JR ProPo Ergo User manual

.60 ASSEMBLY INSTRUCTIONS
Heli Division
ERGO SPECIFICATIONS
Overall Length 55.85"
Overall Height 18.92"
Main Rotor Diameter 60.45"
Tail Rotor Diameter 10.34"
Gear Ratio 9.78:1:5.18
Gross Weight 10.58 lbs.

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 currentAMA sporting license prior to operation of their
models. For further information, you can contact theAMA at:
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302
[phone]
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
[phone] (9am to 5pm CST)
2

3
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 TankAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2-1 Upper Main Frame Section Assembly . . . . . . . . . . . . . . .12
2-2 Upper Main Frame Control Lever Installation . . . . . . . . .13
2-3 Lower Main Frame Assembly . . . . . . . . . . . . . . . . . . . . .14
2-4 Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2-5 Front Radio Bed/Gyro Mounting Plate Installation . . . . .15
2-6 Cooling Fan Shroud Installlation . . . . . . . . . . . . . . . . . . .15
2-7 Upper/Lower Main Frame Assembly Attachment . . . . . .16
3-1 Main Drive Gear/AutorotationAssembly . . . . . . . . . . . . .17
3-2 Main Drive Gear/AutorotationAssembly Installation . . .17
3-3 Landing Gear Assembly Installation . . . . . . . . . . . . . . . .18
3-4 Cooling Fan/Hub Installation . . . . . . . . . . . . . . . . . . . . . .18
3-5 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/SeesawAttachment . . . . . . . . . . . . . .22
4-4 Seesaw MixingArm Installation . . . . . . . . . . . . . . . . . . .22
4-5 Washout Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .23
4-6 Tail Pitch Slide Ring Assembly . . . . . . . . . . . . . . . . . . . .23
4-7 Swashplate/Washout Assembly Installation . . . . . . . . . . .24
4-8 Rotor head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4-9 Flybar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4-10 Flybar PaddleAttachment . . . . . . . . . . . . . . . . . . . . . . . . .26
4-11 Rotor Head/Swashplate Control Rod . . . . . . . . . . . . . . . .27
5-1 Tail Output Shaft/Pulley Assembly . . . . . . . . . . . . . . . . . .28
5-2 Tail Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . .28
5-3 Tail Center Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . .29
5-4 Tail Blade Holder Assembly . . . . . . . . . . . . . . . . . . . . . . .29
5-5 Tail Pitch Control Lever Installation . . . . . . . . . . . . . . . . .30
5-6 Tail Boom Carrier Installation . . . . . . . . . . . . . . . . . . . . .30
5-7 Tail Boom Assembly Installation . . . . . . . . . . . . . . . . . . .31
5-8 Vertical Fin Attachment . . . . . . . . . . . . . . . . . . . . . . . . . .31
5-9 Tail Boom Assembly Installation . . . . . . . . . . . . . . . . . . .32
5-10 Tail Boom/Horizontal Fin Installation . . . . . . . . . . . . . . .32
6-1 Upper Servo Tray Installation . . . . . . . . . . . . . . . . . . . . . .33
6-2 Servo/Switch Harness Installation . . . . . . . . . . . . . . . . . .34
6-3 Tail Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . .35
6-4 Tail Control Rod Installation . . . . . . . . . . . . . . . . . . . . . .35
6-5 Gyro/Receiver/Battery Installation . . . . . . . . . . . . . . . . . .36
Radio System Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7-1 Aileron Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
7-2 Elevator Linkage Installation . . . . . . . . . . . . . . . . . . . . . .38
7-3 Collective Pitch Linkages . . . . . . . . . . . . . . . . . . . . . . . . .39
7-4 Tail Control Rod Servo Connection . . . . . . . . . . . . . . . . .39
7-5 Throttle Linkage Installation (ALL) . . . . . . . . . . . . . . . . .40
7-6 Control Lever/LinkageAdjustment . . . . . . . . . . . . . . . . .41
8-1 Body Assembly/CanopyAttachment . . . . . . . . . . . . . . . .42
8-2 Body Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Decal Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8-3 Main Rotor Blade Assembly . . . . . . . . . . . . . . . . . . . . . . .44
8-4 Main Rotor Blade Final Balancing . . . . . . . . . . . . . . . . . .45
8-5 Main Rotor Blade Final Attachment . . . . . . . . . . . . . . . . .45
ServoAdjustment and Radio Set Up . . . . . . . . . . . . . . . . . . . . . . .46-47
Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48-51
Final Pre-Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Rotor Head/Swashplate/Washout Assembly Parts List . . . . . . . . .54-55
Cyclic Mixing Arms/Elevator/Aileron Control Arms Parts List . .56-57
Start Shaft/Clutch/Engine Assembly Parts List . . . . . . . . . . . . . . .58-59
Upper Main Frame/Radio Tray/Body Set Parts List . . . . . . . . . . .60-61
Lower Main Frame/Landing Gear/Fuel Tank Parts List . . . . . . . .62-63
Tail Boom/Tail Brace/Tail Boom Carrier Parts List . . . . . . . . . . .64-65
Tail Case/Tail Blade Holders/Tail Pitch Plate Parts List . . . . . . . .66-67
INDEX
Section Description Page Section Description Page

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 .60 FEATURES
Heavy-DutyAluminum 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 atAll 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.
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 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.
Superior Parts Fit and Finish
Make assembly trouble free and enjoyable.
4
JRXP783 JRXP8103 JRPCM10SX
Flight Pack Gyro Receiver

5
Double Sided Servo
Mounting Tape
Nylon Wire Ties (to
secure radio wires) 5 Minute Epoxy or Rotor Blade
CA Adhesive
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 .60-.61 R/C Helicopter Engine is required. A special helicopter type muffler is also required
(Webra .61 Heli Engine Shown) (Thunder Tiger Pro .61 Heli Engine Shown)
WEBE675 TTR9695
KSJ355 O.S. Thunder Tiger/Webra Engines
KSJ385 Y.S. Thunder Tiger/Webra Engines

6
Needle Nose Pliers
Drill and Drill Bits
Allen Wrenches: 1.5, 2.0, 2.5, 3.0, 4.0mm
Sandpaper (80-100 Grit) Blade Balancer Adjustable Pliers
Small Hammer Hobby Knife Metric Ruler
Scissors
12 Volt Electric Starter 12 Volt Starting Battery
HAN109HAN110
HAN118
RVO1002
HAN3020 JRP960090
1.5 Volt Glow Plug Battery Remote Glow Plug Adaptor
(For Power Panel Use Only)
Helicopter Fuel 15% - 30%
Pitch Gauge
Fuel Pump
Ball Link Pliers Training Gear (Beginners Only)
Glow Plugs Hex Starting Shaft
Phillips Screwdriver Nut Drivers: 5mm, 7mm
4. TOOLS NEEDED TO ASSEMBLE THE JR ERGO .60 (NOT INCLUDED):
5. FIELD EQUIPMENT REQUIRED (NOT INCLUDED):

7
Socket Head Bolt Self Tapping Screw Flat Washer
.05mm
Flat Head Screw Lock Nut
There are a variety of 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:
CC
C
A
A
B
A
A
B
B
BC
AB
3x8mm Socket Head Bolt
Set Screw
C
A
B
C
C
A
A
A
A
B
2x8mm Flat Head Screw
2.6x10mm Self Tapping Screw AB
B
3mm Flat Washer
AB
B
3mm Lock Nut
Star Washer
AB
B
3mm Star Washer
A
B
Flat Head Cap Screw
AC
B
C
3x8mm Flat Head Cap Screw
A
Hex Nut
AB
B
2mm Hex Nut
C
AB
4x4mm Set Screw
HARDWARE IDENTIFICATION

8
1-1
4x4mm Set Screw
Use Threadlock
..........1 pc
3x6mm Socket Head Bolt
...1 pc
3mm 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 top
Install the Upper Bearing Block so the
bearing is toward the bottom
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 (Use Threadlock)
Complete Assembly
4x4mm Set Screw (Use Threadlock)
Starter Hex Adaptor
Start Shaft Bearing Block
Start Shaft
Clutch Bell Assembly
Be sure that the Bearing with
the 5mm ID faces upward
Pinion Gear
(Use Threadlock when
assembling)
Complete Assembly
Note: It will be necessary to
press the two Bearings
into the Bearing Blocks.
Press the Bearings in
evenly by hand. Do not
use a vise or pliers for
this procedure as
damage could result.
Use Threadlock
UP
UP
Bearing
Bearing

1-3 CONTROL BALL INSTALLATION
1-4 SERVO MIXING LEVER UNIT ASSEMBLY
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 ......1 pc
....1 pc
........1 pc
Nylon Washers ........5 pc
....1 pc
Steel Joint Ball
Steel Joint Ball
Steel Joint Ball
Roll Bell Crank
2x10mm Flat
Head Screw
2x10mm Flat
Head Screw
Mixing Base Arm
(Collective)
2mm Nut
2x8mm Flat Head Screw
(Use Threadlock) 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
(Use Threadlock)
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
(Use Threadlock)
Complete Assembly
Nylon Washers
3x8mm Socket
Head Bolt
Mixing Base Cross Member
Mixing
Lever
Spacer
9
Use Threadlock
Use Threadlock

1-5 ELEVATOR ARM ASSEMBLY
10
2x8mm Flat Head Screw
Steel Joint Ball .........2 pc
Elevator Arm Pin .......2 pc
..........2 pc
2x8mm Flat Head Screw
Steel Joint Ball
Elevator Arm Front
Elevator Arm Pins
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 the correct installation direction of the Swashplate A Arm.
Elevator Arm (Front) Elevator Arm (Rear)
Marked Side Out
Swashplate A
Arm Swashplate A
Arm
Marked Side In