back ........................................................................................ 59
5.3. Stage 3 – Case Sides and Corner Switches ..................................................... 65
5.4. Stage 4 – LCD Panel ........................................................................................ 67
6. The Futaba Service and Test Menu ........................................................................ 73
6.1. Overview ........................................................................................................... 73
6.2. How to Access and Use these Menus on the 9Z .............................................. 73
6.3. Service Menus (Calibration and Upgrade) ........................................................ 75
6.4. Test Menus (Fault Finding & Checking) ........................................................... 76
APPENDIX A. The (Almost) Universal Service Menu Enabler .................................. 77
APPENDIX B. CONNECTION Port PIN-OUT Information ......................................... 78
B.1. 9Z Transmitter Battery Cassette Pin-out Information .............................................. 78
B.2. Futaba RF Module Pin-out Information ................................................................... 78
B.3. Futaba DSC/Trainer Pin-out Information ................................................................. 79
B.4. CAMPAC Pin-out Information.................................................................................. 80
APPENDIX C. COMPONENT PART NUMBERS ...................................................... 81
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
List of Figures:
Figure 1 The 9ZA’s ‘Snap Roll’ switches, that are missing in the 9ZH version ............... 10
Figure 2 The First Version of the Futaba 9Z ................................................................... 11
Figure 3 The Futaba 9ZAW, the second version of the 9Z (aka the 9Z WC1) ................ 12
Figure 4 The FUTABA 9ZAW II, the final and most desirable version (aka the 9Z WC2)
........................................................................................................................................ 12
Figure 5 This Workshop's Manual Structure ................................................................... 13
Figure 6 General Tools Required .................................................................................... 17
Figure 7 Specific Tools - The full toolset required ........................................................... 17
Figure 8 USB ICP PIC programmer with ZIF 'hook up' for the chip in green/blue. ........ 18
Figure 9 Corner Switch Replacement - NOTE: 8U SWITCH PART NO. IS SHOWN! ... 21
Figure 10 Removing the main PCB ................................................................................. 22
Figure 11 Lever up the PCB - Note: Metal Ratchet on Throttle at Right ......................... 22
Figure 12 Making and installing a "Ratchet Smoother”. .................................................. 23
THE UNOFFICIAL WORKSHOP MANUAL
Figure 13 Another example of a ratchet smoother .......................................................... 23
Figure 14 Joystick gimbal removed (Note: new joystick parts for replacement on the
right) ................................................................................................................................ 25
Figure 15 Disassemble the horizontal axis POT and joystick (new joystick parts in 1 & 6)
........................................................................................................................................ 25
Figure 16 Unscrew the ball bearing from the horizontal axis POT .................................. 26
Figure 17 Slice the heat-shrink tubing and desolder the POT ........................................ 26
Figure 18 Assembling a new joystick (note: DIY strengthening collet modification) ....... 27
Figure 19 Remove the vertical axis POT retaining plates and withdraw the POT .......... 27
Figure 20 Desolder the connector PCB (green) from the POT ....................................... 28
Figure 21 The three LCD Button Panels shown on a 9ZHP WC2 .................................. 28
Figure 22 Allen head bolt at the bottom of the 9Z aerial (3/32" or 3mm head) ............... 29
Figure 23 The access hole for the aerial retaining bolt in the battery compartment ....... 30
Figure 24 Label and protect the new battery ................................................................... 31
Figure 25 Removing the top PCB of the LCD Assembly ................................................. 32
Figure 26 Top PCB 'Flipped' and Battery Terminals Exposed ........................................ 32
Figure 27 Removing the LCD Assembly ......................................................................... 33
Figure 28 LCD Assembly removed and partially disassembled ...................................... 34
Figure 29 Complete disassembly of middle PCB and LCD Panel .................................. 35
Figure 30 Blown Schottky Diode on Mini PCB ................................................................ 36
Figure 31 Futaba RF Module Pin-out Numbering ........................................................... 37
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
Figure 32 Weak solder joint in RF Module ...................................................................... 38
Figure 33 Access holes for hard resetting a 9Z .............................................................. 39
Figure 34 Changing the Rotational Position of Joysticks ................................................ 40
Figure 35 Crack in the base of a 9Z joystick adding significant play to the control ......... 41
Figure 36 Metal joystick strengthening collet .................................................................. 42
Figure 37 How to repair a cracked joystick with a collet ................................................. 42
Figure 38 A Backlit 9Z using the 'EL Panel' solution ....................................................... 43
Figure 39 Wiring in the EL Panel, voltage regulator and switch ...................................... 43
Figure 40 Example Voltage Regulator (Check current handling capacity of 78L05) ....... 44
Figure 41 Resistor or short for Mode/Version change .................................................... 45
Figure 42 Optimal antenna position for 2.4 GHz ............................................................. 47
Figure 43 The DHT-U upgrade with connections through DIY RF Module ..................... 48
Figure 44 Modified RF Module for an FrSky DHT-U ....................................................... 49
Figure 45 Fitting a Spektrum DSM module antenna ....................................................... 50
THE UNOFFICIAL WORKSHOP MANUAL
Figure 46 Poor design of the connection on Spektrum DSM module ............................. 51
Figure 47 The 9Z transmitter pack diode jumper ............................................................ 52
Figure 48 9Z Transmitter Battery Disassembly ............................................................... 53
Figure 49 400mA diode on the mini PCB ........................................................................ 53
Figure 50 New 3A diode soldered to PCB (Note: Silver line on diode indicating
orientation) ...................................................................................................................... 54
Figure 51 Adding a 10th Channel to the 9Z .................................................................... 56
Figure 52 9Z Disassembly and Reassembly Process ..................................................... 57
Figure 53 Overview of 9Z Case Disassembly ................................................................. 58
Figure 54 Stage 1 Complete - Module and Battery Removed ........................................ 59
Figure 55 Removing the comfort grips ............................................................................ 60
Figure 56 Removing the bottom cover ............................................................................ 60
Figure 57 Loosen these screws on top cover ................................................................. 61
Figure 58 Lever up back cover ........................................................................................ 62
Figure 59 Label all ribbons and cables on the PCB ........................................................ 62
Figure 60 Screws to loosen to allow play in case sides .................................................. 63
Figure 61 Protect a screwdriver and lever case top up to refit case back ....................... 64
Figure 62 Refit battery hatch ........................................................................................... 64
Figure 63 Allen key screws to remove ............................................................................ 65
Figure 64 Case corner removed and ribbons detached .................................................. 66
Figure 65 Case sides slid outwards and removed .......................................................... 66
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
Figure 66 How the corners "Snap-Slide" into place ........................................................ 67
Figure 67 - Partial Step 3 Disassembly Option ............................................................... 68
Figure 68 Remove these cables to access LCD panel ................................................... 69
Figure 69 Remove and loosen these screws (note those already removed in Stage 3, if
they are still present remove them) ................................................................................. 69
Figure 70 Lever up PCB panel ........................................................................................ 70
Figure 71 LCD Panel now completely removed (retaining plate/lugs on top) ................. 70
Figure 72 LCD Panel flipped over backwards for access ............................................... 71
Figure 73 Ribbon cables with masking tape fed back through case ............................... 71
Figure 74 Cables at sides of LCD Panel that get trapped ............................................... 72
Figure 75 Overview Flowchart for Futaba 9Z Service and Test Menus .......................... 74
Figure 76 Futaba 9Z Service Menus Flowchart .............................................................. 75
Figure 77 Futaba 9Z Test Menus Flowchart ................................................................... 76
Figure 78 Futaba 9Z Transmitter Battery Pin-out ............................................................ 78
THE UNOFFICIAL WORKSHOP MANUAL
Figure 79 Futaba RF Module Pin-out Numbering ........................................................... 78
Figure 80 DSC/Trainer Port Pin-out (6 pin DIN) .............................................................. 79
Figure 81 CAMPAC Pin-Out (Note: Reversed pin numbering) ....................................... 80
List of Tables
Table 1 Possible solutions to common faults and issues ................................................ 14
Table 2 Service and Upgrade Matrix ............................................................................... 16
Table 3 Upgrading to 2.4GHz - Compatibility & Recommendations ............................... 46
Table 4 Available DIY CAMPAC clones .......................................................................... 55
Table 5 Selected component part numbers used in this manual .................................... 82
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
1. INTRODUCTION
1.1. Document Overview
THE UNOFFICIAL WORKSHOP MANUAL
This document brings together the wealth of information that is available on the
Futaba 9Z series of transmitters (ZAP/ZHP, ZAW/ZAH aka WC1, ZAW/ZAH II aka
WC2) into a single workshop manual for servicing, maintaining and upgrading these
radios. Most of the procedures contained in this document have been tested on my
own Futaba ZAP WC2, and they should hold true (in general) for the earlier 9Z
models. Where I have not tried a procedure I have tried to highlight this in the text.
Finally, there are some people I need to thank. There is a lot of information on the
web about the 9z and other Futaba radios. Before I got hold of my 9Z radio and
serviced it there were many others who blazed the trail for me. Without these RC
adventurers out there living (and sometimes blowing up!) the dream, this document
would never have come about. This document presents the work of that huge webwide community – not just us RC guys either – So a really big thanks to all!
1.2. Please help support this work
I’m just a modeler like you – I wrote this in my spare time to help others. I’d like to
write more manuals, but to do that I need to buy the transmitters and stuff. For
example as a follow on to this manual I would like the next project to be a similar
manual for the 14MZ. I can’t do this without your help. I have a young family and
really can’t afford to splash out on kit just to write a new manual, however much I’d
like too (my wife would kill me!). So whether you’d just like to spend a few dollars to
buy me a beer to say thanks, or contribute ten dollars towards a new workshop
manual, my family and I would really appreciate it. A big thank you to the many who
have already supported this work.
To donate please click the button below and give whatever you think this
manual is worth – it all helps to keep the project going:
Click to donate GBP
Click to donate Euros
Click to donate USD
Without your help this manual would not exist.
1.3. Disclaimer & Warning!
If you intend to use this Workshop Manual then you are doing so at your own risk.
Note that only some of the procedures have been tested by me, and then only on
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
my own 9ZAP WC2 (aka 9ZAW II). You can damage your radio, yourself and
others, so please ensure you read the following:
This is not an authorized Futaba document and the author is not employed by
Futaba. The author is a private individual and the information contained in this
document has been assembled from numerous sources and through direct
experimentation; it is not comprehensive and may be incorrect and inaccurate. No
reliance may be placed for any purpose whatsoever on the information or opinions
contained in this document or any other document referenced here-in or oral
statement or on the completeness, accuracy or fairness of such information and/or
opinions herein or therein. All information is provided without any warranties of any
kind and the author makes no representations and disclaims all express and implied
warranties and conditions of any kind, including, without limitation, representations,
warranties or conditions regarding accuracy, timeliness, completeness, noninfringement, merchantability or fitness for any particular purpose. The author
assumes no responsibility to you or any third party for the consequences of any
errors or omissions. Nor does the author accept any liability for any direct or indirect
or consequential loss or damages of any kind resulting from any use of this
document or any information contained in it.
1.4. Distribution and Use
THE UNOFFICIAL WORKSHOP MANUAL
As a private individual or charity you may distribute this document freely in its
entirety provided that no fee is collected for its distribution (other than reasonable
reproduction costs). This document or any part of this document may not be used in
a commercial context or for the purposes of financial gain without the author's
express written permission; it is not the author’s intent to deny permission without
good reasons. To gain permission to use this document in a commercial context or
purpose please visit my website using the following link
http://www.jamesandtracy.co.uk/howto/9Z.htm
.
1.5. How to Report Errors and Get the Most Recent Version
If you have downloaded this document from a third party site, the most recent version of
this manual can be downloaded at:
http://www.jamesandtracy.co.uk/howto/9Z.htm
It would be a good idea to download a new copy of this document from the above link in
any case, as you will be able to leave your email address. This will allow me to
automatically notify you of any major updates, changes, errors or omissions if I become
aware of them. I intend to do this, but don’t take this as a guarantee. Like everyone, I
have a lot else that goes on in my life!
This document release is:
Document: Futaba 9Z - The Unofficial Workshop Manual
Version: 3
Release: 4
Release Date: 17/07/2012
.
This version of the manual may contain inaccuracies and omissions. If you find any
please let me know by visiting the above hyperlink. You’ll not only be helping me, but
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
you’ll help others too! If you have any information you’d like to add to this manual, or
suggestions for it, please also post a message or contact me.
1.6. The Different Futaba 9Z Models
There are 3 main versions of the Futaba 9Z each available in two flavours (Aircraft and
Helicopter). The three main versions comprise:
1. The original 9Z – 9ZAP is the aircraft version and 9ZHP the helicopter.
2. The 9Z World Champion Edition I (WC1) – 9ZAW is the aircraft version and 9ZHW
the helicopter, but this is most commonly referred to as the 9ZAP WC1or 9ZHP
WC1.
3. The 9Z World Champion Edition II (WC2) – 9ZAW II is the aircraft version and
9ZHW II the helicopter, but this is most commonly referred to as the 9ZAP WC2 or
9ZHP WC2.
The differences between the models are very minor for most purposes and, if you can
get an original 9ZAP or WC1 for a decent price, you should not be put off your purchase
just because it’s not a 9ZAP WC2. You can upgrade the set to match the 3 position
switches of the WC2 using this manual and you’re unlikely to notice the other differences
unless you’re a extreme 3D pilot or pattern flyer at the very top of your game. To all
practical purposes any of these sets can be easily upgraded to do everything 99.9% of
flyers could ever need. The key differences between the models are:
THE UNOFFICIAL WORKSHOP MANUAL
1. 9ZAP WC1 – adds Gyro Sensitivity mixing and Fuel Mixture Control. In addition, the
VRA and VRB dials are renamed to ‘Left Dial’ and ‘Right Dial’.
2. 9ZAP WC2 – adds (in addition to WC1), four 3-position switches on the face,
upgraded sticks and increased frame rate of 2048 around centre for digital servos
(analogue servos cannot use this increased response rate)
The differences between Helicopter and Aircraft ‘flavours’ of the 9Z series are the same
throughout:
1. The Helicopter version does not have a throttle ratchet and defaults to Helicopter
models in the software. The 3 position switch is at Switch E on the top left hand side
(this is also useful for gliders)
2. The Aircraft version has a throttle ratchet and defaults to Aircraft models in the
software. It has snap roll switches (see Figure 1) at the back of the transmitter and
the 3 position switch is at the top right hand side.
Figure 1 The 9ZA’s ‘Snap Roll’ switches, that are missing in the 9ZH version
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
If you fly both helicopters and aircraft go for the Aircraft version and upgrade the
transmitter using this manual to make a hybrid 9VH/A version with the best of both
worlds.
THE UNOFFICIAL WORKSHOP MANUAL
Figure 2 The First Version of the Futaba 9Z
The original 9Z is shown in Figure 2 above. Notice the differences when compared to
other 9Z models: The unique PCM1024Z logo between the two dials on the front face
and the unique button text and colouring around the LCD.
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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THE UNOFFICIAL WORKSHOP MANUAL
FUTABA 9Z
Figure 3 The Futaba 9ZAW, the second version of the 9Z (aka the 9Z WC1)
The 9Z WC1 is shown in Figure 3 above. Notice that the differences are in the same
areas as before: the PCM1024Z logo and the buttons around the LCD.
Figure 4 The FUTABA 9ZAW II, the final and most desirable version (aka the 9Z WC2)
The 9Z WC2 is shown in Figure 4 above. Notice the same differences in the same areas
as before. Now it comes with a funky blue colouring (which can appear quite grey except
in bright light). Undoubtedly the coolest of the 9Z’s, but is that worth the extra money?
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
2. HOW TO USE THIS MANUAL
2.1. Document Structure
This workshop manual is split into sections and annexes to help you find the information
you need. The structure of the document is provided below in Figure 5.
1. Introduction
Im portant gene ral i nformation
you need to read .
2. How to Use This Manual
The master index for this
manual , so start here !
The m ast er Serv ic e , Repair
and Upg rade M at ri x ;
General preparation , tools
and techni ques .
THE UNOFFICIAL WORKSHOP MANUAL
3. Ser v i cing t h e 9Z
Specific det ailed
procedures f or serv i cing
and repair .
5. Di sa ssembli ng an d
Reas sembli n g th e 9Z ’s
Case
How to get the case apart
to serv i ce, upgrade or
repair t he item of i nteres t .
6. 9Z’s Service and Test
Menu
How to us e t h e hi dden
soft ware m enu for
cal i brat i on , t est i ng and
upgrade .
4. Upgrading and
Tailoring the 9Z
Specific det ai l ed
procedures for upgrading
and tai l ori ng y our 9Z to
your own requi rem ents .
ANNEXES
Support i ng tec hni cal
inf orm at i on and tool s for
servicing your 9Z.
Figure 5 This Workshop's Manual Structure
You can locate the service procedure you need using the Servicing and Upgrade matrix
in this document section. For example, having found the procedure you need in this
section, you’d then read the detailed process for it in Section 3 (Servicing the 9Z). This
procedure would refer you out to other areas of the document when required; e.g.
“Disassemble to Stage 3 as described in Section 5 (Disassembling and Reassembling
the 9Z’s Case) and now calibrate the Joysticks as described in Section 6 (The Futaba
Service and Test Menu)”.
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
2.2. Servicing and Upgrade Matrix
You can use the following tables to navigate this manual, solve specific issues or fix
faults with your 9Z. Table 1 shows some common faults and issues and the possible ID
of the solution in Table 2. Table 2 below provides a matrix of the service and upgrade
procedures detailed in this manual, the tools required to perform them and the level of
difficulty (refer to the key below the table for an explanation of the symbols). I’ve rated
the level of difficulty based purely on what level of skill I think is needed if the correct
“recommended” tools for the job are used. You can get by without the correct tools for
many of these procedures, but the level of skill required will be significantly increased.
FAULT FINDING POSSIBLE SOLUTION
An alarm is sounding and "Back Up" is flashing on the LCD See ID 9 in Table 2
I cannot change my user name or have forgotten my password See ID 1 in Table 2
I cannot charge my battery through the charge port See ID 12 in Table 2
I cannot cycle my battery pack or use my aftermarket digital charger See ID 21 in Table 2
THE UNOFFICIAL WORKSHOP MANUAL
Poor control around stick centres. Especially a double centre to
controls when moved by small amounts. See ID’s 6 & 17 in Table 2
Poor control around stick centres. Erratic servo movement. Servos do
not centre after control movements, especially when combined with a
‘grinding’ feel to joystick controls. See ID 6 in Table 2
Erratic servo movement to joystick control or servos do not centre after
control movements, especially ‘jumping’ when switching between rates. See ID 2 in Table 2
Soft button panels do not work, require a very ‘positive’ push or work
erratically. See ID 7 in Table 2
Switch A behaves erratically or does not work See ID’s 2 & 14 in Table 2
The "On Air" and Alarm Light does not function See ID’s 13 & 20 in Table 2
Poor signal range (original 35 MHz setup) See ID 8 in Table 2
Poor signal range (following 2.4GHz conversion) See ID 20 in Table 2
Table 1 Possible solutions to common faults and issues
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
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FUTABA 9Z
ID TASK DIFFICULTY SECTION PAGE
Section 3 – SERVICING
THE UNOFFICIAL WORKSHOP MANUAL
1 User Password
2 9Z Transmitter Calibration
3 Replacing Corner Switches
4 Replacing front face controls and switches
5 Removing the throttle ratchet for helicopter flying
6 Replacing joysticks and potentiometers
7 Replacing the LCD button panel
8 Replacing the 35MHz aerial
9 Backup (Lithium) Battery
10 Cleaning the LCD Screen
11 Replacing the LCD Screen
12 Transmitter battery pack
13 RF Module
3.1 20
3.2 20
3.3 20
3.4 21
3.4.1 21
3.4.2 23
3.5 28
3.4 29
3.5 28
3.8 33
3.9 34
3.10 35
3.11 37
14 Hard Resetting the 9Z Back to Factory Settings
Section 4 – UPGRADING
15 Adding extra 3 position switches
16 Tailoring the Reference Plane of Joysticks
17 Strengthening and repairing the Joysticks
18 Backlit LCD Display
19 9Z Mode and Version Change (e.g. ZAP to ZHP)
20 Upgrading to 2.4GHz and Telemetry
21 Cycling and Fast Charging the Transmitter Battery Pack
22 Building a DSC Cable for Direct Servo Control
Building your own CAMPAC for increased model
23
memory
3.12 38
4.1 40
4.2 40
4.3 41
4.4 43
4.5 44
4.6 45
4.7 51
4.8 54
4.9 54
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
THE UNOFFICIAL WORKSHOP MANUAL
24 Building your own PC interface for backing up the 9Z
25 Building a Training Cable for Buddy Boxing
26 Adding a 10th Channel to the 9Z
27 Building your own Futaba Service Menu Enabler
*Key for “Difficulty” Symbols in Above Table:
Symbol Explanation
No experience necessary
You can follow instructions
As above, plus you are comfortable with
household DIY
As all the above, plus you have soldering
experience
4.9 54
4.10 55
4.11 56
APPENDIX
A 77
Specific tools required or recommended
Table 2 Service and Upgrade Matrix
(Section 2.3.2)
Service and Test Menu Enabler required
(Section 6.2)
2.3. Preparation and Tools
This is an important section please read it thoroughly. If you do not have the right tools,
general techniques and mindset for the job, you will at best find it hard and at worst you
could damage your transmitter.
2.3.1. General Tools
The general tools you will require are shown below in Figure 6. The yellow object is the
Universal Service Menu enabler described in APPENDIX A. The tape is to protect your
pliers and screwdrivers. The white card is to stick screws through when you remove
them, and the pen is to label them so you know where they came from. I’d also suggest
you keep a camera handy to take photos for reference when you reassemble the case.
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
Figure 6 General Tools Required
THE UNOFFICIAL WORKSHOP MANUAL
2.3.2. Specific Tools
I would really suggest you invest in a solder pump (blue syringe in Figure 7) and a
variable temperature soldering iron (Blue soldering iron with dial in Figure 7) for any
work involving Printed Circuit Boards. They are both very cheap items and you’ll use
them again and again. Although you can get by without a variable temperature iron, you
must have an iron with a needle/small tip that is suitable for the delicate work of
desoldering and resoldering components. You will not be able to get by without a solder
pump or at the very least some desoldering braid - yes you might get the components off
the board, but you will probably damage them if you’re not using a pump. As a pump
costs something like £2 ($3) you’d be a fool to attempt work without one. You will also
probably need a digital multimeter (yellow meter in Figure 7), get one they’re also cheap.
Figure 7 Specific Tools - The full toolset required
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
If you intend to build your own CAMPAC for the 9Z and have a general interest in
building other electronic RC gadgets then you’ll need a PIC programmer (see Figure 8).
This is a piece of kit that can upload code that you’ve either written yourself or have
downloaded from the internet to a PIC MicroChip. There are loads of different models
out there on the market and some of the Chinese copies are very cheap ($12). Do some
research before you buy, and buy only if you have a wider interest in this equipment.
That said, once you have one there are loads of excellent pre-written circuits and codes
for our hobby, so you don’t need to know about electronics to start making your own
custom kit. Using the programmer is very simple, you just hook it up to the PC and
microchip and then ‘burn’ the code onto the chip as you would a CD or DVD. Key things
to look out for in PIC programmers are:
1. That the PIC Programmer supports the chips you will be using.
2. Has a good source of software updates to remain usable with newer microchips.
3. Has USB connectivity
4. Has ICP (in-circuit programming) capability
5. Has a ZIF (Zero Insertion Force) connection for hooking up to chips
6. External power supply possible (USB power can brown out on some chips)
THE UNOFFICIAL WORKSHOP MANUAL
Figure 8 USB ICP PIC programmer with ZIF 'hook up' for the chip in green/blue.
2.3.3. Working with Printed Circuit Boards (PCBs)
Components on printed circuit boards can be damaged by static electricity. I personally
have never blown up a chip this way, but it pays to be careful. Make sure you’re wearing
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
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FUTABA 9Z
cotton, if possible do not work in a carpeted area, pick up PCBs on the edges, earth
yourself by touching a metal bathroom tap before starting work and frequently earth
yourself on the metal sub-case of the 9Z before touching a PCB. If you’re really worried
you can buy a dedicated earth strap for your wrist very cheaply that you connect to the
9Z sub-case and it will provide a permanent earth, but I don’t have (or use) one and so
far everything has been fine.
2.3.4. Soldering
THE UNOFFICIAL WORKSHOP MANUAL
When you are soldering and desoldering components be as quick as you can as high
temperatures can damage some of them. This is why a variable temperature soldering
iron is such a good idea – you set it at a higher temperature for desoldering and it will
melt the solder before heat can be dispersed to the component. You can also use
crocodile clips as heat sinks to prevent temperature dispersing to delicate components.
There are lots of tutorials on the web about soldering and it’s very simple!
2.3.5. Working with Ribbon Cables
They’re everywhere in the 9Z. You need to be careful how you handle them and that you
don’t trap or damage them. You also need to recognise that you may need to replace
them in some instances just because they’re old (although this has never happened to
me). Do not twist them or force them, ease them back in and out. Do not remove them
with unprotected pliers. They’re likely to be as good as new inside the case, but with age
they become inflexible, and with too much pulling in and out the connectors become
detached from the ribbon. So if you can help it do not remove them unless necessary
and in the worst case, replacements can be sourced from Futaba or DigiKey/Farnell/RS
Components.
2.3.6. Attitude
Attitude….. as in yours! You need to work as if you're disarming and rearming a bomb.
That means slow thoughtful progress. If at any stage you think, "damn, doing that could
blow this thing up, but let's take a gamble" walk away and grab a cuppa! If you find
yourself about to force some bits together, walk away and grab a cuppa! If your kids
come home, walk away and grab a cuppa....well you get my drift! This is your prized
radio you're working on - take your time and keep it calm. Nothing, I repeat nothing in the
9Z, requires you to 'force it', everything clicks easily into place. There are far too many
posts on internet forums saying things like “Grab it here and pull up really hard” or “Give
it a smack here”. If you really feel the need to do this kind of thing for pleasure, invest in
a classic car or try ‘experimenting’ in your sex life, do not do it to your radio!!!
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
THE UNOFFICIAL WORKSHOP MANUAL
3. SERVICING THE 9Z
3.1. User Password
If you have forgotten the user password for your 9Z you can use the Service and Test
Menu to display the password, instead of having to reset it through a hard reset of the
transmitter. You will need a Service and Test Menu enabler to access the information
(see Section 6.2 and APPENDIX A)
The user password can be found on the “System Overview” screen of the Futaba Test
and Service Menus. This is fully described in the diagram in Section 6.3.
3.2. 9Z Transmitter Calibration
It is a good idea to recalibrate your transmitter after a few years of use as the hardware
settings drift. Typical symptoms include servo neutral positions ‘jumping’ at low rates and
sometimes even switches failing to work in one position.
You can test if your transmitter needs recalibration of its joysticks in the following way:
1. Start by selecting a blank (freshly reset) airplane program.
2. Go to the ATV menu
3. Hold both sticks fully up and fully right while switching between AIL, ELE, THR and
RUD. If the pointer below the graph moves even a little while you are switching
channels you radio needs calibration.
4. Repeat step 3 but now holding both sticks fully down and fully left.
5. Finally, repeat step 3 with both sticks cantered (including throttle axis).
To recalibrate your transmitter you’ll need to access the Futaba Service and Test Menu.
This is described in Section 6 (The Futaba Service and Test Menu) and you should refer
to the listed Joystick and Switch recalibration menus for the recalibration procedure.
3.3. Replacing Corner Switches
This procedure relates to a like for like replacement of the Corner Switches. If you wish
to modify a switch (e.g. replace a 2 position switch with a 3 position) you should refer to
Section 4.1 (Adding extra 3 position switches).
1. Disassemble the 9Z’s case to Stage 3 as described in Section 5 (Disassembling and
Reassembling the 9Z’s Case).
2. Disconnect the ribbon cables from the corner switches.
3. Remove the switch from the corner panel by unscrewing the retaining plate
4. Desolder the switch from its mini-PCB
5. Replace with a 9Z switch and solder it to the mini-PCB
Note: The 9Z switches do not have an offset connector pattern like those of the 8U
series, the 8U series switches will fit but they require some gentle bending of the
connectors see Figure 9.
6. Reassemble is a reversal of disassembly
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
THE UNOFFICIAL WORKSHOP MANUAL
Figure 9 Corner Switch Replacement - NOTE: 8U SWITCH PART NO. IS SHOWN!
3.4. Front face controls, gimbals, and POTs
Note: I have not replaced the Front Face Controls so this procedure may be incomplete.
1. Disassemble the 9Z’s case to Stage 2 as described in Section 5 (Disassembling and
Reassembling the 9Z’s Case).
2. Access for general servicing (e.g. greasing bearings and checking POTs) and for
replacement of the front face controls and aerial requires the partial removal of the
main PCB. Make sure you are earthed and protect your tools so you don’t damage
ribbon cables etc., see Section 2.3.
3. Remove the 4 ribbon cables, 2 connectors and 3 screws shown in Figure 10 from
the main PCB.
4. You will now be able to lever up the main PCB as shown in see Figure 11 to gain
access to the front face controls etc.
3.4.1. Removing the Throttle Ratchet for Flying Helicopters
To remove the ratchet action on the Throttle for Helicopter flying, the technique I use is
to make a ‘ratchet smoother’ from a strip of beer can (see Figure 12) or scrap plastic.
This strip is cut to fit under the existing ratchet (see Figure 11) and has a hole in one end
so it can be held in place by the existing ratchet’s screw. This whole assembly of ratchet
and ‘ratchet smoother’ is then screwed back into place (see Figure 13). I find this works
much better than flipping the metal ratchet lever upside down which still results in some
unwanted ‘ratchet’ feel. In all cases I’d advise against sanding down the plastic gear to
remove the ratchet effect as this would likely result in a non-uniform control feel unless
done very, very carefully.
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
THE UNOFFICIAL WORKSHOP MANUAL
Figure 10 Removing the main PCB
Figure 11 Lever up the PCB - Note: Metal Ratchet on Throttle at Right
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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THE UNOFFICIAL WORKSHOP MANUAL
FUTABA 9Z
RATCHET
RA TCHE T S M OOTH E R
GIMBAL GEAR
Figure 12 Making and installing a "Ratchet Smoother”.
RATCHET SMOOTHER MADE FROM DR INKS C A N
Figure 13 Another example of a ratchet smoother
3.4.2. Replacing the Joysticks and Potentiometers (POTS)
The joysticks on the 9Z weaken over time and can crack, whilst you can repair them
using the procedure in Section 3.4, they are easy to replace at the same time as you
service the complete 9Z gimbal assembly (inc. Potentiometer replacement). If you are
replacing the joysticks then you should also replace the POTS at the same time.
Potentiometers or POTS are used in a transmitter to sense how far the user has moved
the joystick. After some years the POTS inner surfaces wear and control becomes
erratic or inaccurate. When this occurs they need to be replaced. This procedure may
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
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FUTABA 9Z
look difficult, but it really isn’t as long as you remember to keep all those little springs
and screws safe once you’ve removed them. POTS are fairly standard items in the
electronic industry, but their calibration value is critical so make sure you get the right
ones. There are two sorts used on the 9Z series of transmitters – one is blue and one is
silver. Futaba can provide exact replacements or you can find the little numbers written
on the POTS and plug this into Google to find an aftermarket replacement. The required
part numbers can be found in APPENDIX C.
To remove and replace the POTS and joysticks in your 9Z simply follow the procedure
below:
1. Remove the 4 Allen key screws around the joystick/gimbals (see Figure 34 on Page
40).
2. Twist out the joystick gimbal and disconnect the associated cable (see Figure 14).
3. Remove the retainers for horizontal axis and remove both the pot and the joystick
(see Figure 15).
4. If you are replacing the joysticks assemble the parts as shown in Figure 18. It may
well be a good idea to add a strengthening collet (see Section 4.3) to the assembly
to prevent future joystick failure as this is a fairly common issue.
THE UNOFFICIAL WORKSHOP MANUAL
5. Unscrew the ball bearing at the end of the pot and remove the horizontal POT from
the assembly (see Figure 16).
6. Slice the heat shrink tubing on the horizontal POTS connectors and desolder the
wires.
7. Solder a new POT onto the wires. It is very important to add new heat shrink tubing
to protect the contacts or you risk a short circuit when in use.
8. Reassemble the POT in the horizontal axis gimbal using red Locktite or similar as
before and re-fit the joystick.
9. Unscrew the vertical axis POT retainers and pop out the POT (see Figure 19).
10. Desolder the connector PCB, solder it onto a new POT (see Figure 20).
11. Finally, reassemble the vertical axis gimbal. Again, make sure you use red Locktite
or similar when installing the new assembly back into the gimbal.
12. Reassemble the rest of the gimbal unit and replace the whole fully serviced unit
back in your 9Z. Reassembly is a reversal of disassembly.
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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THE UNOFFICIAL WORKSHOP MANUAL
FUTABA 9Z
Figure 14 Joystick gimbal removed (Note: new joystick parts for replacement on the right)
Figure 15 Disassemble the horizontal axis POT and joystick (new joystick parts in 1 & 6)
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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FUTABA 9Z
THE UNOFFICIAL WORKSHOP MANUAL
Figure 16 Unscrew the ball bearing from the horizontal axis POT
Figure 17 Slice the heat-shrink tubing and desolder the POT
WARNING: THE INFORM ATION IN THIS MANUAL IS FOR INFORMATION PURPOSES ONLY AND MAY BE INCORRECT, CAUSE DAMAGE
TO YOUR RADIO OR INJURY TO YOURSELF AND OTHERS. IF YOU USE THIS MANUAL YOU DO SO SOLEY AT YOUR OWN RISK.
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