Synergy 999-308, Instruction Manual

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Page 3: ...ss 305 102 CF Lower Frame Brace 305 101 E5 Frame Spacer 103 256 M2 5 Flat Head Cross Recess 305 103 E5 CF Gyro Mount Plate 305 101 E5 Frame Spacer Lower Frame Brace Assembly Page 1 Gyro Mount Plate Assembly WWW SYNERGYRCHELICOPTERS COM ...

Page 4: ...aring 108 105 10x19x5 Radial Bearing 305 104 E5 Third Main Shaft Bearing Block 305 124 E5 Main Shaft Bearing Block Main Shaft Bearing Block Assembly Note Observe orientation of bearing blocks Page 2 WWW SYNERGYRCHELICOPTERS COM ...

Page 5: ...18T Bevel Gear 320 303 Spur Gear Bottom Bearing Block 108 593 5x9x3 Radial Bearing 320 408 Spur Gear Shaft 305 213 13T Spur Gear 320 407 2mm Spur Gear Pin 320 101 TranSupport CF Plate 305 105 E5 TranSupport Standoff 101 306 M3x6 Button Head x12 100 372 M3x12 Set Screw Important TIghten and secure set screw with loctite This set screw secures bevel gear pin Page 3 320 118 Front Trans Bevel Gear IMP...

Page 6: ...reak away Plate 101 306 M3x6 Button Head X2 Front Canopy Mounts 21mm 101 306 M3x6 Button Head 305 117 Key Chain Canopy Mount Female 17mm 305 106 Break away Plate Key Chain Style Canopy Mounts X2 Rear Canopy Mounts 17mm Page 4 WWW SYNERGYRCHELICOPTERS COM ...

Page 7: ...103 256 M2 5 Flat Head Cross Recess 305 101 E5 Frame Spacer 305 107 Front Battery Plate Front Battery Plate Page 5 WWW SYNERGYRCHELICOPTERS COM ...

Page 8: ...103 256 M2 5 Flat Head Cross Recess 305 101 E5 Frame Spacer 305 108 E5 Rear Battery Plate Rear Battery Plate Page 6 WWW SYNERGYRCHELICOPTERS COM ...

Page 9: ...103 256 M2 5 Flat Head Cross Recess 305 101 E5 Frame Spacer 305 109 E5 ESC Mount Plate ESC Mount Plate Page 7 WWW SYNERGYRCHELICOPTERS COM ...

Page 10: ...ton Head 100 310 M3x10 Socket Head 305 111 E5 Main Boom Clamp 305 110 E5 Radio Plate Main Boom Clamps and Radio Plate Note Bolts engaged in pinching mechanism do not require loctite Page 8 WWW SYNERGYRCHELICOPTERS COM ...

Page 11: ...earing Blocks Install ATTENTION DO NOT FULLY TIGHTEN BOLTS YET Note Third Main Shaft Bearing Block is adjustable fore and aft to provide for correct main shaft alignment Note Pay attention to bearing block orientation 305 118 E5 Main Frame CF Page 9 WWW SYNERGYRCHELICOPTERS COM ...

Page 12: ...Battery Plate Install 101 306 M3x6 Button Head NOTE DO NOT FULLY TIGHTEN BOLTS YET Page 10 WWW SYNERGYRCHELICOPTERS COM ...

Page 13: ...101 306 M3x6 Button Head NOTE DO NOT FULLY TIGHTEN BOLTS Gyro Plate and Lower X Brace Install Page 11 WWW SYNERGYRCHELICOPTERS COM ...

Page 14: ...ed for optional tail gear ratios Tail Transmission was designed to slide fore and aft to allow for 4 0 1 gear ratio as well as optional 4 5 1 tail ratio 4 0 1 stock Slide Transmission all the way FORWARD 4 5 1 optional Slide Transmission all the way AFT 4 0 1 52T 13T Stock 4 5 1 54T 12T Optional Page 12 WWW SYNERGYRCHELICOPTERS COM ...

Page 15: ...Main Boom Clamp and Radio Plate Install 100 306 M3x6 Socket Head Bolt Page 13 WWW SYNERGYRCHELICOPTERS COM ...

Page 16: ...d 106 115 Servo Hold Down 107 104 Pivot Ball 2mm 100 252 M2 Nylock Nut Note Servo horn will need to be trimmed in order to avoid interference with gyro sensor mount Important Pivot ball should be located at 16mm from center of servo horn This is important for proper servo resolution Tail Servo Mount Page 14 WWW SYNERGYRCHELICOPTERS COM ...

Page 17: ...100 266 M2 5x6 Socket Head Tail Servo Install Page 15 WWW SYNERGYRCHELICOPTERS COM ...

Page 18: ...100 351 M3 Nylock Nut 21mm Front Canopy Mount See Page 4 17mm Rear Canopy Mount Assembly See Page 4 Note Button Head fits into large frame hole mounts will fit flush against frame 305 101 E5 Frame Spacer 101 306 M3x6 Button Head Page 16 WWW SYNERGYRCHELICOPTERS COM ...

Page 19: ...100 351 M3 Nylock Nut 305 118 E5 Main Frame CF Page 17 WWW SYNERGYRCHELICOPTERS COM Right Frame Canopy Mount Install ...

Page 20: ...Elevator Servo Mounting 100 268 M2 5x8 Socket Head 100 266 M2 5x6 Socket Head 106 115 Servo Hold Down x2 305 112 Elevator Tail Servo Mount X2 Page 18 WWW SYNERGYRCHELICOPTERS COM ...

Page 21: ...Right Frame Install Socket Head Bolts 100 306 M3x6 Socket Head 100 308 M3x8 Socket Head DO NOT TIGHTEN BOLTS YET Page 19 WWW SYNERGYRCHELICOPTERS COM ...

Page 22: ...Right Frame Install Button Head Bolts 101 306 M3x6 Button Head Bolt x12 Page 20 WWW SYNERGYRCHELICOPTERS COM ...

Page 23: ... blocks Note Third bearing block is adjustable fore aft to allow for better alignment of bearing blocks Tighten all frame bolts fully once you are satisfied with frame alignment Tighten Anti Rotation Bracket bolts last 305 120 E5 Anti Rotation Bracket 90 00 FLAT SURFACE Page 21 WWW SYNERGYRCHELICOPTERS COM ...

Page 24: ...Landing Gear Mounts 305 122 E5 Landing Gear Mount 101 306 M3x6 Button Head Page 22 WWW SYNERGYRCHELICOPTERS COM ...

Page 25: ...324 Landing Gear Strut 610 322 Skid Tube Lock 101 308 M3x8 Button Head Note Alternatively if you find the Skid Tube Locks too difficult you can use M4x6 Set Screws to secure the E5 Skid Tube Landing Gear Assembly Page 23 WWW SYNERGYRCHELICOPTERS COM ...

Page 26: ...Landing Gear Install 100 312 M3x12 Socket Head x4 Page 24 WWW SYNERGYRCHELICOPTERS COM ...

Page 27: ...hings must be secured with green or red loctite Note By design the auto hub is symetrical so it can be used in both orientations The One Way Clutch Bearing can be pressed into the Auto Hub in any direction Please pay attention to motor direction and insert auto hub sleeve in the correct orientation Important Bronze bushings must be secured with green or red loctite Page 25 WWW SYNERGYRCHELICOPTERS...

Page 28: ...entation Main Gear and Spur Gear Assembly IMPORTANT Do not over tghten bolts You may crack delrin gears by over tightening Note By design the auto hub is symmetrical so it can be used in both orientations The One Way Clutch Bearing can be pressed into the Auto Hub in any direction Please pay attention to motor direction and insert auto hub sleeve in the correct orientation Your auto hub may be ass...

Page 29: ...hould be oriented facing down against the inner race of the main shaft bearing IMPORTANT Boss on Jesus bolt collar should be facing upward Failure to orient upward will result in excessive verticle movement in the main shaft Main Gear Transmission Installation IMPORTANT Do not over tighten shouldered bolts This will distort auto hub sleeve which will cause auto hub problems Page 27 WWW SYNERGYRCHE...

Page 30: ...108 615 6x15x5 Radial Bearing 305 114 E5 Pinion Support Bearing Block Motor Pinion Support Bearing Block Page 28 WWW SYNERGYRCHELICOPTERS COM ...

Page 31: ...mount patterns This means that the E5 is one of the most configurable helicopters on the market today With parts already available you can also stretch your E5 to accept 600mm rotor blades The battery compartment will accept many pack configurations from 6S to 12S Pinion options range from 12T to 15T Motor Recommendation for E5 550 Class 6S Scorpion 4025 1100 12S Scorpion 4025 630 Motor Recommenda...

Page 32: ...th sides of motor mount to frame assembly IMPORTANT Pinion must rest on lower pinion support radial bearing If configured otherwise you may destroy motor bearings Helical Gear Mesh Set gear mesh with minimal lash but do not set for zero lash High pressure grease is recommended for smooth operation Page 30 WWW SYNERGYRCHELICOPTERS COM ...

Page 33: ...igh current models Current draw can be very high depending on your configuration Choose an ESC that is adequate for your configuration Important Tips Use quality 60 40 rosin core solder with a high temp soldering iron Do not allow motor or ESC wires to interfere with carbon frames Page 31 WWW SYNERGYRCHELICOPTERS COM ...

Page 34: ... M2 Nylock Nut 305 301 E5 Torque Tube Torque Tube Assembly IMPORTANT Secure Torque Tube End with Red Loctite 190mm 7 1 2 Inches 190mm 7 1 2 Inches Secure bearing to Torque Tube with Red Loctite or CA Bearing must be installed before Torque Tube end as the bearing will not slide over the Torque Tube End Page 32 WWW SYNERGYRCHELICOPTERS COM ...

Page 35: ...recommended Drill 3mm hole at 6 5mm from edge of tail boom Note Synergy boom clamps have proven to be adequte for securing the tail boom for most helicopter pilots As an added precaution you may pin the boom with a 3mm bolt Page 33 WWW SYNERGYRCHELICOPTERS COM ...

Page 36: ... Control Guide 610 128 Boom Support Clamp Lite 115 114 Tail Control Guide 305 302 E5 Tail Boom 100 312 M3x12 Socket Head Note CA May be required to secure Tail Control Guide to Tail Boom Tail Boom Assembly Page 34 WWW SYNERGYRCHELICOPTERS COM ...

Page 37: ...1 Use Epoxy or JBWeld 2 Ensure ends are in alignment while glue sets Top attaches to boom clamp Bottom attaches to frames Sand Ends Lightly Before applying glue Sand Ends lightly before applying glue Boom Support Assembly 109 345 3x4x5 Brass Spacer Page 35 WWW SYNERGYRCHELICOPTERS COM ...

Page 38: ... M3 Washer 101 410 M4x10 Button Head Optional if hole is drilled IMPORTANT DO NOT SLIDE TAIL BOOM FORWARD ANY MORE THAN FLUSH WITH FRONT BOOM CLAMP THIS CAN PLACE PRESSURE ON TRANSMISSION GEAR MESH Boom Support Assembly page 35 Tail Boom Assembly page 34 Page 36 WWW SYNERGYRCHELICOPTERS COM ...

Page 39: ...ll OD Small ID Large ID Large OD Ball Race 515 525 Tail Blade Grip 108 503 5x10x3 Radial 107 106 Pivot Ball 108 511 5x10x4 Thrust Bearing IMPORTANT Apply Grease to Thrust Bearing Ball Race 615 324 Tail Rotor Hub for 6mm shaft Tail Rotor Hub Assembly Page 37 WWW SYNERGYRCHELICOPTERS COM ...

Page 40: ...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 Page 38 WWW SYNERG...

Page 41: ...put Shaft 6mm 305 308 E5 Tail Box Spacer 305 618 E5 18T Mushroom Tail Bevel Gear 305 518 E5 18T Tail Bevel Gear 305 304 E5 Verticle Tail Fin CF 305 305 E5 Tail Box Plate Left 305 306 Tail Box Plate Right 108 613 6x13x5 Radial Bearing 101 306 M3x6 Button Head 100 325 M3x25 Socket Head 100 306 M3x6 Socket Head 100 366 M3x6 Set Screw Tail Box Assembly Page 39 WWW SYNERGYRCHELICOPTERS COM ...

Page 42: ...utton Head 106 301 M3 Shim 108 373 3x7x3 Radial Bearing 109 355 3x5x5 Brass Spacer Tail Rotor Bell Crank 108 373 3x7x3 Radial Bearing 100 330 M3x30 Socket Head 107 104 2mm Pivot Ball 100 251 M2 Nut Tail Rotor Bell Crank Assembly Page 40 WWW SYNERGYRCHELICOPTERS COM ...

Page 43: ...100 464 M4x4 Set Screw Note Sizing of ball links is recommended for smooth operation For best results use Boto Sizer Tool Part 700 001 Tail Box Completion Page 41 WWW SYNERGYRCHELICOPTERS COM ...

Page 44: ...you wish to use boom pinning feature you must drill 3mm hole Follow these steps Install Tail Box 1 Ensure Tail Box is vertical 2 Mark drill location 3 Remove tail box and torque tube 4 Drill 3mm hole at marked location 5 Page 42 WWW SYNERGYRCHELICOPTERS COM ...

Page 45: ...with high quality glue such as JB Weld We highly recommend long curing formulas for the best results Do not use CA for this application You will encounter failures Note Lightly sand carbon tail control rod prior to securing with JB Weld Note Tail push rod ends will slide through tail control guides Tail Control Rod Assembly Page 43 WWW SYNERGYRCHELICOPTERS COM ...

Page 46: ...ll Note Adjust ball links so tail rotor bell crank is 90 degrees to tail box while tail servo arm is perfectly vertical This will automatically configure 5 degree torque compensation at tail rotor blades Page 43B WWW SYNERGYRCHELICOPTERS COM ...

Page 47: ...ot Ball Long x3 107 106 Pivot Ball x4 108 373 3x7x3 Radial Bearing 100 316 M3x16 Socket Head 109 352 3x5x2 Brass Spacer 100 312 M3x12 Socket Head 100 364 M3x4 Set Screw 200 401 Swash Plate Assembly WWW SYNERGYRCHELICOPTERS COM Page 44 ...

Page 48: ...r 4mm 305 201 E5 Head Block 305 205 E5 Head Axle 305 203 E5 Pitch Arm 305 204 E5 Axle Pivot 100 308 M3x8 Socket Head 100 306 M3x6 Socket Head 107 106 Pivot Ball 3x4 5mm Small OD Small ID Ball Race Large OD Large ID Important Apply grease to thrust bearing ball race 305 202 E5 Blade Grip Grease Port Thrust Bearings can be greased by utilizing the external Grease Port Head Block and Blade Grip Assem...

Page 49: ...ll Link 100 272 M2 5x12 Set Screw 305 207 E5 Ball Link Adapter 106 301 M3 Shim Note Do not tighten 100 323 bolt until the next page These will pinch and secure the main shaft Page 46 WWW SYNERGYRCHELICOPTERS COM IMPORTANT Remove M2 5x12 Set Screw from Ball Link Adapter before attempting to remove M3x16 Socket Head The M2 5x2 Set Screw is sitting against the M3x16 bolt and will destroy the bolt thr...

Page 50: ...Rotor Head Install 100 320A 3x20 Shouldered Bolt 100 351 M3 Nylock Nut IMPORTANT Do not over tighten 100 320A Bolt IMPORTANT Do not forget to tighten pinch bolts Page 47 WWW SYNERGYRCHELICOPTERS COM ...

Page 51: ...Pitch Link Assembly X2 Note 700 100 Boto Sizer Tool is highly recommended for smooth linkage operation 28mm 107 100 Ball Link 107 043 43mm Rod Page 48 WWW SYNERGYRCHELICOPTERS COM ...

Page 52: ...Aileron and Pitch Servo Install 100 261 M2 5x10 Socket Head 106 115 Servo Hold Down 106 115 Servo Hold Down Page 49 WWW SYNERGYRCHELICOPTERS COM ...

Page 53: ...cket head 310 107 CF Servo Arm IMPORTANT Use Red Loctite to secure Pivot Ball to M3 Nut Servo Horn Assembly Note It is best to determine servo horn position clostest to 90 degrees before fixing CF servo arm to the servo arm wheel Page 50 WWW SYNERGYRCHELICOPTERS COM ...

Page 54: ...Servo Arm Install Page 51 WWW SYNERGYRCHELICOPTERS COM ...

Page 55: ...Alignment Holes Alignment Holes Servo Horn Alignment Holes Page 52 WWW SYNERGYRCHELICOPTERS COM ...

Page 56: ...Cyclic Link Assembly X3 19 30mm 107 100 Ball Link 107 043 43mm Rod Page 53 WWW SYNERGYRCHELICOPTERS COM ...

Page 57: ...Rotor Blade Install 100 435A M4x35 Shouldered Bolt 100 451 M4 Nylock Nut Rotor Blades Not Included For optimum performance use Rail 556mm rotor blades Page 54 WWW SYNERGYRCHELICOPTERS COM ...

Page 58: ...16 Socket Head 305 312 Tail Blade Washers x2 305 312 Tail Blade Washers x2 100 351 M3 Nylock Nut 100 351 M3 Nylock Nut Tail Blade Install Note Counter clockwise rotating tail Install tail blades as illustrated Page 55 WWW SYNERGYRCHELICOPTERS COM ...

Page 59: ... 305 126 Key Chain Canopy Grommet Note Canopy holes may need enlarged to approximately 8 9mm in order to correctly install the canopy rubber grommet 305 125 Key Chain Canopy Mount Male Canopy Assembly Page 56 WWW SYNERGYRCHELICOPTERS COM ...

Page 60: ...Synergy E5 Completed Page 57 WWW SYNERGYRCHELICOPTERS COM ...

Page 61: ...1253 500 Main Rotor Diameter Rotor Disk with 556mm blades 1253 50mm Rotor Disk with 606mm blades 1353 50mm configured with E6 boom Page 58 WWW SYNERGYRCHELICOPTERS COM ...

Page 62: ...258 Tail Rotor Diameter Page 59 WWW SYNERGYRCHELICOPTERS COM ...

Page 63: ...1085mm 214mm 360mm Synergy E5 Dimensions Page 60 WWW SYNERGYRCHELICOPTERS COM ...