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Synergy NSC CONTENDER, Instruction Manual

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Synergy NSC CONTENDER Instruction Manual Download Page 45

Crown Gear Hub Pin Installation

606-924 Crown Gear Hub Pin

1.Align Crown Gear Hub hole with

corresponding Main Shaft hole.

2. Insert Crown Gear Hub Pin until flush 

with Crown Gear Hub

3. Tighten Crown Gear Lock Nut with

17mm or 11/16 in open end wrench. 

-DO NOT OVER TIGHTEN NUT-

  

A41

Summary of Contents for NSC CONTENDER

Page 1: ......

Page 2: ...t If you are new to the hobby we strongly recommend seeking the help and advice from an experienced modeler Operating a model helicopter requires a high degree of diligence and skill If you are new to the hobby it is best to seek help and guidance from experienced radio controlled helicopter pilots This will both greatly speed up the learning process and make it much safer for you For those pilots...

Page 3: ...ly for Torque Tube A27 Tail Bell Crank Assembly A28 Tail Rotor Hub Pitch Slider Installation for Torque Tube A29 Torque Tube Assembly A30 Tail Boom to Torque Tube Assembly A31 Torque Tube Tail Section Completion A32 Torque Tube Input Transmission Assembly A33 Input Transmission Installation A34 Tail Boom Install A35 Main Gear and Main Pulley Assembly A36 Main Belt Pulley Main Gear Installation A37...

Page 4: ...barless System x1 50 55 Nitro Engine x1 50 55 Muffler x1 Pitch Gauge Engine Starter with Starting Wand x1 2S 1800mah Lipo Battery for Regulator x1 6v Regulator x1 600 625mm Main Rotor Blades 85 95mm Tail Rotor Blades Silicone Fuel Tubing Helicopter Fuel 15 30 Glow Plugs Needle Nose Pliers Diagonal Cutting Pliers Phillips Screw Driver Set Hex Drivers 1 5 2 2 5 3 Scissors Grease CA Glue Loctite Blue...

Page 5: ...el Clunk 110 333 Fuel Clunk Tubing 110 331 Fuel Tank Stopper 106 810 Fuel Tank Stopper Grommet Complete Fuel Tank Fuel Tank Assembly A1 Trim fuel tubing to 65mm or desired length so that fuel clunk reaches to the rear of fuel tank ...

Page 6: ...ssembly Complete Landing Gear 101 308 M3x8 Button Head 610 324 Landing Gear Strut 610 322 Skid Tube Lock x4 610 321 Skid Tube Screw Skid Tube Lock Down on to flybar then secure within Skid Tube 106 966 Skid Tube Plug x4 ...

Page 7: ...Way Clutch M4x8 Socket Head x2 107 104 2mm Pivot Ball Long 100 252 M2 Nylock Nut Factory Installed Fan Hub install note Important 1 Slide Fan Hub on to crank shaft then take up end play with engine nut engine washer manditory 2 Tighten down pinch bolts evenly 3 Insert crank locking tool not included and finish tightening engine nut Do not over tighten crank shaft nut only snug It is possible to di...

Page 8: ... 610 162 Start Shaft 108 615 6x15x5 Radial Bearing 110 155 Clutch Bearing Block 108 105 10x19x5 Radial Bearing x2 610 120 20T Pinion Gear 610 125 Clutch Bell Lite 108 614 6x12x4 Radial Bearing 110 158 Clutch Lining Factory Installed Factory Installed Factory Installed Install governor magnet before assembly ...

Page 9: ...luded 106 115 Servo Hold Down 100 212 M2x12 Socket Head x12 100 252 M2 Nylock Nut x6 Servo Horn Servo Screw included with servo Pivot Ball Mount Distance For optimal performance pivot balls should be mounted between 13 5mm from the center of the servo If you are running a flybarless configuation you may want to consider 10mm for better resolution ...

Page 10: ...10 223 3x26 Threaded Spacer 100 376 M3x16 Set Screw 101 308 M3x8 Button Head Right Frame Support Installation A6 610 311 N5C Main Frame 100 308 M3x8 Socket Head Flange oriented on outside of frame Do not over tighten in plastic 100 206 M2x6 Socket Head 610 123 Tail Servo Mount 610 124 N5C Front Frame Spacer Large 100 306 M3x6 Socket Head 610 224 3x6x26 Frame Spacer 100 376 M3x16 Set Screw 610 423 ...

Page 11: ...t Head A7 108 106 10x19x6 Radial Bearing 108 819 8x19x6 Radial Bearing Bearing Block Assembly Installation 510 542 Main Shaft Bearing Block Lite 510 542 Main Shaft Bearing Block Lite DO NOT FULLY TIGHTEN THESE BOLTS YET ...

Page 12: ...Servo Tray Installation Do not fully tighten screws A8 100 306 M3x6 Socket Head ...

Page 13: ...r sensor at this time X2 Belt Idler for Belt Drive System Only 101 306 M3x6 Button Head 100 320 M3x20 Socket Head 610 319 Idler Brace 610 317 Idler Mount Block A9 108 384 3x8x4 Radial Bearing 610 318 Belt Tension Idler 109 352 3x5x2 Brass Spacer 108 384 3x8x4 Radial Bearing Clutch Bell Belt Idler Installation Belt Idler Assembly ...

Page 14: ...lock 100 310 M3x10 Socket Head 100 310 M3x10 Socket Head Left Frame Side Assembly 610 311 Main Frame Install Bearing Flange to outside of frame A10 Step 1 610 122 Throttle Servo Mount 100 206 M2x6 Socket Head 101 306 M3x6 Button Head 610 317 Idler mount Block ...

Page 15: ...rew 610 422 Canopy Stand Off 100 306 M3x6 Socket Head 100 354 M3 Washer 100 310 M3x10 Socket Head Do not over tighten in plastic Do not tighten bolts completely until next step Left Frame Assembly 100 306 M3x6 Socket Head A11 Step 2 100 376 M3x16 Set Screw 610 423 N5C Canopy Stand Off Front 100 306 M3x6 Socket Head Belt Idler Assembly 100 320 M3x20 Socket Head 100 266 M2 5x6 Socket Head 100 306 M3...

Page 16: ... a flat surface Slide main shaft into main shaft bearing blocks to make sure the main shaft spins freely Be sure that side frames are 90 degrees to the flat surface Once you have achieved the correct frame alignment you may finish tightening frame bolts Front view A12 ...

Page 17: ...Landing Gear Fuel Tank Installation Fuel Tank Assembly 106 807 Tank Edge Grommet Landing Gear Assembly 100 316 M3x16 Socket Head A13 110 419 Fuel Tubing Grommet Frame ...

Page 18: ...ized Motor 610 126 Motor Mount Lite M3x12 Socket Head 606 305 Motor Spacer Note Ensure engine is vertically aligned with clutch stack Start shaft should rotate freely and bottom of clutch should be parallel with bottom of clutch bell ...

Page 19: ...42 Fan Shroud Right 610 343 Fan Shroud Left 100 312 M3x12 Socket Head 100 210 M2x10 Socket Head 100 312 M3X12 Socket Head Fan Shroud Installation Do not over tighten A15 610 224 3x6x26 Threaded Frame Spacer ...

Page 20: ...ot ball to bell crank 101 306 M3x6 Button Head 610 228 Bell Crank Spacer 610 225 Bell Crank Shaft 107 106 Short Pivot Ball 100 464 M4x4 Flat Point Set Screw 100 464 M4x4 Flat Point Set Screw 610 222 Outside Elevator Bell Crank 610 226 Inside Elevator Bell Crank Do not fix bell cranks to shaft until the next page where they will fit into the frame A16 X2 ...

Page 21: ...lateral movement in elevator bell crank assembly Pinch inside bell crank to outside bell crank then tighten set screws 101 306 M3x6 Button Head Cyclic Bell Crank Installation A17 Note Bell Crank alignment hole in frame for ease of correct setup 100 464 M3x4 Flat Point Set Screw 100 464 M3x4 Flat Point Set Screw ...

Page 22: ... Assembly Note If you purchased the N5c with torque tube proceed to page A20 Step 1 Tail Bell Crank Assembly 100 335 M3x35 Socket Head x5 101 306 M3x6 Button Head x4 108 616 6x13x5 Flange Bearing 610 224 3x6x26 Spacer 615 124 Tail Output Shaft 615 314 9T Tail Pulley for 6mm shaft 100 364 M3x4 Set Screw 615 320 Tail Belt 115 111 Main Boom Clamp Lite 615 311 Tail Box Plate Belt Drive Tail Box Assemb...

Page 23: ...ad 615 135 Vertical Tail Fin 108 616 6x13x5 Flange Bearing 109 357 3x5x7 Brass Spacer 108 384 3x8x4 Radial Bearing 109 357 3x5x7 Brass Spacer 615 316 Belt Tension Idler Do not over tighten belt idler bolt Over tightening will cause bearings inside idler to bind 615 140 Tail Boom ...

Page 24: ...5mm Shim 108 511 5x10x4 Thrust Bearing 515 525 HD Tail Blade Grip 108 503 5x10x3 Radial Bearing 107 106 Pivot Ball 615 324 HD Tail Rotor Hub Tail Thrust Bearing Note Large OD Large ID Inside Small OD Small ID Outside Shim goes between Thrust and Radial GREASE THRUST BEARING INNER RACE DO NOT OVER TIGHTEN ...

Page 25: ...l Pitch Link 106 813 Tail Slider Lock Ring 606 921 Tail Pitch Link Pin 506 920 E Ring 115 321 Pitch Plate Use Medium CA to secure 2mm pivot ball 1 After installing lock ring be sure that the radial bearings do not have lateral load on them Adjust lock ring as needed to ensure smooth operation 2 Secure lock ring with CA or Epoxy Red Loctite Tail Pitch Slider to Tail Pitch Plate for extra security A...

Page 26: ...il Pitch Slider Tail Rotor Hub Installation A22 Size Links for free tail slider operation 100 316 M3x16 Socket Head 100 351 M3 Nylock Nut 100 351 M3 Nylock Nut Note If you purchased the N5c with torque tube proceed to page A25 ...

Page 27: ...sh Rod Guides A23 Slide Tail Control Guide to approx 265mm from the front of the boom Place the rear Tail Control Guide behind Boom Support Clamp 106 965 Tail Push Rod Sleeve 100 310 M3x10 Socket Head 615 128 Boom Support Clamp Lite Approx 5mm Insert 78mm threaded rod approximately 62mm into carbon tube Use Medium CA to glue threaded rod into carbon rod ...

Page 28: ...00 308 M3x8 Socket Head 100 335 M3x35 Socket Head Belt Drive Tail Boom Installation A24 Slide belt and boom through main boom clamps until boom is flush with second boom clamp Secure bolts 100 308 M3x8 Socket Head 100 351 Nylock Nut ...

Page 29: ...ead x2 610 223 3x26 Spacer 610 121 Boom Support Spacer x2 100 354 M3 Washer x2 Lightly sand carbon rod use medium CA to secure boom support end Boom Support Assembly A25 115 119 Boom Support End 109 345 3x4x5 Brass Spacer 615 117 Carbon Boom Support Rod ...

Page 30: ...00 351 M3 Nylock Nut 615 121 Tail Bearing Plate 108 613 6x13x5 Radial Bearing A26 615 126 Tail Input Bevel Gear 108 121 12x18x4 Radial 615 131 Tail Input Bearing Spacer 615 118 Metal Tail Box 615 321Output Shaft Sleeve 615 124 Tail Output Shaft 615 322 Tail Gear Pin 615 125 Tail Output Bevel Gear 100 364 M3x4 Cup Point Set Screw Tail Box Assembly for Torque Tube Use 6mm Shim 106 601 to remove tail...

Page 31: ...Ball 108 373 Radial Bearing 109 355 3x5x5 Spacer 615 122 Tail Bell Crank Plastic Insert Use CA or Epoxy to secure plastic insert Tail Bell Crank Assembly 100 320 3x20 Socket Head 106 301 3mm Shim 100 351 M3 Nylock Nut Do not over tighten Make sure tail bell crank moves freely after install A27 ...

Page 32: ...Slider Installation for torque tube Note direction of tail blade grips Torque tube tail rotor grips are trailing edge control 100 464 M4x4 Set Screw Ball Links need sizing for smooth operation We recommend the Boto Sizer 700 001 A28 ...

Page 33: ...olt 615 129 Torque Tube 108 814 8x14x4 Radial Bearing 615 120 TT Bearing Housing 106 809 TT O Ring Torque Tube Assembly Glue radial bearings on to torque tube using CA or Epoxy See below illustration for spacing Use Red or Green Loctite to secure torque tube end into torque tube A29 230 220 ...

Page 34: ...om Torque Tube Completed Tail Boom Torque Tube Assembly 107 078 78mm Rod 107 100 Ball Link 106 965 Tail Push Rod Sleeve x2 Use JBWeld or Medium CA to secure 78mm rod into carbon tail push rod Be very careful not to fracture the carbon rod during installation or making adjustments A30 10 Measure approx 10mm between ball link and carbon tube Leave enough threads for adjustment ...

Page 35: ... if you decide that you would like to drill a locating hole in the boom This is generally not needed but some people feel more comfortable with this configuration Torque Tube Tail Section Completion Optional 3mm tapped hole for tail boom locating Boom Support Assembly 101 412 M4x12 Button Head A31 ...

Page 36: ...0 Tail Input Shaft 610 138 TT Coupler Insert 610 139 TT Coupler 100 366 M3x6 Cup Point Set Screw 100 366 M3x6 Cup Point Set Screw 610 134 Input Shaft Bearing Block Front 610 135 18T Tail Input Pinion 610 137 Input Shaft Bearing Block Rear Torque Tube Input Transmission Assembly A32 100 364 Cup Point Set Screw ...

Page 37: ...Input Transmission Installation 100 310 M3x10 Socket Head 100 306 M3x6 Socket Head 615 130 TT Doubler Plate 100 310 M3x10 Socket Head 100 306 M3x6 Socket Head 615 130 TT Doubler Plate A33 ...

Page 38: ...Tail Boom Installation Slide Tail Boom through boom clamps until edge of tail boom is flush with edge of front boom clamp Ensure torque tube end aligns and engages with input coupler A34 ...

Page 39: ...bly Main Belt Pulley Assembly A35 610 170 170T Main Gear If you purchaced Torque Tube N5c finish Main Gear Auto Hub skip Main Belt Pulley Assembly and proceed to page A38 Note Auto Hub Assembly can be flipped around if one way bearing is installed opposite from this display Do not attempt to remove one way clutch 610 143 Main Pulley Flange 610 141 Main Belt Pulley 42T 103 204 M2x4 Type I Cross Rec...

Page 40: ...ockwise Main Gear Assembly Main Pulley Assembly 610 150 Main Shaft Collar 100 261 M2 5x10 Socket Head 610 140 Main Shaft Main Belt Pulley and Main Gear Installation Install main shaft with smalller 8mm end pointing down A36 ...

Page 41: ...A M3x20 Shouldered Socket Head 100 351 M3 Nylock Nut x2 Gently push down on main shaft while pressing up on main shaft collar After tightening main shaft collar ensure there is no vertical play in the main shaft Belt Drive Train Install Step 2 A37 ...

Page 42: ...01 208 M2x6 Button Head x8 610 132 Crown Gear Hub Lock Nut 610 131 Crown Gear Hub Screw Crown Gear Hub Lock Nut on loosely for now This will be tightened later Crown Gear Assembly A38 610 136 Crown Gear ...

Page 43: ...r pinching do not need loctite Crown Main Gear Installation Main Gear Assembly and Crown Gear Assembly are inserted into the frames together in this step After installation gently press down on Main Shaft while lifting up on Main Shaft Collar and tighten 2 5x10mm Main Shaft Collar bolt A39 ...

Page 44: ...o hub lock ring and main shaft Secure other side with nylock nut Once complete slide Crown Gear Assembly back down for next step 100 364 M3 Nylock Nut 100 325A M3x25 Socket Head Shouldered DO NOT OVER TIGHTEN This only needs to be gently tighten Auto Hub Bolt Install A40 ...

Page 45: ...4 Crown Gear Hub Pin 1 Align Crown Gear Hub hole with corresponding Main Shaft hole 2 Insert Crown Gear Hub Pin until flush with Crown Gear Hub 3 Tighten Crown Gear Lock Nut with 17mm or 11 16 in open end wrench DO NOT OVER TIGHTEN NUT A41 ...

Page 46: ... 364 3x4mm Cup Point Set Screws x2 Crown Gear mesh may be adjusted by loosening two 18T pinion set screws and sliding pinion fore aft Correct mesh is obtained when outer tooth of pinion is aligned with outer tooth of crown gear A42 ...

Page 47: ... 295mm Tail Linkage Rod 107 100 Ball Link 109 352 3x5x2 Spacer 100 316 M3x16 Socket Head 108 373 3x7x3 Radial Attention If you are using an OS55HZ motor screw the 107 106 Pivot Ball into the top of the Tail Offset Bell Crank This will allow the Tail Linkage Rod to clear the mid range carb needle 100 212 M2x12 Socket Head x4 107 104 2mm Pivot Ball 100 252 2mm Nut 106 115 Servo Hold Down x2 A43 ...

Page 48: ...ad 606 922 2 5mm Washout Pin 108 364 3x6x2 5 Flange Bearing 108 364 3x6x2 5 Flange Bearing 100 308 M3x8 Socket Head 620 119 Flybar Control Arm 100 364 M3x4 Set Screw 620 123 Flybar 100 365 M3x4 Set Screw 100 308 M3x8 Socket Head 620 115 Head Button 120 121 Flybar Control Arm Stand Off 107 106 Pivot Ball 109 351 3x5x1 6 Brass Spacer Flybar Rotor Head Assembly X2 THIS STEP FOR FLYBAR HEADS ONLY A44 ...

Page 49: ...ivot Ball 107 108 Long Pivot Ball 107 108 Long Pivot Ball 100 364 M3x4 Set Screw 120 214 Washout Link 606 923 Washout Link Pin 506 920 E Ring 109 355 3x5x5 Brass Spacer 108 373 3x7x3 Radial Bearing 100 312 M3x12 Socket Head 107 106 Pivot Ball 100 310 M3x10 Socket Head Swashplate and Washout Assembly A45 620 213 Washout Control Arm Flybarless configurations can ignore washout assembly but still nee...

Page 50: ...k 107 012 12mm Rod 107 101 Short Ball Link 100 316 M3x16 Socket Head 108 373 3x7x3 Bearing 109 356 3x5x6 5 Spacer 620 116 Bell Mixer 107 106 Pivot Ball 108 373 3x7x3 Bearing 107 106 Pivot Ball Flybar Blade Grip Assembly Rotor Head Assembly Note We recommend only using amount of shims needed to take up lateral play in blade grips Dampers are stiff enough to where they will not need compression If d...

Page 51: ...Rotorhead to Swashplate Assembly THIS PAGE FOR FLYBAR CONFIGURATION ONLY A47 X2 62 107 100 Ball Link 107 100 Ball Link 107 078 78mm Control Rod ...

Page 52: ...ure bolt travels through both Head Block as well as the hole in the main shaft Make sure this bolt is securely tightened as it pinches the head block onto the main shaft LINK LENGTH GOOD FOR BOTH FLYBAR AND FLYBARLESS CONFIGURATIONS 24 107 100 Ball Link 107 100 Ball Link 107 043 43mm Rod ...

Page 53: ...M3x12 Socket Head 100 308 M3x8 Socket Head 100 306 M3x6 Socket Head 520 513 FBL Blade Grip Arm 100 312 M3x12 Socket Head Apply Grease Flybarless Head Assembly Inner Swash Driver Assembly 620 111 FBL Head Block 520 514 FBL Main Blade Grip 620 211 FBL Washout Hub 106 301M3 Shim 108 383 3x8x3 Radial Bearing 620 214 FBL Washout Arm 109 352 3x5x2 Brass Spacer 108 383 3x8x3 Radial Bearing 100 312 M3x12 ...

Page 54: ...tch links Flybarless Head Installation Align Swash Driver paralell with head block Adjust height of swash driver so washout link is 90 degrees to Washout Arm at zero degrees collective pitch See illustration below Correct A50 Do not make washout arm parallel with washout base as zero degrees pitch Approx 56mm 9 0 ...

Page 55: ...Elevator Linkage X2 A51 Approx 58 50mm 107 100 Ball Link 107 078 78mm Rod 107 100 Ball Link ...

Page 56: ...Aileron Linkage X2 A52 Approx 107mm 107 100 Ball Link 107 100 Ball Link 107 126 126mm Rod ...

Page 57: ...Pitch Servo Linkage A53 Approx 83mm 107 100 Ball Link 107 100 Ball Link 107 102 102mm Rod X2 ...

Page 58: ...Throttle Linkage 100 212 M2x12 Socket Head A54 Approx 85mm 107 100 Ball Link 107 100 Ball Link 107 102 102mm Rod ...

Page 59: ...unter Sunk Screw 610 314 Carbon Fiber Radio Plate Route all wires as you see fit 1 Some radio gear may fit in between frames 2 Install CF Radio Plate 3 Install Radio Gear on CF Radio Plate 4 Radio Plate Installation A55 ...

Page 60: ...olt 100 451 M4 Nylock Nut 110 418 Conopy Gromet X4 Use Medium CA to secure canopy gromets to canopy Canopy and Blades A56 610 404 Fiberglass Canopy Accepts 600mm 630mm Blades 100 316 M3x16 Socket Head 510 425 Canopy Thumb Screw ...

Page 61: ...412 1270 ...

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