.32-.36 AND .46 ASSEMBLY INSTRUCTIONS
ERGO SPECIFICATIONS
Overall Length |
46.5" |
Tail Rotor Diameter |
9.17" |
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Overall Height |
16.38" |
Gear Ratio |
9.78:1:5.18 |
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Main Rotor Diameter |
48.5" (.32-.36) |
Gross Weight |
6.75-7.0 lbs. |
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50" (.46 3D) |
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INTRODUCTION
Congratulations on your purchase of the JR Ergo helicopter kit.
This kit has been both engineered and manufactured by JR with help from some of Japan’s top R/C helicopter engineers (now employed by JR).
As you may well know, the name JR has for years been synonymous with state- of-the-art, high quality radio control systems known the world over for their exceptional reliability and engineering.
JR now brings this reputation and knowledge into the helicopter market with the development of the Ergo and the organization of the JR heli division. Years in the making, the Ergo’s superior quality and exceptional parts fit and finish create a new standard of quality that was previously unavailable.
Before you begin the assembly of your Ergo, we suggest that you first review the entire instruction manual to become familiar with the assembly sequences and parts layout.
WARNING
The radio controlled model helicopter contained in this kit is not a toy, but a sophisticated piece of equipment. This product is not recommended for use by children. Radio controlled models such as this are capable of causing both property damage and/or bodily harm to both the operator/assembler and/or spectator if not properly assembled and operated. Horizon Hobby Distributors assumes no liability for damage that could occur from the assembly and/or use/misuse of this product.
AMA INFORMATION
We strongly encourage all prospective and current R/C aircraft pilots to join the Academy of Model Aeronautics. The AMA is a non-profit organization which provides services to model aircraft pilots. As an AMA member you will receive a monthly magazine entitled Model Aviation, as well as a liability insurance plan to cover against possible accident or injury. All AMA charter aircraft clubs require individuals to hold a current AMA sporting license prior to operation of their
models. For further information, you can contact the AMA at:
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302
(317) 287-1256
PRE-ASSEMBLY INFORMATION
When first opening your Ergo kit, you will notice that all of the parts are packaged and numbered to coordinate with the assembly step numbers of this instruction manual.
All small hardware (nuts, bolts, washers, etc.) for each step are separated and packaged separately within the main parts bags. When beginning a section, you will need to open only the bag with the corresponding number to the section you are going to start. It is suggested that you place all of the hardware in an open container (e.g., coffee can) during assembly so as not to lose any of the small parts. It may also be helpful to familiarize yourself with the various sizes of screws, bolts, nuts, etc., as illustrated in the appropriate assembly section before you begin assembly. At the end of each assembly, in most cases, there should be no parts remaining.
Great care has been taken in filling the bags with the correct quantity of parts and hardware for each section. However, occasionally mistakes do happen. In the event that you find a parts shortage or are in need of technical assistance, please contact your local JR heli division parts dealer, or contact the Horizon Service Center directly.
Horizon Service Center
4105 Fieldstone Road
Champaign, IL 61821 (217) 355-9511 (9am to 5pm CST)
2
INDEX
Section |
Description |
Page |
|
Section |
Description |
Page |
Tools |
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. .4-6 |
|
5-2 |
Tail Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . |
. . .27 |
Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . .7 |
|
5-3 |
Tail Center Hub Assembly . . . . . . . . . . . . . . . . . . . . . |
. . .28 |
|
1-1 |
Clutch Bell/Start Shaft Assembly . . . . . . . . . . . . . . . . . |
. . .8 |
|
5-4 |
Tail Blade Holder Assembly . . . . . . . . . . . . . . . . . . . . |
. . .28 |
1-2 |
Tail Drive Pinion/Bearing Block Assembly . . . . . . . . . |
. . .8 |
|
5-5 |
Tail Pitch Control Lever Installation . . . . . . . . . . . . . . |
. . .29 |
1-3 |
Control Ball Installation . . . . . . . . . . . . . . . . . . . . . . . . |
. . .9 |
|
5-6 |
Tail Fin Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . .29 |
1-4 |
Servo Mixing Lever Unit Assembly . . . . . . . . . . . . . . |
. . .9 |
|
5-7 |
Tail Boom Carrier Installation . . . . . . . . . . . . . . . . . . |
. . .30 |
1-5 |
Elevator Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . |
. .10 |
|
5-8 |
Tail Boom Assembly Installation . . . . . . . . . . . . . . . . |
. . .30 |
1-6 |
Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. .10 |
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5-9 |
Tail Boom Brace Assembly . . . . . . . . . . . . . . . . . . . . |
. . .31 |
2-1 |
Upper Main Frame Section Assembly . . . . . . . . . . . . . |
. .11 |
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5-10 |
Tail Boom Brace Installation . . . . . . . . . . . . . . . . . . . |
. . .31 |
2-2 |
Upper Main Frame Control Lever Installation . . . . . . . |
. .12 |
|
6-1 |
Upper Servo Tray Installation . . . . . . . . . . . . . . . . . . . |
. . .32 |
2-3 |
Lower Main Frame Assembly . . . . . . . . . . . . . . . . . . . |
. .13 |
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6-2 |
Servo/Switch Harness Installation . . . . . . . . . . . . . . . |
. . .33 |
2-4 |
Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . |
. .13 |
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6-3 |
Tail Control Rod Assembly . . . . . . . . . . . . . . . . . . . . |
. . .34 |
2-5 |
Front Radio Bed/Gyro Mounting Plate Installation . . . |
. .14 |
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6-4 |
Tail Control Rod Installation . . . . . . . . . . . . . . . . . . . |
. . .34 |
2-6 |
Cooling Fan Shroud Installlation . . . . . . . . . . . . . . . . . |
. .14 |
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6-5 |
Gyro/Receiver/Battery Installation . . . . . . . . . . . . . . . |
. . .35 |
2-7 |
Upper/Lower Main Frame Assembly Attachment . . . . |
. .15 |
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Radio System Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . .36 |
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3-1 |
Main Drive Gear/Autorotation Assembly . . . . . . . . . . . |
. .16 |
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7-1 |
Aileron Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . .37 |
3-2 |
Main Drive Gear/Autorotation Assembly Installation |
. . .16 |
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7-2 |
Elevator Linkage Installation . . . . . . . . . . . . . . . . . . . |
. . .37 |
3-3 |
Landing Gear Assembly Installation . . . . . . . . . . . . . . |
. .17 |
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7-3 |
Collective Linkage Installation . . . . . . . . . . . . . . . . . . |
. . .38 |
3-4 |
.32/.36 Cooling Fan/Hub Installation . . . . . . . . . . . . . . |
. .17 |
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7-4 |
Tail Control Rod Servo Connection . . . . . . . . . . . . . . |
. . .38 |
3-4.1 |
.46 Cooling Fan Installation . . . . . . . . . . . . . . . . . . . . . |
. .18 |
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7-5 |
Throttle Linkage Installation (ALL) . . . . . . . . . . . . . . |
. . .39 |
3-5 |
.32/.36 Engine Mount Attachment . . . . . . . . . . . . . . . . |
. .18 |
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8-1 |
Body Assembly/Canopy Attachment . . . . . . . . . . . . . |
. . .40 |
3-5.1 |
.46 Engine Mount Attachment . . . . . . . . . . . . . . . . . . . |
. .19 |
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8-2 |
Body Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . .40 |
3-6 |
Clutch Assembly Attachment (ALL) . . . . . . . . . . . . . . |
. .19 |
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8-3 |
Main Rotor Blade Balancing . . . . . . . . . . . . . . . . . . . |
. . .41 |
3-7 |
Engine Installation (ALL) . . . . . . . . . . . . . . . . . . . . . . . |
. .20 |
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8-4 |
Main Rotor Blade Attachment . . . . . . . . . . . . . . . . . . |
. . .41 |
3-8 |
Installation of the Muffler . . . . . . . . . . . . . . . . . . . . . . . |
. .20 |
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Servo Adjustment and Radio Set Up . . . . . . . . . . . . . . . . . . . . . . . |
42-43 |
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4-1 |
Rotor Head Hub Assembly . . . . . . . . . . . . . . . . . . . . . . |
. .21 |
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Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
44-49 |
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4-2 |
Main Blade Holder Assembly . . . . . . . . . . . . . . . . . . . . |
. .21 |
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Final Pre-Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . .50 |
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4-3 |
Main Blade Holder/Seesaw Attachment . . . . . . . . . . . . |
. .22 |
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General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . .51 |
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4-4 |
Seesaw Mixing Arm Installation . . . . . . . . . . . . . . . . . |
. .22 |
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Rotor Head/Swashplate/Washout Assembly Parts List . . . . . . . . . |
52-53 |
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4-5 |
Swashplate/Washout Assembly Installation . . . . . . . . . |
. .23 |
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Start Shaft/Clutch/Engine Assembly Parts List . . . . . . . . . . . . . . . |
54-55 |
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4-6 |
Rotor Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . |
. .24 |
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Cyclic Mixing Arms/Elevator/Aileron Control Arms Parts List . . |
56-57 |
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4-7 |
Flybar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. .25 |
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Upper Main Frame/Radio Tray/Body Set Parts List . . . . . . . . . . . |
58-59 |
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4-8 |
Flybar Paddle Attachment . . . . . . . . . . . . . . . . . . . . . . . |
. .25 |
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Lower Main Frame/Landing Gear/Fuel Tank Parts List . . . . . . . . |
60-61 |
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4-9 |
Rotor Head/Swashplate Control Rod Installation . . . . . |
. .26 |
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Tail Boom/Tail Brace/Tail Boom Carrier Parts List . . . . . . . . . . . |
62-63 |
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5-1 |
Tail Output Shaft/Pulley Assembly . . . . . . . . . . . . . . . . |
. .27 |
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Tail Case/Tail Blade Holders/Tail Pitch Plate Parts List . . . . . . . . |
64-65 |
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3
ERGO .32-.36 AND ERGO .46 3D FEATURES
Heavy-Duty Aluminum Quad Frame System
Provides excellent rigidity and vibration absorption.
One-Way Hex Start Shaft System
Provides positive starting. Starter shaft utilizes a one-way bearing that allows the shaft to stop after the engine is started.
Wide Spread Tail Output Shaft Bearings
Reduces vibration and improves control response.
Belt-Driven Tail Rotor Design
Provides easy adjustment and low maintenance. Also eliminates the need for optional/expensive tube drive shafts.
Precision Ball Bearings at All Critical Locations
Provide low wear, high precision and reduced maintenance.
Unique Cyclic Mixing Control System
Offers easy adjustment and precise control.
Self-Aligning One-Piece Steel Clutch System
Offers easy installation and adjustment with exceptional reliability.
Pre-Assembled Control Linkages
High quality JR ball links are installed and pre-adjusted to take the guesswork out of assembly while saving building time.
Straight Blade Axle Rotor Head Design
Provides high responsiveness and solid blade tracking.
Low Drag Flybar Paddles
Provide quick yet smooth cyclic response at all flight speeds.
Heavy-Duty Main Blade Grips With 4mm Blade Bolts
Provide a solid and secure mounting surface to easily handle the stresses of radical 3D flight.
Rearward Facing Engine Design
Provides easy access to the glow plug for starting. Engine slips easily through the main frame for trouble-free engine maintenance.
Heavy-Duty Tail Boom Carrier
Provides increased structural rigidity and improved tail rotor precision.
Pre-Finished Main Rotor Blades (.30 Kit)
Provide easy assembly with excellent flight characteristics.
Superior Parts Fit and Finish
Make assembly trouble free and enjoyable.
ITEMS REQUIRED TO COMPLETE THE JR ERGO
(not
supplied
in
kit)
1. RADIO SYSTEM REQUIREMENTS (NOT INCLUDED):
6-channel or greater R/C helicopter system with 5 servos, 1000 mAh receiver battery and gyro.
4
2. ENGINE REQUIREMENTS (NOT INCLUDED):
A .32-.36 R/C Helicopter Engine (Ergo .30) or .46 R/C Helicopter Engine (Ergo .46) |
A special helicopter type muffler is also required |
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(JRP960078 Ergo .32-.36 Muffler Shown)
(Webra .33 Heli Engine Shown) |
(Thunder Tiger Pro .46 Heli Engine Shown) |
(JRP960079 Ergo .46 Muffler Shown)
3. BUILDING SUPPLIES (NOT INCLUDED):
The following items are needed to complete the assembly of the JR Ergo:
Fuel Filter |
Silicone Fuel Tubing |
Whip Antenna |
Glow Plugs |
Double Sided Servo |
Locktite 242 or |
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Mounting Tape |
equivalent |
Nylon Wire Ties To |
Spiral Tubing |
Secure Radio Wires |
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5
4. TOOLS NEEDED TO ASSEMBLE THE JR ERGO (NOT INCLUDED):
Phillips Screwdirver |
Nut Drivers: 5mm, 7mm |
Needle Nose Pliers |
Scissors |
Drill and Drill Bits |
Small Hammer |
X-Acto Knife |
Metric Ruler |
Allen Wrenches: 1.5, 2.0, 2.5, |
Blade Balancer |
3.0mm |
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5. FIELD EQUIPMENT REQUIRED (NOT INCLUDED):
12 Volt Electric Starter |
12 Volt Starting Battery |
1.5 Volt Glow Plug Battery |
Remote Glow Plug Adaptor |
Helicopter Fuel 15% - 30% |
Fuel Pump |
Hex Starting Shaft |
Pitch Gauge |
Ball Link Pliers |
Training Gear (Beginners Only) |
6
HARDWARE IDENTIFICATION
There are many various sizes and shapes of hardware included in this kit. Prior to assembly, please be careful to identify each screw by matching it to the full size screw outlines included in each step.
All of the hardware, screws, nuts, etc., contained in the Ergo kit are described in the following A, B, C manner:
A |
B |
C |
3x8mm |
Socket Head Bolt |
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A |
B
A B |
C |
4x4mm |
Set Screw |
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A |
B
C Set Screw
A |
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B |
3mm |
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Spring Washer |
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A |
.05mm |
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B Spring Washer
A |
B |
2mm |
Hex Nut |
A
B Hex Nut
A |
B |
C |
2.6x10mm |
Self Tapping Screw |
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A |
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B |
C |
Tapping Screw |
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A |
B |
C |
2x8mm |
Flat Head Screw |
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A |
B
C Flat Head Screw
A B |
C |
3x8mm |
Flat Head Cap Screw |
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A |
B
C Flat Head Cap Screw
A |
B |
3mm |
Flat Washer |
A |
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.05mm |
B Flat Washer |
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A |
B |
3mm |
Lock Nut |
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A |
B Lock Nut
7
1-1 |
CLUTCH BELL/START SHAFT ASSEMBLY |
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Starter Hex Adaptor
Complete Assembly
Use Threadlock
3x4mm Set Screw
Start Shaft
Shaft Bearing Block
Bell Assembly
Note: Be sure to allow a slight amount of clearance between the Start Hex Adaptor and the Bearing Block to prevent binding.
1-2 |
TAIL DRIVE PINION/BEARING BLOCK ASSEMBLY |
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Use Threadlock
...1 pc
3x6mm Socket Head Bolt
.........1 pc
3mm Flat Washer
Tail Drive Pinion
Bearing Blocks
Tail Drive Pinion
with Shaft
Install the Upper Bearing Block so that |
UP |
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the bearing is toward the top: |
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Bearing
Install the Lower Bearing Block so the bearing face is toward the bottom:
3x6mm Socket Head Bolt
3mm Flat
Front Tail Belt Pulley
(Install Flat Side Up)
Complete Assembly
UP
Bearing
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1-3 |
CONTROL BALL INSTALLATION |
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2x8mm Flat Head Screw |
Mixing Lever (3 pc) |
Use Threadlock |
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(Prepare 3 Sets) |
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2mm Nut |
Roll Bell Crank |
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Steel Joint Ball |
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Steel Joint Ball |
2mm Nut |
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2x10mm Flat |
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Head Screw (8 pc) |
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Mixing Base Arm |
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(Collective) |
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Joint Ball (9 pc) |
2x10mm Flat |
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Head Screw |
1-4 |
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SERVO MIXING LEVER UNIT ASSEMBLY |
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........2 pc |
Use Threadlock |
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Complete Assembly |
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Flat Head Screw |
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3x8mm Socket |
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........1 pc |
Head Bolt |
Nylon Washers |
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Socket Head Bolt |
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Socket Head Bolt |
....1 pc |
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........5 pc |
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Mixing Lever Bushing B |
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Washers |
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........1 pc |
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Nylon Washers |
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Mixing Lever Bushing A |
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Flat Washer |
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........1 pc |
3x8mm Flat Head Screw |
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Lever Spacer |
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Mixing |
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Lever |
........1 pc |
Mixing Base Cross Member |
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Spacer |
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Lever Bushing A |
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Mixing Base Arm (Roll) |
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Nylon |
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Washer |
Lever Bushing B |
......1 pc |
After assembly, any additional play or |
3x8mm Flat Head Screw |
3mm Flat |
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Washer |
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Mixing Lever Unit can |
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3x28mm Socket Head Bolt |
Mixing Base Cross Member ....1 pc |
adding additional Nylon |
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Washers as needed. |
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1-5 |
ELEVATOR ARM ASSEMBLY |
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Elevator Arm Front |
Elevator Arm Rear |
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Swashplate A |
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2x8mm Flat Head Screw |
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Arms |
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Steel Joint Ball |
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Elevator Arm Pin |
......2pc |
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Steel Joint Ball |
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Steel Joint Ball |
2x8mm Flat |
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2x8mm Flat Head Screw |
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Head Screw |
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Elevator Arm Pin |
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Caution: Be sure to note correct Swashplate A Arm installation direction.
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Tap-in gently with |
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Elevator Arm |
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Marked Side In |
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a small hammer. |
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Swashplate A |
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Swashplate A |
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Swashplate A Arm |
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Edge of Work Bench |
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Elevator Arm (Front) |
Elevator Arm (Rear) |
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1-6 FUEL TANK ASSEMBLY
Tap
Fuel Tank Clunk
* Silicone Tube (Small)
Tank Grommet
Nipple
Silicone Fuel Tubing (not incuded)
Connects to Engine Carburetor
* Trim before installation to a length of 58mm
Fuel Tank
After assembly, check to be sure the Fuel Tank Clunk can move from the bottom to the top of the tank without touching the back wall of the Fuel Tank.
10
2-1 |
UPPER MAIN FRAME SECTION ASSEMBLY |
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Use Threadlock On |
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All Screws |
UP |
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.......... |
21 pc |
3x8mm Socket Head Bolt |
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.......... |
1 pc |
3x10mm Socket Head Bolt |
UP |
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.......... |
11 pc |
3mm Flat Washer |
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Body Mounting Standoffs Shaft ....... |
2 pc |
.......... |
4 pc |
2.6x8mm Self Tapping Screw |
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Upper Main Shaft Bearing Block
Bearing Flush |
Position so the side |
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with Flange |
of the bearing block |
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that has the bearing |
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Bearing |
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flush with the flange |
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is upward.
Lower Main Shaft Bearing Block
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Bearing Flush |
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Position so side of |
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with Flange |
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the bearing block |
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that has the bearing |
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flush with the flange |
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Bearing |
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is downward. |
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Tail Control
Rod Guide
Socket Head Bolt
Body Mounting Standoff:
Bearing side must face
Note: Both the Clutch Bell/Start Shaft Assembly |
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(Step 1-1) and the Tail Drive Pinion/ |
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to use the two |
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Bearing Block Assembly (Step 1-2) are |
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Standoffs for this |
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temporarily installed at this time. These |
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assemblies will be adjusted and secured |
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in Step 3-2. |
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2.6x8mm Self Tapping |
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Body Mounting |
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Screw (4pc) |
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Standoff: Short |
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*Bearing side must |
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face downward |
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Upper Main Frame |
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3mm Flat Washer |
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(11 pc) |
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3x8mm Socket Head Bolt |
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Servo Mounting Plates |
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(21 pc) |
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11
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2-2 |
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UPPER MAIN FRAME CONTROL LEVER INSTALLATION |
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Use Threadlock |
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Elevator Arm Bushing |
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Note: Be sure to install the Elevator |
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Nylon Washer |
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Arm Units in their proper |
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Nylon Washer |
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location as there is a “Front” |
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Elevator Arm Bushing |
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and a “Rear” Unit (Step 1-5). |
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3x8mm Socket Head Bolt |
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Nylon Washer
3x6mm Socket Head Bolt
3x8mm Socket Head Bolt
Roll Bellcrank |
Nylon Washer |
Spacer |
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Mixing Base Nut |
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3x22mm Socket |
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Head Bolt |
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3x6mm Socket Head Bolt |
........2 pc |
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3x6mm Socket |
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Head Bolt |
Washout Arm |
3mm Flat Washer |
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3x8mm Socket Head Bolt |
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Bushing |
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Attach the pre-finished Control Rods to the |
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3x22mm Socket Head Bolt ......1 pc |
Mixing Levers/Control Arms as shown: |
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Top View |
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A |
B |
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3mm Lock Nut |
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Nylon Washers |
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........1 pc |
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3mm Flat Washer |
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........1 pc |
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C |
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Roll Bellcrank Spacer |
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Washout Arm Bushing |
........1 pc |
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Pre-Adjusted Length |
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Elevator Arm Bushing |
........2 pc |
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Rod Length |
Pre-Adjusted Length |
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A |
110mm |
92mm |
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B |
45mm |
24mm |
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Mixing Base Nut |
........2 pc |
C |
75mm |
59mm |
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12
2-3 |
LOWER MAIN FRAME ASSEMBLY |
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Lower Main Frame |
........ 4pc |
2.6x8mm Self Tapping Screw (4 pc) |
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3x8mm Socket Head Bolt |
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........4 pc |
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3mm Lock Nut |
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........4 pc |
3mm Lock Nut |
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(4 pc) |
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Lower Frame Angle (2 pc) |
2.6x8mm Self Tapping Screw |
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Servo Mounting Plate |
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2-4 |
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3x8mm Socket Head Bolt (4 pc) |
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FUEL TANK INSTALLATION |
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Note: Install the Fuel Tank and Tank Mounting Rubber into the lower frame halves before attaching the Main Frame Standoffs.
When securing Standoffs to frame, position |
of the level surface to |
prevent twisting during tightening. |
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Use Threadlock
Main Frame Standoff,
60mm
Tank Mounting |
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Lower Main Frame |
3x8mm Socket |
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Head |
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........2 pc |
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3x8mm Socket Head Bolt |
Fuel Tank |
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........4 pc |
Main Frame Standoff, |
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60mm |
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3x10mm Socket Head Bolt |
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3x8mm Socket Head Bolt |
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Main Frame Standoff, 60mm ........ 3 pc |
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3x10mm Socket Head Bolt (4 pc)
Tank Mounting
13
2-5 |
FRONT RADIO BED/GYRO MOUNTING PLATE INSTALLATION |
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Gyro Mounting Plate
........ |
6 pc |
Use Threadlock |
3x10mm Socket Head Bolt |
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Front Radio Bed |
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........ |
2 pc |
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3x18mm Set Screw |
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Body Mounting Standoff Long ........ |
2 pc |
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Body Mounting
Standoff Long
3x10mm Socket
Head Bolt (6 pc)
3x18mm Set Screw (2 pc)
Body Mount Standoff, Long
2-6 |
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COOLING FAN SHROUD INSTALLATION |
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........4 pc
2.6x8mm Self Tapping Screw
Ergo .46 Fan Shroud Adjustment
When installing a .46 size engine it will be necessary to trim the bottom portion of the Fan Shroud as shown:
Cooling Fan Shroud
2.6x8mm Self
Tapping Screw
1 7/8" |
3/4" |
2.6x8mm Self Tapping Screw
Remove
14
2-7 |
UPPER/LOWER MAIN FRAME ASSEMBLY ATTACHMENT |
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12 pc |
Use Threadlock On |
3x22mm Socket Head Bolt ........ |
All Screws |
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Main Frame Standoff, 32mm ........ |
6 pc |
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Main Frame Spacer, 12.5mm ........ |
12 pc |
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Main Frame Spacer, 12.5mm (12 pc)
Main Frame Standoff, 32mm (6 pc)
3x22mm Socket Head Bolt (12 pc)
3x22mm Socket Head Bolt
15
3-1 |
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MAIN DRIVE GEAR/AUTOROTATION ASSEMBLY |
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3x6mm Socket Head Bolt (4 pc) |
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[Tighten equally to prevent |
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warping of Main Drive Gear] |
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Use Threadlock |
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Main Drive Gear |
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.......4 pc |
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3x6mm Socket Head Bolt |
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Autorotaion Assembly
3-2 |
MAIN DRIVE GEAR/AUTOROTATION ASSEMBLY INSTALLATION |
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Main Shaft Collar |
Use Threadlock |
8mm |
4x4mm Set Screw (4 pc) |
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........4 pc |
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4x4mm Set Screw |
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Main Rotor Shaft |
3x22mm Socket Head Bolt ......1 pc |
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........1 pc |
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3mm Lock Nut |
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3mm |
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Autorotation Hub
3mm Lock Nut
1.Secure the Autorotation Hub to the Main Rotor Shaft using the 3x22mm Socket Head Bolt. Next, slide the Main Shaft Collar onto the Main Rotor Shaft. While pulling upward on the Main Rotor Shaft, secure the Main Shaft Collar to the
Main Rotor Shaft using the four 4x4mm Set Screws.
3x22mm Socket Head Bolt
2.Once the Main Shaft Assembly is in place, adjust the gear mesh of the Clutch Bell and Tail Belt Pinion Gears, and secure the bolts left loose from Step 2-1.
16
3-3 |
LANDING GEAR ASSEMBLY INSTALLATION |
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........4 pc
4x4mm Set Screw
........4 pc
3x12mm Socket Head Bolt
........4 pc
3mm Flat Washer
........4 pc
3mm Lock Nut
3x12mm Socket Head Bolt (4 pc)
3mm Flat Washer (4 pc)
Landing Gear Dampers (4 pc)
3mm Lock 
Nut (4 pc)
Landing Strut
4x4mm Set Screw (4 pc)
Antenna Tube
Landing Skid Cap
Landing Skid
20mm
3-4 |
.32-.36 CO0LING FAN/HUB INSTALLATION |
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For proper installation of the fan assembly, it is neccessary for the engine to have the prop drive washer installed.
Note: If you are building the Ergo .46 3D Version, proceed to Step 3-4.1
O.S. .32SX-H Installation
For proper installation of this engine, it will be necessary to purchase the O.S. Prop Drive Washer for this engine (Part #23408000).
*It is recommended that a Piston Locking Tool be used to properly secure the Fan Assembly to the engine.
Use Threadlock
........4 pc
3x5mm Socket Head Bolt
Nut Supplied with Engine
3x5mm Head Bolt (4
Cooling Fan .32-.36
Prop drive washer must be used for correct installation
Cooling Fan Hub .32-.36
* Revolution 1003 Piston Locking Tool
(Purchased Separately)
17
3-4.1 |
.46 COOLING FAN INSTALLATION |
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Nut Supplied with Engine
Note: If you are building the Ergo .32-.36 Version, proceed to Step 3-5.
Note: It will not be necessary to use the four 3x5mm
Socket Head Bolts included in this screw bag.
Note: It will be necessary to shorten the Crankshaft of the engine to allow clearance. Test fit the Fan Assembly to determine the correct amount to be removed. On the Thunder Tiger Pro .46 Heli Engine, it will be necessary to remove 1/2" from the tip of the Crankshaft.
*It is recommended that a Piston Locking Tool be used to properly secure the Cooling Fan Assembly to the engine.
Use Threadlock
Aluminum Cooling Fan
(Ergo .46)
Revolution 1003 Piston Locking To
(Purchased Separately)
3-5 |
.32-.36 ENGINE MOUNT ATTACHMENT |
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Note: If you are building the Ergo .46 3D Version proceed to Step 3-5.1.
Engine 36
Use Threadlock
......4 pc
3x15mm Socket Head Bolt
........4 pc
3mm Flat Washer
3mm Serrated Washer
Motor Mount Direction
Top
Shorter Distance
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Longer Distance |
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3mm Flat |
3x15mm Socket |
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Washer (4 pc) |
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Bottom |
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Head Bolt |
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It is is
18
3-5.1 |
.46 ENGINE MOUNT ATTACHMENT |
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Engine Mount .46 |
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Use Threadlock |
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Fan Assembly: .46 |
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........4 pc |
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3x15mm Socket Head Bolt |
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3mm Flat Washer |
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3mm Serrated Washer |
........4 pc |
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Motor Mount Direction: |
Motor Mount Direction: |
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Thunder Tiger |
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O.S. |
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Top |
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Top |
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Distance |
Distance |
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Tiger |
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FS |
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Pro .46 |
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R-H |
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Distance |
Shorter Distance |
Head |
Bottom
It is important to note the proper direction that the Motor Mount is installed to achieve the correct alignment of the engine.
3-6 |
CLUTCH ASSEMBLY ATTACHMENT (ALL) |
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Use Threadlock
........1 pc
2x8mm Flat Head Screw
........2 pc
3x5mm Socket Head Bolt
........1 pc
2mm Hex Nut
........2 pc
3mm Flat Washer
........1 pc
Steel Joint Ball
2mm Hex Nut
*see note
Steel Joint Ball
2x8mm Flat Head Screw
*Note: When installing the Thunder Tiger Pro .46 Heli Engine, it will be necessary to replace the Standard Throttle Arm with the Long Offset Arm supplied with the engine.
Clutch Assembly
3mm Flat Washer (2 pc)
3x5mm Socket Head Bolt (2 pc)
19
3-7 |
ENGINE INSTALLATION (ALL) |
........4 pc |
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3x10mm Socket Head Bolt |
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........4 pc |
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3mm Flat Washer |
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3mm Flat Washer (4 pc) |
3x10mm Socket Head Bolt (4 pc)
Correct Incorrect
Adjust the height and position of the Engine as shown so the bottom of the Clutch Assembly is flush with the bottom of the Clutch Bell. Also check to insure that the Engine and Clutch Bell are parallel.
*It is highly recommended that you insert the Muffler Bolts into the Engine Case prior to installing the engine in the frame.
3-8 |
INSTALLATION OF THE MUFFLER |
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Note: The installation shown is for a .32-.36 size |
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........1 pc |
engine with the JR muffler (JRP960078). |
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Installation of other .32-.36/.46 engine |
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Pressure Tap |
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muffler combinations may vary. Please refer |
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to your engine/muffler instructions for proper |
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installation. |
3x30mm Socket Head Bolt |
.......2 pc |
Pressure Fuel Line Attachment |
Use Threadlock |
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3x30mm Socket Head Bolts
(*Inserted in Step 3-7)
JR .32-.36 Muffler Shown
(Purchased Separately, JRP960078)
20
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