JR ProPo ERGO .32 Assembly Instructions Manual Download Page 3

Page: 3 / 66

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

Section Description

Page

Summary of Contents for ERGO .32

Page 1: ...6 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 Weight 6 75 7 0 lbs H...

Page 2: ...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 inj...

Page 3: ...d 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...

Page 4: ...y 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 li...

Page 5: ...IREMENTS 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...

Page 6: ...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 Startin...

Page 7: ...ded in each step All of the hardware screws nuts etc contained in the Ergo kit are described in the following A B C manner C C C A A B A A B B B C A B 3x8mm Socket Head Bolt Set Screw C A B C C A A A...

Page 8: ...Flat Washer 1 pc CLUTCH BELL START SHAFT ASSEMBLY 1 2 TAIL DRIVE PINION BEARING BLOCK ASSEMBLY Install the Lower Bearing Block so the bearing face is toward the bottom Install the Upper Bearing Block...

Page 9: ...mm Flat Head Screw Mixing Lever 3 pc Prepare 3 Sets 2mm Nut 9 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 mo...

Page 10: ...ect 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 ca...

Page 11: ...ket 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 1...

Page 12: ...ng Nylon Washer 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...

Page 13: ...surface to prevent twisting during tightening 13 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 F...

Page 14: ...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 Sc...

Page 15: ...MENT 15 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 Soc...

Page 16: ...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 Clut...

Page 17: ...iston 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 Landi...

Page 18: ...oved 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 A...

Page 19: ...ad 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 Wa...

Page 20: ...s 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 co...

Page 21: ...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 H...

Page 22: ...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 Space...

Page 23: ...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 downwar...

Page 24: ...d 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 3x...

Page 25: ...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 Fl...

Page 26: ...ndard 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...

Page 27: ...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 Tai...

Page 28: ...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 3...

Page 29: ...hese 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...

Page 30: ...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...

Page 31: ...ut 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 Soc...

Page 32: ...he 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...

Page 33: ...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...

Page 34: ...pping 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 Ro...

Page 35: ...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 befo...

Page 36: ...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...

Page 37: ...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...

Page 38: ...s 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 Se...

Page 39: ...n 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...

Page 40: ...o 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 Chec...

Page 41: ...or 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 sho...

Page 42: ...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 thr...

Page 43: ...ht 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...

Page 44: ...V 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...

Page 45: ...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...

Page 46: ...W 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 SA...

Page 47: ...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 REVOLUTIO...

Page 48: ...HI INH ACT THROTTLE HOLD 16 R L 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 S...

Page 49: ...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...

Page 50: ...es 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 blad...

Page 51: ...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 exce...

Page 52: ...OUT 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 96001...

Page 53: ...ybar 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 Th...

Page 54: ...54 START SHAFT CLUTCH ENGINE ASSEMBLY 96005 960016 960004 960006 960040 960003 960007 960018 970009 960011 960018 960019 960078 optional 960008 960039 950032...

Page 55: ...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 Bla...

Page 56: ...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 9600...

Page 57: ...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 2x8m...

Page 58: ...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: ...g 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 Link...

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 96003...

Page 61: ...cket 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 Grom...

Page 62: ...TAIL BOOM TAIL BRACE TAIL BOOM CARRIER 960047 960048 983002 960045 960046 960046 960044 983001 960042 960041 960043 62...

Page 63: ...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...

Page 64: ...7 960053 970027 960049 981003 960054 960053 960074 970001 960055 980007 981003 960045 32 36 AND 46 ASSEMBLY INSTRUCTIONS ERGO SPECIFICATIONS Overall Length 46 5 Overall Height 16 38 Main Rotor Diamete...

Page 65: ...ocket 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 960...

Page 66: ...Heli Division Revised 3 4 97...

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