Ergocraft Contract Solutions JR Ergo Assembly Instructions Manual

[Page 1] Ergocraft Contract Solutions JR Ergo

.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 Weight 6.75-7.0 lbs....

[Page 2] Ergocraft Contract Solutions JR Ergo

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 J...

[Page 3] Ergocraft Contract Solutions JR Ergo

3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 1-1 Clutch Bell/Start Shaft Assembly . . . . . . ....

[Page 4] Ergocraft Contract Solutions JR Ergo

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-Dut...

[Page 5] Ergocraft Contract Solutions JR Ergo

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):...

[Page 6] Ergocraft Contract Solutions JR Ergo

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 Helico...

[Page 7] Ergocraft Contract Solutions JR Ergo

7 Socket Head Bolt Tapping Screw Flat Washer .05mm .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 s...

[Page 8] Ergocraft Contract Solutions JR Ergo

8 1-1 3x4mm Set Screw 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. Start...

[Page 9] Ergocraft Contract Solutions JR Ergo

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 Wash...

[Page 10] Ergocraft Contract Solutions JR Ergo

1-5 ELEVATOR ARM ASSEMBLY 10 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...

[Page 11] Ergocraft Contract Solutions JR Ergo

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 t...

[Page 12] Ergocraft Contract Solutions JR Ergo

2-2 UPPER MAIN FRAME CONTROL LEVER INSTALLATION 12 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/Contr...

[Page 13] Ergocraft Contract Solutions JR Ergo

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 TANK INSTALLATION Note: Install the Fuel Tank and Tank Mounting Rubber into the lower frame halves before at...

[Page 14] Ergocraft Contract Solutions JR Ergo

2-5 FRONT RADIO BED/GYRO MOUNTING PLATE INSTALLATION 2-6 COOLING FAN SHROUD INSTALLATION 14 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 insta...

[Page 15] Ergocraft Contract Solutions JR Ergo

2-7 UPPER/LOWER MAIN FRAME ASSEMBLY ATTACHMENT 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 He...

[Page 16] Ergocraft Contract Solutions JR Ergo

16 3-1 MAIN DRIVE GEAR/AUTOROTATION ASSEMBLY 3-2 MAIN DRIVE GEAR/AUTOROTATION ASSEMBLY INSTALLATION 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 Autorota...

[Page 17] Ergocraft Contract Solutions JR Ergo

3-3 LANDING GEAR ASSEMBLY INSTALLATION 3-4 .32-.36 CO0LING FAN/HUB INSTALLATION 17 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 Vers...

[Page 18] Ergocraft Contract Solutions JR Ergo

3-4.1 .46 COOLING FAN INSTALLATION 3-5 .32-.36 ENGINE MOUNT ATTACHMENT 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....

[Page 19] Ergocraft Contract Solutions JR Ergo

3-5.1 .46 ENGINE MOUNT ATTACHMENT 3-6 CLUTCH ASSEMBLY ATTACHMENT (ALL) 19 *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. I...

[Page 20] Ergocraft Contract Solutions JR Ergo

3-7 ENGINE INSTALLATION (ALL) 3-8 INSTALLATION OF THE MUFFLER 20 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 ...

[Page 21] Ergocraft Contract Solutions JR Ergo

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 Hol...

[Page 22] Ergocraft Contract Solutions JR Ergo

4-3 MAIN BLADE HOLDER/SEESAW ATTACHMENT 4-4 SEESAW MIXING ARM INSTALLATION 22 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 .....

[Page 23] Ergocraft Contract Solutions JR Ergo

4-5 SWASHPLATE/WASHOUT ASSEMBLY INSTALLATION 23 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 installin...

[Page 24] Ergocraft Contract Solutions JR Ergo

4-6 ROTOR HEAD INSTALLATION 24 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 ...

[Page 25] Ergocraft Contract Solutions JR Ergo

4-7 FLYBAR INSTALLATION 4-8 FLYBAR PADDLE ATTACHMENT 25 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 par...

[Page 26] Ergocraft Contract Solutions JR Ergo

4-9 ROTOR HEAD/SWASHPLATE CONTROL ROD INSTALLATION 26 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 - 1...

[Page 27] Ergocraft Contract Solutions JR Ergo

27 5-1 TAIL OUTPUT SHAFT/PULLEY ASSEMBLY 5-2 TAIL 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...

[Page 28] Ergocraft Contract Solutions JR Ergo

5-3 TAIL CENTER HUB ASSEMBLY 28 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 * ...

[Page 29] Ergocraft Contract Solutions JR Ergo

5-5 TAIL PITCH CONTROL LEVER INSTALLATION 5-6 TAIL FIN ATTACHMENT 29 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 ...

[Page 30] Ergocraft Contract Solutions JR Ergo

5-7 TAIL BOOM CARRIER INSTALLATION 5-8 TAIL BOOM ASSEMBLY INSTALLATION 30 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 5-1...

[Page 31] Ergocraft Contract Solutions JR Ergo

5-9 TAIL BOOM BRACE ASSEMBLY 5-10 TAIL BOOM BRACE INSTALLATION 31 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 th...

[Page 32] Ergocraft Contract Solutions JR Ergo

32 6-1 UPPER SERVO TRAY 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 over- tighten the mounting s...

[Page 33] Ergocraft Contract Solutions JR Ergo

6-2 SERVO/SWITCH HARNESS INSTALLATION 33 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 a...

[Page 34] Ergocraft Contract Solutions JR Ergo

6-3 TAIL CONTROL ROD ASSEMBLY 6-4 TAIL CONTROL ROD INSTALLATION 34 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 ...

[Page 35] Ergocraft Contract Solutions JR Ergo

6-5 GYRO/RECEIVER/BATTERY INSTALLATION 35 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 n...

[Page 36] Ergocraft Contract Solutions JR Ergo

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 cont...

[Page 37] Ergocraft Contract Solutions JR Ergo

7-1 AILERON LINKAGES 7-2 ELEVATOR LINKAGE INSTALLATION 37 ......... 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 Sp...

[Page 38] Ergocraft Contract Solutions JR Ergo

7-3 COLLECTIVE LINKAGE INSTALLATION 7-4 TAIL CONTROL ROD SERVO CONNECTION 38 ..........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 ...........

[Page 39] Ergocraft Contract Solutions JR Ergo

7-5 THROTTLE LINKAGE INSTALLATION (ALL) 39 ..........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 SEL...

[Page 40] Ergocraft Contract Solutions JR Ergo

8-1 BODY ASSEMBLY/CANOPY ATTACHMENT 8-2 BODY ATTACHMENT 40 ..........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 secur...

[Page 41] Ergocraft Contract Solutions JR Ergo

8-3 MAIN ROTOR BLADE BALANCING 8-4 MAIN ROTOR BLADE ATTACHMENT 41 .........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 ro...

[Page 42] Ergocraft Contract Solutions JR Ergo

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 C...

[Page 43] Ergocraft Contract Solutions JR Ergo

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 autorota...

[Page 44] Ergocraft Contract Solutions JR Ergo

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% �...

[Page 45] Ergocraft Contract Solutions JR Ergo

D/R % % EXP % % D/R % % EXP % % TRIM OFFSET CHANNEL THR (1) AIL (2) ELE (3) RUD (4) GER (5) PITCH (6)...

[Page 46] Ergocraft Contract Solutions JR Ergo

46 EA • A • E • CF D/R % % EXP % % D/R % % EXP % % TRIM OFFSET CHANNEL THR (1) AIL ...

[Page 47] Ergocraft Contract Solutions JR Ergo

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....

[Page 48] Ergocraft Contract Solutions JR Ergo

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) T...

[Page 49] Ergocraft Contract Solutions JR Ergo

EXP L 1 2 3 4 5 6 H OFF IN 0 50 100 N • OUT 0 50% Power 100% Power ON HOV.SEL —— HOV HOV HOV HOV HOV HOV —— 1 OFF IN 0 50 100 • ON OUT 40% Power 50% Power 100% Power 2 OFF IN 0 50 100 • ON OUT 100% Power 50% Power 100% Power 3 OFF IN 0 ...

[Page 50] Ergocraft Contract Solutions JR Ergo

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 ta...

[Page 51] Ergocraft Contract Solutions JR Ergo

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 corros...

[Page 52] Ergocraft Contract Solutions JR Ergo

52 ROTOR HEAD/SWASHPLATE/WASHOUT 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 96008...

[Page 53] Ergocraft Contract Solutions JR Ergo

53 ROTOR HEAD/SWASHPLATE/WASHOUT ASSEMBLY PARTS LIST PART # DESCRIPTION QUANTITY COMMENTS /ADDITIONAL CONTENTS 960012 Washout Assembly 1 Complete w/all Components 960013 Washout Base 1 960014 Swashplate As...

[Page 54] Ergocraft Contract Solutions JR Ergo

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] Ergocraft Contract Solutions JR Ergo

55 START 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...

[Page 56] Ergocraft Contract Solutions JR Ergo

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] Ergocraft Contract Solutions JR Ergo

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 -...

[Page 58] Ergocraft Contract Solutions JR Ergo

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] Ergocraft Contract Solutions JR Ergo

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 ...

[Page 60] Ergocraft Contract Solutions JR Ergo

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] Ergocraft Contract Solutions JR Ergo

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 ...

[Page 62] Ergocraft Contract Solutions JR Ergo

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

[Page 63] Ergocraft Contract Solutions JR Ergo

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 ...

[Page 64] Ergocraft Contract Solutions JR Ergo

64 TAIL CASE/TAIL BLADE HOLDERS/TAIL PITCH PLATE 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 ASSEMBLY INSTRUCTIONS ERGO SPECIFICATI...

[Page 65] Ergocraft Contract Solutions JR Ergo

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 ...

[Page 66] Ergocraft Contract Solutions JR Ergo

Heli Division Revised 3/4/97 ...