Bergen Observer EB Construction Manual

Text of Bergen Observer EB User Guide:

• Bergen Observer EB, Slide the pitch slider onto the shaft engaging the ball into the delrin cup at the same time. Locate the Heavy Duty tail hub and 1 ea 3X4 setscrew. Note the divot on the output shaft. Install the hub onto the shaft lining up the hole in the hub with the divot in the shaft, secure with the 3X4 setscrew and loctite. Only 1 setscrew is required and suggested. Tail blade grips are next, note the radial bearings are preinstalled, and order of installation of the thrust bearings. Install 1 blade grip, then the 10m spacer. T

• Bergen Observer EB, Install the tank under the rear tray and secure with the 2 long tye-wraps provided, running the tye-wraps through slots in the tray. On the carburetor you will find an idle adjustment screw, remove it and throw it away. Install the throttle arm on the carb, in the direction shown. With the carburetor butterfly halfway open, you want the throttle arm pointing straight away from the carb. The idea here is to center the throw of the arm for setup purposes. Fit the air filter base to the carb, w

• Bergen Observer EB, Install 1 ea thrust bearing block w/4 ea 3X8 SHCS and 1 ea standard bearing block w/2ea 3X35 SHCS and 2 ea 3M locknuts onto the front end of the extension arms. Note the orientation of the blocks and bearings. The thrust bearing block is installed on the bottom, with the hump down. Leave the bolts loose for now. Through one turret arm, install 12 ea 3X35 SHCS and place flat on the table. Install 1 ea “G10 block with 10m hole”, one ea “Extension Arm and Turret Brace”, and 4 ea standard bearing blocks onto the 3X35 SHCS. Note the orientation of the bearing blocks.

• To static track the tail blades, try this. Fold both blades up against the blade grips. Push one blade in until it touches the bolt for the vertical fin mount. Without changing the pitch, carefully rotate the tail system until the opposite blade comes close to the same bolt. Adjust the length of one

• Bergen Observer EB, Assemble the tail pitch bellcrank by installing a 3X7X3 flanged bearing in one side, the aluminum spacer, Then the opposite bearing. Insert the 3X16 with 6M shoulder SHCS through the bearings and spacer, with the delrin cup on top, and add a 3M brass washer on to the bolt as a spacer. Thread this into the pitch arm on the gearbox, but do not tighten yet. Thread a 3M locknut onto the bolt and set the tension on the bearings by tightening the bolt, then tightening the nut to secure.

• Bergen Observer EB, Install the pull start using 4 ea 4X12 SHCS. Again, loctite isn’t needed, however if you feel the need, you can use a drop of CA glue in place of loctite. Note the orientation of the pull start handle, on the same side as the carburetor insulator block. On the opposite end of the engine, install the fan shroud mount plate, using 4 ea 5X12 SHCS and loctite this time. Also note the orientation of the plate; this will be important when you mount the fan shroud. Installing and dial indicating the fan will be more accurate with the spark plug removed. Seat the fan on the tapered end of the crank, and install the 6X25 SHCS

• Bergen Observer EB, To get the full 360 degree rotation with out winding up the servo wires, try this little tip. With a 12” long servo extension wire, remove the male plug by lifting the tabs and pulling the connectors out. Remove the 2 thru bolts in the long vertical shaft, one in the pulley and one in the turret arm. Feed the wire without the plug up through the shaft. Reinstall the plug on the wires and carefully reinstall the bolts through the shaft without cutting the wire. Connect the tilt servo to th

• Bergen Observer EB, Install the lower frame assembly onto the landing gear, using 4 ea 3X16 SHCS and 3M locknuts. Center and rotate the skid tubes to your liking, then drill a #50 pilot hole in the boss, into the aluminum skid tube, on the underside of the gear and install the 2 ea 3X8 self tapping screws. I typically install these into the rear cross bar, leaving the front crossbar able to flex. Install the engine into the lower frames, spark plug facing to the rear (remove the plug for ease of installation). Note the vertical slots i

• Bergen Observer EB, The tail servo mount is installed between the vertical and horizontal fins using 2 sets of boom clamps, and 4 ea 3X30 SHCS and 4 ea 3M locknuts. It’s position will be adjusted after installing the servo. The push rod can be installed also, but will need to be adjusted later as well. Use the 140mm pushrod. Install the boom assembly into the boom clamps at the rear of the frames, pushing it all the way in to engage the dogbone into the delrin cup. Once engaged,

• Bergen Observer EB, When both bearings are installed, center the seesaw tube by tapping on the head of the bolts. The seesaw tube should pivot freely. Install the seesaw tube endcaps, pushing them on until flush with the end, and securing with a 3X4 setscrew and loctite, in the inner hole. The setscrew should engage the slot on the tube. Also install the short balls in the outermost hole at this time. Install 2 ea 3X5 panhead screws to secure the bearings in the headblock, being careful not to get any loctite in the bearings. Insert the head axle into the head, and push some grease into the gap around the head axle, on both sides of the hea

• Bergen Observer EB, Flybar installation is next. Insert the flybar through the seesaw tube bearings; install a 4mm special washer on each side, then the flybar arms. Center the flybar, measuring both sides from the flybar arm to the end, with the flybar arm pushed all the way to the seesaw tube. Secure the flybar arms with a 3X4 setscrew and loctite, making sure the flybar arms are parallel with each other. Install the flybar paddles

• Bergen Observer EB, Install the fuel tank, starting with locating where the fuel fittings will be installed in the tank. Slide the tank under the battery tray and mark where you want the fittings. Drill a #16 hole in the tank at the spots marked. Install a single end fitting on the top of the tank for the vent line, and one on the side for the return line. Make a clunk line using the double end fitting and clunk securing the ends with a tye-wrap, making sure the line is long enough to reach t

• Bergen Observer EB, Begin assembling the camera mount by installing the Front Frame Block and Arm Mounts to the “flying squirrel”, noting the orientation, with 8 ea 3X16 SHCS and 3M locknuts. Don’t tighten these just yet. Place an extension arm on one side, and install 4 ea 3X35 SHCS through the Front Frame Blocks, then place the opposite extension arm on the bolts and thread 4 ea 3M locknuts on the bolts. Now tighten all the bolts, pulling the extension arms up to the “flying squirrel” tightly. Install an “Ex

• Insert the 3X7X3 flanged bearings into the arms, 2 ea into each arm. Insert the 3X16 SHCS with 6M shoulder through the bearings and put 1 ea 3M brass washer on the bolt. Note the orientation. Thread the bolt into the washout hub, then install a 3X4 setscrew in the same hole from the opposite side. Set the tension on the bear

• Bergen Observer EB, Introduction The first of its kind, interchangeable modular engineered helicopter to accommodate the beginner to a FAI expert… An idea in 1994 to manufacture an interchangeable, modular helicopter, led to the research and development in 1995. Focusing on quality, engineering details, and price, a prototype was produced. After extensive test flights and fine-tuning, the INTREPID HELICOPTER is now what you see today. The first of its kind, strength combined with simplicity for easy maintenance and flying. Although beginners can successfully build and fly their INTREPID, the process can be made significantly easier with

• Bergen Observer EB, Begin assembly of the tail system with the “dogbone”. Insert the crosspin and secure with a 3X4 setscrew from inside the dogbone with loctite. Locate 2 ea arrow shafts, they are aluminum, and you will see a silver dot on each end. Cut 1” off of each end of both arrow shafts. This is to remove the part of the arrow shaft that is not machined to the proper size. Now cut 1 arrow shaft 16 ¼ “ long, the other 17” long. Install the long arrow shaft onto the input shaft of the gearbox, using a collar with only 1 ea 3X3 setscrew to se

• The collective servo is installed between the frames, with the spline to the rear. The aileron servo is installed on the mount between the collective arms, spline to the rear. Install tail rotor servo into rear mount plate with spline forward. The following is the setup we use for JR radio systems. Futaba

• The pushrod from the swashplate to the bell-hiller mixer is 98 mm from center to center, using the 75 mm long pushrods. DS 811 servos used for picture taking only. We DO NOT recommend them for use in your Observer EB. Begin installing servos, starting with the throttle servo. Snap the plastic servo mounts into the slots in the frames and inst

• Bergen Observer EB, Congratulations on your purchase of a Bergen R/C Helicopters Observer EB. The EB stands for Extended Boom, allowing the use of 810 mm rotor blades. There are a few things we recommend in the assembly and use of your Observer EB, and we’ll spell those out as we go, but for now, our first recommendation is a good quality set of hardened allen drivers. We have found that standard allen wrenches are too soft, and you run the risk of rounding off the inside hex of the SHCS that we use in the assembly of the helicopter. You will also need Blue Loctite throughout the assembly, and some good quality grease that is

• You can install Pool Noodles on the landing gear as a visual aid; you may need to divert the exhaust as shown to prevent melting the foam. Install the Pan and Tilt receiver in between the framework at the top, with padding, and secure with tye- wraps or Velcro. The battery pack is secured lower down in the frames, again

• Bergen Observer EB, Install the rear bulkhead using 4 ea 3X16 SHCS and 3M locknuts, then install the landing gear skid bars, front and rear, using 4 ea 3X8 FHCS. Assemble the rear battery tray with battery tray spacers, using 6 ea 3X8 FHCS and loctite. Install the battery tray into the frames using 4 ea 3X8 SHCS and loctite. Note the tray spacers are on top. Install the “Front Frame Block and Arm Mount” on the rear of the butterfly, using 4 ea 3X16 SHCS and 3M locknuts.

• Bergen Observer EB, Press the flanged bearings into the upper frames, making certain to seat the flange down. Be sure to make a right and a left, with the flange on the inside of the frames. Put a drop of CA glue around the outer edge of the bearings to secure them in place, being careful not to get any glue in the bearing itself. Insert the axles into one side frame and slide the opposite side frame onto the axles. Slide the upper framework onto the bulkheads, and install 4 ea 3X35 SHCS through the holes in the frames and bulkheads. Secure with 4 ea 3M locknuts. Install 4 ea 3X8 SHCS and 3M washers into the triple bearing block above

• Bergen Observer EB, Collective servo wheel is installed with the offset to the rear; pushrods are 50 mm long, center to center using 30mm long pushrods. The throttle servo wheel just uses one ball and pushrod, but still needs to be centered, with ball at the top. Throttle pushrod is 173 mm long center to center using the 140 mm long pushrod. With the servo centered, the throttle arm should also be centered with the carb at half throttle. Setting up the throttle requires some math☺. Make sure the throttle curve in your radio is a straight line from 0 to 100, no curve just yet. Throttle

• Bergen Observer EB, Insert the elevator yoke into the upper frames, with the longer of shaft on the right side of the helicopter. Find the 2 main shaft bearing blocks. Note the cutout portion on the lower bearing block. Install the lower main shaft bearing block, using 2 ea 3X35 SHCS, note the orientation of the bearing, facing up. The elevator yoke is removed for clarity. Install the upper main shaft bearing block, using 4 ea 3X8 SHCS also note the orientation of the bearing, facing down this time, hump side up. Loosely install 2 ea 3M locknuts on the lower bolts. Assemble the tail drive tra

• Bergen Observer EB, Locate the delrin bushings, steel inserts and 4X16 SHCS. Note the chamfer on the steel insert. Install with the chamfer toward the head of the bolt. Install the delrin bushings onto the fan hub using loctite, and tighten securely. Assemble the clutch components, clutch, clutch bell, triple bearing block, and retaining collar w/3X3 setscrews. Use loctite on the setscrews in the retaining collar. Install the clutch system onto the

• Bergen Observer EB, Start with the landing gear. Assemble the skids and cross bars as shown, leaving them loose for now. Locate the landing gear skid bars in bag #1, use them to locate and drill 2 holes in each cross bar. Center the skid bar fore and aft, as well as side to side, and use a #30 or 1/8 th drill bit to drill through the cross bar. Set the landing gear aside for now. Gather all of the engine components. Note the tapered end of the crankshaft. Also notice the sharp edge at the end of the taper. You’ll want to remove that sharp edge, either by buffing or carefully grinding the edge. Install the pull

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