Page 1
.32-.36 AND .46 ASSEMBLY INSTRUCTIONS ERGO SPECIFICATIONS Overall Length 46.5" Tail Rotor Diameter 9.17" Overall Height 16.38" Gear Ratio 9.78:1:5.18 Main Rotor Diameter 48.5" (.32-.36) Gross Weight 6.75-7.0 lbs. 50" (.46 3D) Heli Division...
Page 2
INTRODUCTION Congratulations on your purchase of the JR Ergo helicopter kit. models. For further information, you can contact the AMA at: This kit has been both engineered and manufactured by JR with help from some Academy of Model Aeronautics of Japan’s top R/C helicopter engineers (now employed by JR).
INDEX Section Description Page Section Description Page Tools ..........4-6 Tail Gear Case Assembly .
Page 4
(not supplied in kit) 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.
Page 5
(Webra .33 Heli Engine Shown) (Thunder Tiger Pro .46 Heli Engine Shown) (JRP960079 Ergo .46 Muffler Shown) 3. BUILDING SUPPLIES (NOT INCLUDED): The following items are needed to complete the assembly of the JR Ergo: Silicone Fuel Tubing Fuel Filter Whip Antenna...
4. TOOLS NEEDED TO ASSEMBLE THE JR ERGO (NOT INCLUDED): Nut Drivers: 5mm, 7mm Needle Nose Pliers Scissors Phillips Screwdirver Drill and Drill Bits Small Hammer X-Acto Knife Metric Ruler Blade Balancer Allen Wrenches: 1.5, 2.0, 2.5, 3.0mm 5. FIELD EQUIPMENT REQUIRED (NOT INCLUDED):...
HARDWARE IDENTIFICATION There are many various sizes and shapes of hardware included in this kit. All of the hardware, screws, nuts, etc., contained in the Ergo kit are described in Prior to assembly, please be careful to identify each screw by matching it to the the following A, B, C manner: full size screw outlines included in each step.
CLUTCH BELL/START SHAFT ASSEMBLY Starter Hex Adaptor ..1 pc Complete Assembly 3x4mm Set Screw Use Threadlock * 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.
CONTROL BALL INSTALLATION Mixing Lever (3 pc) 2x8mm Flat Head Screw (Prepare 3 Sets) Use Threadlock ..1 pc 2x8mm Flat Head Screw 2mm Nut Roll Bell Crank ..8 pc Steel Joint Ball 2x10mm Flat Head Screw 2mm Nut Steel Joint Ball ..9 pc Steel Joint Ball ..3 pc...
ELEVATOR ARM ASSEMBLY Elevator Arm Rear Elevator Arm Front ..2pc Swashplate A 2x8mm Flat Head Screw Arms ..2pc Steel Joint Ball ..2pc Elevator Arm Pin Steel Joint Ball Steel Joint Ball 2x8mm Flat Head Screw 2x8mm Flat Head Screw Elevator Arm Pin Caution: Be sure to note correct Swashplate A Arm installation direction.
UPPER MAIN FRAME SECTION ASSEMBLY Upper Main Shaft Bearing Block Use Threadlock On Position so the side Bearing Flush All Screws with Flange of the bearing block that has the bearing ..21 pc Bearing flush with the flange 3x8mm Socket Head Bolt is upward.
UPPER MAIN FRAME CONTROL LEVER INSTALLATION Use Threadlock Elevator Arm Bushing Note: Be sure to install the Elevator Nylon Washer Arm Units in their proper Nylon Washer location as there is a “Front” Elevator Arm Bushing 3x8mm Socket Head Bolt and a “Rear”...
FRONT RADIO BED/GYRO MOUNTING PLATE INSTALLATION Gyro Mounting Plate ..6 pc Use Threadlock 3x10mm Socket Head Bolt Front Radio Bed ..2 pc 3x18mm Set Screw ..2 pc Body Mounting Standoff Long Body Mounting Standoff Long 3x10mm Socket Head Bolt (6 pc) 3x18mm Set Screw (2 pc) Body Mount Standoff, Long 3x10mm Socket...
UPPER/LOWER MAIN FRAME ASSEMBLY ATTACHMENT Use Threadlock On ..12 pc All Screws 3x22mm Socket Head Bolt ..6 pc Main Frame Standoff, 32mm ..12 pc Main Frame Spacer, 12.5mm Main Frame Spacer, 12.5mm (12 pc) Main Frame Standoff, 32mm (6 pc) 3x22mm Socket Head Bolt (12 pc) 3x22mm Socket Head Bolt...
MAIN DRIVE GEAR/AUTOROTATION ASSEMBLY 3x6mm Socket Head Bolt (4 pc) [Tighten equally to prevent warping of Main Drive Gear] Use Threadlock Main Drive Gear ..4 pc 3x6mm Socket Head Bolt Autorotaion Assembly MAIN DRIVE GEAR/AUTOROTATION ASSEMBLY INSTALLATION Main Shaft Collar Use Threadlock 4x4mm Set Screw (4 pc) ..4 pc...
3-4.1 .46 COOLING FAN INSTALLATION Nut Supplied with Engine Note: If you are building the Ergo .32-.36 Version, proceed to Step 3-5. Note: It will not be necessary to use the four 3x5mm Socket Head Bolts included in this screw bag. Note: It will be necessary to shorten the Crankshaft of the engine to allow clearance.
3-5.1 .46 ENGINE MOUNT ATTACHMENT Engine Mount .46 Fan Assembly: .46 Use Threadlock ..4 pc 3mm Serrated 3x15mm Socket Head Bolt Washer (4 pc) ..4 pc 3mm Flat Washer ..4 pc 3mm Serrated Washer Motor Mount Direction: Motor Mount Direction: Thunder Tiger O.S.
ENGINE INSTALLATION (ALL) ..4 pc 3x10mm Socket Head Bolt ..4 pc 3mm Flat Washer 3mm Flat Washer (4 pc) 3x10mm Socket Head Bolt (4 pc) Correct Incorrect Adjust the height and position of the Engine as shown so the bottom of the Clutch *It is highly recommended that you insert Assembly is flush with the bottom of the Clutch Bell.
ROTOR HEAD HUB ASSEMBLY 3x6mm Socket Head Bolt Use Threadlock Head Button ..1 pc 3x6mm Socket Head Bolt ..2 pc 3x8mm Socket Head Bolt 3x8mm Socket Head Bolt (2 pc) Phase Adjustment Ring Main Rotor Hub (insert onto base of Main Rotor Hub) MAIN BLADE HOLDER ASSEMBLY Steel Joint Ball Two Sets Required...
SWASHPLATE/WASHOUT ASSEMBLY INSTALLATION *Washout Assembly Swashplate Assembly Upper Swashplate Ring Connect the two Washout Links to the correct upper Swashplate Balls as shown. Complete Assembly *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.
ROTOR HEAD INSTALLATION ..1 pc 3x18mm Socket Head Bolt Completed Rotor Head Assembly ..1 pc 3mm Lock Nut 3mm Lock Nut 3x18mm Socket Head Bolt Rotor Hub Pin Washout Base Note: Be sure to engage thePhase Adjusting Ring into the Washout Base Groove before securing the Rotor Head Assembly in place.
FLYBAR INSTALLATION Flybar Control Arm (2 pc) Use Threadlock 4x4mm Set Screw *Flybar Bushings (2 pc) (2 pc) ..2 pc 4x4mm Set Screw * Be sure to insert Flybar Bushings into the Seesaw Shaft before inserting Flybar. Flybar Flybar Centering Note: Center the Flybar in the Seesaw Shaft before securing the two Flybar Control Arms.
ROTOR HEAD/SWASHPLATE CONTROL ROD INSTALLATION *Double Link A (2 pc) (Washout Arm to Main Blade Holder) Pre-Assembled Control Rod Identification: Washout Arm to Flybar Control Arm (1 Piece Double Link) 47mm Swashplate to Roll Bellcrank Note: Ergo .46 3D Kit (2.3mmx30mm Threaded Rod) Your Ergo .46 3D Kit includes an additional set of Double Links (B Style #960081).
TAIL OUTPUT SHAFT/PULLEY ASSEMBLY Complete Assembly ..1 pc Spring Pin Tail Output Shaft Hammer Spring Pin Short Distance Note correct direction of Tail Edge of Work Bench Output Shaft during assembly. Long Distance Tail Case Pulley TAIL GEAR CASE ASSEMBLY 3x12mm Self Tapping Screw 3x12mm Self...
TAIL CENTER HUB ASSEMBLY * Be certain to apply Locktite to the two 3x3mm Set Screw (2pc) 3x3mm set screws and attach securely to the tail output shaft so the set screws Tail Center Hub engage into the tail output shaft hole. Failure to secure this assembly properly can result in tail rotor failure during flight.
TAIL PITCH CONTROL LEVER INSTALLATION ..1 pc 2x8 Flat Head Screw ..1 pc 2x20mm Socket Head Bolt ..1 pc 2mm Flat Washer ..1 pc Steel Joint Ball ..1 pc Tail Lever Bushing Snap Tail Pitch Control Lever Onto Ball 2mm Flat Washer Steel Joint Ball Tail Lever Bushing 2x8mm Flat...
TAIL BOOM CARRIER INSTALLATION 3mm Lock Nut Tail Boom Carrier (L&R) ..4 pc 3x15mm Socket Head Bolt 3mm Lock Nut ..2 pc 3x40mm Socket Head Bolt ..6 pc 3mm Lock Nut * Do not fully tighten at this time. These bolts will be secured in Step 5-10.
TAIL BOOM BRACE ASSEMBLY Tail Brace Connector ..1 pc 2.6x12mm Socket Head Bolt 2.6x15mm Socket Head Bolt ..1 pc 2.6x15mm Socket Head Bolt 2.6x12mm Socket Head Bolt Tail Brace Tube Tail Brace T End 5-10 TAIL BOOM BRACE INSTALLATION ..2 pc 3x8mm Socket Head Bolt 3mm Lock Nut ..1 pc...
UPPER SERVO TRAY INSTALLATION 3x8mm Socket Head Bolt (4 pc) Upper Servo Tray ..4 pc 3x8mm Socket Head Bolt RADIO INSTALLATION SUGGESTIONS Be sure to install four rubber servo grommets and eyelets to each servo prior to It is suggested that both the receiver and gyro amplifier be isolated from vibration installation.
TAIL CONTROL ROD ASSEMBLY Thread Link 8mm onto Control Rod Tail Control Rod Bushings (5 pc) Universal Link (2 pc) ..5 pc Tail Control Rod Bushing Tail Control Rod ..2 pc Universal Link Thread Link 8mm onto Control Rod TAIL CONTROL ROD INSTALLATION Tail Contol Rod Guide (4 pc) Tail Control Rod Clip located on Main Fram...
GYRO/RECEIVER/BATTERY INSTALLATION 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 Gyro that the surfaces are free from oil, residue, etc. Clean if neccessary to insure proper adhesion.
RADIO SYSTEM PREPARATION The following preparations are suggested for use with JR radio systems. These suggested adjustments are necessary to insure correct installation and However, these procedures are applicable to most other brand radio systems. attachment of the control linkages and servo horns. TRANSMITTER PREPARATION Set all trim levers, trim knobs and switches to the neutral or zero previously to another model, reset all functions and input values to the...
AILERON LINKAGES A Special Note To Beginners: It is suggested that the maximum travel limits for aileron, elevator, pitch and rudder controls be reduced to 70%..1 pc Note: Attach the steel joint ball to the correct hole as shown below: 2x8mm Flat Head Screw Servo Horn ..1 pc...
COLLECTIVE LINKAGE INSTALLATION Note: Make certain that the Collective Servo Reversing Directions Servo is in the neutral or hover Reverse 2x8mm Flat Head Screw 90° position before securing the Futaba Reverse Servo Horn to the Servo. Steel Joint Ball Servo Horn 2mm Hex Nut 2.3x35mm All Threaded Rod 20mm...
BODY ASSEMBLY/CANOPY ATTACHMENT Rubber Grommets (4 pc) Body Note: It will be necessary to trim away the unwanted plastic *Canopy (Trim prior to attachment) off the canopy and side 2.3x8mm Self window areas using an Tapping Screw X-Acto knife. (5 pc) Drill four 15/64"...
MAIN ROTOR BLADE BALANCING Main Rotor Blades Step 1 Step 2 Drinking Glass (2 pc) Final Static Balancing Spanwise C.G. Balancing To static balance the main rotor blades, it is suggested to either Place each rotor blade on a sharp edge of a table as attach each blade to a “seesaw”...
FINAL SERVO ADJUSTMENT AND RADIO SET UP Now that the radio system is completely installed into the helicopter, it is A. Pitch Curve Adjustment necessary to check and adjust the following: Using a pitch gauge (optional) set the low, mid and high stick pitch settings as shown in the diagram below.
Page 43
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. Stunt &...
XF622 DATA SHEET #1 ERGO .32/.46 (INITIAL SET-UP) FACTORY PRE-SET GEAR FACTORY PRE-SET PITCH NORM NORM NORM NORM NORM NORM REVERSE SW SUB-TRIM Adjust so that no trim is required Adjust for Full +80% +80% +100% +150% TRAVEL ADJUST Power Adjust for –80% –80%...
Page 45
XP642 DATA SHEET #1 ERGO .32/.46 (INITIAL SET-UP) * Note: Before flying, confirm that all controls Modulation S-PCM • Z-PCM • PPM (FM) function in their proper direction. Model Number Model Name CHANNEL THR (1) AIL (2) ELE (3) RUD (4) GER (5) PITCH (6) NORM...
Page 46
XP642 DATA SHEET #2 ERGO .32/.46 (INITIAL SET-UP WITH 3D PITCH/THROTTLE CURVE) Modulation S-PCM • Z-PCM • PPM (FM) * Note: Before flying, confirm that all controls function in their proper direction. Model Number Model Name CHANNEL THR (1) AIL (2) ELE (3) RUD (4) GER (5)
Page 47
XP-783 DATA SHEET MODEL NO. ERGO .32/.46 (INITIAL SET-UP) MODEL NAME ERGO .32/.46 MODULATION S-PCM • Z-PCM • PPM AILE ELEV RUDD AUTO ST-1 INH • ACT 90 % 70 % (POS.1) ST-2 INH • ACT D/R • R 100% 100% 100% AUX 2 INPUT...
Page 48
MODEL NO. (84) _____________________________________ PCM10SX DATA SHEET ERGO .32/.46 (INITIAL SET-UP) MODEL NAME (81) ERGO .32/.46 MODULATION (85) SPCM-ZPCM-PPM THRO AILE ELEV RUDD GEAR PITCH AUX2 AUX3 AUX4 AUX5 REVERSE SW (11) Adjust for L 80% D 80% L 100% +150% Full Power TRAVEL ADJUST...
PCM10SX DATA SHEET ERGO .32/.46 (INITIAL SET-UP) CONTINUED 50% Power 100% Power • —— —— HOV.SEL THRO • CURVE 100% Power 40% Power 50% Power (18) • 100% Power 50% Power 100% Power TH,TRIM=SLOW HOV.T=CENTER • • -2° Pitch 5° Pitch 10°...
FINAL PRE-FLIGHT CHECK Once all assemblies have been completed, please review the following and that each servo horn is secured with a servo horn mounting screw. suggestions before attempting initial flights. • Verify that the gyro is operational and compensating in the correct direction (detailed in Step 8, page 42).
GENERAL MAINTENANCE Engine Check to insure that all universal links fit freely but securely to the control balls. After each day of flying, fully drain the fuel tank. Then, start the engine If there is excessive play noted, replace the universal link in question. and let it idle until the engine and the fuel line are completely burned off.
UPPER MAIN FRAME/RADIO TRAY/BODY SET PARTS LIST PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS 960001 Autorotation Assembly Complete w/Four 3x6mm Socket Head Bolts 960002 Main Drive Gear 88T Complete w/Four 3x6mm Socket Head Bolts 960009 Main Rotor Shaft 960017 Main Shaft Bearing Block Complete w/Bearing 960029 Upper Main Frame...
LOWER MAIN FRAME/LANDING GEAR/FUEL TANK PARTS LIST PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS 960010 Cooling Fan Shroud 4 - 2.6x8mm Self Tapping Screws 960026 Gyro Mounting Plate 4 - 3x10mm Socket Head Bolts 960027 Lower Frame Angles 960028 Front Radio Bed 960030 Lower Main Frame 960032...
Need help?
Do you have a question about the JR Ergo and is the answer not in the manual?
Questions and answers