JR Ergo 32, 36, 46 User Manual

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Page 1

.32-.36 AND .46 ASSEMBLY INSTRUCTIONS

ERGO SPECIFICATIONS

Overall Length 46.5" Overall Height 16.38" Main Rotor Diameter 48.5" (.32-.36)

50" (.46 3D)

Tail Rotor Diameter 9.17" Gear Ratio 9.78:1:5.18 Gross W eight 6.75-7.0 lbs.

Page 2

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)

Page 3

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1-1 Clutch Bell/Start Shaft Assembly . . . . . . . . . . . . . . . . . . . .8

1-2 Tail Drive Pinion/Bearing Block Assembly . . . . . . . . . . . .8

1-3 Control Ball Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1-4 Servo Mixing Lever Unit Assembly . . . . . . . . . . . . . . . . .9

1-5 Elevator Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .10

1-6 Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2-1 Upper Main Frame Section Assembly . . . . . . . . . . . . . . .11

2-2 Upper Main Frame Control Lever Installation . . . . . . . . .12

2-3 Lower Main Frame Assembly . . . . . . . . . . . . . . . . . . . . .13

2-4 Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2-5 Front Radio Bed/Gyro Mounting Plate Installation . . . . .14

2-6 Cooling Fan Shroud Installlation . . . . . . . . . . . . . . . . . . .14

2-7 Upper/Lower Main Frame Assembly Attachment . . . . . .15

3-1 Main Drive Gear/Autorotation Assembly . . . . . . . . . . . . .16

3-2 Main Drive Gear/Autorotation Assembly Installation . . .16

3-3 Landing Gear Assembly Installation . . . . . . . . . . . . . . . .17

3-4 .32/.36 Cooling Fan/Hub Installation . . . . . . . . . . . . . . . .17

3-4.1 .46 Cooling Fan Installation . . . . . . . . . . . . . . . . . . . . . . .18

3-5 .32/.36 Engine Mount Attachment . . . . . . . . . . . . . . . . . .18

3-5.1 .46 Engine Mount Attachment . . . . . . . . . . . . . . . . . . . . .19

3-6 Clutch Assembly Attachment (ALL) . . . . . . . . . . . . . . . .19

3-7 Engine Installation (ALL) . . . . . . . . . . . . . . . . . . . . . . . . .20

3-8 Installation of the Muffler . . . . . . . . . . . . . . . . . . . . . . . . .20

4-1 Rotor Head Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . .21

4-2 Main Blade Holder Assembly . . . . . . . . . . . . . . . . . . . . . .21

4-3 Main Blade Holder/Seesaw Attachment . . . . . . . . . . . . . .22

4-4 Seesaw Mixing Arm Installation . . . . . . . . . . . . . . . . . . .22

4-5 Swashplate/Washout Assembly Installation . . . . . . . . . . .23

4-6 Rotor Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .24

4-7 Flybar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

4-8 Flybar Paddle Attachment . . . . . . . . . . . . . . . . . . . . . . . . .25

4-9 Rotor Head/Swashplate Control Rod Installation . . . . . . .26

5-1 Tail Output Shaft/Pulley Assembly . . . . . . . . . . . . . . . . . .27

5-2 Tail Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . .27

5-3 Tail Center Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . .28

5-4 Tail Blade Holder Assembly . . . . . . . . . . . . . . . . . . . . . . .28

5-5 Tail Pitch Control Lever Installation . . . . . . . . . . . . . . . . .29

5-6 Tail Fin Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5-7 Tail Boom Carrier Installation . . . . . . . . . . . . . . . . . . . . .30

5-8 Tail Boom Assembly Installation . . . . . . . . . . . . . . . . . . .30

5-9 Tail Boom Brace Assembly . . . . . . . . . . . . . . . . . . . . . . .31

5-10 Tail Boom Brace Installation . . . . . . . . . . . . . . . . . . . . . .31

6-1 Upper Servo Tray Installation . . . . . . . . . . . . . . . . . . . . . .32

6-2 Servo/Switch Harness Installation . . . . . . . . . . . . . . . . . .33

6-3 Tail Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . .34

6-4 Tail Control Rod Installation . . . . . . . . . . . . . . . . . . . . . .34

6-5 Gyro/Receiver/Battery Installation . . . . . . . . . . . . . . . . . .35

Radio System Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

7-1 Aileron Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

7-2 Elevator Linkage Installation . . . . . . . . . . . . . . . . . . . . . .37

7-3 Collective Linkage Installation . . . . . . . . . . . . . . . . . . . . .38

7-4 Tail Control Rod Servo Connection . . . . . . . . . . . . . . . . .38

7-5 Throttle Linkage Installation (ALL) . . . . . . . . . . . . . . . . .39

8-1 Body Assembly/Canopy Attachment . . . . . . . . . . . . . . . .40

8-2 Body Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

8-3 Main Rotor Blade Balancing . . . . . . . . . . . . . . . . . . . . . .41

8-4 Main Rotor Blade Attachment . . . . . . . . . . . . . . . . . . . . .41

Servo Adjustment and Radio Set Up . . . . . . . . . . . . . . . . . . . . . . .42-43

Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-49

Final Pre-Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Rotor Head/Swashplate/Washout Assembly Parts List . . . . . . . . .52-53

Start Shaft/Clutch/Engine Assembly Parts List . . . . . . . . . . . . . . .54-55

Cyclic Mixing Arms/Elevator/Aileron Control Arms Parts List . .56-57

Upper Main Frame/Radio Tray/Body Set Parts List . . . . . . . . . . .58-59

Lower Main Frame/Landing Gear/Fuel Tank Parts List . . . . . . . .60-61

Tail Boom/Tail Brace/Tail Boom Carrier Parts List . . . . . . . . . . .62-63

Tail Case/Tail Blade Holders/Tail Pitch Plate Parts List . . . . . . . .64-65

INDEX

Section Description Page

Page 4

ITEMS REQUIRED TO COMPLETE THE JR ERGO

1. RADIO SYSTEM REQUIREMENTS (NOT INCLUDED):

6-channel or greater R/C helicopter system with 5 servos, 1000 mAh receiver battery and gyro.

(not supplied in kit)

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.

Page 5

Double Sided Servo

Mounting Tape

Locktite 242 or

equivalent

Nylon Wire Ties To

Secure Radio Wires

Spiral Tubing

Silicone Fuel Tubing

Whip Antenna

Fuel Filter

Glow Plugs

2. ENGINE REQUIREMENTS (NOT INCLUDED):

3. BUILDING SUPPLIES (NOT INCLUDED):

The following items are needed to complete the assembly of the JR Ergo:

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

(Webra .33 Heli Engine Shown)

(Thunder Tiger Pro .46 Heli Engine Shown)

(JRP960078 Ergo .32-.36 Muffler Shown)

(JRP960079 Ergo .46 Muffler Shown)

Page 6

Needle Nose Pliers

Drill and Drill Bits

Allen Wrenches: 1.5, 2.0, 2.5,

3.0mm

Blade Balancer

Small Hammer

X-Acto Knife

Metric Ruler

Scissors

12 Volt Electric Starter

12 Volt Starting Battery

1.5 Volt Glow Plug Battery

Remote Glow Plug Adaptor

Helicopter Fuel 15% - 30%

Pitch Gauge

Fuel Pump

Ball Link Pliers

Training Gear (Beginners Only)

Hex Starting Shaft

Phillips Screwdirver

Nut Drivers: 5mm, 7mm

4. TOOLS NEEDED TO ASSEMBLE THE JR ERGO (NOT INCLUDED):

5. FIELD EQUIPMENT REQUIRED (NOT INCLUDED):

Page 7

Socket Head Bolt

Tapping Screw

Flat W asher

.05mm

Flat Head Screw

Lock Nut

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:

3x8mm Socket Head Bolt

Set Screw

2x8mm Flat Head Screw

2.6x10mm Self T apping Scre w

3mm Flat W asher

3mm Lock Nut

Spring W asher

3mm Spring W asher

Hex Nut

2mm Hex Nut

4x4mm Set Screw

HARDWARE IDENTIFICA TION

Flat Head Cap Screw

3x8mm Flat Head Cap Screw

Page 8

1-1

3x4mm Set Screw

* When installing the Start Shaft Bearing Block Assembly, be sure the Bearing Block is positioned so the Bushing faces upward toward the starter hex adaptor, with the bearing toward the Clutchbell Assembly.

Starter Hex Adaptor

*Start Shaft Bearing Block

Start Shaft

Complete Assembly

Clutch Bell Assembly

..........1 pc

3x6mm Socket Head Bolt

...1 pc

3mm Flat Washer

.........1 pc

CLUTCH BELL/ST AR T SHAFT ASSEMBLY

1-2

T AIL DRIVE PINION/BEARING BLOCK ASSEMBLY

Install the Lower Bearing Block so the bearing face is toward the bottom:

Install the Upper Bearing Block so that the bearing is toward the top:

Note: Be sure to allow a slight amount of

clearance between the Start Hex Adaptor and the Bearing Block to prevent binding.

Tail Drive Pinion

Bearing Blocks

Tail Drive Pinion

with Shaft

Front Tail Belt Pulley (Install Flat Side Up)

3mm Flat Washer

3x6mm Socket Head Bolt

Complete Assembly

Bearing

Use Threadlock

Page 9

1-3

2x8mm Flat Head Screw

2x10mm Flat Head Screw

........1 pc

........8 pc

Steel Joint Ball

........9 pc

2mm Nut

........3 pc

3x8mm Flat Head Screw

3x8mm Socket Head Bolt

........2 pc

Mixing Lever Bushing B

......1 pc

....1 pc

........1 pc

Nylon Washers

........5 pc

....1 pc

CONTROL BALL INST ALLATION

1-4

SERVO MIXING LEVER UNIT ASSEMBLY

Steel Joint Ball

Joint Ball (9 pc)

Roll Bell Crank

2x10mm Flat Head Screw (8 pc)

2x10mm Flat

Head Screw

Mixing Base Arm

(Collective)

2mm Nut

2x8mm Flat Head Screw

Mixing Lever (3 pc)

(Prepare 3 Sets)

2mm Nut

3x28mm Socket Head Bolt

Mixing Lever Spacer

........1 pc

Mixing Lever Bushing A

........1 pc

3mm Flat Washer

........1 pc

After assembly, any additional play or movement in the Mixing Lever Unit can be reduced by adding additional Nylon Washers as needed.

Nylon

Washer

3mm Flat

Washer

3x28mm Socket Head Bolt

Nylon Washers

Mixing Lever Bushing B

Mixing Lever Bushing A

3x8mm Flat Head Screw

Mixing Base Arm (Roll)

Mixing Base Cross Member

3x8mm Flat Head Screw

Complete Assembly

Nylon Washers

3x8mm Socket

Head Bolt

Mixing Base Cross Member

Mixing Lever Spacer

Use Threadlock

Page 10

1-5

ELEVATOR ARM ASSEMBLY

2x8mm Flat Head Screw

Steel Joint Ball

......2pc

Elevator Arm Pin

......2pc

..........2pc

2x8mm Flat Head Screw

Steel Joint Ball

Elevator Arm Front

Elevator Arm Pin

Steel Joint Ball

Swashplate A Arm

Swashplate A

Arms

Edge of Work Bench

Elevator Arm

Tap-in gently with

a small hammer.

Elevator Arm Rear

2x8mm Flat Head Screw

Caution: Be sure to note correct Swashplate A Arm installation direction.

Elevator Arm (Front)

Elevator Arm (Rear)

Marked Side Out

Swashplate A

Arm

Swashplate A

Arm

Marked Side In

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.

Fuel Tank

Silicone Fuel Tubing

(not incuded)

Connects to Engine Carburetor

* Trim before installation to a length of 58mm

Nipple

Tank Grommet

* Silicone Tube (Small)

Fuel Tank Clunk

Silicone Fuel Tubing

(not included)

Connects to Muffler Pressure Tap

1-6

FUEL T ANK ASSEMBLY

Page 11

2-1

UPPER MAIN FRAME SECTION ASSEMBLY

Note: Be sure to use the two shorter Body

Mount Standoffs for this installation.

Note: Both the Clutch Bell/Start Shaft Assembly

(Step 1-1) and the Tail Drive Pinion/ Bearing Block Assembly (Step 1-2) are temporarily installed at this time. These assemblies will be adjusted and secured in Step 3-2.

3x8mm Socket Head Bolt

..........21 pc

Body Mounting Standoffs Shaft

.......2 pc

3mm Flat Washer

..........11 pc

2.6x8mm Self Tapping Screw

..........4 pc

3x10mm Socket Head Bolt

..........1 pc

Tail Control

Rod Guide

3x10mm Socket Head Bolt

Body Mounting Standoff: Short

Bearing side must face upward*

Body Mounting Standoff: Short

3x8mm Socket Head Bolt (21 pc)

3mm Flat Washer (11 pc)

*Bearing side must

face downward

Servo Mounting Plates

Upper Main Frame

2.6x8mm Self Tapping Screw (4pc)

Upper Main Shaft Bearing Block

Position so the side of the bearing block that has the bearing flush with the flange is upward.

Lower Main Shaft Bearing Block

Bearing Flush with Flange

Bearing

Bearing Flush with Flange

Position so side of the bearing block that has the bearing flush with the flange is downward.

Use Threadlock On

All Screws

Page 12

2-2

UPPER MAIN FRAME CONTROL LEVER INST ALLATION

Note: Be sure to install the Elevator

Arm Units in their proper location as there is a “Front” and a “Rear” Unit (Step 1-5).

Attach the pre-finished Control Rods to the Mixing Levers/Control Arms as shown:

Nylon Washer

Elevator Arm Bushing

3x8mm Socket Head Bolt

3x6mm Socket Head Bolt

Elevator Arm Bushing

Nylon Washer

3x8mm Socket Head Bolt

Nylon Washer

3x22mm Socket Head Bolt

3x8mm Socket Head Bolt

........2 pc

........4 pc

........1 pc

Nylon Washers

........5 pc

......1 pc

3x22mm Socket Head Bolt

........1 pc

Elevator Arm Bushing

........2 pc

Mixing Base Nut

........2 pc

........1 pc

Rod Length Pre-Adjusted Length

110mm 92mm

45mm 24mm 75mm 59mm

A B

Roll Bellcrank

Spacer

3x6mm Socket Head Bolt

Washout Arm

Bushing

Top View

3mm Flat Washer

Mixing Base Nut

Pre-Adjusted Length

Washout Arm Bushing

3mm Flat Washer

3x6mm Socket Head Bolt

Roll Bellcrank Spacer

........1 pc

3mm Lock Nut

Use Threadlock

Page 13

2-3

LOWER MAIN FRAME ASSEMBLY

3x8mm Socket Head Bolt

........ 4pc

3mm Lock Nut

........4 pc

2.6x8mm Self Tapping Screw

........4 pc

2-4

FUEL T ANK INSTALLATION

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 the bottoms of the level surface to

prevent twisting during tightening.

2.6x8mm Self Tapping Screw (4 pc)

2.6x8mm Self Tapping Screw

Servo Mounting Plate

3x8mm Socket Head Bolt (4 pc)

Lower Main Frame

3mm Lock Nut

(4 pc)

Lower Frame Angle (2 pc)

Main Frame Standoff, 60mm

Main Frame Standoff,

60mm

3x10mm Socket Head Bolt (4 pc)

Tank Mounting

3x8mm Socket Head Bolt

Fuel Tank

3x8mm Socket

Head Bolt

Tank Mounting

Lower Main Frame

3x8mm Socket Head Bolt

........2 pc

3x10mm Socket Head Bolt

........4 pc

Main Frame Standoff, 60mm

........ 3 pc

Use Threadlock

Page 14

2-5

FRONT RADIO BED/GYRO MOUNTING PLA TE INSTALLATION

2-6

COOLING FAN SHROUD INSTALLA TION

3x18mm Set Screw

Body Mounting Standoff Long

........2 pc

3x10mm Socket Head Bolt

........6 pc

........2 pc

2.6x8mm Self Tapping Screw

........4 pc

When installing a .46 size engine it will be necessary to trim the bottom portion of the Fan Shroud as shown:

Front Radio Bed

Body Mounting

Standoff Long

3x10mm Socket

Head Bolt

2.6x8mm Self

Tapping Screw

Cooling Fan Shroud

2.6x8mm Self Tapping Screw

3x18mm Set Screw (2 pc)

Body Mount Standoff, Long

3x10mm Socket Head Bolt (6 pc)

Gyro Mounting Plate

Ergo .46 Fan Shroud Adjustment

3/4"1 7/8"

Remove

Use Threadlock

Page 15

2-7

UPPER/LOWER MAIN FRAME ASSEMBLY A TT ACHMENT

Main Frame Standoff, 32mm

Main Frame Spacer, 12.5mm

........12 pc

3x22mm Socket Head Bolt

........12 pc

........6 pc

Main Frame Spacer, 12.5mm (12 pc)

Main Frame Standoff, 32mm (6 pc)

3x22mm Socket

Head Bolt (12 pc)

3x22mm Socket Head Bolt

Use Threadlock On

All Screws

Page 16

3-1

MAIN DRIVE GEAR/AUTOROT ATION ASSEMBL Y

3-2

MAIN DRIVE GEAR/AUTOROT ATION ASSEMBL Y INSTALLA TION

3x6mm Socket Head Bolt

.......4 pc

3mm Lock Nut

........1 pc

4x4mm Set Screw

........4 pc

......1 pc

3x22mm Socket Head Bolt

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.

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.

3x6mm Socket Head Bolt (4 pc)

[Tighten equally to prevent warping of Main Drive Gear]

Main Drive Gear

Autorotaion Assembly

Main Shaft Collar

8mm

3mm

4x4mm Set Screw (4 pc)

Main Rotor Shaft

3mm Lock Nut

3x22mm Socket Head Bolt

Autorotation Hub

Use Threadlock

Page 17

3-3

LANDING GEAR ASSEMBLY INST ALLA TION

3-4

.32-.36 CO0LING FAN/HUB INSTALLA TION

3mm Lock Nut

........4 pc

3x12mm Socket Head Bolt

........4 pc

3mm Flat Washer

........4 pc

4x4mm Set Screw

........4 pc

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.

3x5mm Socket Head Bolt

........4 pc

3x12mm Socket Head Bolt (4 pc)

3mm Flat Washer (4 pc)

Landing Strut

Landing Gear Dampers (4 pc)

Landing Skid Cap

Landing Skid

20mm

Antenna Tube

4x4mm Set Screw (4 pc)

3mm Lock

Nut (4 pc)

Cooling Fan Hub .32-.36

Cooling Fan .32-.36

Nut Supplied with Engine

3x5mm Socket

Head Bolt (4 pc)

Use Threadlock

For proper installation of the fan assembly, it is neccessary for the engine to have the prop drive washer installed.

Prop drive washer must be

used for correct installation

* Revolution 1003 Piston Locking Tool

(Purchased Separately)

Page 18

3-4.1

.46 COOLING FAN INSTALLA TION

3-5

.32-.36 ENGINE MOUNT A TTACHMENT

Note: If you are building the Ergo .46 3D Version proceed to Step 3-5.1.

Longer Distance

Shorter Distance

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.

3x15mm Socket Head Bolt

3mm Flat Washer

........4 pc

3mm Serrated Washer

........4 pc

Top

Bottom

Motor Mount Direction

Engine Mount .32-.36

3mm Serrated Washer (4 pc)

3x15mm Socket Head Bolt

3mm Flat Washer (4 pc)

Nut Supplied with Engine

* Revolution 1003 Piston Locking Too

(Purchased Separately)

It is important to note the proper direction that the motor mount is installed to achieve the correct alignment of the engine.

Aluminum Cooling Fan

(Ergo .46)

Use Threadlock

......4 pc

Page 19

3-5.1

.46 ENGINE MOUNT A TTACHMENT

3-6

CLUTCH ASSEMBLY A TT ACHMENT (ALL)

*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.

It is important to note the proper direction that the Motor Mount is installed to achieve the correct alignment of the engine.

3mm Flat Washer

........4 pc

3x15mm Socket Head Bolt

........4 pc

3mm Serrated Washer

........4 pc

2x8mm Flat Head Screw

........1 pc

3mm Flat Washer

........2 pc

Steel Joint Ball

........1 pc

3x5mm Socket Head Bolt

........2 pc

2mm Hex Nut

........1 pc

Engine Mount .46

Fan Assembly: .46

3mm Serrated Washer (4 pc)

3x15mm Socket Head Bolts (4 pc)

Shorter Distance

Longer Distance

3mm Flat

Washer (4 pc)

2mm Hex Nut

Clutch Assembly

3mm Flat Washer (2 pc)

3x5mm Socket Head Bolt

(2 pc)

2x8mm Flat Head Screw

Steel Joint Ball

*see note

Top

Bottom

Motor Mount Direction:

Thunder Tiger

Motor Mount Direction:

O.S.

Thunder Tiger

Pro .46

Top

O.S. .46 FS

R-H

Shorter Distance

Use Threadlock

Page 20

3-7

ENGINE INST ALLATION (ALL)

3-8

INST ALLATION OF THE MUFFLER

Pressure Tap

........1 pc

3x30mm Socket Head Bolt

.......2 pc

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.

Note: The installation shown is for a .32-.36 size

engine with the JR muffler (JRP960078). Installation of other .32-.36/.46 engine muffler combinations may vary. Please refer to your engine/muffler instructions for proper installation.

3x10mm Socket Head Bolt

........4 pc

3mm Flat Washer

........4 pc

3x10mm Socket Head Bolt (4 pc)

3mm Flat Washer (4 pc)

Pressure Fuel Line Attachment

3x30mm Socket Head Bolts (*Inserted in Step 3-7)

JR .32-.36 Muffler Shown (Purchased Separately, JRP960078)

Pressure Tap

Correct

Incorrect

Use Threadlock

Page 21

4-1

ROTOR HEAD HUB ASSEMBLY

4-2

MAIN BLADE HOLDER ASSEMBLY

3x6mm Socket Head Bolt

........1 pc

3x8mm Socket Head Bolt

......2 pc

2x10mm Flat Head Screw

........2 pc

Steel Joint Ball

........2 pc

3x6mm Self Tapping Screw

........4 pc

Main Blade Holder Bearing

........4 pc

Outer Main Blade Bearing Spacer

........2 pc

Inner Main Blade Bearing Spacer

........2 pc

3x6mm Socket Head Bolt

Head Button

3x8mm Socket Head Bolt

(2 pc)

Phase Adjustment Ring

(insert onto base of Main Rotor Hub)

Main Rotor Hub

Two Sets Required

Main Blade Holder Bearing

Main Blade Holder

Main Blade Holder Bearing

Steel Joint Ball

2x10mm Flat Head Screw

Outer Main Blade Bearing Spacer

Inner Main Blade Bearing Spacer

3x6mm Self Tapping Screw

Use Threadlock

Page 22

4-3

MAIN BLADE HOLDER/SEESAW ATT ACHMENT

4-4

SEESAW MIXING ARM INSTALLA TION

Blade Holder Spacer A

........2 pc

4mm Lock Nut

........2 pc

Seesaw Spacer (Steel)

........2 pc

3x16mm Socket Head Bolt

........2 pc

3x16mm Socket Head Bolt

........2 pc

2x10mm Flat Head Screw

........4 pc

3mm Flat Washer

........6 pc

Nylon Washer

........4 pc

Steel Joint Ball

........4 pc

Blade Spindle Shaft

Damper Rubber (2 pc)

Blade Holder Spacer

(Bevel Inward) (2 pc)

4mm Lock Nut (2 pc)

3x5mm Button Head Bolt

(2 pc)

Seesaw Shaft

Seesaw Spacer (Steel)

(2 pc)

Nylon Washer

3mm Flat Washers

Nylon Washer

3mm Flat Washer

3x16mm Socket

Head Bolt

Mixing Arm Bushing

Seesaw Mixing Arm

Steel Joint Ball

2x10mm Flat Head Screw (2 pc)

Two Sets Required

Use Threadlock

3x5mm Button Head Bolt

Page 23

4-5

SWASHPLATE/WASHOUT ASSEMBLY INSTALLATION

Connect the two Washout Links to the correct upper Swashplate Balls as shown.

Complete Assembly

*Washout Assembly

Swashplate Assembly

Upper Swashplate Ring

*SWASHOUT ASSEMBLY INSTALLATION

When installing the washout assembly be sure the long flange of the mixing base is positioned downward (toward the swashplate) with the short portion facing upward.

Long portion of mixing base flange must face downward.

Washout Assembly

Page 24

4-6

ROTOR HEAD INST ALLATION

3x18mm Socket Head Bolt

........1 pc

3mm Lock Nut

........1 pc

Note: Be sure to engage thePhase

Adjusting Ring into the Washout Base Groove before securing the Rotor Head Assembly in place.

3mm Lock Nut

Completed Rotor Head Assembly

3x18mm Socket Head Bolt

Rotor Hub Pin

Washout Base

Page 25

4-7

FLYBAR INST ALLA TION

4-8

FLYBAR PADDLE ATTACHMENT

3mm Lock Nut

........2 pc

4x4mm Set Screw

........2 pc

* Be sure to insert Flybar Bushings into the Seesaw Shaft before inserting Flybar.

Check to insure that the two Flybar Control Arms are parallel to the center line of the Flybar.

Note: Center the Flybar in the Seesaw Shaft before securing the two Flybar Control Arms.

Thread each Flybar Paddle onto the Flybar until the threaded tip of the Flybar protrudes approximately 4mm.

Adjust each Flybar Paddle so they are parallel to the Flybar Control Arms, and to each other. Secure to the Flybar using two 3mm Lock Nuts.

Note proper direction of each Flybar Paddle (short portion forward, clockwise rotation).

*Flybar Bushings (2 pc)

Flybar Control Arm (2 pc)

4x4mm Set Screw

(2 pc)

Flybar

Flybar Centering

Center Line

3mm Lock Nut (2 pc)

Flybar Paddle (2 pc)

Use Threadlock

Page 26

4-9

ROTOR HEAD/SWASHPLATE CONTROL ROD INSTALLATION

Note: Ergo .46 3D Kit

Your Ergo .46 3D Kit includes an additional set of Double Links (B Style #960081). These links are designed to provide proper blade pitch for 3D Flight (+10° thru -10°).

Using the Standard Double Link “A” will provide a Standard Blade Pitch Range (+15 thru -4).

Standard Double Links “A” are recommended for all training and sport flying applications.

Pre-Assembled Control Rod Identification:

Swashplate to Roll Bellcrank

(2.3mmx30mm Threaded Rod)

Swashplate to Washout Arm

(2.3mmx40mm Threaded Rod)

*Double Link A (2 pc)

(Washout Arm to

Main Blade Holder)

11mm

19mm

Washout Arm to Flybar Control Arm

(1 Piece Double Link)

47mm

Page 27

5-1

T AIL OUTPUT SHAFT/PULLEY ASSEMBLY

5-2

T AIL GEAR CASE ASSEMBLY

Spring Pin

........1 pc

3x12mm Self Tapping Screw

........3 pc

Tail Output Shaft Bearing

........2 pc

2.6x12mm Socket Head Bolt

........4 pc

2.6mm Hex Nut

........4 pc

Note: Be sure to position the

Tail Gear Case onto the shorter slotted side of the Tail Boom.

Tail Output Shaft

Short Distance

Tail Case Pulley

Edge of Work Bench

Complete Assembly

Spring Pin

Hammer

Longer (Helicopter)

Shorter (Tail Gear Case)

2.6mm Hex Nut (4 pc)

Tail Boom

Tail Drive Belt

2.6x12mm Socket Head Bolt (4 pc)

Tail Output

Shaft Bearing

Tail Gear Case (L/R)

Tail Output

Shaft Bearing

3x12mm Self

Tapping Screw

3x12mm Self

Tapping Screw

Tail Boom

Long Distance

Note correct direction of Tail Output Shaft during assembly.

Use Threadlock

Page 28

5-3

T AIL CENTER HUB ASSEMBLY

3x3mm Set Screw

.......2 pc

3mm Lock Nut

........2 pc

Tail Blade Holder Bearing

........4 pc

2x8mm Socket Head Bolt

........4 pc

3x15mm Socket Head Bolt

.......2 pc

3mm Lock Nut

........2 pc

2mm Hex Nut

........4 pc

* Be sure to note direction of Tail Rotor Blades during assembly.

5-4

T AIL BLADE HOLDER ASSEMBLY

Tail Output Shaft Hole

Tail Blade Holder w/Ball

(Outside)

3x15mm Socket

Head Bolt

2x8mm Socket

Head Bolt

Tail Blade Holder w/o Ball (Inside)

Rotation

2mm Hex Nut

3mm Lock Nut

Tail Rotor Blade

Rotation

Two Sets Required

* Be certain to apply Locktite to the two 3x3mm set screws and attach securely to the tail output shaft so the set screws engage into the tail output shaft hole. Failure to secure this assembly properly can result in tail rotor failure during flight.

Tail Center Hub

Tail Blade Holder Bearing

(4pc)

Tail Slide Ring Assembly

3x3mm Set Screw (2pc)

Use Threadlock

3mm Lock Nut (2 pc)

Page 29

5-5

T AIL PITCH CONTROL LEVER INSTALLATION

5-6

T AIL FIN ATTACHMENT

3mm Lock Nut

........4 pc

3x8mm Socket Head Bolt

........2 pc

3x10mm Socket Head Bolt

........1 pc

3x12mm Socket Head Bolt

........2 pc

2x20mm Socket Head Bolt

.......1 pc

2mm Flat Washer

........1 pc

Tail Lever Bushing

........1 pc

3x12mm Self Tapping Screw

........3 pc

2x8 Flat Head Screw

........1 pc

Steel Joint Ball

........1 pc

* Do not completly secure these bolts as this assembly will need to be correctly positioned in Step 5-10.

* Note: Please attach the Tail Boom Decal Stripe (located on the decal sheet) prior to attaching the horizontal fin/brace clamp.

Tail Lever Bushing

2x20mm Socket Head Bolt

3x10mm Socket Head Bolt

Vertical Fin

Horizontal Fin

3x12mm Self Tapping

Screw (3 pc)

*3x12mm Socket Head Bolt (2 pc)

*3x8mm Socket Head Bolt (2 pc)

Horizontal Fin/Brace Clamp (L&R) * Tail Boom Decal Stripe

3mm Lock Nut (4 pc)

2x8mm Flat Head Screw

Steel Joint Ball

Tail Pitch Control Lever

Snap Onto

Ball

2mm Flat Washer

Page 30

5-7

T AIL BOOM CARRIER INSTALLATION

5-8

T AIL BOOM ASSEMBLY INST ALLATION

3mm Lock Nut

........6 pc

3x15mm Socket Head Bolt

........4 pc

3x40mm Socket Head Bolt

........2 pc

* Do not fully tighten at this time. These bolts will be secured in Step 5-10.

Slide the Tail Boom through the Tail Boom Carrier and engage the Tail Drive Belt over the Front Pulley. Be certain to note the correct rotation (direction shown below. Set the belt tension per the directions below.).

Note: It may be necessary to add one thickness

of electrical tape around the end of the Tail Boom to insure positive attachment to the Tail Boom Carrier.

Secure Bolts completly after inserting Tail Boom making sure that the Tail Output Shaft is exactly 90° to the Main Rotor Shaft.

Rotate the Tail Drive Belt in the direction shown before installing it onto the front pulley. It is extremely important to install the belt in the proper direction to insure correct rotation of the Tail Rotor Blades.

Belt tension should be set so when pressing with your finger, both sides of the belt do NOT come in contact with each other. Be sure not to set the belt too tight, as this can cause vibration and a loss of power.

3mm Lock Nut

Tail Boom Carrier (L&R)

*3x15mm Socket Head Bolt

*3x40mm Socket Head Bolt

Tail Output Shaft Pulley

Front Pulley

Page 31

5-9

T AIL BOOM BRACE ASSEMBLY

5-10

T AIL BOOM BRACE INSTALLATION

2.6x12mm Socket Head Bolt

........1 pc

2.6x15mm Socket Head Bolt

......1 pc

3mm Lock Nut

........1 pc

3x8mm Socket Head Bolt

........2 pc

3x10mm Socket Head Bolt

........1 pc

Secure the four Socket Head Bolts left loose from Step 5-6.

Make sure that the Horizontal Fin is level.

Tail Brace Connector

2.6x15mm Socket Head Bolt

Tail Brace Tube

Tail Brace T End

2.6x12mm Socket Head Bolt

3x10mm Socket Head Bolt

3mm Lock Nut

3x8mm Socket Head Bolt (2 pc)

Page 32

6-1

UPPER SERVO TRA Y INSTALLATION

RADIO INSTALLATION SUGGESTIONS

Be sure to install four rubber servo grommets and eyelets to each servo prior to installation. When securing the servos to the helicopter, be sure not to overtighten the mounting screws.

All servo rods contained in this kit have been pre-adjusted to fit JR servos. If you are installing a different brand radio system, please adjust the rod lengths to the correct dimensions as listed in these instructions.

When adjusting control rods, be sure to adjust each universal link the same amount so as not to unthread one link too far.

It is suggested that both the receiver and gyro amplifier be isolated from vibration by wrapping them in foam, then securing them to the model using double-sided servo tape.

Be sure to keep all servo lead wires, etc., away from all servo arms, rods, and sharp edges of the helicopter’s mechanics. Group these wires together after final installation using small nylon wire ties.

3x8mm Socket Head Bolt

......4 pc

3x8mm Socket Head Bolt (4 pc)

Upper Servo Tray

Page 33

6-2

SERVO/SWITCH HARNESS INST ALLATION

2.6x12mm Self Tapping Screw

......20 pc

2.6mm Flat Washer (4 Per Servo)

......20 pc

* Note correct Servo Output Shaft orientation dring installation.

2.6x12mm Self Tapping Screw

2.6mm Flat Washer

Inner Holes are for JR Servos

Outer Holes are for Futaba Servos

2.6mm Flat Washer

2.6x12mm Self Tapping Screw

Switch Harness

Switch Damper Rubber

Switch

Screws Supplied

with Switch

Rudder

Switch Cover

Page 34

6-3

T AIL CONTROL ROD ASSEMBLY

6-4

T AIL CONTROL ROD INSTALLATION

Insert the Tail Control Rod Assembly into the four guides through the inner holes. Adjust the spacing of the guides as shown below and secure using the four 2x8mm Self Tapping Screws as shown.

Note: Be sure to use the inside hole of

the Tail Control Rod Guide during assembly.

2x8mm Self Tapping Screw

......4 pc

Universal Link (2 pc)

Tail Control Rod Bushings (5 pc)

Tail Control Rod

Thread Link 8mm onto Control Rod

Tail Contol Rod Guide (4 pc)

2x8mm Self Tapping Screw

Tail Control Rod Clip located on Main Fram

140mm 140mm 140mm

140mm

Tail Control Rod Bushing

......5 pc

Universal Link

......2 pc

Page 35

6-5

GYRO/RECEIVER/BATTER Y INST ALLATION

Caution: Be certain when installing the Gyro to the

Gyro Mounting Plate that it does not come in contact with the frame of the helicopter, and that the surfaces are free from oil, residue, etc. Clean if neccessary to insure proper adhesion.

Note: Nylon Wire Ties, Double Sided Servo Tape,

and Spiral Tubing are not included in this kit.

* Wrap with foam or sponge rubber individually before installation.

Gyro

Spiral Tubing

(Available at local auto supply store)

Receiver*

Nylon Wire Tie Nicad RX Battery Pack

Gyro Amp*

Servo Tape

Gyro Gain Controller

Double Sided Servo Tape

Page 36

The following preparations are suggested for use with JR radio systems. However, these procedures are applicable to most other brand radio systems.

These suggested adjustments are necessary to insure correct installation and attachment of the control linkages and servo horns.

TRANSMITTER PREPARATION

RECEIVER FLIGHT PACK PREP ARATION

SERVO HORN INST ALLA TION SUGGESTIONS

1. Set all trim levers, trim knobs and switches to the neutral or zero positions.

2. Turn the transmitter power switch to the “on” position.

3. If you are using a computer radio system that has been adjusted

previously to another model, reset all functions and input values to the factory preset position.

4. Move the throttle/collective control stick to the center or half stick position. Next slide the throttle trim lever to the full low position.

1. With the transmitter still on, slide the receiver switch to its “on” position. All servos should move to the neutral, or center, position.

2. Check to insure that all servos operate with the appropriate control stick.

3. Rest the throttle stick to the center position, making sure the throttle trim is still at low.

4. Turn off the receiver switch first, followed by the transmitter.

For proper operation, it is important that the servo horns are positioned on the servos in the “exact” neutral position. Although most computer radio systems offer a sub-trim feature, it is suggested that the servo horns be manipulated on the servos to achieve the “exact” neutral settings.

Since the servo output spline on a JR system has an odd number of teeth (21), it is possible to reposition the servo arm on the servo at 90° intervals to achieve the proper neutral attachment of the servo horn.

Once the correct arm of the servo horn has been established, it is suggested that the remaining, unused arms be removed from the servo horn as shown in the installation diagrams.

It will also be necessary to enlarge the appropriate hole in the servo horn slightly to allow correct installation of the steel control balls to the servo horn.

RADIO SYSTEM PREPARATION

Page 37

7-1

AILERON LINKAGES

7-2

ELEVATOR LINKAGE INST ALLA TION

......... 1 pc

2x8mm Flat Head Screw

..........1 pc

Steel Joint Ball

.........1 pc

2mm Hex Nut

..........2pc

2x8mm Flat Head Screw

..........2pc

Steel Joint Ball

..........2pc

2mm Hex Nut

A Special Note To Beginners: It is suggested that the maximum travel limits for aileron, elevator, pitch and rudder controls be reduced to 70%. Note: Attach the steel joint ball to the correct hole as shown below:

Make sure the Aileron Trim is in the center position before attaching the Servo Arm to the Servo.

Be sure to remove the excess Servo Horn Arms as shown. Secure the Servo Horn using the Servo Horn Screw.

Attach the Steel Joint Ball to the bottom side of the Servo Horn.

Make sure the Elevator Trim is in the center position before attaching the Servo Arm to the Servo.

At this time, check to insure that the Swashplate is at a 90° angle to the Main Rotor Shaft in both fore/aft and right/left directions.

Be sure to remove the excess Servo Horn Arms as shown. Secure the Servo Horn using the Servo Horn Screw.

Servo Reversing Directions

JR Normal

Futaba Normal

2x8mm Flat Head Screw

Steel Joint Ball

2mm Hex Nut

2.3x35mm All Threaded Rod

20mm

21mm

Futaba

Use this Horn

Futaba

10.5mm

Servo Horn Hole Selection

Right

Left

90˚

Servo Horn

2mm Hex Nut (2 pc)

Servo Horn (2 pc)

Steel Joint Ball (2 pc)

2x8mm Flat Head Screw (2 pc)

2.3x60mm All Threaded Rod

39mm

Servo Horn Hole Selection

Use This Hole

10.5mm 10.5mm

40mm

90˚

Down

90˚

Futaba

Servo Reversing Directions

JR Normal

Futaba Normal

Page 38

7-3

COLLECTIVE LINKAGE INST ALLATION

7-4

T AIL CONTROL ROD SERVO CONNECTION

..........1 pc

2x8mm Flat Head Screw

..........1 pc

Steel Joint Ball

..........1 pc

2mm Hex Nut

..........1 pc

2x8mm Flat Head Screw

..........1 pc

Steel Joint Ball

..........1 pc

2mm Hex Nut

Note: Make certain that the Collective

Servo is in the neutral or hover position before securing the Servo Horn to the Servo.

Be sure to remove the excess Servo Horn Arms as shown. Secure the Servo Horn using the Servo Horn Screw.

Note: Make certain that the Tail Rotor Servo is in the

neutral or hover position before securing the Servo Horn to the Servo.

Be sure to remove the excess Servo Horn Arms as shown. Secure the Servo Horn using the Servo Horn Screw.

An Important Note: Check to insure the Tail Control Rod can slide through the Tail Control Rod Guides smoothly before connecting it to the Servo. If resistance is felt, rotate the Tail Control Rod Guides slightly until the Control Rod slides smoothly.

2x8mm Flat Head Screw

Steel Joint Ball

2mm Hex Nut

Servo Horn

10.5mm

12.5mm

Use This Hole

Futaba

Servo Horn Hole Selection

Use This Hole

Futaba

Servo Horn Hole Selection

2.3x35mm All Threaded Rod

20mm

21mm

90°

Tail Control Lever Position at Center Stick

90°

Left

Right

2x8mm Flat Head Screw

Steel Joint Ball

2mm Hex Nut

Servo Horn

Servo Reversing Directions

JR Reverse

Futaba Reverse

Servo Reversing Directions

JR Reverse

Futaba Reverse

Servo Reversing Directions

JR Reverse

Futaba Normal

Page 39

7-5

THROTTLE LINKAGE INST ALLATION (ALL)

..........1 pc

2x8mm Flat Head Screw

..........1 pc

Steel Joint Ball

..........1 pc

2mm Hex Nut

Note: Make sure that the Throttle Trim

is in the low position before attaching the Servo Horn.

SERVO HORN SELECTION/LINKAGE ADJUSTMENTS

THROTTLE ARM/SERVO HORN POSITIONS

JR System/Webra .33 Engine or Thunder Tiger Pro .46 Heli Engine

JR System/O.S. .32SX-H Engine

Futaba System/Webra .33 Engine or Thunder Tiger Pro .46 Heli Engine

Futaba System/O.S. .32SX-H Engine

Be sure to remove the excess Servo Horn Arms as shown. Secure the Servo Horn using the Servo Horn Screw.

*To avoid differential throttle travel, make certain both the throttle arm and the servo horn are positioned as shown in the above diagrams.

1/2 Stick (Throttle) Position

(Throttle Barrel 1/2 open)

Low Stick (Throttle) Position (Throttle Barrel Fully Closed)

High Stick (Throttle) Position

(Throttle Barrel Fully Open)

To achieve the correct position of the throttle/servo arm, it may be necessary to re-position the throttle arm on the carburetor. It may also be necessary to adjust the length of the throttle linkage slightly to achieve full open and closed positions of the carburetor. It is also possible to increase/reduce the travel of the throttle servo through

the travel adjust function found in most computer radio systems. If this function is used, make sure the values for the high and low positions remain equal (same value for high/low). If these values are not equal, this will create a differential, or uneven movement of the throttle, making rotor RPM adjustment and fine tuning more difficult.

2x8mm Flat Head Screw

Steel Joint Ball

2mm Hex Nut

Servo Horn

Low

Throttle

High

Throttle

12.5mm

2.3x75mm

58mm

60mm

59mm

57mm

Use This Hole

90°

Servo Reversing Directions

JR Reverse

Futaba Reverse

Page 40

8-1

BODY ASSEMBLY/CANOPY A TT ACHMENT

8-2

BODY A TTACHMENT

..........5 pc

2.3x8mm Self Tapping Screw

*After trimming, attach the canopy to the body temporarily with tape. Next drill five 1/16" holes through both the canopy and the body and secure using the 2.3x8mm screws provided.

Note: It will be necessary to trim

away the unwanted plastic off the canopy and side window areas using an X-Acto knife.

Slide the completed body over the mechanics and secure through the four canopy mount standoffs as shown.

Check to insure that the body does not come contact with any portion of the Main Frame, Muffler, Servo/Servo Horns, etc. Trim for clearance if necessary.

Body

Drill four 15/64" holes and insert Rubber Grommets as shown.

2.3x8mm Self Tapping Screw (5 pc)

*Canopy (Trim prior to attachment)

Rubber Grommets (4 pc)

Page 41

8-3

MAIN ROTOR BLADE BALANCING

8-4

MAIN ROTOR BLADE A TTACHMENT

.........2 pc

4mm Lock Nut

.........2 pc

4x30mm Socket Head Bolt

Firmly secure the main rotor blades to the rotor head as shown above. Be certain to note the proper direction of the rotor blades when assembling (clockwise rotation). Main blades should be tightened so they can pivot when moderate pressure is applied. Do not allow the main blades to swing freely within the main blade holders.

Spanwise C.G. Balancing

Place each rotor blade on a sharp edge of a table as shown and adjust so each rotor blade “teeters” on the edge of the table. If the blades are correctly balanced, they should be at an equal distance to the edge of the table. If they are not, apply tape to the center of the light or short blade until equal distance can be achieved.

Final Static Balancing

To static balance the main rotor blades, it is suggested to either attach each blade to a “seesaw” type blade balancer (RVO1001), or bolt each of the two blades together through the blade mounting holes shown and suspend this unit between two drinking glasses. Add blade tracking tape (from decal sheet) to the tip of the light or high blade until they each become level to the table surface.

Step 1 Step 2

Main Rotor Blades

Drinking Glass (2 pc)

4x30mm Socket Head Bolt

4mm Lock Nut

Page 42

Now that the radio system is completely installed into the helicopter, it is necessary to check and adjust the following:

1. Servo Direction (Servo Reversing)

Check to insure that all servos have been set to the correct direction as shown in the Control Linkage Installation Section (Steps 7-1 to 7-5).

2. Dual Rates

It is suggested that for initial flights, the dual rate function values be set as follows:

0 Position (low rate) 60% 1 Position (high rate) 100%

3. Exponential Settings

It is suggested that the exponential rate settings remain in the 0 value position until the initial test flights. After initial flights, adjust the exponential values to achieve the desired control feel.

4. Sub-Trim Settings

It is suggested that the correct neutral settings be achieved without the use of the sub-trim feature. If sub-trim is used for final flight adjustments, it is not suggested that the sub-trim values exceed 10. If the sub-trim values are greater, readjust the control linkages and reset the sub-trims to 0.

5. Tra vel Adjustment

The travel adjustment feature allows the control surface to be

adjusted to achieve maximum travel, or surface deflection. When using

this feature, it is extremely important that the high/low, up/down values for each channel be set at an equal value or a differential movement will occur (Diagram B). It is especially important that the throttle and collective pitch travel limits are set to an equal value (Diagram A).

Please refer to the diagrams below for clarification.

6. Pitch/Throttle Curve Adjustment

It is very important that the throttle and pitch curves are adjusted properly to achieve the best performance from your helicopter. When properly adjusted, the main rotor head RPM should remain consistent throughout all maneuvers and throttle stick positions. A constant RPM will also help to improve the effectiveness and accuracy of the tail rotor and gyro systems.

A. Pitch Curve Adjustment Using a pitch gauge (optional) set the low, mid and high stick pitch settings as shown in the diagram below. Use the travel adjust feature to set the maximum high and low pitch required for all flight modes. This pitch travel can then be reduced by altering the pitch curves as shown below.

Note: * To achieve this pitch range settings with the Ergo, it will be

necessary to use the optional “B” style double link set (#960081). (This item is included with the Ergo .46 kit.)

Note: When using the “B” style double link set for 3D flight, the

maximum pitch range is altered to +10¯ – ¯10, reducing the + pitch range for autorotations.

FINAL SERVO ADJUSTMENT AND RADIO SET UP

Correct

100

+10°

0°

-10°

+13°

5°

-5°

13°

8.5°

-5°

13° 10°

5°

-5°

-2°

Incorrect

Hovering (Linear Curve)

Flight Mode

Flight Mode 2 (optional)

Flight Mode

Stick Position

Low

Half High Low

Half

High

Stick Position

Low

Half

High

Stick Position

Low

Half

High

Stunt & Aerobatic Flight

Autorotation

3D Flight (Ergo 46)

100

Straight & Linear Servo Travel

Non-Linear Servo Travel

Flight Application Low Pitch Hovering Pitch High Pitch Mode (Low Stick) (Half Stick) (High Stick)

N Hovering -2° 5° 10°

I Stunt & Aerobatic Flight -5° 5° 8.5°

*2 3D Flight (Ergo 46) -10° 0° 10°

H Auto-Rotation -5° 5° 13°

100

Pitch Range Settings

Pitch Curve Settings

Pitch Range Pitch Range

Page 43

It will also be necessary to set the correct idle speed of the engine when the throttle hold function is activated.

This idle value is located within the throttle hold function. This will allow the engine to remain at idle when practicing autorotations.

7. Revolution Mixing

It will be necessary to adjust the revolution mixing to properly compensate for the torque of the engine during all flight conditions (except autorotation).

Since there are many variables that can alter the value of the revolution mixing (engine, blade pitch, fuel, etc.), it will be necessary to fine tune this function during test flights.

The following values are shown only as a starting point toward achieving proper compensation:

Flight Mode N Flight Mode 1 Flight Mode 2 (3D)

Up 35 Up 15 Up 15

Down 30 Down 10 Down 15

8. Gyro Gain Adjustment

It will be necessary to adjust the “gain” or compensation of the gyro to create the correct amount of “holding power” necessary for a solid

neutral tail rotor. The intent of the gyro is to compensate for abrupt movements, or wind direction changes, working in conjunction with the revolution mixing function.

For hovering, it is recommended that you start with the gyro gain at approximately 60°, and continue to increase slightly until the tail of the helicopter “hunts”, then reduce the value slightly.

This same adjustment will also be necessary to achieve proper forward flight. Generally, the gyro gain for forward flight will be approximately 10% - 20% less than that of the established hover gain due to aerodynamic forces present in forward flight.

If you are using a dual rate gyro, adjust the gain so that you are using “higher” gain setting for hover, and the “lower” gain setting for forward flight.

It will also be necessary to confirm the direction that the gyro compensates when the body of the helicopter is rotated.

To do this, turn the radio system on and suspend the helicopter by the main rotor head. Next, move the rudder stick to the right and watch the direction that the tail rotor servo arm travels. Now while watching the tail rotor servo arm, rotate the body of the helicopter counter clockwise. The servo arm should move in the same direction as when the rudder stick was moved to the left.

If the arm moves in the opposite direction, reverse the gyro and re-test.

Note: The throttle curve examples shown correspond to

the pitch curve examples show in Step 6A.

100%

50%

40%

0% Idle

Power Output

Hovering (Linear Curve)

Stick Position

Low Half

High

Flight Mode

100%

50%

0% Idle

Power Output

Stunt & Aerobatic Flight

Stick Position

Low

Half

High

Flight Mode

100%

50%

0% Idle

3D Flight (Optional)

Stick Position

Low

Half

High

Flight

Mode 2

Power Output

B. Throttle Curve Settings

Below are several examples of possible throttle curves during various flight conditions.

Since throttle curves can vary greatly due to engine and muffler combinations, it will be necessary to fine tune and adjust these values during test flights to achieve a constant main rotor RPM.

Page 44

XF622 DATA SHEET #1 ERGO .32/.46 (INITIAL SET-UP)

REVERSE SW

SUB-TRIM

TRAVEL ADJUST

(TRV ADJ.)

THR AIL ELE RUD GER PITCH

GEAR SW FACTORY PRE-SET

NORM NORM NORM NORM NORM NORM

REV REV REV REV REV REV

+80%

–80%

+80%

–80%

+ –

+100%

–100%

–%

+150%

–150%

N 0% 50% 100%

S 40% 50%

N -2° Pitch 5° Pitch 10° Pitch

S -5° Pitch 5° Pitch 8.5° Pitch

H -5° Pitch 5° Pitch 13° Pitch

THRO CURVE

TLN, T2N, THN

TLS, T2S

PITCH CURVE

PLN, P2N, PHN PLS, P2S, PHS PLH, P2H, PHH

L2H

DUAL RATE POS 0 90% 90%

(A1, EL) POS 1 100% 100%

AILE ELEV

REVO MIX UP (U) 35%

(RV) DOWN (D) 30%

HOLD RUDD OFFSET (HLD)

+ –

THRO HOLD POSITION

ON OFF

HOLD

D/R SW FACTORY PRE-SET

TYP AC HE

MDL 1 2

Adjust so that no trim is required

Adjust for Full

Power

Adjust for

Engine Off

Adjust for Idle

REVERSE SW

SUB-TRIM

TRAVEL ADJUST

(TRV ADJ.)

THR AIL ELE RUD GER PITCH

GEAR SW FACTORY PRE-SET

NORM NORM NORM NORM NORM NORM

REV REV REV REV REV REV

+80%

–80%

+80%

–80%

+ –

+100%

–100%

–%

+150%

–150%

N 0% 50% 100%

100% 50%

N -2° Pitch 5° Pitch 10° Pitch

-10° Pitch 0° Pitch 10° Pitch

H -5° Pitch 5° Pitch 13° Pitch

THRO CURVE

TLN, T2N, THN

TLS, T2S

PITCH CURVE

PLN, P2N, PHN

PLS, P2S, PHS

PLH, P2H, PHH

L2H

DUAL RATE POS 0 90% 90%

(A1, EL) POS 1 100% 100%

AILE ELEV

REVO MIX UP (U) 35%

(RV) DOWN (D) 35%

HOLD RUDD OFFSET (HLD)

+ –

THRO HOLD POSITION

ON OFF

HOLD

D/R SW E.A A E. CF

TYP AC HE

MDL 1 2

Adjust so that no trim is required

Adjust for Full

Power

Adjust for

Engine Off

Adjust for Idle

**S

* Before flying, confirm that all controls function in the proper direction.

**Note: Flight Mode “S” shown is for 3D type flying only

and is not recommended for use by entry-level pilots.

XF622 DATA SHEET #2 ERGO .32/.46 (INITIAL SET-UP WITH 3D PITCH/THROTTLE CURVE)

Page 45

D/R % % EXP % %

TRIM OFFSET

CHANNEL THR (1) AIL (2) ELE (3) RUD (4) GER (5) PITCH (6)

NORM NORM NORM NORM NORM NORM

••••• •

REV REV REV REV REV REV

SUB-TRIM Adjust so that no trim is required TRAVEL ADJUST + % + % + % + % + %

(TRV ADJ.) - % - % - % - % - % FAIL-SAFE (S-PCM) Adjust only if S-PCM modulation is selected

80 80 100 100 150 80 80 100 100 150

90 90 20 20

100 100

20 20

0 50 100

40 50

Adjust for full power

Adjust only if Z-PCM

modulation is selected

Store trim positions after

initial test flight

Factory Pre-Sets

Adjust for idle

35 35

Adjust for engine off

REVERSE SW

* Note: Before flying, confirm that all controls

function in their proper direction.

FAIL-SAFE TIME (ZPCM)

AILE (AI) ELEV (EL)

POS O

POS 1

L 2 H N S N

S H

THRO CURVE TLN, T2N, THN,

TLS, T2S PITCH CURVE

PLN, P2N, PHN, PLS, P2S, PHS,

PLH, P2H, PHH

% % % % %

-2° pitch 5° pitch 10° pitch

-5° pitch 5° pitch 8.5° pitch

-5° pitch 5° pitch 13° pitch

DUAL

RATE

•

EXP

D/R SW

GEAR SW

REVO-MIX

(RV)

HOLD RUDD OFFSET

(OFFSET HLD)

UP (U)

% %

DOWN (D)

+ –

THRO HOLD

(HLD)

ON OF

PROG. MIX

CHANNEL

MASTER SLAVE MIX SWITCH OFFSET +GAIN -GAIN

ON • F1 • FO • H

POSITION

Modulation S-PCM • Z-PCM • PPM (FM) Model Number 1 Model Name E32

XP642 DATA SHEET #1 ERGO .32/.46 (INITIAL SET-UP)

Page 46

EA • A • E • CF

D/R % % EXP % %

TRIM OFFSET

CHANNEL THR (1) AIL (2) ELE (3) RUD (4) GER (5) PITCH (6)

NORM NORM NORM NORM NORM NORM

••••• •

REV REV REV REV REV REV

SUB-TRIM Adjust so that no trim is required TRAVEL ADJUST + % + % + % + % + %

(TRV ADJ.) - % - % - % - % - % FAIL-SAFE (S-PCM) Adjust only if S-PCM modulation is selected

80 80 100 100 150 80 80 100 100 150

90 90 20 20

100 100

20 20

0 50 100

100 50

Adjust for full power

Adjust only if Z-PCM

modulation is selected

Store trim positions after

initial test flight

Factory Pre-Sets

Adjust for idle

30 30

Adjust for engine off

REVERSE SW

* Note: Before flying, confirm that all controls

function in their proper direction.

** Note: Flight mode “S” (Stunt) shown is for

3D type flying only and is not recommended for use by entry level pilots.

FAIL-SAFE TIME (Z-PCM)

AILE (AI) ELEV (EL)

POS O

POS 1

L 2 H N S N

S H

THRO CURVE TLN, T2N, THN,

TLS, T2S PITCH CURVE

PLN, P2N, PHN, PLS, P2S, PHS,

PLH, P2H, PHH

% % %

% %

-2° pitch 5° pitch 10° pitch

-10°

pitch

0° pitch 10° pitch

-5° pitch 5° pitch 13° pitch

DUAL

RATE

•

EXP

D/R SW

GEAR SW

REVO-MIX

(RV)

HOLD RUDD OFFSET

(OFFSET HLD)

UP (U)

% %

DOWN (D)

+ –

THRO HOLD

(HLD)

ON OF

PROG. MIX

CHANNEL

MASTER SLAVE MIX SWITCH OFFSET +GAIN -GAIN

ON • F1 • FO • H

POSITION

Modulation S-PCM • Z-PCM • PPM (FM) Model Number 2 Model Name E46

XP642 DATA SHEET #2 ERGO .32/.46 (INITIAL SET-UP WITH 3D PITCH/THROTTLE CURVE)

Page 47

ST-1 INH

•

ACT

ST-2 INH

•

ACT

THRO AILE ELEV RUDD GEAR PITCH AUX2

REVERSESW

SUB-TRIM

TRAVEL

L 80% D 80% L 100% + % H 150% + %

ADJUST

R 80% U 80% R 100% – % L 150% – % S(TYPE) Z(TYPE) HOLD•1.0 S•0.5S •0.25S

OFFSET

CHANNEL + POS – POS SW OFFSET

PROGRAM MIX

MIX A

%%%%

MIX B

%%%%

L123H

THRO

N 0 % % 50% % 100%

CURVE 1 40% % 50% %

(TH:) *2 100% % 50% %

PITCH

N -2° Pitch 5° Pitch 10° Pitch

CURVE

1 -5° Pitch 5° Pitch 8.5° Pitch

(PI:)

*2 -10° Pitch 0° Pitch 10°Pitch

H -5° Pitch 5° Pitch 13° Pitch

AILE ELEV RUDD

D/R 90 % 90% 70 %

D/R EXP 25% 25% 30%

EXP

D/R 100% 100% 100%

EXP % % 40%

STUNT TRIM INH

•

ACT

NORMAL

UP (U.N.) 35%

DOWN (D.N.) 30%

STUNT

UP (U.S.) 15 %

DOWN (D.S.) 15%

HOLD RUDD OFFSET

ACC-MIX %

NORM NORM NORM NORM NORM NORM NORM

REV REV REV REV REV REV REV

THRO-HOLD

(HOLD)

INH

•

ACT

POS

INVERTED

(INV.P)

REVOLUTION

MIX

(RV)

INH

•

ACT

AUTO

D/R

(POS.1)

AUX 2 INPUT

D/R • R

HOLD

FAIL-

SAFE

MODEL NO. MODEL NAME ERGO .32/.46 MODULATION S-PCM • Z-PCM • PPM

XP-783 DATA SHEET ERGO .32/.46 (INITIAL SET-UP)

Adjust as necessary during flight

Adjust so that no trim is required

Adjust for

Full Power

Adjust for

Engine Off

Adjust for

Idle

* Note: Flight Mode 2 shown is for 3D type flying only with 0° pitch at half stick. This is not recommended for use by entry-level pilots.

**Before flying, confirm that all controls function in the proper direction.

Page 48

THRO AILE ELEV RUDD GEAR PITCH AUX2 AUX3 AUX4 AUX5

RRRRRRRRRR NNNNNNNNNN

L 80% D 80% L 100% + % +150% + % + % + % + % R 80% U 80% R 100% – % –150% – % – % – % – %

%%%%

REVERSE SW (11)

TRAVEL ADJUST

(12)

SUB-TRIM (15)

TRIM RATE (83)

AILE ELEV RUDD

D/R 90% 90% 70%

0 EXP 25% 25% 30%

TYPE NORM NORM NORM

D/R 100% 100% 100%

1 EXP % % 40%

TYPE

D/R % % %

2 EXP % % %

TYPE

ST-1 INH

•

ACT 0 •1 • 20 •1 • 20 •1 •2

ST-2 INH

•

ACT 0 •1 • 20 •1 •20 •1 •2

ST-3 INH

•

ACT 0 •1 • 20 •1 •20 • 1 • 2

ST-4 INH

•

ACT 0 •1 •20 •1 •20 •1 • 2

HOLD INH

•

ACT 0 •1 • 20 •1 • 20 •1 •2

ST-1 INH

•

ACT

ST-2 INH

•

ACT

ST-3 INH

•

ACT

ST-4 INH

•

ACT

D/R EXP

(13)

AUTO

D/R

(23)

STUNT

TRIM

(25)

PROGRAM

MIX

(51) - (58)

HOLD

INH•

HOLD

SW GEAR

POS

AUTO CUT INH • ACT

POS

FLIGHT

INH •

GEAR

EXTRA AILE

GEAR

INH •

GEAR

SW HOLD

INVERTED

INH •

INVT

SW HOLD

PIT.

LOW INH • ACT

LEVER

HI INH • ACT

THROTTLE

HOLD

(16)

MIX SW INH

•

ACT

4→1

MIX (41)

INH

•

AUX 3

•

AUTO

0 85% 1 50% 2

NR S1 S2 S3 S4 HD INV

GYRO

SENS

(44)

FUNCTION

SELECT

(16)

CHANNEL

TRIM SW OFFSET +GAIN –GAIN

MASTER SLAVE

INH OFF NR•S1•S2•S3•S4

•

→

•

ACT ON MX•HD•INV INH OFF NR

•S1•S2•S3•

•

→

•

ACT ON MX•HD•INV INH OFF NR

•S1•S2•S3•

•

→

•

ACT ON MX•HD•INV INH OFF NR

•S1•S2•S3•

•

→

•

ACT ON MX•HD•INV

EXP L 1 2 3 4 5 6 H

INH OFF NR•S1•S2•S3•S4 OFF IN 0 100

•

→

••

ACT ON MX•HD•INV ON OUT

INH OFF NR•S1•S2•S3•S4 OFF IN 0 100

•

→

••

ACT ON MX•HD•INV ON OUT

INH OFF NR•S1•S2•S3•S4 OFF IN 0 100

•

→

••

ACT ON MX•HD•INV ON OUT

INH OFF NR•S1•S2•S3•S4 OFF IN 0 100

•

→

••

ACT ON MX•HD•INV ON OUT

MODEL NO. (84) _____________________________________ MODEL NAME (81) ERGO .32/.46 MODULATION (85) SPCM-ZPCM-PPM

PCM10SX DATA SHEET ERGO .32/.46 (INITIAL SET-UP)

Adjust for

Full Power

Adjust for

Engine Off

Adjust so that no trim is required

Adjust for Idle

0 1 1

Adjust as necessary

during flight.

Page 49

EXP L 1 2 3 4 5 6 H

OFF

IN 0 50 100

•

OUT 0 50% Power 100% Power

HOV.SEL

——

HOV HOV HOV HOV HOV HOV

——

OFF IN 0 50 100

•

ON OUT 40% Power 50% Power

100% Power

OFF IN 0 50 100

•

ON OUT 100% Power 50% Power 100% Power

OFF IN 0 100

•

ON OUT

OFF IN 0 100

•

ON OUT

OFF

IN 0 50 100

•

OUT -2° Pitch 5° Pitch 10° Pitch

HOV.SEL

——

HOV HOV HOV HOV HOV HOV

——

OFF IN 0 100

•

ON OUT -5° Pitch 5° Pitch 8.5°Pitch

OFF IN 0 100

•

ON OUT -10° Pitch 0° Pitch 10° Pitch

OFF IN 0 100

•

ON OUT

OFF IN 0 100

•

ON OUT

HOLD

OFF IN 0 100

•

ON OUT -5° Pitch 5° Pitch 13° Pitch

INVT

OFF IN 0 100

•

ON OUT

TRIM OFFSET

HV.T HV.P LO.P HI.P AILE ELEV RUDD

(82)

THRO

CURVE

(18)

TH,TRIM=SLOW

HOV .T=CENTER

PITCH

CURVE

(68)

P,TRIM=CENTER

HOV .P=CENTER

RIGHT

•

LEFT

POS

HOV 6°Pitch

ZERO 0°Pitch

UP 35

NORM DN 30

–P 0

STNT1

+P 15 –P 15

STNT2

+P 15 –P 15

STNT3

+P –P

STNT4

+P –P

HOLD RUDD OFS.

ATS

REVO-MIX

(47)

MODE HOLD • 1.0s • 0.5s • 0.25s

MEMORY

S MEMORY

FAILSAFE

(77)

TYPE 1s • 3s(90°) • 3s(120°)

SWASH + •

—

SW NR • S1 • S2 • S3 • S4 • HD

EXP

AILE %

GAIN ELEV %

PITCH %

SWASH

TYPE

(65)

VOL %

TIME

ATS ACC-MIX

(48)

PCM10SX DATA SHEET ERGO .32/.46 (INITIAL SET -UP) CONTINUED

*Note: Flight Mode 2 shown is for 3D type flying only with 0° pitch at half stick.

This is not recommended for use by entry-level pilots.

**Before flying, confirm that all controls function in the proper direction.

Page 50

Once all assemblies have been completed, please review the following suggestions before attempting initial flights.

• Review the instruction book and confirm that all assembly steps have been completed thoroughly.

• Check to verify that the tail rotor assembly rotates in the correct direction (see the diagram below).

• Check to insure that all servos are operating smoothly and in the correct direction. Also verify that there is no binding in the control rods

and that each servo horn is secured with a servo horn mounting screw.

• Verify that the gyro is operational and compensating in the correct direction (detailed in Step 8, page 42).

• Make sure that both the transmitter and receiver have been fully charged (refer to your radio system instructions for proper charging procedures).

• Check to insure that the throttle is working properly and in the correct direction.

FINAL PRE-FLIGHT CHECK

Correct Main/Tail Rotor Rotation Direction

BLADE TRACKING IDENTIFICATION

A: Use two different blade tracking tape colors (e.g., black and red) at

the tip of each main rotor blade.

B: Use the same color blade tracking tape located at different positions

on each rotor blade.

Note: Adding additional blade tracking tape to the rotor blades at this stage

will make it necessary to re-static balance the main rotor blades.

Blade Labeling for Tracking Purposes

BLADE TRACKING ADJUSTMENT

Blade “tracking” is an adjustment to the main rotor blade pitch that must be accomplished during the initial test flights.

Although the blade pitch angle in each blade may appear equal, it is still possible for a set of main rotor blades to run “out of track”, making adjustment necessary.

Main rotor blades that are out of track with one another can cause vibration, instability, and a loss of power due to additional drag.

On the initial flight, it will be necessary to increase the blade speed to just before

lift-off RPM and view the rotor disc at eye level from a safe distance (approximately 15 to 20 feet).

Note which blade is running low (by colored tracking tape) and increase the pitch of the low blade one turn of the ball link at a time until each blade runs in track (on the same plane).

Please refer to the diagrams below to identify the different tracking situations, as well as several methods to mark each rotor blade for tracking identification.

Incorrect

Out of Track

Correct

In Track

Caution: Be sure to maintain a safe distance from the helicopter

(15 to 20 feet) when tracking main rotor blades.

Adjustment is Necessary

Adjustment is NOT Necessary

Red

Black

Red

Black

Rotate the Main Rotor counter clockwise (backward) and note the rotation of the Tail Rotor.

Page 51

Engine

After each day of flying, fully drain the fuel tank. Then, start the engine and let it idle until the engine and the fuel line are completely burned off. It is also suggested that an after-run oil be used to prevent premature engine corrosion.

Tail Rotor Belt

Periodically check the tension on the Tail Drive Belt (as shown in Step 5, page 29) to insure that it has sufficient tension for proper engagement. It is especially important to check this after initial test flights.

Check All Nuts and Bolts

A helicopter is subject to high vibration during flight. It is important to check that all screws, nuts and bolts are properly secured after each day of flying. It is also suggested that you perform a “quick” inspection between each initial test flight for approximately the first 6 to 10 flights.

Check Ball Link Wear

Check to insure that all universal links fit freely but securely to the control balls. If there is excessive play noted, replace the universal link in question.

Battery Maintenance

Check to insure that your batteries are properly mounted and charged. The most frequent cause of crashes (aside from pilot error) is battery failure or disconnection. Be certain that your batteries are fully charged and limit your flight time to 3 or 4 flights between charging. If more flight time is required, purchase a reliable quick field charger.

Cleaning

At the end of each flight or flying session, wipe down your helicopter with a clean towel or rag. This is also a good time to inspect all parts for tightness or fatigue. Remember, a clean, well-maintained helicopter will provide you with many hours of trouble-free flight.

GENERAL MAINTENANCE

Page 52

ROTOR HEAD/SWASHPLA TE/W ASHOUT ASSEMBLY

980049

960062

960070

960068

980023

960071

960064

983003

983004

970029

960066

960063

960067

960069

981004

970030

960065

970002

970013

960060

960059

960013

970011

960012

970010

970001

960014

970006

970004

960081

960075

Page 53

ROTOR HEAD/SWASHPLA TE/W ASHOUT ASSEMBLY PARTS LIST

PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS

960012 Washout Assembly 1 Complete w/all Components 960013 Washout Base 1 960014 Swashplate Assembly 1 3 - 2x8mm Flat Head Screws

4 - 2x10mm Flat Head Screws

7 - Steel Joint Balls 960059 Flybar Paddles 2 2 - 3mm Lock Nuts 960060 Flybar 2 960061 Rotor Head Assembly 1 Complete w/all Components 960062 Head Button 1 1 - 3x6mm Socket Head Bolt 960063 Main Blade Holder 2 2 - 2x10mm Flat Head Screws

2 - Steel Joint Balls 960064 Main Rotor Body 1 2 - 3x8mm Socket Head Bolts 960065 Mixing Arms 2 2 - Mixing Arm Bushings

4 - Nylon Washers

4 - 2x10mm Flat Head Screws

4 - Steel Joint Balls

2 - 3x16mm Socket Head Bolts

6 - 3mm Flat Washers 960066 Main Rotor Hub 1 1 - Washout Pin

1 - Oiless Bushing 960067 Seesaw Shaft 1 2 - Seesaw Collars

2 - 3x5mm Button Head Cap Screws

2 - Flybar Bushings 960068 Blade Spindle Shaft 1 2 - 4mm Lock Nuts 960069 Flybar Control Arm 2 2 - 4mm Set Screws 960070 Blade Damper Rubber 4 960071 Blade Holder Spacer A 2 960075 Linkage Set A 1 2 - 2.3x20mm Threaded Rod

1 - 2.3x30mm Threaded Rod

2 - 2.3x40mm Threaded Rod

10 - Universal Ball Links

2 - Double Link A 960081 3D Double Link 4 970001 Steel Joint Ball w/2x8mm Screw 10 10 - 2x8mm Flat Head Screws 970002 Steel Joint Ball w/2x10mm Screw 10 10 - 2x10mm Flat Head Screws 970004 Universal Ball Links 10 970006 Double Link 4 970010 Washout Link 2 2 - Washout Link Pins 970011 Washout Arm 2 2 - Washout Arm Bushings

4 - Nylon Washers

2 - 3x15mm Socket Head Bolts

2 - 3mm Flat Washers 970012 Washout Arm Bushing 2 970013 Mixing Arm Bushing 2 970029 Seesaw Spacer Collar 2 970030 Main Blade Bearing Spacer 2 2 - Inner Bearing Spacers

2 - Outer Bearing Spacers 980023 Main Blade Bolt Set 2 2 - 4mm Lock Nuts 980049 Nylon Washer .5 10 980051 Nylon Washer 1.3 10 981004 Main Blade Holder Bearing 2 983003 Main Rotor Blade (.32-.36) 2 Pre-Covered & Weighted 983004 Main Rotor Blade (.46) 2

Page 54

STAR T SHAFT/CLUTCH/ENGINE ASSEMBLY

96005

960016

960004

960006

960040

960003

960007

960018

970009

960011

960018

960019

960078

(optional)

960008 960039

950032

Page 55

STAR T SHAFT/CLUTCH/ENGINE ASSEMBLY PARTS LIST

PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS

960003 Clutch Assembly 1 Complete w/One-Way Bearing

2 - 3x5mm Socket Head Bolts

960004 Clutch Bell Assembly 1 Complete w/Pinion Gear, Clutch Lining

and Oiless Bushing 960005 Starter Hex Adaptor 1 Complete w/One 4x4mm Set Screw 960006 Start Shaft Assembly 1 960007 Front Tail Belt Pulley 1 Complete w/One 3x6mm Socket Head Bolt 960008 Engine Mount .32-.36 1 Complete w/Four 3x10mm Socket Head

Bolts and Four 3mm Flat Washers 960039 Engine Mount .46 1 960011 Cooling Fan Blades .32-.36 1 Complete w/Four 3x5mm Socket Head Bolts 960016 Start Shaft Bearing Block 1 Complete w/Bearing 960018 Tail Drive Pinion Bearing Block 1 Complete w/Bearing 960019 Fan Hub .32-.36 1 960040 Aluminum Fan Assembly .46 1 970009 Tail Drive Pinion w/Shaft 1 Complete w/One 3x6mm Socket Head Bolt and

One 3mm Flat Washer 960078 .32-.36 Muffler 1 Complete w/One Pressure Tap

Page 56

CYCLIC MIXING ARMS/ELEVATOR/AILERON CONTROL ARMS

960024

970002

980049

960025

970003

970015

960023

970019

970018

970017

970014

960015

970012

980049

960076

970004

970016

980049

960021

960022

970016

960020

960022

970003

Page 57

CYCLIC MIXING ARMS/ELEVATOR/AILERON CONTROL ARMS PARTS LIST

PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS

960015 Roll Bellcrank 1 Complete w/Bushing

2 - Steel Joint Balls 2 - 2x8mm Flat Head Screws 2 - 2mm Hex Nuts

960020 Elevator Arm: Front 1 Complete w/Bushing

Steel Joint Ball 2x8mm Flat Head Screw

960021 Elevator Arm: Rear 1 Complete w/Bushing

Steel Joint Ball

2x8mm Flat Head Screw 960022 Swashplate A Arm 2 Complete w/2 A-Arm Pins 960023 Mixing Base Arm: Roll 1 Complete w/Bushing 960024 Mixing Base Arm: Collective 1 Complete w/Bushing

Steel Joint Ball

2x8mm Flat Head Screw

2mm Hex Nut 960025 Mixing Lever: Cyclic 3 Complete w/Bushings

6 - Steel Joint Balls

6 - 2x8mm Flat Head Screws 960076 Linkage Set B 1 1 - 2.3x45mm Threaded Rod

1 - 2.3x75mm Threaded Rod

1 - 2.3x10mm Threaded Rod

6 - Universal Links 970002 Steel Joint Ball w/2x10mm Screw 10 970003 Mixing Base Nut 2 970004 Universal Ball Link 10 970012 Washout Arm Bushing 2 970014 Mixing Lever Bushing A 2 970015 Mixing Lever Bushing B 2 970016 Elevator Arm Bushing 2 970017 Roll Bellcrank Spacer 2 970018 Mixing Lever Spacer 2 970019 Mixing Base Cross Member 1 980049 Nylon Washer .5mm 10

Page 58

UPPER MAIN FRAME/RADIO TRAY/BODY SET

960031

982002

960072

982001

970004

960077

970008

970005

970022

960035

960009

960002

960001

970005

960017

970020

960029

970024

Page 59

PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS

960001 Autorotation Assembly 1 Complete w/Four 3x6mm Socket Head Bolts 960002 Main Drive Gear 88T 1 Complete w/Four 3x6mm Socket Head Bolts 960009 Main Rotor Shaft 1 960017 Main Shaft Bearing Block 1 Complete w/Bearing 960029 Upper Main Frame 2 960031 Servo Mounting Plates 4 8 - 2.6x8mm Self Tapping Screws

8 - 2.6x12mm Self Tapping Screws 8 - 2.6mm Flat Washers

960035 Upper Servo Tray 1 4 - 3x8mm Socket Head Bolts

12 - 2.6x12mm Self Tapping Screws 12 - 2.6mm Flat Washers

960072 Rubber Grommet 4 960077 Linkage Set C 1 2 - 2.3x35mm Threaded Rod

2 - 2.3x60mm Threaded Rod 1 - 2.3x75mm Threaded Rod

10 - Universal Ball Links 970004 Universal Ball Links 10 970005 Autorotation Shaft Hub Sleeve 1 Complete w/Clip 970008 Main Shaft Collar 1 Complete w/Four 4x4mm Set Screws 970020 Main Frame Standoff: 32mm 2 970022 Body Mounting Standoff 4 2-3x8mm Socket Head Bolts

2-3x18mm Socket Head Bolts 970024 Main Frame Spacer 12.5mm 6 982001 Ergo .32/.46 Body Set 1 4 - Rubber Gromments

5 - 2.3x8mm Self Tapping Screws 982002 Ergo .32/.46 Canopy 1 5 - 2.3x8mm Self Tapping Screws 960073 Ergo .32/.46 Decal Set 1

UPPER MAIN FRAME/RADIO TRA Y/BODY SET P ARTS LIST

Page 60

LOWER MAIN FRAME/LANDING GEAR/FUEL TANK

960030

960026

960027

970022

960010

970021

960030

960027

960028

970022

960038

960037

960039

960038

970023

960033

980015

960036

960117

980013

980036

960040

960034

Page 61

PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS

960010 Cooling Fan Shroud 1 4 - 2.6x8mm Self Tapping Screws 960026 Gyro Mounting Plate 1 4 - 3x10mm Socket Head Bolts 960027 Lower Frame Angles 2 960028 Front Radio Bed 1 960030 Lower Main Frame 2 960032 Landing Gear Set 1 2 - Landing Skids

2 - Landing Struts 4 - Skid Caps 4 - 3x4mm Set Screws 4 - 3x12mm Socket Head Bolts 4 - 3mm Flat Washers

4 - 3mm Lock Nuts 960033 Landing Struts 2 4 - 3x4mm Set Screws 960034 Landing Skids 2 4 - Skid Caps 960036 Antenna Tube 3 960037 Fuel Tank Set 1 1 - Fuel Stopper

1 - Tank Grommet

2 - Installation Rubbers

1 - Silicone Fuel Tubing

1 - Fuel Clunk 960038 Tank Mounting Rubber 2 970021 Main Frame Standoff: 60mm 2 970022 Body Mounting Standoff 4 2 - 3x8mm Socket Head Bolt

2 - 3x18mm Socket Head Bolt 970023 Landing Skid Caps 4 970025 Switch Damper Rubber 4 960117 Landing Gear Damper 4

LOWER MAIN FRAME/LANDING GEAR/FUEL TANK PARTS LIST

Page 62

TAIL BOOM/TAIL BRACE/TAIL BOOM CARRIER

960047

960048

983002

960045

960046

960044

983001

960042

960041

960043

Page 63

PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS

960041 Tail Brace Set 1 1 - Tail Brace Tube

1 - Tail Brace Connector 1 - Tail Brace T End 1 - 2.6x12mm Socket Head Bolt

1 - 2.6x15mm Socket Head Bolt 960042 Tail Brace Tube 1 960043 Tail Brace T End 1 2 - 3x8mm Socket Head Bolt

1 - 2.6x15mm Socket Head Bolt 960044 Tail Brace Connector 1 1 - 2.6x12mm Socket Head Bolt 960045 Tail Fin Set 1 1 - Vertical Fin

1 - Horizontal Fin

3 - 3x12mm Self Tapping Screw

2 - 3x12mm Socket Head Bolts

2 - 3mm Lock Nuts 960046 Horizontal Tail

Fin/Brace Clamp 1 2 - 3x8mm Socket Head Bolts

2 - 3x12mm Socket Head Bolts

5 - 3mm Lock Nuts

1 - 3x10mm Socket Head Bolt 960047 Tail Boom Carrier 1 2 - 3x40mm Socket Head Bolts

4 - 3x15mm Socket Head Bolts

6 - 3mm Lock Nuts 960048 Tail Rod Guide Set 4 4 - Tail Rod Guides

5 - Tail Rod Guide Collars

1 - Tail Control Rod Guide

4 - 2x8mm Self Tapping Screws

1 - 3x10mm Socket Head Bolt 983001 Tail Boom 1 983002 Tail Control Rod 1

TAIL BOOM/TAIL BRACE/TAIL BOOM CARRIER P ARTS LIST

Page 64

TAIL CASE/TAIL BLADE HOLDERS/TAIL PITCH PLA TE

960051

960056

970026

970222

960052

960050

960058

970028

960057

960053

970027

960049

981003

960054

960053

960074

970001

960055

980007

981003

960045

.32-.36 AND .46 ASSEMBL Y INSTRUCTIONS

ERGO SPECIFICATIONS

Overall Length 46.5" Overall Height 16.38" Main Rotor Diameter 48.5" (32-36)

50" (46 3D)

Tail Rotor Diameter 9.17" Gear Ratio 9.78:1:5.18 Gross Weight 6.75-7.0 lbs.

Heli Division

Page 65

PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS

960045 Tail Fin Set 1 1 - Horizntal Fin

1 - Vertical Fin 3 - 3x12mm Self Tapping Screws 2 - 3x12mm Socket Head Bolts

2 - 3mm Lock Nuts 960049 Tail Drive Belt 1 960050 Tail Slide Ring Assembly 1 Complete w/all Components 960051 Tail Rotor Blades 2 960052 Tail Blade Holder Set 2 2 - 3x15mm Socket Head Bolts

4 - 2x8mm Socket Head Bolts

2 - 3mm Lock Nuts

4 - 2mm Hex Nuts 960053 Tail Case Set (L&R) 1 4 - 2.6x12mm Socket Head Bolts

4 - 2.6mm Hex Nuts

1 -3x10mm Socket Head Bolt 960054 Tail Pitch Control Lever 1 1 - Lever Bushing

1 - 2x20mm Socket Head Bolt

1 - 2mm Flat Washer

1 - Steel Joint Ball

1 - 2x8mm Flat Head Screw 960055 Tail Case Pulley 1 1 - Pressure Pin 960056 Tail Pitch Link 2 Complete w/2 Link Pins 960057 Tail Pitch Plate 2 960058 Tail Slide Ring 1 Complete w/Bearing 960074 Ergo .32/.46 Assembly Manual 1 970001 Steel Joint Ball w/2x8mm Screw 10 10 - 2x8mm Flat Head Screws 970222 Tail Center Hub, 1 Piece 1 970027 Tail Output Shaft 1 970028 Tail Slide Ring Sleeve 1 981003 Tail Output Shaft Bearing 2

TAIL CASE/TAIL BLADE HOLDERS/TAIL PITCH PLA TE PARTS LIST

Page 66

Heli Division

Revised 3/4/97