Avantco Aurora 90 Electric User manual

TM
All manuals and user guides at all-guides.com
all-guides.com

2AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
AVANT Aurora 90 Electric
Assembly Manual V2.01
LIABILITY DISCLAIMER
This kit is for a radio controlled (RC) helicopter. RC Helicopters are not
toys. Moving parts can present a hazard to operators, bystanders and
anyone or anything that could be reached by the RC helicopter. Improper
operation, maintenance or assembly can potentially cause a helicopter to
pose a danger to persons or objects including but not limited to the
possibility of causing serious physical injury and even death. This product
is intended to be used by experienced adult radio control helicopter pilots
under controlled safety conditions and on locations properly authorized
and setup for safe flying and away from other people. Under no
circumstance should a minor be allowed to operate this or any radio
controlled helicopter without the approval, supervision and direction of his
parent or legal guardian who takes full responsibility for the minor's
actions. Do not operate an RC helicopter within the vicinity of homes,
trees, electrical lines during inclement weather or rain or near crowds of
people. After leaving its facilities the manufacturer has no way of
maintaining control or supervision over the assembly and/or operation of
the helicopter.
The manufacturer and/or its agents assume no responsibility or liability
whatsoever for any damages including but not limited to ones generated
by incidental or consequential damages.
The operator of the helicopter assumes all responsibility and liability that
could be result from the correct or incorrect operation of the helicopter.
Symbols:
Important, Correct, Incorrect, Danger, Allow it to set for some time before
continuing
All manuals and user guides at all-guides.com

AVANT Aurora Electric 90 Assembly Manual _3
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
Before you start assembling:
Get the latest manual: It’s highly recommended that you get the latest version of the
manual. Please download a copy by clicking here and use that copy instead of this one.
Important: Using a piece of #400 sanding paper sand the edges of the carbon fiber pieces
that will be close to any electronic wires. Sharp edges can cut into the electric wires and
since carbon fiber is conductive it can possibly create an electrical shortcut. Sharp edges can
also cut into power wires creating shorts that could make the motor operation fail. Whenever
you’re ready to install a carbon fiber piece that will be close to servo wiring make sure to
sand its edges to prevent wire chafing and a possible electrical short circuit.
Bag #1
M3x8
M3 Locknut (2)
Canopy Post Short
A
V900217
Left Frame AV920351
M3x8 (2)
Install the back Canopy Mount
M3 Locknut (2)
Canopy Post Long
AV900217
M3x8 (2)
M3x8 (1)
Install the front canopy mount
Canopy Post Tab
AV000102
All manuals and user guides at all-guides.com

4AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
26mm frame spacers (9)
AV000108
M3x8 (8)
All manuals and user guides at all-guides.com

AVANT Aurora Electric 90 Assembly Manual _5
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
Bag #2
AV900223
(Sharp edge should
point toward the
sleeve)
M2.5x8 (6)
M2.5 washer (6)
Using six M2.5x8 screws install
the Main gear onto the pre-
assembled main gear hub
AV900212
AV900224
Using six M3x6 button head screws
install the constant drive gear onto
the constant drive hub.
M3x6 Button Head
(
6
)
A
V900211
A
V900218
M4 Pin, Part of
A
V000801
p
ack
VERY IMPORTANT NOTE:
Use Blue or Red Loctite on the mainshaft
pin itself. This will prevent it from sliding
out even if the setscrew becomes lose. Do
not over tighten the M6 setscrew.
M6 x 10 Setscrew
R
AV900239
BB
B
All manuals and user guides at all-guides.com

6AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
M3x8 (2)
AV000120
B
M3x8 (5)
Note: This one is a
Button Head M3x8
Open bearing
side faces up
Open bearing
side faces down
Open bearing
side faces up
AV000100 (3)
AV900239
B
All manuals and user guides at all-guides.com
all-guides.com

AVANT Aurora Electric 90 Assembly Manual _7
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
AV920354
AV920354
AV920354
AV000100
R
M3x4 Setscrew
B
B
M3x8 (4)
B
Make sure
there is a flat
spot in the
motor shaft for
the M4
setscrew
The motor and pinion
stack assembly can slide.
Make sure that the pinion
has the least amount of
play possible by bringing it
close to the main gear.
There can be a slight higher
spot so use that spot to
make it the closest contact
point between pinion and
main gear
M3x8 (6)
M3 washers (6)
AV000101
BButton Head
All manuals and user guides at all-guides.com

8AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
VERY IMPORTANT!!!
READ AND FOLLOW THE TAIL GEAR MESH METHOD
Failure to do so can cause the tail gears to fail in flight
This is the method used to do a correct mesh on the Aurora tail gears. This applies to both
the front set (the set inside the frames) and the back set (the set inside the tailcase). The
Aurora has a large window to inspect the gears inside the frames as well as the ones inside
the tailcase.
Frame inspection window. Tailcase inspection window.
There are three things that need to be assured for a correct mesh in the Aurora: Flush
alignment, No Play and Lubrication.
1) Flush alignment: Make sure that the gears are aligned so that the inner side of the teeth
are in the same plane flush to each other at the point of contact.
2) No Play: Make sure there is no play between the gears.
3) Lubrication: Make sure to lubricate the gears with silicone spray oil or a few drops of oil
like tri-flow before each flying day you can also use nitro fuel as lubricant letting the alcohol
evaporate leaving the fuel's oil as lubricant.
1) Flush Alignment:
In order to illustrate how to achieve it here's a couple of pictures of gears aligned incorrectly
followed by a couple of pictures of correctly aligned ones.
All manuals and user guides at all-guides.com

AVANT Aurora Electric 90 Assembly Manual _9
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
Wrong alignment case #1:
Top gear too forward Wrong alignment case #2:
Bottom gear too forward
Flush alignment is easily achieved because the kit
brings four sets of three bearings spacing washers of
0.1, 0.2 and 0.3mm thickness. Combining them you
can get from 0.1mm to 0.6mm spacing (0.1), (0.2),
(0.1+0.2), (0.3), (0.3+0.1), (0.3+0.2),
(0.3+0.2+0.1). In order to align them flush you
simply select thinner washer shims for the one that's
too forward or thicker for the one that's not forward
enough.
All manuals and user guides at all-guides.com

10 AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
2) No Play:
The second and very important thing to make sure you have is that there is absolutely no
play between the gears.
In order to make sure that there is no play between the gears hold one of the shaft firmly
while trying to rotate the other one back and forth. There should be no movement on the
gear. If there is movement simply increase the thickness on BOTH shafts the SAME amount
so that the flush alignment from step 1 is not lost and try again.
Once set as described it'll take a few flights for the gears to set and break in.
3) Lubrication:
The same oil that will be left as residue from your flight session is used as lubricant. At the
beginning of the flight day drop a few drops of fuel rotate the main rotor a few turns and let
the alcohol evaporate for a couple of minutes leaving the oil residue for lubrication.
Before you start measure the thickness of
the bearing shims using a caliper.
Identify and separate the 0.3 mm from the
0.2 and the 0.1mm shims.
Start the shimming with 0.4mm (0.3mm +
0.1mm) on both shafts.
Remember the three steps:
1) Flush alignment
2) No Play
3) Lubrication
All manuals and user guides at all-guides.com

AVANT Aurora Electric 90 Assembly Manual _11
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
Bag #3
Before inserting the M2 spring pin (black one) you can make it easier to insert it into the 2mm shaft hole by
crimping the tip of the spring pin very slightly to make the tip of the pin sharper.
To insert the pin you can use a vise, an arbor press or if you don't have one of those you can also use a set of
pliers set in the wider opening as shown in the picture below. If needed you can use some cardboard at the
bottom of the gear to protect it from marring.
All manuals and user guides at all-guides.com
all-guides.com

12 AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
Assemble the vertical pickup shaft as
shown on the picture.
Note that the spring pin (black one) is the
one above and the dowel pin (silver one) is
the one at the bottom side.
M2 Spring Pin
M2 Dowel Pin
AV900213 0.3 shim washer
0.1 shim washer
M3x4mm Setscrew
AV900206
AV900206
AV900216
AV000104
B
AV900243
Assemble the torque input shaft assembly
as shown. The spacing between the blocks
is set by the holes in the frames.
M3x4mm Setscrew
B
M2 Dowel Pin
AV900213
0.3 shim washer 0.1 shim washer
AV900206
M2.5 Dowel Pin
AV900241
M3x4mm Setscrew
AV000109
All manuals and user guides at all-guides.com

AVANT Aurora Electric 90 Assembly Manual _13
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
M3x8 (8)
B
All manuals and user guides at all-guides.com

14 AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
Canopy Post Long
AV900217
Canopy Post
Tab AV000102
M3x8 (2)
M3 Locknut (2)
M3x8
M3 Locknut
(
2
)
Canopy Post Short
A
V900217
M3x8
M3x8 (2)
Bag #4
M3x8 (31)
M3 washers (6) used on
motor mount and pinion
bearing block
Note:
Remember to use six M3 washers on the screws that
hold the motor mount and the pinion bearing block.
AV920350
B
B
All manuals and user guides at all-guides.com

AVANT Aurora Electric 90 Assembly Manual _15
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
M2.5 washer
M2.5x8
AV000123 (5)
M4x4 cup point
Setscrew
AV000137
AV000112
AV000111
Short CCPM spacer
AV000111
AV000123
AV000123 (3) Long CCPM
spacer
M4x4 Setscrew
Bag #5
M4x4 cup point Setscrew
AV000111
B
B
AV000112
All manuals and user guides at all-guides.com

16 AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
AV000124 (7)
M3x4 Setscrew (3)
AV000110 AV000113
B
AV000111
AV000112
AV000112
AV000111
AV000111
All manuals and user guides at all-guides.com
all-guides.com

AVANT Aurora Electric 90 Assembly Manual _17
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
AV000107
M4x4 Setscrew (2)
M3x8 (4)AV000114
Swashplate Assembly
Bag #6
M3x5 Setscrew cup point (4)
AV900214
AV900232
Use soapy water (soap dissolved
in water) to lubricate the sliding of the
aluminum skids into the landing gear
struts. You can also wedge a flat
screwdriver in the front of the skid to
hel
p
rotate it while insertin
g
it.
B
All manuals and user guides at all-guides.com

18 AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
M3x10 (4)
M3 Washers (4)
M3 Locknut (4) M3x10 (4)
M3 Washers (4)
M3 Locknut (4)
Bag #7
Torque Tube and Tail Assembly:
Insert the plug into the
torque tube end Make sure it's all the
way in up to the ridge
A
fter the CA cures Install the
Soft O-Ring in the grove.
AV000614
Insert the bearing into the shell and then apply CA
glue to the edge and quickly slide into the shell.
AV900202
All manuals and user guides at all-guides.com

AVANT Aurora Electric 90 Assembly Manual _19
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
Put a couple of drops of thin CA on the TT in the area
where you're going to install the bearing and while
keeping it horizontal rotate the TT making the bead
cover the area around where the bearing fits.
Absorb the excess from the bottom with a paper napkin.
If you want to accelerate the cure breath some over the
CA to make the humidity of your breath cure the CA.
Once you do that your bearing will sit nice and tight on
that bed of CA and will allow you to make adjustments
by rotating the tube to check for misalignment. After it's
aligned put a final drop of CA making it wick in between
the bearing inner race and the TT and let it cure.
If you want to make it extra secure you can also use the
torque tube connector as a guide for a small drill bit and
drill a small notch on the torque tube to help secure the
setscrew onto the tube.
All manuals and user guides at all-guides.com

20 AVANT Aurora Electric 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
When tightening the 6mm
shaft collar pull the shaft slightly
outward while pushing the collar
inward to eliminate an
y
p
la
y
.
B
M2 Dowel Pin
AV900213 0.3 shim washer
0.1 shim washer
M2.5 Dowel Pin
AV900241
M3x4mm Setscrew
AV000109
M3x4mm Setscrew
AV900228
B
M3x5
M3x5
Insert the m3x5mm setscrews and tighten them only until the head is flush with the connector’s
outside surface. Apply thin CA between the tube and the connector after the setscrews are tightened. If
you want to make it extra secure you can also use the torque tube connector's setscrew holes as a guide
for a small drill bit and drill a small notch on the torque tube to help secure the setscrew onto the tube..
AV900202
All manuals and user guides at all-guides.com