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Thread: Unofficial Futaba 9Z Service Manual Available - Repair, Upgrade & Service Information

  1. #1

    Unofficial Futaba 9Z Service Manual Available - Repair, Upgrade & Service Information

    Hi guys,

    Thought you might find this useful as I use a 9Z with my FPV setup and I'm sure I'm not the only one



    I've just released Version 3 of the Futaba 9Z Unofficial Workshop Manual which can be downloaded from my website through this link.

    http://www.jamesandtracy.co.uk/howto/howto.htm

    This is a major update over previous versions and now contains over 20 pages of additional information, bringing the document to over 80 pages. Please be aware you'll need a PDF reader compatible with v7 and above to read the document. I've listed the full contents below.

    Have fun!

    Quincross

    ---------------contents of manual below------------

    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
    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
    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
    4.10. Building a Training Cable for Buddy Boxing 55
    4.11. Futaba 10Z upgrade - Adding a 10th 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) 76
    6.4. Test Menus (Fault Finding & Checking) 77
    APPENDIX A. The (Almost) Universal Service Menu Enabler 78
    APPENDIX B. CONNECTION Port PIN-OUT Information 79
    B.1. 9Z Transmitter Battery Cassette Pin-out Information 79
    B.2. Futaba RF Module Pin-out Information 79
    B.3. Futaba DSC/Trainer Pin-out Information 80
    B.4. CAMPAC Pin-out Information 81
    APPENDIX C. COMPONENT PART NUMBERS 82


    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
    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
    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
    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
    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 76
    Figure 77 Futaba 9Z Test Menus Flowchart 77
    Figure 78 Futaba 9Z Transmitter Battery Pin-out 79
    Figure 79 Futaba RF Module Pin-out Numbering 79
    Figure 80 DSC/Trainer Port Pin-out (6 pin DIN) 80
    Figure 81 CAMPAC Pin-Out (Note: Reversed pin numbering) 81

    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 83
    Last edited by Quincross; 20th July 2012 at 12:08 PM.

  2. #2
    RTFM aeryck's Avatar
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    I already have your unofficial manual for my 9z and it's great. Thanks for taking the time to put it together

    Oh, and welcome to the Lab!
    Far better is it to dare mighty things, even though checkered by failure; than to take rank with those who neither enjoy much or suffer much, because they live in the gray twilight that knows not victory nor defeat.

  3. #3
    Thanks mate - and cheers for the welcome. IToday I realised that I'd been lurking for ages and should really give something back to the forum, hence should probably post the manual. This place and RCG were what got me setup in FPV really (although my setup is pretty bog standard low-entry OTS at present)!

  4. #4
    RTFM aeryck's Avatar
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    Nothing wrong with that; sometimes a simple setup without all the bells and whistles is the best way to go. Btw, i did notice a couple minor typos in the service manual; when i have a second i'll get you the details. One specific i remember is in your list of pinouts on the various plugs, the numbered list didnt restart at 0 for the 6-pin DIN listing.. so instead of pins 0 - 6 they list as pins 6 - 12 (since the list above it for the module plug pinout used numbers 1 - 5).
    Far better is it to dare mighty things, even though checkered by failure; than to take rank with those who neither enjoy much or suffer much, because they live in the gray twilight that knows not victory nor defeat.

  5. #5
    Hopefully that was in version 1? I hope the majority of the typo's have been corrected in the new version which only hit the streets a few days ago. Mind you, a whole load more have probably been added when I put the new chapters in!

    FPV: Yeah...I know, I like it and it does the job, but then you see the bling on the net and you think.....maybe I need to spend $$$....then the reality of your bank balance hits you

  6. #6
    RTFM aeryck's Avatar
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    Quote Originally Posted by Quincross View Post
    Hopefully that was in version 1? I hope the majority of the typo's have been corrected in the new version which only hit the streets a few days ago. Mind you, a whole load more have probably been added when I put the new chapters in!

    FPV: Yeah...I know, I like it and it does the job, but then you see the bling on the net and you think.....maybe I need to spend $$$....then the reality of your bank balance hits you
    It was in a version i downloaded two days ago to update the one i already had... dated july 2012.

    I hear ya on the gear. Bank balance always plays a role, and i've got caught up in the 'bling is cool' thing too, only to realize its much simpler with a plane i can just chuck a battery in and fly without having to worry about calibrations, intricate ground setups, and the like. I dont even really usse my antenna tracker much since its just that much more gear to cart to and from the field.
    Far better is it to dare mighty things, even though checkered by failure; than to take rank with those who neither enjoy much or suffer much, because they live in the gray twilight that knows not victory nor defeat.

  7. #7
    Thanks!

    I just bought a 9Z specifically for FPV. Thanks so much for publishing this info.
    Just out of curiosity (and since I am new to Futaba), did you guys make any FPV specific tweaks to the 9Z?

    I'm slowly getting my head around how to program it. It seems pretty powerful.

  8. #8
    RTFM aeryck's Avatar
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    Quote Originally Posted by MrFollies View Post
    Thanks!

    I just bought a 9Z specifically for FPV. Thanks so much for publishing this info.
    Just out of curiosity (and since I am new to Futaba), did you guys make any FPV specific tweaks to the 9Z?

    I'm slowly getting my head around how to program it. It seems pretty powerful.
    I havent made any fpv specific tweaks yet but i did buy a secondhand tlrs uhf tx that was already prewired to a futaba rf module so i just slap the module in the back of the radio and i've got uhf control. I read somewhere that it might be a good idea to wire the +v pin of the rf module header direct to switched power instead of using the radio's circuit board as those traces may not be able to handle the current of a tlrs in 2W power mode. Works fine on 500mW though.
    Far better is it to dare mighty things, even though checkered by failure; than to take rank with those who neither enjoy much or suffer much, because they live in the gray twilight that knows not victory nor defeat.

  9. #9
    FPV & 9Z: Nothing specific in terms of setup beyond the norm - conditions are useful and I have one norm & 3 FPV conditions one of which rotates the cam with the rudder/ailerons, the other is a kind of 'panic' condition. I've mostly messed with getting the pass-through on the FrSky module working.

    9Z Manual: Ahhhhh! You're right it's b****! well done it again!!! I hate Word and it's number lists, I put that right so many times....Ah well prepare to see V3R5 in the next few days to correct that error....again!

  10. #10
    RTFM aeryck's Avatar
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    Quote Originally Posted by Quincross View Post
    FPV & 9Z: Nothing specific in terms of setup beyond the norm - conditions are useful and I have one norm & 3 FPV conditions one of which rotates the cam with the rudder/ailerons, the other is a kind of 'panic' condition. I've mostly messed with getting the pass-through on the FrSky module working.

    9Z Manual: Ahhhhh! You're right it's b****! well done it again!!! I hate Word and it's number lists, I put that right so many times....Ah well prepare to see V3R5 in the next few days to correct that error....again!
    No worries, mistakes happen especially with those damn numbered lists. The manual's still great, just passing along proofreading stuff.

    I'm still setting up my 9z w/ my airframes, but its kinda tricky because i flew with a dx8 before, and the channels dont match up. The rx on my twinstar is buried in the fuse so i cant move channels around on the rx - going to have to do it all on the radio.
    Far better is it to dare mighty things, even though checkered by failure; than to take rank with those who neither enjoy much or suffer much, because they live in the gray twilight that knows not victory nor defeat.

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