THUNDER TIGER Raptor 90 3D Quick guide

1
5
7
MAIN FRAME ASSEMBLY
8 9
1-1-1 Pinion Gear Subassembly
11
13 14 15 16 17 181920
21
22
25 26 27
29 30 33 34
36
3531
37
383940
4
1-3-1 Rod Guide Collar Subassembly
1-5-1 Aileron Lever Subassembly
1-5-2 Metal Elevator Parallel Lever Subassembly
1-5-3 Elevator Control Lever Subassembly
1-5-4 Pitch Control Frame Subassembly
1-1-4 Elevator Control Arm Subassembly
1-6-1 Wash Out Subassembly
ROTOR HEAD ASSEMBLY
TAIL ASSEMBLY
3-1-1 Tail Transmission Subassembly
FINAL ASSEMBLY
4-3-1 Skid Subassembly
4-4-1 Tail Support Subassembly
INSTALLATION OF PERIPHERAL EQUIPMENT
5-4-1 Body Subassembly
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 4
2 HMC3-12B Socket Screw M3x12 21
3 BK0087 Washer d3xD8x1.4 22
4 BK0274 Tank Rubber Grommets 4
5 BK0380 Rear Frame L 1
6 BK0381 Rear Frame R 1
7 BK0629 Washer 4
No. Material No. Description Qty.
1 HME3-18.5B Set Screw M3x18.5 2
2 HMC3-25B Socket Screw M3x25 10
3 BK0087 Washer d3xD8x1.4 10
4 BK0103 Body Fitting Post 2
5 BK0658 Frame Spacer S 2
6 1-1 Upper Frame Assembly 1
7 1-2 Lower Frame Assembly 1
8 1-3-1 Rod Guide Collar Subassembly 2
No. Material No. Description Qty.
1 BK0389 Rod Guide Collar 1
2 BK0658 Frame Spacer S 2
No. Material No. Description Qty.
1 BK0667 Servo Frame 1
2 HSE3-12B M3x12 Self-Tapping Screw 6
3 1-3 Main Frame Assembly 1
No. Material No. Description Qty.
1 HMC2-6B Socket Screw M2x6 1
2 HMC3-10B Socket Screw M3x10 1
3 HMC3-25B Socket Screw M3x25 1
4 HME3-3B Set Screw M3x3 1
5 HMJ3-20N Self-Tapping Screw M3x20 2
6 HMS4 E Ring 1
7 HMY2-10 Pin 2x10 1
8 BK0086 Ball link 4.8x20 2
9 BK0088 Washer d3xD5x0.5 3
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 BK0876 Elevator Control Arm 1
2 BK0075 Link Ball
φ
4.8 1
3 HMF2-8N Philip Machine Screw M2x8 1
No. Material No. Description Qty.
1 BK0882 Elevator Push Pull Lever 1
2 HMV840ZZY BRG d4xD8x3 2
3 BK0075 Link Ball
φ
4.8 3
4 HMJ2-8N Selfing-Tapping Screw M2x8 3
5 BK0410 Collar d3xD4x13 1
No. Material No. Description Qty.
1 HMS15 E Ring 4
2 BK0880 Elevator Link Shaft 2
3 BK0455 Metal Elevator Control Arm 1
4 BK0663 Elevator Arm Link 2
No.Material No.DescriptionQty.
1BK0093Link Rod 2x462
2BK0086Ball Link 4.8x2.04
3BK0547Hardened Main Shaft1
4BK0234Lock Ring1
5HSA3-6BButton Head Socket Screw M3x62
No.Material No.DescriptionQty.
1HMJ2-10NM2x10 Self-Tapping Screw2
2HMC3-12BSocket Screw M3x122
3HMV840ZZYBRG d4xD8x34
4BK0088Washer d3x5x0.52
5BK0472Washout base1
6BK0342Flybar Control Lever2
7BK0343Washout Link2
8BK0075Link Ball
φ
4.82
9BK0409Collar d3xD4x72
10BK0487Pin2
11 HMS15 E Ring2
No.Material No.DescriptionQty.
1BK0086Ball Link φ 4.84
2BK0292Link Rod 2.3x242
3BK0408Collar d3xD4x5.52
4BV0549Washout Base Guidance Ring1
No.Material No.DescriptionQty.
5HMC3-10BSocket Screw M3x102
6HMC3-12B Socket Screw M3x12 1
72-1-1Flybar Seesaw Subassembly1
82-1-2Metal Main Rotor Hub Subassembly1
No. Material No. Description Qty.
1 HMV740ZZ BRG d4xD7x2.5 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 HMJ2-8N Self-Tapping Screw M2x8 1
5 HMC3-10B Socket Screw M3x10 3
6 HMJ3-20N Self-Tapping Screw M3x20 1
7 HME3-4B Set Screw M3x4 1
8 HMM3Z Locknut M3 3
9 BK0075 Link Ball 4.8 1
No. Material No. Description Qty.
1 HMC3-30B Socket Screw M3x30 2
2 HMC3-14B Socket Screw M3x14 2
3 HMM3Z Locknut M3 4
4 BK0086 Ball Link 4.8x20 2
5 BK0278 Machined Washer 2
6 BK0403 Rod Guide 4
7 BK0404 Tail Rotor Blade 2
No. Material No. Description Qty.
8 BK0877 3D Vertical Fin 1
9 BK0650 Tail Boom 1
10 BK0707 Rear Servo Rod 1
11 BK0347 Tail Push Rod A 1
12 BK0653 Tail Push Rod B 1
13 3-1-1 Tail Transmission Subassembly 1
14 3-1-3 Tail Drive Shaft Subassembly 1
No. Material No. Description Qty.
1 BK0617 Bolt M4x25 1
2 BK0086 Ball Link 4.8x20 4
3 BK0318 Link Rod 2.3x95 2
4 HMM4Z Locknut M4 1
5 2-1 Rotor Head Assembly 1
No. Material No. Description Qty.
1 HME4-5B Set Screw M4x5 4
2 BK0397 Skid Brace 2
3 BK0398 Skid Pipe End Cap 4
4 BK0668 Skid Pipe 2
No.Material No.DescriptionQty.
15-4-1Body Subassembly1
No.Material No.DescriptionQty.
1HMJ2-6BM2x6 Self-Tapping Screw6
2HSE3-12BM3x12 Self-Tapping Screw2
3BK0102d3xD6x11Grommet2
4BK0098Body ClipA1
5BK0099Body Clip B1
6BK0429Body1
7BK0428Canopy1
8JV0186Decal1
9BK0473Body Support1
10BK0474Rubber CAP2
11HNLR6R Pin2
No.Material No.DescriptionQty.
1*****Main Rotor Blade2
2BK0446Rotor Bolt M5x352
3HMM5ZLocknut M52
TABLE OF CONTENTS
REPAIR AND REPLACEMENT PARTS
Purchase replacement parts from the hobby shop where you have purchased the Raptor 90!3D. Please contact
the Thunder Tiger distributor in your country, and the distributor can tell you where to obtain the parts. For example,
in the U.S, all Thunder Tiger products are distributed by Ace Hobby Distributors. On the web site www.acehobby.com,
there is a list of all the hobby shops in the USA that can order any Thunder Tiger parts from Ace for you. Technical
questions regarding the Raptor will be answered quickly by sending an email to [e-mail] or call
Technical Support at 949-833-7498. In Europe, Asia and Australia, please contact the distributor in your country.
WARNING
To ensure safety, please read the instruction manual thoroughly before assembly. Radio control helicopters are
sophisticated equipment, and not toys. Radio control model helicopters are capable of causing serious bodily injury
if not properly assembled or operated. The manufacturer and distributors assume no liability for damages that could
occur from the assembly or use of this product. This product is designed for hobby use only. Operating model
helicopters requires diligence and skill. The best way to ensure quick and successful learning is to seek help and
guidance from accomplished pilots. It is strongly recommended to join the appropriate radio control modeling governing
society in your country. For example, in the United States, it is strongly encouraged to join the Academy of Model
Aeronautics. AMA is a nonprofit organization that provides members in the United States with liability insurance
and monthly modeling magazines. For further information or to find a model helicopter club, please contact AMA
at:
Academy of Model aeronautics
515 East Memorial Drive
Muncie, IN 47302
USA
[phone]
We also encourage you to subscribe to different radio control helicopter magazines and learn about RC flying events,
new flying techniques, safety procedures, and hints. Rotory Modeler is a bi-monthly and Model Helicopter Techniques
is a quarterly newsletter published in the USA. Model Helicopter World is a month magazine published by Traplet
Publication in England and sold worldwide. Rotor is a monthly German magazine. Helico is a Swiss quarterly
magazine.
ATTENTION
We are unable to accept replacement or return of this model after it has been used or assembly has begun.
It is legally prohibited to duplicate or reprint this manual in any format without a written permission from the
manufacturer.
The manufacturer has the right to make changes to this model or instruction without notice.
We have done our best to the accuracy of information in this manual. If you are aware of any mistake, we welcome
you to notify us.
We will not accept any responsibility for any accident, breakdown, fault or trouble caused by improper usage of
this model. Please thoroughly inspect your model and range check the radio before flight. Please keep the model
in its best condition in order to enjoy it.
This model does not include all the items necessary for flying, such as engine, serevos, gyro...etc.
It is difficult for beginners to fly RC helicopters by themselves. It is highly recommended that beginners seek the
help of experienced RC helicopter pilots. We recommend beginners start with an inexpensive model such as the
Thunder Tiger Raptor 30 that is also designed by Mr. Taya.
RC helicopters are not toys. The manufacturer does not assume the liability for any property or bodily damage
caused by the model or the operator.
OTHER ITEMS REQUIRED
6
BODYSUPPORT INSTALLATION
Insert the aluminum support
tube through the servo frame.
Insert the "R" pins through the
two holes in the support tube
to prevent the tube from
moving in the servo frame.
Install two rubber ends onto
the support tube.The rubber
ends will dampen shake or
vibration generated by the
engine.
Glow Plug Wrench
12V Battery
1.5V Glow Starter
(1.2V~1.5V)
Rubber Band
(Included)
Foam
Remote Glow Plug
Extension
1-2-2 Cooling Fan Casing Subassembly
1-2-3 Fuel Tank Subassembly
No. Material No. Description Qty.
1 BK0062 Fuel Tank Stopper 1
2 BB0374 Silcon Tube (L=105mm) 1
3 BK0445 Fuel Plug 1
4 BK0463 Fuel Tank Nipple 1
5 BK0503-1 Fuel Tank 1
6 BE1867 Clunk Weight 1
1-5-5 Header Tank Subassembly
No. Material No. DescriptionQty.
1 HMC3-25B Socket Screw M3x251
2 BK0087 Washer d3xD8x1.41
3 BV0502 HeaderTank1
4 BK0506 Tank Mount1
5 BK0698 HeaderTank Supporter1
The Raptor 90 3D kit includes a header fuel tank that can be
attached to the right of the side frame.
23
2-1-1 Flybar Seesaw Subassembly
24
2-1-2 Metal Main Rotor Hub Subassembly
2
4.Final Assembly ---------------------------------------------------------------------------------------------- 29
4-1 Installation of Rotor Head (Bag H)----------------------------------------------------------------------30
4-2 Installation of Engine --------------------------------------------------------------------------------------31
4-2-1 Engine Subassembly -------------------------------------------------------------------------------32
4-3 Installation of Landing Skid------------------------------------------------------------------------------- 33
4-3-1 Skid Subassembly -----------------------------------------------------------------------------------33
4-4 Installation of Tail Assembly ----------------------------------------------------------------------------- 34
4-4-1 Tail Support Subassembly------------------------------------------------------------------------ 34
5.Installation of Peripheral Equipment ----------------------------------------------------------- 35
5-1 Installation of Servo - Part 1 (Bag I) ------------------------------------------------------------------ 36
5-2 Installation of Servo - Part 2 (Bag I) ------------------------------------------------------------------ 37
5-3 Installation of Receiver and Gyro ---------------------------------------------------------------------- 38
5-4 Installation of Body (Bag J) ------------------------------------------------------------------------------39
5-4-1 Body Subassembly ----------------------------------------------------------------------------------39
5-5 Installation of Rotor Blades (Bag K) ------------------------------------------------------------------- 40
6.Settings --------------------------------------------------------------------------------------------------------- 41
6-1 Setting up Gear Backlash ------------------------------------------------------------------------------- 42
6-2 Setting up of Stabilizer Paddles ------------------------------------------------------------------------43
6-3 Setting up of Blade Pitch Angle ----------------------------------------------------------------------- 43
6-3-1 Collective Travel for Hovering ------------------------------------------------------------------ 44
6-3-2 Collective Travel for 3D --------------------------------------------------------------------------- 44
6-3-3 Configuring the Raptor 90 for 3D --------------------------------------------------------------- 45
Attention --------------------------------------------------------------------------------------------------------------46
7.Parts List Section -------------------------------------------------------------------------------------------49
Raptor 90 3D Exclusive Parts -------------------------------------------------------------------------------- 50
Raptor 90 3D Spare Parts List ------------------------------------------------------------------------------- 55
Raptor 90 3D Optional Parts List ---------------------------------------------------------------------------- 61
3
Thank you very much for purchasing the Thunder Tiger Raptor 90 3D R/C helicopter. The design of Raptor
90 3D is based on the original Raptor 90 series helicopter and modified for extreme aerobatics. It has all
needed must-have optional parts for 3D flying, such as metal main rotor hub, non-linear flapping damper,
metal BRG, 3D light paddles and so on. It also adopts the push-pull control system on collective pitch
and elevator to achieve the most precise control. The flybar ratio is changeable to fit all kinds of flying
style. Use of high quality material make the helicopter one tough machine that can handle everyday 3D
beating. Raptor 90 3D is born for 3D flying, and you don’t have to do any further modification for aggressive
3D maneuver. This is by far the best machine you have never seen. Just enjoy the model and have fun.
UNIQUE SIDEFRAME SYSTEM
Aluminum side plates are used in conjunction with molded material to construct the main structure. This
design produces minimum weight with maximum strength. If the sideframes were completely made of
molded material, then to achieve equal strength the plastic would have to be very thick and heavy. Using
molded material at the right place avoids using metal angle brackets or putting compound bends in metal
frames. Slots have been added in the frame design to permit the use of optional gear ratios to optimize
engine performance to suit any pilot's demand.
BELL-HIILLER MIXING CONTROL UNIT
Main rotor control geometry has been carefully engineered to minimize cross-coupling in collective and
cyclic commands. Blade pitch arms and the Bell-Hiller mixing arms are designed at an angle such that
the pushrod interlinking them are at 90 degrees when the blades are at 0 degree. The pilots will get the
symmetrical cyclic control feel and flybar authority either at +10 or -10 degrees of collective. We design
this system with the 3-D pilot in mind. We guarantee you this whole design philosophy provides a strong
and accurate control mechanism.
SHAFT DRIVE TAIL ROTOR
The Raptor 90 3D is designed with a constant drive tail rotor system to permit full tail rotor control during
autorotations. 180 autos, backward autos and pirouette autos are all within your reach now. It has the
same aluminum torque tube system as the Thunder Tiger/Taya Imperio helicopter. This allows obtaining
the maximum performance from any modern heading lock gyros.
3D CAD DESIGN
We use the latest 3D Computer Aided Design to design and manufacture the Raptor 90 3D. Our high-
tech CAD program allows simulation of all moving parts to ensure no interference. The analysis automatically
analyze the weight, the mass distribution, and inertia to help us pursue a design that will provide the high
level of maneuverability needed for all-out 3-D aerobatics.
INTRODUCTION
Socket Drivers
Hex WrenchGrease
Blue Loctite
Instant Glue
Hobby Knife
Metric
4-way Wrench
Scissors
Diagonal Pliers
Open End Wrench
5.5mm
Needle Nose PliersScrew Driver
7mm
5.5mm
7mm
8mm
5.5mm
7mm
8mm
10mm
Epoxy
Ball Link Pliers
No. Material No. Description Qty.
1 HMV6800ZZY BRG d10xD19x5 1
2 HME4-5B Set Screw M4x5 2
3 HMS5 E Ring M5x8 1
4 HMV696Z BRG d6xD15x5 1
5 BK0388 Clutch BRG Case 2
6 BK0659 Frame Space M 4
7 BK0594 Starter Coupling 1
8 BK0592 Starter Shaft 1
9 BK0422 Drive Pinion 11T 1
10 BK0366 Pinion Gear Nut 1
11 BV0522-2 Clutch Bell Set 1
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 2
2 HMC3-12B Socket Screw M3x12 4
3 BK0087 Washer d3xD8x1.4 6
4 BK0393 Pitch Frame Cross Member 1
5 BK0394 Pitch Frame Cross Member Nut 2
6 BK0375T Upper Frame 2
No. Material No. Description Qty.
1 HMM3Z Locknut M3 4
2 HMC3-25B Socket Screw M3x25 4
3 BK0820BL Landing Skid Damper 4
4 4-3-1 Skid Subassembly 1
No.Material No.DescriptionQty.
1HMC3-8BSocket Screw M3x84
2HMQ16Retaining Ring1
3BK0357Tail Drive Spur Gear 83T1
4BK0359One Way Clutch Shaft1
5BV0368Auto Rotation Hub1
6BK0356Main Spur Gear 91T1
1-6-2 Main Gear Subassembly
(3)
(2)
(4)
(6)
(5)
(1)
The carbon rear servo plate is secured
by two Lower 3mm bolts from the plastic
tail boom bracket.
10
1-1-2 Pitch Guide L Subassembly
1-1-3 Pitch Guide R Subassembly
No. Material No. Description Qty.
1 BK0384 Pitch Guide Collar L 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
The side with a number should face
in because the opening on both sides
are differeent.
The hole on the plastic control arm has different
opening sizes on the two sides.Always snap the
bigger opening to the ball on swashplate gently and
afterward please check to make sure it is securely
attached and there is no damage or cracking.
INSTALLATION OF THE LINKS
Bigger Hole Face to Swashplate
Extended 6mm Hex
Starting Tool
Fuel Pump
Heli Engine (90size)
9609 PRO-90H(R)
Glow Fuel(15%-30%)
Glow Plug
Hi-torque 12V Electric starter
Receiver
Transmitter
(helicopter type, 6 or
more channels) High Speed/Torque Servo x 4
Rudder Servo x 1
Battery Switch harness
Heading Lock
Gyro
In order to enjoy a safe and enjoyable experience, please read the manual carefully and completely understand
the helicopter structure and operation before the first flight.
Read the warnings to avoid injuries to you and others.
WARNING – The following could cause heavy injury or death if used incorrectly.
Keep the model away from other people or animal when starting the engine.
Do not fly any model helicopter near or above people or cars. Models can sometimes lose
control due to pilot or mechanical failure.
WARNING – The following could also cause serious injury or death if not careful.
Take precaution with model fuel. Model engine glow fuel is highly flammable.
Please check the model carefully before each flight. Make sure that nothing has loosened up
or come apart.
Make sure everything moves freely without binding or excessive friction.
Do not operate the model in rain, snow, thunderstorm, or adverse weather.
WARNING – The following could also cause serious injury or death if not careful.
Please make sure that your radio frequency is not used before flight. If someone else is flying
with the same frequency as your radio, do not turn on your transmitter. Otherwise, it can cause
a crash and even bodily and property damages.
Please monitor the fuel level during flight and land before running out of fuel.
Before each flight, please check that all servos and controls move properly.
Do not modify any parts or use other than genuine Thunder Tiger parts.
Do not fly in places that are forbidden by law.
Use Loctite on screws that do not use a locknut.
When operating the model, please beware that no loose cloth or jewelry can get entangled in
the model helicopter.
Make sure the transmitter and receiver switches are on before starting the engine.
Do not touch the engine or the muffler right after flying because they are very hot.
Do not use this model for anything other than hobby.
WARNING – The following damages can happen to the model.
Do not leave the model in a car for a long time. The heat in the summer or the cold in the
winter and the humidity can cause damage to the model.
Be careful and watch the sharp edges and corners on the model.
BUILDING HINT – The instruction is divided into six assembly chapters:
Main Frame, Rotor Head, Tail Rotor, Final Assembly, Radio Installation, and Settings. There
are many major assembly steps in each chapter, please follow the instruction to do each "
Subassembly" first, then combine the subassemblies into a major assembly.
Upper Frame Assembly
Lower Frame Assembly
12
1-2-1 Tail Drive Unit Subassembly
No. Material No. Description Qty.
1 HME3-4B Set Screw M3x4 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 BK0362 Tail Drive Bevel Gear A 1
5 BK0363 Tail Drive Bevel Gear B 1
6 BK0364 Tail Drive Pinion 1
7 BK0365 Tail Drive Gear Shaft 1
8 BK0382 Tail Boom Bracket L 1
9 BK0383 Tail Boom Bracket R 1
10 BK0414 Pin 2x12 2
11 BK0660 Frame Spacer L 5
Main Frame Assembly Installation of Pitch Frame
No. Material No. DescriptionQty.
1 HMJ2-10N M2x10 Self-Tapping Screw1
2 HMV840ZZY BRG d4xD8x32
3 HMV1280ZZY BRG d8xD12x3.52
4 BK0336 Pitch Frame1
5 BK0075 Link Ball
φ
4.81
Optional: add a tiny drop of thick CAon the outside rim of the fovr ball
bearings before inserting them into the plastic Pitch Frame. Be careful
not to get any glue into the ball bearings.Add a tiny drop of thick CA
glue at the tip of the M2x10 self-tapping screw (No. 1) before
screwing it into the Pitch Frame.
32
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
No. Material No. Description Qty.
1 BK0385 Pitch Guide Collar R 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
Tip: When setting up the phase
adjustment ring, the flybar and
the tail boom can be the
reference. When the flybar and
the tail boom are centered, the
inner balls of swashplate should
be aligned with the outer balls.
Tighten the socket screw on the
phase ring at this moment.
NOTE: Improper alignment will
cause unwanted mixing.
No. Material No. Description Qty.
1 ******** 90 Class Heli Engine 1
2 ******** Nut (Comes With the Engine) 1
3 HMC4-8B Socket Screw M4x8 2
4 HMC4-18B Socket Screw M4x18 4
No. Material No. Description Qty.
5 HMO10 Washer d9.5xD16x1 1
6 BK0349 Engine Mount 1
7 BV0380 Cooling Fan 1
8 BV0521 Heavy Duty Clutch 1
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.85
2BK0086Ball Link 4.8x208
3BK0104Servo Mounting Plate6
4BK0105Rod Joint1
5BK0318Link Rod 2.3x952
6BK0436Link Rod 2.3x552
7BK0833Servo Block4
8HMC2516BSocket Screw M2.5x164
No.Material No.DescriptionQty.
9HMM25Lock Nut M2.54
10HML2Nut5
11HME4-5BSet Screw2
12HMF2-8NPhillips Machine Screw M2x85
13HSE2614NSelt-Tapping Screw4
14HSE2630NSelt-Tapping Screw4
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.87
2BK0086Ball Link 4.8x204
3BK0095Link Rod 2.3x761
4BK0104Servo Mounting Plate4
5BK0833Servo Block2
6BK0834Pitch Lever Fixed Plate1
7BK0839Link Rod 2.3x301
8BK0881Washer1
9BK0883Pitch Push Pull Lever1
No.Material No.DescriptionQty.
10BK0884Collar, d3xD4xW121
11BV0085Pitch Link Rod2
12HMC3-20BSocket Screw M3x201
13HMV840ZZYBearing d4xD8xW32
14HMF2-8NPhilip Maching Screw M2x84
15HMJ2-8NSelt-Tapping Screw M2x83
16HML2Nut4
17HSE2614NSelt-Tapping Screw M2.6x148
18HSE2620NSelt-Tapping Screw M2.6x204
No.Material No.DescriptionQty.
1****Switch1
2****Receiver Battery1
3****Receiver1
No.Material No.DescriptionQty.
4****Gyro
5BK0106Foam2
6 BE1052Antenna Pipe1
PV0517ONEWAYBEARING GREASE
The hole on the Flybar Control Rod has different
opening on two sides.Always snap the bigger opening
to the link ball.
Bigger Hole
Face to ControlArm
10.5mm10.5mm
When installing pinion gear, add a small drop of Loctite to the
threads. Make sure not to get Loctite on lower clutch bell bearing.
Important:
For 90 class engine, we recommend the 11 teeth pinion for 3D
flying.
The servo tray and cooling fan shrouds on the Raptor 90 are different from the
Raptor 60 in order to accommodate the full head sink on the O.S 91. engine.
If using T.T 90, Y.S 91 or Webra 91 engine, make sure to install the fan shroud
baffle with two self-tapping screws. This will ensure optimal cooling of your engine
head.
Add CA glue Add CA glue
It is necessary to add grease inside the one way clutch before your
first flight.The clutch might lock up once grease is gone.The one
way clutch grease( PV0517) is recommended for this lubrication.
Make sure the inside ofAuto Rotation Hub is clean without any dirt
before you insert the one way clutch shaft.
Add Loctite
Add Loctite on
the threads
For 3D flying, it is recommended to use
lower flybar ratio setting.
Self-Tapping Screw, No. 10 Collar, and No. 11 Washer, with two
No. 1 Bearings. Attach a No. 9 Link Ball with a No. 4 Screw.
Upon finishing Step 3-1-1, make sure there are no extra parts
left on your workbench.
Elevator Control
Pushrod
Glue the two plastic halves of
the paddle with CAglue before
installation on flybar.
Add Loctite
the tail boom by tightening the four screws on the helicopter.
Visually check from the rear of the helicopter to make sure the
tail rotor output shaft is perpendicular to the main rotor shaft.
Add the tail boom supports.
Add Loctite
The thrust bearing washer with the
SMALLER inner hole should be closer to
the rotor blade.
The thrust bearing washer with the BIGGER
inner hole should be closer to the main rotor
shaft.
4-2-1 Engine Subassembly
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add CA Glue
Introduction -------------------------------------------------------------------------------------------------------- 3
Other Items Required -------------------------------------------------------------------------------------- 4
Warning --------------------------------------------------------------------------------------------------------------- 5
Assembly
1. Main Frame Assembly --------------------------------------------------------------------------------- 7
1-1 Upper Frame Assembly (Bag A) ---------------------------------------------------------------------- 8
1-1-1 Pinion Gear Subassembly ------------------------------------------------------------------------ 9
1-1-2 Pitch Guide Left Subassembly ------------------------------------------------------------------10
1-1-3 Pitch Guide Right Subassembly -----------------------------------------------------------------10
1-1-4 Elevator Control Arm Subassembly------------------------------------------------------------ 10
1-2 Lower Frame Assembly (Bag B) ----------------------------------------------------------------------11
1-2-1 Tail Drive Unit Subassembly ---------------------------------------------------------------------12
1-2-2 Cooling Fan Casing Subassembly -------------------------------------------------------------13
1-2-3 Fuel Tank Subassembly ------------------------------------------------------------------------13
1-3 Main Frame Assembly (Bag C) -------------------------------------------------------------------------14
1-3-1 Rod Guide Collar Subassembly----------------------------------------------------------------- 14
1-4 Installation of Servo Frame (Bag C) ------------------------------------------------------------------- 15
1-5 Installation of Pitch Frame (Bag D) -------------------------------------------------------------------- 16
1-5-1 Aileron Lever Subassembly ---------------------------------------------------------------------17
1-5-2 Metal Elevator Parallel Lever Subassembly -------------------------------------------------17
1-5-3 Elevator Control Lever Subassembly --------------------------------------------------------- 17
1-5-4 Pitch Control Frame Subassembly -------------------------------------------------------------18
1-5-5 Header Tank Subassembly ----------------------------------------------------------------------18
1-6 Installation of Main Shaft (Bag E) ----------------------------------------------------------------------19
1-6-1 Wash Out Subassembly -------------------------------------------------------------------------20
1-6-2 Main Gear Subassembly -------------------------------------------------------------------------20
2. Rotor Head Assembly -----------------------------------------------------------------------------------21
2-1 Metal Rotor Head Assembly (Bag F) -----------------------------------------------------------------22
2-1-1 Flybar Seesaw Subassembly --------------------------------------------------------------------23
2-1-2 Metal Main Rotor Hub Subassembly ----------------------------------------------------------24
3.Tail Assembly -------------------------------------------------------------------------------------------------25
3-1 Tail Assembly (Bag G) ----------------------------------------------------------------------------------- 26
3-1-1 Tail Transmission Subassembly --------------------------------------------------------------- 27
3-1-2 Tail Rotor Subassembly --------------------------------------------------------------------------- 28
3-1-3 Tail Drive Shaft Subassembly -------------------------------------------------------------------28
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(4)
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(7)
(8)
(3)
(15)
(14)
The Liner is pre-glued on the
inside of clutch bell with 30 min
epoxy.
1-1 1-2 1-3
( 2 ) (1)
1-4
(1)
(2)
1-5 1-6
(7)
(1)
(5)(4)
(9)
(3)
2-1
3-1 4-1
(5)
(3)
(2)
(1)
4-3
(4)
(2)
4-4
(2)
(7)
(1)
(3)
(5)
(8)
4-2
(3)
(1)
(2)
5-15-2
5-3
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(6)
(1)
(3)
(2)
(5)
5-4
5-5
(2)
(3)
No. Material No. Description Qty.
8 BK0660 Frame Spacer L 3
9 BK0376T Lower Metal Frame 2
10 BV0870 Metal Lower BRG Block 1
11 1-2-1 Tail Drive Unit Subassembly 1
12 1-2-2 Cooling Fan Casing Subassembly 1
13 1-2-3 Fuel Tank Subassembly 1
No. Material No. Description Qty.
7 BK0659 Frame Spacer M 2
8 BV0869 Metal Upper BRG Block 1
9 1-1-1 Pinion Gear Subassembly 1
10 1-1-2 Pitch Guide L Subassembly 1
11 1-1-3 Pitch Guide R Subassembly 1
12 1-1-4 Elevator Control Arm Subassembly 1
(3)
No. Material No. Description Qty.
10 BK0093 Link Rod 2x46 1
11 BK0407 Collar d3xD4x4.5 2
12 BK0410 Collar d3xD4x13 2
13 1-5-1 Aileron Lever Subassembly 1
14 1-5-2 Metal Elevator Parallel Lever Subassembly 1
15 1-5-3 Elevator Control Lever Subassembly 1
16 1-5-4 Pitch Control Frame Subassembly 1
17 1-5-5 Header Tank Subassembly 1
No.Material No.DescriptionQty.
6HMM4BLucknut M41
7BK0617Bolt M4x251
8BV0504Metal Swashplate1
91-6-1Washout Subassembly1
101-6-2Main Gear Subassembly1
No. Material No. Description Qty.
10 BK0076 Collar d3xD4x10 1
11 BK0088 Washer d3xD5x0.5 1
12 BK0346 Tail Pitch Control Lever 1
13 BK0370 Tail Case L 1
14 BK0371 Tail Case R 1
15 BK0372 Tail Input Bevel Gear 1
16 BK0373 Tail Output Bevel Gear 1
17 HMY2-12 Pin 2x12 1
18 3-1-2 Tail Rotor Subassembly 1
No. Material No. DescriptionQty.
1 HMM3Z Locknut M36
2 HMC3-16B Socket Screw M3x162
3 HMC3-20B Socket Screw M3x202
4 HMC3-25B Socket Screw M3x252
5 HMC3-30B Socket Screw M3x302
6 BK0087 Washer d3xD8x1.44
No. Material No. DescriptionQty.
1 HMJ2-8N Self-Tapping Screw M2x8 4
2 BK0447 Tail Support Rod End4
3 BK0669 Tail Support Rod2
No. Material No. Description Qty.
1 HMC4-42B Muffler Bolt M4x42 2
2 HMT4B Spring Washer 2
3 ******** Muffler ( 90 ) 1
4 4-2-1 Engine Subassembly 1
5 HMC4-12B Socket Screw M4x12 4
6 BK0435 Washer d4xD11xW1.7 4
BAG A
BAG B
BAG C BAG C BAG D
(L) (R)
BAG E
BAG F
BAG G
BAG H
BAG I
97.5mm
48mm
(3)
Throttle
Collective Pitch
(2)
BAG I
BAG J
BAG K
(11) (8)
(7)
(2)
(6)
(3)
(5)
(9)
(4)
Please complete subassembly steps 1-2-1 through 1-2-3 first. Then attach the subassemblies to the two Lower Frames. Note
that the Metal Lower BRG is installed with the bearing open side facing up. Please add a small drop of Loctite on every bolt
before screwing it into the aluminum hex spacer. Do not apply Loctite to the bolts which are going to secure the Lower BRG
Block at this moment.
Assemble the upper main frames by starting with the two Metal Upper Frames. The Pinion Gear Subassembly must be assembled
first according to Figure 1-1-1. Next insert three hex-shape frame spacers into the plastic Pitch Guide according to Figure 1-1-2
and 1-1-3. Assemble the Elevator Control Arm subassembly according to 1-1-4. Insert it in between the two Upper Frames. The
metal Elevator Control Arm is not symmetrical. The side with the longer profruding round knob should be on the right side of the
helicopter. Then attach the other subassemblies to the Upper Frames. Locate Hex Wrenches in BAG L which you need for
assembly.
Please add a tiny drop of non-permanent type Loctite on the tip of all bolts before screwing them into the hex shaped aluminum
frame spacers. Never use too much Loctite, otherwise it will become nearly impossible to remove later on for servicing. Only use
the non-permanent type of Loctite. If encountering difficulty in removing any bolt that was locked up by Loctite, heat up the head
of the screw or bolt with the tip of a hot soldering iron, it will help soften the cured Loctite.
For the kit, parts are bagged according to each major assembly and are labeled "Bag A, Bag
B, etc." The heading for each assembly indicates which bag to open. As a go od practice,
only open up the bag that you need for the particular assembly. Check the parts in that bag
against the parts list shown for each assembly as well as each sub-assembly to make sure
there are no missing parts. To prevent losing small hardware, please empty the small nuts
and bolts and parts into small plastic trays on your work table. At the end of each major
assembly, there should be no left over parts.
The fuel tank comes assembled from the factory because every tank has been
checked for leak. If you were to take the tank apart here is how to put it back
together. Install the silicone fuel line to the Fuel Nipple. Then add the rubber
fuel tank stopper and the clunk weight. The stock silicone fuel line is very soft
and thin which is designed to allow the clunk to pick up fuel easily during 3-D
aerobatics. The pickup line should be inspected and replaced if necessary every
month, otherwise when it becomes soggy it can break off. A thicker silicone line
maybe substituted but make sure the clunk will reach the bottom when moving
the fuel tank to all different orientations.
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(2)
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(1)
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(5)
As show in Figure 1-3-1, insert two hex
Frame Spacers S into the plastic Rod
Guide Collars. Then join the Upper
Frame Assembly to the Lower Frame
Assembly according to drawing 1-3.
Secure the Set Screws (No.1) to the
frames, and fit the Body Posts (No.4)
to the Set Screews. The two Body Posts
will be used to secure the canopy in the
future. Add Loctite on all bolts and
inside BK0103 threaded hole.
Install the one-piece servo frame with six self-tapping screws.
Do not use Loctite when attaching self-tapping screws to plastic
parts. Loctite is only for threading metal into metal parts. Assemble the constant drive Main Gear Subassembly according to Figure 1-6-2 first.Then build up the Wash Out Subassembly
according to 1-6-1. Insert the No.3 Main Shaft into the bearings and then add the No.4 Lock Ring and slide in the Main Gear
Subassembly.Add two M3x6 Button Head Screws to the Locking Ring, and the two screws are threaded into the holes on the
main rotor shaft.
The locking ring prevents the main shaft from sliding up. Line up the hole on the main gear and the main shaft, then insert M4x2 5
mm Bolt through them. Place a 4 mm M4 locknut on the other side of the autorotation hub, and then tighten the Bolt. Do not
over tighten the Bolt, otherwise the autorotation assembly will be distorted. Loosen the 3mm bolts holding the Upper and lower
bearing blocks for the 12mm main shaft. Wiggle the main shaft in the bearing blocks until the main shaft spins freelyin the bea rings.
This ensures the upper and lower bearing blocks are aligned. Push the lower bearing block up until the mainshaft has no up
and down play.Then tighten the 3mm bolts for the upper and lower bearing blocks.
Insert the pin into the Washout Link.Add a tiny drop of Loctite on the inside
and outside of BK0409 Collar which will help give a completely slop free
control system. Do not let the Loctite seep into the bearing.Adjust the
tightness of the M3x12 bolts so the mixing arms can move freely but without
wobble or racheting the ball bearings.Add a tiny drop of thick CAglue at
the tip of the M2x10 self-tapping screw (No. 1) before screwing it into the
Flybar Control Levers (No. 6).
Make the two pushrods for controlling the blade pitch.The distance 43 mm is measured between the center of two pushrod holes.
Attach the Seesaw Hub of the Control PaddleAssembly to the Main Rotor Head with Socket Screws (M3x10).
Please add a small drop of Loctite along the entire length of the M3x10 Socket Screw (No.5) and on the outside of the collar
d3xD4x5.5 (No.3).Temporarily install the Washout Base Guidence Ring, but do not tighten the No.6 M3 Socket Screw yet.
Assemble the tail transmission subassembly according to 3-
1-1 and 3-1-2 first. And the tail drive shaft subassembly according
to 3-1-3.But do not close the two halves of the tail transmission
tightly. You will do this when you are ready to install the gearbox
onto the tail boom.
When installing the tail transmission, make sure the housings
match the hole on to the tail boom. Add Carbon Vertical Fin with
machined washer and Locknut, then tighten the five 3 mm bolts.
Add carbon Vertical Fin with Pom washer and Locknut.
Before inserting the finished tail drive shaft assembly into the
tail boom, add some flexible silicone glue or ZAP Goop glue
around the outside of the tail drive bearing housing. This will
prevent the bearing housing from spinning inside the tail boom.
(7)
Install bearings No. 2 and No.3 into the Tail Cases. Install No.
16 Tail Bevel Gear onto the Tail Shaft. Gently tap the No. 17
Pin into the Bevel Gear and Tail Shaft. Then secure the pin
with a No. 7 Set Screw with Loctite.
After installing the M3x4 set screws, try pushing on the 2x12
pin with a small Allen wrench to make sure the set screw has
locked the pin in place securely. Before closing the two halves
of the Tail Cases, please check the gear mesh between gears
No. 15 and No. 16. If the gears mesh too tight, then a 5 mm
i.d. washer should be added to move the gear No. 16 further
out. If there exists too much freeplay, then a 5 mm i.d. washer
to push gear No. 16 closer to gear No. 15.
Install the No. 12 Tail Pitch Control Lever as shown with No. 6
Slide four No. 6 Rod Guides onto the tail boom. Do not glue
them onto the tail boom yet. Add a tiny drop of CA glue to the
pushrod guide after you finish building the entire helicopter.
Before adding glue, make sure the tail pushrod is hooked up
to the servo and the rod travels in a straight line and moves
very smoothly.
Congratulation, we are almost done. Install the finished main
rotor head onto the 12 mm rotor main shaft. Secure it with a
M4x20 Bolt and M4 Locknut. Make up two 113.5 mm long
pushrods and attach them to the Bell-Hiller mixing arm.
Before installing the plastic end caps, please
add a drop of slow, thick CA glue on the
rim of the end caps and on the inside edge
of the aluminum skid.
Slide the finished tail boom into the helicopter.The four bolts
on the helicopter must be loose in order to insert the tail boom.
Make sure the tail drive shaft is inserted into the front receptacle
properly. Check this by turning the main rotor head. Secure
Secure the two ends to the rod with Epoxy, making sure the
two metal ends are perpendicular to each other.
(4)
Attach the engine into the side frames, with four M4x12 bolts and
four washers, but do not tighten until Section 6-1.
Install the muffler after you have building the entire helicopter.
Always add Loctite on the muffler bolts.
Install the servos and make up the pushrods according to the drawings.The distance between the steel ball and the center of
servo arm are shown in the drawing. Use them as a guide.These distances are used in conjunction with the servo travels (ATV
or End point) set to 100% for all the channels in the transmitter.Tune them later on to suit your personal flying style.
Attach the rudder servo to the rear mounted carbon plate with four 2.6mm bolts and four M2.6 locknut.
Make up the throttle and collective control pushrods according
to the drawing. Use the outermost hole on the carburetor throttle
control arm.Attach the steel ball on the throttle servo arm at
approximately the same distance as the steel ball on the throttle
arm.
Make up the throttle at 97.5mm long first, and then adjust the
pushrod length and throttle servoATV or Endpoint so full throttle
stick command will open the carburetor barrel fully.And full low
stick and low throttle trim will close the carburetor barrel completely.
Install the receiver and receiver battery. Even though the receiver and battery can be attached to the helicopter tray by using
double sided foam tape, but it is better to wrap the receiver and battery separately using half inch or 10 mm thickfoam. Then
secure them to the tray using six to eight rubberbands, or Velcro bands.
Carefully cut out the canopy (windshield) using scissors.The
best scissors to use are (TTR 1304) designed to cut RC car
bodies and Canopy. Install the canopy to the body using six
small screws. Drill small holes in the canopy and body for the
holes. Drill two more holes for the rubber grommets.
Refer to color box and apply the decals (In BAG M) .
Tools for Assembly
The Raptor 90 3D is designed for easy maintenance using standard hobby tools. Please only use genuine Thunder Tiger parts.
Please keep the model clean and well tuned. It will provide you with long lasting pleasure in return.
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(3)(16)(8)
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Add Loctite
(Included)
Add a tiny drop of thick CA glue at the tip of the M2x10
self-tapping screw (No. 1) before screwing it into the
Aileron Levers.
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(10)
(11)
Make up the landing gear according to the
drawing.
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(1)
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(3)
(1)
No. Material No. Description Qty.
1 HSE3-6B Self-Tapping Screw M3x6 2
2 BK0660 Frame Spacer L 4
3 BK0662 Cooling Fan Baffle 1
4 BK0665 Fan Casing L 1
5 BK0666 Fan Casing R 1
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(1)
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(1)
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Assemble the metal flybar control arms according to the drawings. Slide Flybar ControlArm onto the No.18 Flybar Rod. Slide
the flybar into the No.17 Seesaw Hub. Make sure the Flybar has equal protrusion from each side of the SeesawHub measure
them with a ruler, then install and tighten the No.8 HME4-5B set screws.Add the paddles. Make sure the two paddles and the
two flybar control arms are all parallel. Lock the paddles with No.6 set screws.
Assemble and install the No.10 Mixing Levers and No.5 Bearings according to the drawing using No.12 Collar andNo.9 d3xD5x0.5
washer.
Note:Before installing the Mixing Lever (No.10), please add a small drop of Loctite along the entire length of the M3x18 button
head socket screw (No.4) and on the outside of the collar d3xD4x13 (No.12). Be careful do not let the Loctite seep into the bear ings.
There are two choices of hole positions on the aluminum seesaw for attaching the mixing lever arm.The outside hole gives higher
Bell-Hiller mixing ratio. For aggressive 3D flying, you can attach the Bell-Hiller mixing arms to the inner hole which gives low er
flybar ratio.
(6)
No.Material No.DescriptionQty.
10BK0324Mixing Lever2
11BK0406LPaddle Root2
12BK0410Collar d3xD4x132
13BK0416Paddle Stopper2
14BK0432LFlybar Paddle2
15BK0633Flybar Control Frame2
16 BK0871 Longer StabilizerArm 2
17 BV0865 Longer Seesaw 1
18 BK0866 SUS Flybar 1
No.Material No.DescriptionQty.
1HMF2-8NPhillips Machine Screw M2x82
2HMJ2-10NSelfing-Tapping Screw M2x104
3HMC3-10BSocket Screw M3x102
4 HMC3-18B Socket Screw 2
5HMV840ZZYBRG d4xD8x34
6HME4-3BSet Screw M4x34
7HME4-5BSet Screw M4x52
8BK0075Link Ball
φ
4.86
9BK0088Washer d3xD5x0.52
Insert the aluminum Main Rotor Hub Pin and the Flap Dampers. (might need to apply silicone grease for easy installation). Push
the No.7 Feathering Spindle into the dampers and the rotor hub.Add No. 14 Flybar Control Rod. Slide both finished Main Rotor
Grip onto the feathering spindle and the secure with two M4x10 bolts and washers according to the drawing.Use two Allen
wrenches to tighten the two M4x10 bolts simultaneously.
Important Note:
The Raptor 90 3D kits come with non-linear flap damper for aggressive 3D flying.You may choose to experiment adding from
one up to three 0.4mm thick shim (No.10) washers between the washer (No.8) and bearing to further stiffen the main rotor flapping.
Stiffing the main rotor head will speed up the cyclic transient response, but may cause the helicopter fuselage to oscillate at arou nd
1600 RPM.This oscillation characteristic exists for all helicopters with hard 3D flap dampers.The inner dampers should be
replaced periodically if a lot of 3D flying has been done. When the dampers are worn, the main rotor blades canflap excessivel y
during some 3D maneuvers and risk touching the tail boom.
Add flexible silcone glue or ZAP
Goop glue around the outside
before inserting into the tail
boom from the front side.
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(2) (1)
(4)
180mm
25mm
(1)
(3)
(2) (3)
The optionalThunderTiger Remote Glow PlugAdaptor (#3803)
is recommended as shown, making starting easy without the
removal of your canopy.
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(1)
(4)
(2)
Cut a hole at the
front air scoop for
backward flights.
(7)
No.Material No.DescriptionQty.
9BK0477Washer2
10BK0703Flap Damper Washer 0.4mm6
11BK0874Inner Damper2
12BK0875Outer Dampper2
13BK0075Ling Ball
φ
4.82
14BK0664Flybar Control Rod2
15BK0319Main Rotor Pitch Housing2
16BV0548-1Metal Main Rutor Hub1
No.Material No.DescriptionQty.
1HMC4-10BSocket Screw M4x102
2HMJ2-12NSelf-Tapping Screw M2x122
3HMV1680BRG d8xD16x54
4HMX0816Thrust Bearing d8xD16x52
5BK0330Main Rotor Hub Pin1
6 BK0325Thrust Washer 2
7BK0326Spindle1
8BK0435Washer2
Fiberglass or Carbon Rotor Blade
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(1)
(5)
Add Loctite when setting up the
gearmesh in step 6-1.
(7)
No.Material No.DescriptionQty.
7BK0539Carbon Rear Servo Plate1
8BK0878Bracket (Top)1
9BK0879Bracket (Bottom)1
103-1TailAssembly1
114-4-1Tail Support Subassembly2
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Engine System
Use a high quality 90 size 2-stroke
model helicopter engine, such as the
Thunder Tiger TT PRO-90H, OS 91
SZ-H, YS 91 ST, Webra 91, or
equivalent. Please beware, some
engines may not fit because of their
shape and size. The Raptor 90 3D
kit comes with a cooling fan hub to fit
the TT PRO-90H, OS 91 SZ-H, Webra
91.
We recommend a high quality muffler
or tuned exhaust system designed to
fit on the left side of the model.
Rotor Blades
It is important to use main rotor blades
that are of high quality and suitable
for your flying style. If fiberglass or
carbon graphite blades are used, the
length should be between 680 and
710 mm. Blade weight should be
between 170 and 200 grams.
Starter System
To start the engine, it is necessary to
use an electric starter with a 6mm
shaft extension. The starter and the
6 mm extension are available from
Thunder Tiger, the part numbers are
No.2675 and No.3801.
Use a strong high torque 12 volt
electric starter which is designed for
models.
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(4)
Add a small drop of Loctite.
Make sure it locks the pin.
Install BK0364 and BK0362 onto BK0365 Tail Gear Drive Shaft. Then insert the
two Pins and secure them with two M3x4 Set Screws. Add a tiny drop of Loctite
on the set screw thread before inserting them. Always use a very small amount
of Loctite liquid on the thread, otherwise it may be nearly impossible to remove
the set screws in the future for servicing. After installing the two M3x4 set screws
(No. 1), try to push on the 2x12 pins with a small Allen wrench to make sure the
set screws have locked the pins in place securely. Install the four ball bearings
and the hex shaped Frame Spacers according to the drawing. Before closing
the two halves of the Tail Boom Brackets, please check the gear mesh between
gears No. 4 and No. 5. If there exists too much freeplay, add some 5 mm i.d.
washers on top of gear No. 4. (The 5 mm i.d. washers are provided in BAG G).
Add a small drop of Loctite.
Make sure it locks the pin.
Shim Washer
(3)
(5)
(4)
(2)
(3)
(1)
Add CAGlue
Standard flybar ratio
Lower flybar ratio
Mild 3D Flying
Extreme 3D Flying
(3)
(8)
(2)
(7)
(5)
(1)
Attach the engine mount to the engine using four 4mm bolts and Loctite.
The cooling fan hub is threaded to fit the OS, TT or Webra only. Place the washer that came with your engine onto the engine
crankshaft first. Then screw the fan hub onto the engine. Add a tiny drop of Loctite on the engine nut. Do not use too much
Loctite. Tighten the engine nut using a socket head wrench while grabbing the fan with a towel. The nut should be tighten securely.
For 50-size or bigger engines, we do not recommend using a piston locking tool on the glow plug hole because that may damage
the engine. Attach the No. 8 Heavy Duty Clutch to the fan hub. Add a drop of Loctite on the threads of the M4x8 bolts. The
threads on the aluminum cooling fan hub are for the TT 70H, OS 61 SX, OS 61LX, OS 70H, TT 90H, OS 91 or Webra 91 engines.
If YS 61, 80 or 91 engines are used, the fan hub must be re-tapped by the modeler to M8x1mm thread size or purchase a optional
plastic fan hub with threads for the YS engine(PV0198YS) or the metal fan for the YS (PV0293YS).
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(5)
Please complete subassemblies 1-5-1 through 1-5-5 first, then add them to the Main Frame. Fit the Pitch Control Frame
Subassembly. Attach the E Ring on the left side of the Metal Elevator Control Arm. Then fit the Elevator Control Lever to the
right side, insert the pin and fix it with a set screw. Secure the Pitch Control Frame with a M3*10 Socket Screw and a collar on
the left side. And attach the Elevator Push Pull Lever to the right side of the Pitch Control Frame as shown. Adjust the two bolts
so that the Pitch Control Frame can move freely without excessive play. Finally, add the two plastic Aileron Levers and the 66.5mm
elevator pushrod. Add the Washers (BK0088) to make sure that the Aileron Lever and the Metal Elevator Parallel Lever will not
touch each other during operation.
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Outer hole for standard.
Inner hole for extreme 3D.
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(9) (12) (5)
(2)
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(3)
Add Loctite
Add Loctite
Add Loctite
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Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
30mm
(2)
Paddle
Flybar
A Arm
Phase
Adjustment
Ring
Swash
plate
Boom
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(1) (10) (12)
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Pitch push-pull subassembly
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(1)
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(2)
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Add Loctite
Add Epoxy
Add Epoxy
(13)
(14)
(17) (15)
(16)

1
5
7
MAIN FRAME ASSEMBLY
8 9
1-1-1 Pinion Gear Subassembly
11
13 14 15 16 17 18 1920
21
22
25 26 27
29 30 33 34
36
3531
37
383940
4
1-3-1 Rod Guide Collar Subassembly
1-5-1 Aileron Lever Subassembly
1-5-2 Metal Elevator Parallel Lever Subassembly
1-5-3 Elevator Control Lever Subassembly
1-5-4 Pitch Control Frame Subassembly
1-1-4 Elevator Control Arm Subassembly
1-6-1 Wash Out Subassembly
ROTOR HEAD ASSEMBLY
TAIL ASSEMBLY
3-1-1 Tail Transmission Subassembly
FINAL ASSEMBLY
4-3-1 Skid Subassembly
4-4-1 Tail Support Subassembly
INSTALLATION OF PERIPHERAL EQUIPMENT
5-4-1 Body Subassembly
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 4
2 HMC3-12B Socket Screw M3x12 21
3 BK0087 Washer d3xD8x1.4 22
4 BK0274 Tank Rubber Grommets 4
5 BK0380 Rear Frame L 1
6 BK0381 Rear Frame R 1
7 BK0629 Washer 4
No. Material No. Description Qty.
1 HME3-18.5B Set Screw M3x18.5 2
2 HMC3-25B Socket Screw M3x25 10
3 BK0087 Washer d3xD8x1.4 10
4 BK0103 Body Fitting Post 2
5 BK0658 Frame Spacer S 2
6 1-1 Upper Frame Assembly 1
7 1-2 Lower Frame Assembly 1
8 1-3-1 Rod Guide Collar Subassembly 2
No. Material No. Description Qty.
1 BK0389 Rod Guide Collar 1
2 BK0658 Frame Spacer S 2
No. Material No. Description Qty.
1 BK0667 Servo Frame 1
2 HSE3-12B M3x12 Self-Tapping Screw 6
3 1-3 Main Frame Assembly 1
No. Material No. Description Qty.
1 HMC2-6B Socket Screw M2x6 1
2 HMC3-10B Socket Screw M3x10 1
3 HMC3-25B Socket Screw M3x25 1
4 HME3-3B Set Screw M3x3 1
5 HMJ3-20N Self-Tapping Screw M3x20 2
6 HMS4 E Ring 1
7 HMY2-10 Pin 2x10 1
8 BK0086 Ball link 4.8x20 2
9 BK0088 Washer d3xD5x0.5 3
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 BK0876 Elevator Control Arm 1
2 BK0075 Link Ball
φ
4.8 1
3 HMF2-8N Philip Machine Screw M2x8 1
No. Material No. Description Qty.
1 BK0882 Elevator Push Pull Lever 1
2 HMV840ZZY BRG d4xD8x3 2
3 BK0075 Link Ball
φ
4.8 3
4 HMJ2-8N Selfing-Tapping Screw M2x8 3
5 BK0410 Collar d3xD4x13 1
No. Material No. Description Qty.
1 HMS15 E Ring 4
2 BK0880 Elevator Link Shaft 2
3 BK0455 Metal Elevator Control Arm 1
4 BK0663 Elevator Arm Link 2
No. Material No. DescriptionQty.
1 BK0093 Link Rod 2x462
2 BK0086 Ball Link 4.8x2.04
3 BK0547 Hardened Main Shaft1
4 BK0234 Lock Ring1
5 HSA3-6B Button Head Socket Screw M3x62
No.Material No.DescriptionQty.
1HMJ2-10NM2x10 Self-Tapping Screw2
2HMC3-12BSocket Screw M3x122
3HMV840ZZYBRG d4xD8x34
4BK0088Washer d3x5x0.52
5BK0472Washout base1
6BK0342Flybar Control Lever2
7BK0343Washout Link2
8BK0075Link Ball
φ
4.82
9BK0409Collar d3xD4x72
10BK0487Pin2
11 HMS15 E Ring2
No.Material No.DescriptionQty.
1BK0086Ball Link φ 4.84
2BK0292Link Rod 2.3x242
3BK0408Collar d3xD4x5.52
4BV0549Washout Base Guidance Ring1
No.Material No.DescriptionQty.
5HMC3-10BSocket Screw M3x102
6HMC3-12B Socket Screw M3x12 1
72-1-1Flybar Seesaw Subassembly1
82-1-2Metal Main Rotor Hub Subassembly1
No. Material No. Description Qty.
1 HMV740ZZ BRG d4xD7x2.5 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 HMJ2-8N Self-Tapping Screw M2x8 1
5 HMC3-10B Socket Screw M3x10 3
6 HMJ3-20N Self-Tapping Screw M3x20 1
7 HME3-4B Set Screw M3x4 1
8 HMM3Z Locknut M3 3
9 BK0075 Link Ball 4.8 1
No. Material No. Description Qty.
1 HMC3-30B Socket Screw M3x30 2
2 HMC3-14B Socket Screw M3x14 2
3 HMM3Z Locknut M3 4
4 BK0086 Ball Link 4.8x20 2
5 BK0278 Machined Washer 2
6 BK0403 Rod Guide 4
7 BK0404 Tail Rotor Blade 2
No. Material No. Description Qty.
8 BK0877 3D Vertical Fin 1
9 BK0650 Tail Boom 1
10 BK0707 Rear Servo Rod 1
11 BK0347 Tail Push Rod A 1
12 BK0653 Tail Push Rod B 1
13 3-1-1 Tail Transmission Subassembly 1
14 3-1-3 Tail Drive Shaft Subassembly 1
No. Material No. Description Qty.
1 BK0617 Bolt M4x25 1
2 BK0086 Ball Link 4.8x20 4
3 BK0318 Link Rod 2.3x95 2
4 HMM4Z Locknut M4 1
5 2-1 Rotor Head Assembly 1
No. Material No. Description Qty.
1 HME4-5B Set Screw M4x5 4
2 BK0397 Skid Brace 2
3 BK0398 Skid Pipe End Cap 4
4 BK0668 Skid Pipe 2
No.Material No.DescriptionQty.
15-4-1Body Subassembly1
No.Material No.DescriptionQty.
1HMJ2-6BM2x6 Self-Tapping Screw6
2HSE3-12BM3x12 Self-Tapping Screw2
3BK0102d3xD6x11Grommet2
4BK0098Body ClipA1
5BK0099Body Clip B1
6BK0429Body1
7BK0428Canopy1
8JV0186Decal1
9BK0473Body Support1
10BK0474Rubber CAP2
11HNLR6R Pin2
No.Material No.DescriptionQty.
1*****Main Rotor Blade2
2BK0446Rotor Bolt M5x352
3HMM5ZLocknut M52
TABLE OF CONTENTS
REPAIR AND REPLACEMENT PARTS
Purchase replacement parts from the hobby shop where you have purchased the Raptor 90!3D. Please contact
the Thunder Tiger distributor in your country, and the distributor can tell you where to obtain the parts. For example,
in the U.S, all Thunder Tiger products are distributed by Ace Hobby Distributors. On the web site www.acehobby.com,
there is a list of all the hobby shops in the USA that can order any Thunder Tiger parts from Ace for you. Technical
questions regarding the Raptor will be answered quickly by sending an email to [e-mail] or call
Technical Support at 949-833-7498. In Europe, Asia and Australia, please contact the distributor in your country.
WARNING
To ensure safety, please read the instruction manual thoroughly before assembly. Radio control helicopters are
sophisticated equipment, and not toys. Radio control model helicopters are capable of causing serious bodily injury
if not properly assembled or operated. The manufacturer and distributors assume no liability for damages that could
occur from the assembly or use of this product. This product is designed for hobby use only. Operating model
helicopters requires diligence and skill. The best way to ensure quick and successful learning is to seek help and
guidance from accomplished pilots. It is strongly recommended to join the appropriate radio control modeling governing
society in your country. For example, in the United States, it is strongly encouraged to join the Academy of Model
Aeronautics. AMA is a nonprofit organization that provides members in the United States with liability insurance
and monthly modeling magazines. For further information or to find a model helicopter club, please contact AMA
at:
Academy of Model aeronautics
515 East Memorial Drive
Muncie, IN 47302
USA
[phone]
We also encourage you to subscribe to different radio control helicopter magazines and learn about RC flying events,
new flying techniques, safety procedures, and hints. Rotory Modeler is a bi-monthly and Model Helicopter Techniques
is a quarterly newsletter published in the USA. Model Helicopter World is a month magazine published by Traplet
Publication in England and sold worldwide. Rotor is a monthly German magazine. Helico is a Swiss quarterly
magazine.
ATTENTION
We are unable to accept replacement or return of this model after it has been used or assembly has begun.
It is legally prohibited to duplicate or reprint this manual in any format without a written permission from the
manufacturer.
The manufacturer has the right to make changes to this model or instruction without notice.
We have done our best to the accuracy of information in this manual. If you are aware of any mistake, we welcome
you to notify us.
We will not accept any responsibility for any accident, breakdown, fault or trouble caused by improper usage of
this model. Please thoroughly inspect your model and range check the radio before flight. Please keep the model
in its best condition in order to enjoy it.
This model does not include all the items necessary for flying, such as engine, serevos, gyro...etc.
It is difficult for beginners to fly RC helicopters by themselves. It is highly recommended that beginners seek the
help of experienced RC helicopter pilots. We recommend beginners start with an inexpensive model such as the
Thunder Tiger Raptor 30 that is also designed by Mr. Taya.
RC helicopters are not toys. The manufacturer does not assume the liability for any property or bodily damage
caused by the model or the operator.
OTHER ITEMS REQUIRED
6
BODYSUPPORT INSTALLATION
Insert the aluminum support
tube through the servo frame.
Insert the "R" pins through the
two holes in the support tube
to prevent the tube from
moving in the servo frame.
Install two rubber ends onto
the support tube.The rubber
ends will dampen shake or
vibration generated by the
engine.
Glow Plug Wrench
12V Battery
1.5V Glow Starter
(1.2V~1.5V)
Rubber Band
(Included)
Foam
Remote Glow Plug
Extension
1-2-2 Cooling Fan Casing Subassembly
1-2-3 Fuel Tank Subassembly
No. Material No. Description Qty.
1 BK0062 Fuel Tank Stopper 1
2 BB0374 Silcon Tube (L=105mm) 1
3 BK0445 Fuel Plug 1
4 BK0463 Fuel Tank Nipple 1
5 BK0503-1 Fuel Tank 1
6 BE1867 Clunk Weight 1
1-5-5 Header Tank Subassembly
No. Material No. Description Qty.
1 HMC3-25B Socket Screw M3x25 1
2 BK0087 Washer d3xD8x1.4 1
3 BV0502 Header Tank 1
4 BK0506 Tank Mount 1
5 BK0698 Header Tank Supporter 1
The Raptor 90 3D kit includes a header fuel tank that can be
attached to the right of the side frame.
23
2-1-1 Flybar Seesaw Subassembly
24
2-1-2 Metal Main Rotor Hub Subassembly
2
4.Final Assembly ---------------------------------------------------------------------------------------------- 29
4-1 Installation of Rotor Head (Bag H)----------------------------------------------------------------------30
4-2 Installation of Engine --------------------------------------------------------------------------------------31
4-2-1 Engine Subassembly -------------------------------------------------------------------------------32
4-3 Installation of Landing Skid------------------------------------------------------------------------------- 33
4-3-1 Skid Subassembly -----------------------------------------------------------------------------------33
4-4 Installation of Tail Assembly ----------------------------------------------------------------------------- 34
4-4-1 Tail Support Subassembly------------------------------------------------------------------------ 34
5.Installation of Peripheral Equipment ----------------------------------------------------------- 35
5-1 Installation of Servo - Part 1 (Bag I) ------------------------------------------------------------------ 36
5-2 Installation of Servo - Part 2 (Bag I) ------------------------------------------------------------------ 37
5-3 Installation of Receiver and Gyro ---------------------------------------------------------------------- 38
5-4 Installation of Body (Bag J) ------------------------------------------------------------------------------39
5-4-1 Body Subassembly ----------------------------------------------------------------------------------39
5-5 Installation of Rotor Blades (Bag K) ------------------------------------------------------------------- 40
6.Settings --------------------------------------------------------------------------------------------------------- 41
6-1 Setting up Gear Backlash ------------------------------------------------------------------------------- 42
6-2 Setting up of Stabilizer Paddles ------------------------------------------------------------------------43
6-3 Setting up of Blade Pitch Angle ----------------------------------------------------------------------- 43
6-3-1 Collective Travel for Hovering ------------------------------------------------------------------ 44
6-3-2 Collective Travel for 3D --------------------------------------------------------------------------- 44
6-3-3 Configuring the Raptor 90 for 3D --------------------------------------------------------------- 45
Attention --------------------------------------------------------------------------------------------------------------46
7.Parts List Section -------------------------------------------------------------------------------------------49
Raptor 90 3D Exclusive Parts -------------------------------------------------------------------------------- 50
Raptor 90 3D Spare Parts List ------------------------------------------------------------------------------- 55
Raptor 90 3D Optional Parts List ---------------------------------------------------------------------------- 61
3
Thank you very much for purchasing the Thunder Tiger Raptor 90 3D R/C helicopter. The design of Raptor
90 3D is based on the original Raptor 90 series helicopter and modified for extreme aerobatics. It has all
needed must-have optional parts for 3D flying, such as metal main rotor hub, non-linear flapping damper,
metal BRG, 3D light paddles and so on. It also adopts the push-pull control system on collective pitch
and elevator to achieve the most precise control. The flybar ratio is changeable to fit all kinds of flying
style. Use of high quality material make the helicopter one tough machine that can handle everyday 3D
beating. Raptor 90 3D is born for 3D flying, and you don’t have to do any further modification for aggressive
3D maneuver. This is by far the best machine you have never seen. Just enjoy the model and have fun.
UNIQUE SIDEFRAME SYSTEM
Aluminum side plates are used in conjunction with molded material to construct the main structure. This
design produces minimum weight with maximum strength. If the sideframes were completely made of
molded material, then to achieve equal strength the plastic would have to be very thick and heavy. Using
molded material at the right place avoids using metal angle brackets or putting compound bends in metal
frames. Slots have been added in the frame design to permit the use of optional gear ratios to optimize
engine performance to suit any pilot's demand.
BELL-HIILLER MIXING CONTROL UNIT
Main rotor control geometry has been carefully engineered to minimize cross-coupling in collective and
cyclic commands. Blade pitch arms and the Bell-Hiller mixing arms are designed at an angle such that
the pushrod interlinking them are at 90 degrees when the blades are at 0 degree. The pilots will get the
symmetrical cyclic control feel and flybar authority either at +10 or -10 degrees of collective. We design
this system with the 3-D pilot in mind. We guarantee you this whole design philosophy provides a strong
and accurate control mechanism.
SHAFT DRIVE TAIL ROTOR
The Raptor 90 3D is designed with a constant drive tail rotor system to permit full tail rotor control during
autorotations. 180 autos, backward autos and pirouette autos are all within your reach now. It has the
same aluminum torque tube system as the Thunder Tiger/Taya Imperio helicopter. This allows obtaining
the maximum performance from any modern heading lock gyros.
3D CAD DESIGN
We use the latest 3D Computer Aided Design to design and manufacture the Raptor 90 3D. Our high-
tech CAD program allows simulation of all moving parts to ensure no interference. The analysis automatically
analyze the weight, the mass distribution, and inertia to help us pursue a design that will provide the high
level of maneuverability needed for all-out 3-D aerobatics.
INTRODUCTION
Socket Drivers
Hex WrenchGrease
Blue Loctite
Instant Glue
Hobby Knife
Metric
4-way Wrench
Scissors
Diagonal Pliers
Open End Wrench
5.5mm
Needle Nose PliersScrew Driver
7mm
5.5mm
7mm
8mm
5.5mm
7mm
8mm
10mm
Epoxy
Ball Link Pliers
No. Material No. Description Qty.
1 HMV6800ZZY BRG d10xD19x5 1
2 HME4-5B Set Screw M4x5 2
3 HMS5 E Ring M5x8 1
4 HMV696Z BRG d6xD15x5 1
5 BK0388 Clutch BRG Case 2
6 BK0659 Frame Space M 4
7 BK0594 Starter Coupling 1
8 BK0592 Starter Shaft 1
9 BK0422 Drive Pinion 11T 1
10 BK0366 Pinion Gear Nut 1
11 BV0522-2 Clutch Bell Set 1
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 2
2 HMC3-12B Socket Screw M3x12 4
3 BK0087 Washer d3xD8x1.4 6
4 BK0393 Pitch Frame Cross Member 1
5 BK0394 Pitch Frame Cross Member Nut 2
6 BK0375T Upper Frame 2
No. Material No. Description Qty.
1 HMM3Z Locknut M3 4
2 HMC3-25B Socket Screw M3x25 4
3 BK0820BL Landing Skid Damper 4
4 4-3-1 Skid Subassembly 1
No.Material No.DescriptionQty.
1HMC3-8BSocket Screw M3x84
2HMQ16Retaining Ring1
3BK0357Tail Drive Spur Gear 83T1
4BK0359One Way Clutch Shaft1
5BV0368Auto Rotation Hub1
6BK0356Main Spur Gear 91T1
1-6-2 Main Gear Subassembly
(3)
(2)
(4)
(6)
(5)
(1)
The carbon rear servo plate is secured
by two Lower 3mm bolts from the plastic
tail boom bracket.
10
1-1-2 Pitch Guide L Subassembly
1-1-3 Pitch Guide R Subassembly
No. Material No. Description Qty.
1 BK0384 Pitch Guide Collar L 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
The side with a number should face
in because the opening on both sides
are differeent.
The hole on the plastic control arm has different
opening sizes on the two sides.Always snap the
bigger opening to the ball on swashplate gently and
afterward please check to make sure it is securely
attached and there is no damage or cracking.
INSTALLATION OF THE LINKS
Bigger Hole Face to Swashplate
Extended 6mm Hex
Starting Tool
Fuel Pump
Heli Engine (90size)
9609 PRO-90H(R)
Glow Fuel(15%-30%)
Glow Plug
Hi-torque 12V Electric starter
Receiver
Transmitter
(helicopter type, 6 or
more channels) High Speed/Torque Servo x 4
Rudder Servo x 1
Battery Switch harness
Heading Lock
Gyro
In order to enjoy a safe and enjoyable experience, please read the manual carefully and completely understand
the helicopter structure and operation before the first flight.
Read the warnings to avoid injuries to you and others.
WARNING – The following could cause heavy injury or death if used incorrectly.
Keep the model away from other people or animal when starting the engine.
Do not fly any model helicopter near or above people or cars. Models can sometimes lose
control due to pilot or mechanical failure.
WARNING – The following could also cause serious injury or death if not careful.
Take precaution with model fuel. Model engine glow fuel is highly flammable.
Please check the model carefully before each flight. Make sure that nothing has loosened up
or come apart.
Make sure everything moves freely without binding or excessive friction.
Do not operate the model in rain, snow, thunderstorm, or adverse weather.
WARNING – The following could also cause serious injury or death if not careful.
Please make sure that your radio frequency is not used before flight. If someone else is flying
with the same frequency as your radio, do not turn on your transmitter. Otherwise, it can cause
a crash and even bodily and property damages.
Please monitor the fuel level during flight and land before running out of fuel.
Before each flight, please check that all servos and controls move properly.
Do not modify any parts or use other than genuine Thunder Tiger parts.
Do not fly in places that are forbidden by law.
Use Loctite on screws that do not use a locknut.
When operating the model, please beware that no loose cloth or jewelry can get entangled in
the model helicopter.
Make sure the transmitter and receiver switches are on before starting the engine.
Do not touch the engine or the muffler right after flying because they are very hot.
Do not use this model for anything other than hobby.
WARNING – The following damages can happen to the model.
Do not leave the model in a car for a long time. The heat in the summer or the cold in the
winter and the humidity can cause damage to the model.
Be careful and watch the sharp edges and corners on the model.
BUILDING HINT – The instruction is divided into six assembly chapters:
Main Frame, Rotor Head, Tail Rotor, Final Assembly, Radio Installation, and Settings. There
are many major assembly steps in each chapter, please follow the instruction to do each "
Subassembly" first, then combine the subassemblies into a major assembly.
Upper Frame Assembly
Lower Frame Assembly
12
1-2-1 Tail Drive Unit Subassembly
No. Material No. Description Qty.
1 HME3-4B Set Screw M3x4 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 BK0362 Tail Drive Bevel Gear A 1
5 BK0363 Tail Drive Bevel Gear B 1
6 BK0364 Tail Drive Pinion 1
7 BK0365 Tail Drive Gear Shaft 1
8 BK0382 Tail Boom Bracket L 1
9 BK0383 Tail Boom Bracket R 1
10 BK0414 Pin 2x12 2
11 BK0660 Frame Spacer L 5
Main Frame Assembly Installation of Pitch Frame
No. Material No. Description Qty.
1 HMJ2-10N M2x10 Self-Tapping Screw 1
2 HMV840ZZY BRG d4xD8x3 2
3 HMV1280ZZY BRG d8xD12x3.5 2
4 BK0336 Pitch Frame 1
5 BK0075 Link Ball
φ
4.8 1
Optional: add a tiny drop of thick CA on the outside rim of the fovr ball
bearings before inserting them into the plastic Pitch Frame. Be careful
not to get any glue into the ball bearings. Add a tiny drop of thick CA
glue at the tip of the M2x10 self-tapping screw (No. 1) before
screwing it into the Pitch Frame.
32
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
No. Material No. Description Qty.
1 BK0385 Pitch Guide Collar R 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
Tip: When setting up the phase
adjustment ring, the flybar and
the tail boom can be the
reference. When the flybar and
the tail boom are centered, the
inner balls of swashplate should
be aligned with the outer balls.
Tighten the socket screw on the
phase ring at this moment.
NOTE: Improper alignment will
cause unwanted mixing.
No. Material No. Description Qty.
1 ******** 90 Class Heli Engine 1
2 ******** Nut (Comes With the Engine) 1
3 HMC4-8B Socket Screw M4x8 2
4 HMC4-18B Socket Screw M4x18 4
No. Material No. Description Qty.
5 HMO10 Washer d9.5xD16x1 1
6 BK0349 Engine Mount 1
7 BV0380 Cooling Fan 1
8 BV0521 Heavy Duty Clutch 1
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.85
2BK0086Ball Link 4.8x208
3BK0104Servo Mounting Plate6
4BK0105Rod Joint1
5BK0318Link Rod 2.3x952
6BK0436Link Rod 2.3x552
7BK0833Servo Block4
8HMC2516BSocket Screw M2.5x164
No.Material No.DescriptionQty.
9HMM25Lock Nut M2.54
10HML2Nut5
11HME4-5BSet Screw2
12HMF2-8NPhillips Machine Screw M2x85
13HSE2614NSelt-Tapping Screw4
14HSE2630NSelt-Tapping Screw4
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.87
2BK0086Ball Link 4.8x204
3BK0095Link Rod 2.3x761
4BK0104Servo Mounting Plate4
5BK0833Servo Block2
6BK0834Pitch Lever Fixed Plate1
7BK0839Link Rod 2.3x301
8BK0881Washer1
9BK0883Pitch Push Pull Lever1
No.Material No.DescriptionQty.
10BK0884Collar, d3xD4xW121
11BV0085Pitch Link Rod2
12HMC3-20BSocket Screw M3x201
13HMV840ZZYBearing d4xD8xW32
14HMF2-8NPhilip Maching Screw M2x84
15HMJ2-8NSelt-Tapping Screw M2x83
16HML2Nut4
17HSE2614NSelt-Tapping Screw M2.6x148
18HSE2620NSelt-Tapping Screw M2.6x204
No.Material No.DescriptionQty.
1****Switch1
2****Receiver Battery1
3****Receiver1
No.Material No.DescriptionQty.
4****Gyro
5BK0106Foam2
6 BE1052Antenna Pipe1
PV0517ONEWAYBEARING GREASE
The hole on the Flybar Control Rod has different
opening on two sides.Always snap the bigger opening
to the link ball.
Bigger Hole
Face to ControlArm
10.5mm10.5mm
When installing pinion gear, add a small drop of Loctite to the
threads. Make sure not to get Loctite on lower clutch bell bearing.
Important:
For 90 class engine, we recommend the 11 teeth pinion for 3D
flying.
The servo tray and cooling fan shrouds on the Raptor 90 are different from the
Raptor 60 in order to accommodate the full head sink on the O.S 91. engine.
If using T.T 90, Y.S 91 or Webra 91 engine, make sure to install the fan shroud
baffle with two self-tapping screws. This will ensure optimal cooling of your engine
head.
Add CA glue Add CA glue
It is necessary to add grease inside the one way clutch before your
first flight.The clutch might lock up once grease is gone.The one
way clutch grease( PV0517) is recommended for this lubrication.
Make sure the inside ofAuto Rotation Hub is clean without any dirt
before you insert the one way clutch shaft.
Add Loctite
Add Loctite on
the threads
For 3D flying, it is recommended to use
lower flybar ratio setting.
Self-Tapping Screw, No. 10 Collar, and No. 11 Washer, with two
No. 1 Bearings. Attach a No. 9 Link Ball with a No. 4 Screw.
Upon finishing Step 3-1-1, make sure there are no extra parts
left on your workbench.
Elevator Control
Pushrod
Glue the two plastic halves of
the paddle with CAglue before
installation on flybar.
Add Loctite
the tail boom by tightening the four screws on the helicopter.
Visually check from the rear of the helicopter to make sure the
tail rotor output shaft is perpendicular to the main rotor shaft.
Add the tail boom supports.
Add Loctite
The thrust bearing washer with the
SMALLER inner hole should be closer to
the rotor blade.
The thrust bearing washer with the BIGGER
inner hole should be closer to the main rotor
shaft.
4-2-1 Engine Subassembly
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add CA Glue
Introduction -------------------------------------------------------------------------------------------------------- 3
Other Items Required -------------------------------------------------------------------------------------- 4
Warning --------------------------------------------------------------------------------------------------------------- 5
Assembly
1. Main Frame Assembly --------------------------------------------------------------------------------- 7
1-1 Upper Frame Assembly (Bag A) ---------------------------------------------------------------------- 8
1-1-1 Pinion Gear Subassembly ------------------------------------------------------------------------ 9
1-1-2 Pitch Guide Left Subassembly ------------------------------------------------------------------10
1-1-3 Pitch Guide Right Subassembly -----------------------------------------------------------------10
1-1-4 Elevator Control Arm Subassembly------------------------------------------------------------ 10
1-2 Lower Frame Assembly (Bag B) ----------------------------------------------------------------------11
1-2-1 Tail Drive Unit Subassembly ---------------------------------------------------------------------12
1-2-2 Cooling Fan Casing Subassembly -------------------------------------------------------------13
1-2-3 Fuel Tank Subassembly ------------------------------------------------------------------------13
1-3 Main Frame Assembly (Bag C) -------------------------------------------------------------------------14
1-3-1 Rod Guide Collar Subassembly-----------------------------------------------------------------14
1-4 Installation of Servo Frame (Bag C) ------------------------------------------------------------------- 15
1-5 Installation of Pitch Frame (Bag D) -------------------------------------------------------------------- 16
1-5-1 Aileron Lever Subassembly ---------------------------------------------------------------------17
1-5-2 Metal Elevator Parallel Lever Subassembly -------------------------------------------------17
1-5-3 Elevator Control Lever Subassembly --------------------------------------------------------- 17
1-5-4 Pitch Control Frame Subassembly -------------------------------------------------------------18
1-5-5 Header Tank Subassembly ----------------------------------------------------------------------18
1-6 Installation of Main Shaft (Bag E) ----------------------------------------------------------------------19
1-6-1 Wash Out Subassembly -------------------------------------------------------------------------20
1-6-2 Main Gear Subassembly -------------------------------------------------------------------------20
2. Rotor Head Assembly -----------------------------------------------------------------------------------21
2-1 Metal Rotor Head Assembly (Bag F) -----------------------------------------------------------------22
2-1-1 Flybar Seesaw Subassembly --------------------------------------------------------------------23
2-1-2 Metal Main Rotor Hub Subassembly ----------------------------------------------------------24
3.Tail Assembly -------------------------------------------------------------------------------------------------25
3-1 Tail Assembly (Bag G) ----------------------------------------------------------------------------------- 26
3-1-1 Tail Transmission Subassembly --------------------------------------------------------------- 27
3-1-2 Tail Rotor Subassembly --------------------------------------------------------------------------- 28
3-1-3 Tail Drive Shaft Subassembly -------------------------------------------------------------------28
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The Liner is pre-glued on the
inside of clutch bell with 30 min
epoxy.
1-1 1-2 1-3
( 2 ) (1)
1-4
(1)
(2)
1-5 1-6
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(1)
(5)(4)
(9)
(3)
2-1
3-1 4-1
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(3)
(2)
(1)
4-3
(4)
(2)
4-4
(2)
(7)
(1)
(3)
(5)
(8)
4-2
(3)
(1)
(2)
5-15-2
5-3
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(1)
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(2)
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5-4
5-5
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(3)
No. Material No. Description Qty.
8 BK0660 Frame Spacer L 3
9 BK0376T Lower Metal Frame 2
10 BV0870 Metal Lower BRG Block 1
11 1-2-1 Tail Drive Unit Subassembly 1
12 1-2-2 Cooling Fan Casing Subassembly 1
13 1-2-3 Fuel Tank Subassembly 1
No. Material No. Description Qty.
7 BK0659 Frame Spacer M 2
8 BV0869 Metal Upper BRG Block 1
9 1-1-1 Pinion Gear Subassembly 1
10 1-1-2 Pitch Guide L Subassembly 1
11 1-1-3 Pitch Guide R Subassembly 1
12 1-1-4 Elevator Control Arm Subassembly 1
(3)
No. Material No. Description Qty.
10 BK0093 Link Rod 2x46 1
11 BK0407 Collar d3xD4x4.5 2
12 BK0410 Collar d3xD4x13 2
13 1-5-1 Aileron Lever Subassembly 1
14 1-5-2 Metal Elevator Parallel Lever Subassembly 1
15 1-5-3 Elevator Control Lever Subassembly 1
16 1-5-4 Pitch Control Frame Subassembly 1
17 1-5-5 Header Tank Subassembly 1
No.Material No.DescriptionQty.
6HMM4BLucknut M41
7BK0617Bolt M4x251
8BV0504Metal Swashplate1
91-6-1Washout Subassembly1
101-6-2Main Gear Subassembly1
No. Material No. Description Qty.
10 BK0076 Collar d3xD4x10 1
11 BK0088 Washer d3xD5x0.5 1
12 BK0346 Tail Pitch Control Lever 1
13 BK0370 Tail Case L 1
14 BK0371 Tail Case R 1
15 BK0372 Tail Input Bevel Gear 1
16 BK0373 Tail Output Bevel Gear 1
17 HMY2-12 Pin 2x12 1
18 3-1-2 Tail Rotor Subassembly 1
No. Material No. Description Qty.
1 HMM3Z Locknut M3 6
2 HMC3-16B Socket Screw M3x16 2
3 HMC3-20B Socket Screw M3x20 2
4 HMC3-25B Socket Screw M3x25 2
5 HMC3-30B Socket Screw M3x30 2
6 BK0087 Washer d3xD8x1.4 4
No. Material No. Description Qty.
1 HMJ2-8N Self-Tapping Screw M2x8 4
2 BK0447 Tail Support Rod End 4
3 BK0669 Tail Support Rod 2
No. Material No. Description Qty.
1 HMC4-42B Muffler Bolt M4x42 2
2 HMT4B Spring Washer 2
3 ******** Muffler ( 90 ) 1
4 4-2-1 Engine Subassembly 1
5 HMC4-12B Socket Screw M4x12 4
6 BK0435 Washer d4xD11xW1.7 4
BAG A
BAG B
BAG C BAG C BAG D
(L) (R)
BAG E
BAG F
BAG G
BAG H
BAG I
97.5mm
48mm
(3)
Throttle
Collective Pitch
(2)
BAG I
BAG J
BAG K
(11) (8)
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(2)
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(3)
(5)
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(4)
Please complete subassembly steps 1-2-1 through 1-2-3 first. Then attach the subassemblies to the two Lower Frames. Note
that the Metal Lower BRG is installed with the bearing open side facing up. Please add a small drop of Loctite on every bolt
before screwing it into the aluminum hex spacer. Do not apply Loctite to the bolts which are going to secure the Lower BRG
Block at this moment.
Assemble the upper main frames by starting with the two Metal Upper Frames. The Pinion Gear Subassembly must be assembled
first according to Figure 1-1-1. Next insert three hex-shape frame spacers into the plastic Pitch Guide according to Figure 1-1-2
and 1-1-3. Assemble the Elevator Control Arm subassembly according to 1-1-4. Insert it in between the two Upper Frames. The
metal Elevator Control Arm is not symmetrical. The side with the longer profruding round knob should be on the right side of the
helicopter. Then attach the other subassemblies to the Upper Frames. Locate Hex Wrenches in BAG L which you need for
assembly.
Please add a tiny drop of non-permanent type Loctite on the tip of all bolts before screwing them into the hex shaped aluminum
frame spacers. Never use too much Loctite, otherwise it will become nearly impossible to remove later on for servicing. Only use
the non-permanent type of Loctite. If encountering difficulty in removing any bolt that was locked up by Loctite, heat up the head
of the screw or bolt with the tip of a hot soldering iron, it will help soften the cured Loctite.
For the kit, parts are bagged according to each major assembly and are labeled "Bag A, Bag
B, etc." The heading for each assembly indicates which bag to open. As a good practice,
only open up the bag that you need for the particular assembly. Check the parts in that bag
against the parts list shown for each assembly as well as each sub-assembly to make sure
there are no missing parts. To prevent losing small hardware, please empty the small nuts
and bolts and parts into small plastic trays on your work table. At the end of each major
assembly, there should be no left over parts.
The fuel tank comes assembled from the factory because every tank has been
checked for leak. If you were to take the tank apart here is how to put it back
together. Install the silicone fuel line to the Fuel Nipple. Then add the rubber
fuel tank stopper and the clunk weight. The stock silicone fuel line is very soft
and thin which is designed to allow the clunk to pick up fuel easily during 3-D
aerobatics. The pickup line should be inspected and replaced if necessary every
month, otherwise when it becomes soggy it can break off. A thicker silicone line
maybe substituted but make sure the clunk will reach the bottom when moving
the fuel tank to all different orientations.
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As show in Figure 1-3-1, insert two hex
Frame Spacers S into the plastic Rod
Guide Collars. Then join the Upper
Frame Assembly to the Lower Frame
Assembly according to drawing 1-3.
Secure the Set Screws (No.1) to the
frames, and fit the Body Posts (No.4)
to the Set Screews. The two Body Posts
will be used to secure the canopy in the
future. Add Loctite on all bolts and
inside BK0103 threaded hole.
Install the one-piece servo frame with six self-tapping screws.
Do not use Loctite when attaching self-tapping screws to plastic
parts. Loctite is only for threading metal into metal parts. Assemble the constant drive Main Gear Subassembly according to Figure 1-6-2 first.Then build up the Wash Out Subassembly
according to 1-6-1. Insert the No.3 Main Shaft into the bearings and then add the No.4 Lock Ring and slide in the Main Gear
Subassembly. Add two M3x6 Button Head Screws to the Locking Ring, and the two screws are threaded into the holes on the
main rotor shaft.
The locking ring prevents the main shaft from sliding up. Line up the hole on the main gear and the main shaft, then insert M4x25
mm Bolt through them. Place a 4 mm M4 locknut on the other side of the autorotation hub, and then tighten the Bolt. Do not
over tighten the Bolt, otherwise the autorotation assembly will be distorted. Loosen the 3mm bolts holding the Upper and lower
bearing blocks for the 12mm main shaft. Wiggle the main shaft in the bearing blocks until the main shaft spins freely in the bearings.
This ensures the upper and lower bearing blocks are aligned. Push the lower bearing block up until the main shaft has no up
and down play. Then tighten the 3mm bolts for the upper and lower bearing blocks.
Insert the pin into the Washout Link.Add a tiny drop of Loctite on the inside
and outside of BK0409 Collar which will help give a completely slop free
control system. Do not let the Loctite seep into the bearing.Adjust the
tightness of the M3x12 bolts so the mixing arms can move freely but without
wobble or racheting the ball bearings.Add a tiny drop of thick CAglue at
the tip of the M2x10 self-tapping screw (No. 1) before screwing it into the
Flybar Control Levers (No. 6).
Make the two pushrods for controlling the blade pitch.The distance 43 mm is measured between the center of two pushrod holes.
Attach the Seesaw Hub of the Control PaddleAssembly to the Main Rotor Head with Socket Screws (M3x10).
Please add a small drop of Loctite along the entire length of the M3x10 Socket Screw (No.5) and on the outside of the collar
d3xD4x5.5 (No.3).Temporarily install the Washout Base Guidence Ring, but do not tighten the No.6 M3 Socket Screw yet.
Assemble the tail transmission subassembly according to 3-
1-1 and 3-1-2 first. And the tail drive shaft subassembly according
to 3-1-3.But do not close the two halves of the tail transmission
tightly. You will do this when you are ready to install the gearbox
onto the tail boom.
When installing the tail transmission, make sure the housings
match the hole on to the tail boom. Add Carbon Vertical Fin with
machined washer and Locknut, then tighten the five 3 mm bolts.
Add carbon Vertical Fin with Pom washer and Locknut.
Before inserting the finished tail drive shaft assembly into the
tail boom, add some flexible silicone glue or ZAP Goop glue
around the outside of the tail drive bearing housing. This will
prevent the bearing housing from spinning inside the tail boom.
(7)
Install bearings No. 2 and No.3 into the Tail Cases. Install No.
16 Tail Bevel Gear onto the Tail Shaft. Gently tap the No. 17
Pin into the Bevel Gear and Tail Shaft. Then secure the pin
with a No. 7 Set Screw with Loctite.
After installing the M3x4 set screws, try pushing on the 2x12
pin with a small Allen wrench to make sure the set screw has
locked the pin in place securely. Before closing the two halves
of the Tail Cases, please check the gear mesh between gears
No. 15 and No. 16. If the gears mesh too tight, then a 5 mm
i.d. washer should be added to move the gear No. 16 further
out. If there exists too much freeplay, then a 5 mm i.d. washer
to push gear No. 16 closer to gear No. 15.
Install the No. 12 Tail Pitch Control Lever as shown with No. 6
Slide four No. 6 Rod Guides onto the tail boom. Do not glue
them onto the tail boom yet. Add a tiny drop of CA glue to the
pushrod guide after you finish building the entire helicopter.
Before adding glue, make sure the tail pushrod is hooked up
to the servo and the rod travels in a straight line and moves
very smoothly.
Congratulation, we are almost done. Install the finished main
rotor head onto the 12 mm rotor main shaft. Secure it with a
M4x20 Bolt and M4 Locknut. Make up two 113.5 mm long
pushrods and attach them to the Bell-Hiller mixing arm.
Before installing the plastic end caps, please
add a drop of slow, thick CA glue on the
rim of the end caps and on the inside edge
of the aluminum skid.
Slide the finished tail boom into the helicopter. The four bolts
on the helicopter must be loose in order to insert the tail boom.
Make sure the tail drive shaft is inserted into the front receptacle
properly. Check this by turning the main rotor head. Secure
Secure the two ends to the rod with Epoxy, making sure the
two metal ends are perpendicular to each other.
(4)
Attach the engine into the side frames, with four M4x12 bolts and
four washers, but do not tighten until Section 6-1.
Install the muffler after you have building the entire helicopter.
Always add Loctite on the muffler bolts.
Install the servos and make up the pushrods according to the drawings.The distance between the steel ball and the center of
servo arm are shown in the drawing. Use them as a guide.These distances are used in conjunction with the servo travels (ATV
or End point) set to 100% for all the channels in the transmitter.Tune them later on to suit your personal flying style.
Attach the rudder servo to the rear mounted carbon plate with four 2.6mm bolts and four M2.6 locknut.
Make up the throttle and collective control pushrods according
to the drawing. Use the outermost hole on the carburetor throttle
control arm.Attach the steel ball on the throttle servo arm at
approximately the same distance as the steel ball on the throttle
arm.
Make up the throttle at 97.5mm long first, and then adjust the
pushrod length and throttle servoATV or Endpoint so full throttle
stick command will open the carburetor barrel fully.And full low
stick and low throttle trim will close the carburetor barrel completely.
Install the receiver and receiver battery. Even though the receiver and battery can be attached to the helicopter tray by using
double sided foam tape, but it is better to wrap the receiver and battery separately using half inch or 10 mm thickfoam. Then
secure them to the tray using six to eight rubberbands, or Velcro bands.
Carefully cut out the canopy (windshield) using scissors.The
best scissors to use are (TTR 1304) designed to cut RC car
bodies and Canopy. Install the canopy to the body using six
small screws. Drill small holes in the canopy and body for the
holes. Drill two more holes for the rubber grommets.
Refer to color box and apply the decals (In BAG M) .
Tools for Assembly
The Raptor 90 3D is designed for easy maintenance using standard hobby tools. Please only use genuine Thunder Tiger parts.
Please keep the model clean and well tuned. It will provide you with long lasting pleasure in return.
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Add Loctite
(Included)
Add a tiny drop of thick CA glue at the tip of the M2x10
self-tapping screw (No. 1) before screwing it into the
Aileron Levers.
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Make up the landing gear according to the
drawing.
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(1)
No. Material No. Description Qty.
1 HSE3-6B Self-Tapping Screw M3x6 2
2 BK0660 Frame Spacer L 4
3 BK0662 Cooling Fan Baffle 1
4 BK0665 Fan Casing L 1
5 BK0666 Fan Casing R 1
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Assemble the metal flybar control arms according to the drawings. Slide Flybar ControlArm onto the No.18 Flybar Rod. Slide
the flybar into the No.17 Seesaw Hub. Make sure the Flybar has equal protrusion from each side of the SeesawHub measure
them with a ruler, then install and tighten the No.8 HME4-5B set screws.Add the paddles. Make sure the two paddles and the
two flybar control arms are all parallel. Lock the paddles with No.6 set screws.
Assemble and install the No.10 Mixing Levers and No.5 Bearings according to the drawing using No.12 Collar andNo.9 d3xD5x0.5
washer.
Note:Before installing the Mixing Lever (No.10), please add a small drop of Loctite along the entire length of the M3x18 button
head socket screw (No.4) and on the outside of the collar d3xD4x13 (No.12). Be careful do not let the Loctite seep into the bear ings.
There are two choices of hole positions on the aluminum seesaw for attaching the mixing lever arm.The outside hole gives higher
Bell-Hiller mixing ratio. For aggressive 3D flying, you can attach the Bell-Hiller mixing arms to the inner hole which gives low er
flybar ratio.
(6)
No.Material No.DescriptionQty.
10BK0324Mixing Lever2
11BK0406LPaddle Root2
12BK0410Collar d3xD4x132
13BK0416Paddle Stopper2
14BK0432LFlybar Paddle2
15BK0633Flybar Control Frame2
16 BK0871 Longer StabilizerArm 2
17 BV0865 Longer Seesaw 1
18 BK0866 SUS Flybar 1
No.Material No.DescriptionQty.
1HMF2-8NPhillips Machine Screw M2x82
2HMJ2-10NSelfing-Tapping Screw M2x104
3HMC3-10BSocket Screw M3x102
4 HMC3-18B Socket Screw 2
5HMV840ZZYBRG d4xD8x34
6HME4-3BSet Screw M4x34
7HME4-5BSet Screw M4x52
8BK0075Link Ball
φ
4.86
9BK0088Washer d3xD5x0.52
Insert the aluminum Main Rotor Hub Pin and the Flap Dampers. (might need to apply silicone grease for easy installation). Push
the No.7 Feathering Spindle into the dampers and the rotor hub.Add No. 14 Flybar Control Rod. Slide both finished Main Rotor
Grip onto the feathering spindle and the secure with two M4x10 bolts and washers according to the drawing.Use two Allen
wrenches to tighten the two M4x10 bolts simultaneously.
Important Note:
The Raptor 90 3D kits come with non-linear flap damper for aggressive 3D flying.You may choose to experiment adding from
one up to three 0.4mm thick shim (No.10) washers between the washer (No.8) and bearing to further stiffen the main rotor flapping.
Stiffing the main rotor head will speed up the cyclic transient response, but may cause the helicopter fuselage to oscillate at arou nd
1600 RPM.This oscillation characteristic exists for all helicopters with hard 3D flap dampers.The inner dampers should be
replaced periodically if a lot of 3D flying has been done. When the dampers are worn, the main rotor blades canflap excessivel y
during some 3D maneuvers and risk touching the tail boom.
Add flexible silcone glue or ZAP
Goop glue around the outside
before inserting into the tail
boom from the front side.
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180mm
25mm
(1)
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(2) (3)
The optionalThunderTiger Remote Glow PlugAdaptor (#3803)
is recommended as shown, making starting easy without the
removal of your canopy.
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(2)
Cut a hole at the
front air scoop for
backward flights.
(7)
No.Material No.DescriptionQty.
9BK0477Washer2
10BK0703Flap Damper Washer 0.4mm6
11BK0874Inner Damper2
12BK0875Outer Dampper2
13BK0075Ling Ball
φ
4.82
14BK0664Flybar Control Rod2
15BK0319Main Rotor Pitch Housing2
16BV0548-1Metal Main Rutor Hub1
No.Material No.DescriptionQty.
1HMC4-10BSocket Screw M4x102
2HMJ2-12NSelf-Tapping Screw M2x122
3HMV1680BRG d8xD16x54
4HMX0816Thrust Bearing d8xD16x52
5BK0330Main Rotor Hub Pin1
6 BK0325Thrust Washer 2
7BK0326Spindle1
8BK0435Washer2
Fiberglass or Carbon Rotor Blade
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Add Loctite when setting up the
gearmesh in step 6-1.
(7)
No. Material No. Description Qty.
7 BK0539 Carbon Rear Servo Plate 1
8 BK0878 Bracket (Top) 1
9 BK0879 Bracket (Bottom) 1
10 3-1 Tail Assembly 1
11 4-4-1 Tail Support Subassembly 2
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Engine System
Use a high quality 90 size 2-stroke
model helicopter engine, such as the
Thunder Tiger TT PRO-90H, OS 91
SZ-H, YS 91 ST, Webra 91, or
equivalent. Please beware, some
engines may not fit because of their
shape and size. The Raptor 90 3D
kit comes with a cooling fan hub to fit
the TT PRO-90H, OS 91 SZ-H, Webra
91.
We recommend a high quality muffler
or tuned exhaust system designed to
fit on the left side of the model.
Rotor Blades
It is important to use main rotor blades
that are of high quality and suitable
for your flying style. If fiberglass or
carbon graphite blades are used, the
length should be between 680 and
710 mm. Blade weight should be
between 170 and 200 grams.
Starter System
To start the engine, it is necessary to
use an electric starter with a 6mm
shaft extension. The starter and the
6 mm extension are available from
Thunder Tiger, the part numbers are
No.2675 and No.3801.
Use a strong high torque 12 volt
electric starter which is designed for
models.
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Add a small drop of Loctite.
Make sure it locks the pin.
Install BK0364 and BK0362 onto BK0365 Tail Gear Drive Shaft. Then insert the
two Pins and secure them with two M3x4 Set Screws. Add a tiny drop of Loctite
on the set screw thread before inserting them. Always use a very small amount
of Loctite liquid on the thread, otherwise it may be nearly impossible to remove
the set screws in the future for servicing. After installing the two M3x4 set screws
(No. 1), try to push on the 2x12 pins with a small Allen wrench to make sure the
set screws have locked the pins in place securely. Install the four ball bearings
and the hex shaped Frame Spacers according to the drawing. Before closing
the two halves of the Tail Boom Brackets, please check the gear mesh between
gears No. 4 and No. 5. If there exists too much freeplay, add some 5 mm i.d.
washers on top of gear No. 4. (The 5 mm i.d. washers are provided in BAG G).
Add a small drop of Loctite.
Make sure it locks the pin.
Shim Washer
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(4)
(2)
(3)
(1)
Add CA Glue
Standard flybar ratio
Lower flybar ratio
Mild 3D Flying
Extreme 3D Flying
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(2)
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(5)
(1)
Attach the engine mount to the engine using four 4mm bolts and Loctite.
The cooling fan hub is threaded to fit the OS, TT or Webra only. Place the washer that came with your engine onto the engine
crankshaft first. Then screw the fan hub onto the engine. Add a tiny drop of Loctite on the engine nut. Do not use too much
Loctite. Tighten the engine nut using a socket head wrench while grabbing the fan with a towel. The nut should be tighten securely.
For 50-size or bigger engines, we do not recommend using a piston locking tool on the glow plug hole because that may damage
the engine. Attach the No. 8 Heavy Duty Clutch to the fan hub. Add a drop of Loctite on the threads of the M4x8 bolts. The
threads on the aluminum cooling fan hub are for the TT 70H, OS 61 SX, OS 61LX, OS 70H, TT 90H, OS 91 or Webra 91 engines.
If YS 61, 80 or 91 engines are used, the fan hub must be re-tapped by the modeler to M8x1mm thread size or purchase a optional
plastic fan hub with threads for the YS engine(PV0198YS) or the metal fan for the YS (PV0293YS).
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Please complete subassemblies 1-5-1 through 1-5-5 first, then add them to the Main Frame. Fit the Pitch Control Frame
Subassembly. Attach the E Ring on the left side of the Metal Elevator Control Arm. Then fit the Elevator Control Lever to the
right side, insert the pin and fix it with a set screw. Secure the Pitch Control Frame with a M3*10 Socket Screw and a collar on
the left side. And attach the Elevator Push Pull Lever to the right side of the Pitch Control Frame as shown. Adjust the two bolts
so that the Pitch Control Frame can move freely without excessive play. Finally, add the two plastic Aileron Levers and the 66.5mm
elevator pushrod. Add the Washers (BK0088) to make sure that the Aileron Lever and the Metal Elevator Parallel Lever will not
touch each other during operation.
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Outer hole for standard.
Inner hole for extreme 3D.
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Add Loctite
Add Loctite
Add Loctite
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Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
30mm
(2)
Paddle
Flybar
A Arm
Phase
Adjustment
Ring
Swash
plate
Boom
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Pitch push-pull subassembly
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(2)
(3)
Add Loctite
Add Epoxy
Add Epoxy
(13)
(14)
(17) (15)
(16)

1
5
7
MAIN FRAME ASSEMBLY
8 9
1-1-1 Pinion Gear Subassembly
11
13 14 15 16 17 18 19 20
21
22
25 26 27
29 30 33 34
36
3531
37
383940
4
1-3-1 Rod Guide Collar Subassembly
1-5-1 Aileron Lever Subassembly
1-5-2 Metal Elevator Parallel Lever Subassembly
1-5-3 Elevator Control Lever Subassembly
1-5-4 Pitch Control Frame Subassembly
1-1-4 Elevator Control Arm Subassembly
1-6-1 Wash Out Subassembly
ROTOR HEAD ASSEMBLY
TAIL ASSEMBLY
3-1-1 Tail Transmission Subassembly
FINAL ASSEMBLY
4-3-1 Skid Subassembly
4-4-1 Tail Support Subassembly
INSTALLATION OF PERIPHERAL EQUIPMENT
5-4-1 Body Subassembly
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 4
2 HMC3-12B Socket Screw M3x12 21
3 BK0087 Washer d3xD8x1.4 22
4 BK0274 Tank Rubber Grommets 4
5 BK0380 Rear Frame L 1
6 BK0381 Rear Frame R 1
7 BK0629 Washer 4
No. Material No. Description Qty.
1 HME3-18.5B Set Screw M3x18.5 2
2 HMC3-25B Socket Screw M3x25 10
3 BK0087 Washer d3xD8x1.4 10
4 BK0103 Body Fitting Post 2
5 BK0658 Frame Spacer S 2
6 1-1 Upper Frame Assembly 1
7 1-2 Lower Frame Assembly 1
8 1-3-1 Rod Guide Collar Subassembly 2
No. Material No. Description Qty.
1 BK0389 Rod Guide Collar 1
2 BK0658 Frame Spacer S 2
No. Material No. Description Qty.
1 BK0667 Servo Frame 1
2 HSE3-12B M3x12 Self-Tapping Screw 6
3 1-3 Main Frame Assembly 1
No. Material No. Description Qty.
1 HMC2-6B Socket Screw M2x6 1
2 HMC3-10B Socket Screw M3x10 1
3 HMC3-25B Socket Screw M3x25 1
4 HME3-3B Set Screw M3x3 1
5 HMJ3-20N Self-Tapping Screw M3x20 2
6 HMS4 E Ring 1
7 HMY2-10 Pin 2x10 1
8 BK0086 Ball link 4.8x20 2
9 BK0088 Washer d3xD5x0.5 3
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 BK0876 Elevator Control Arm 1
2 BK0075 Link Ball
φ
4.8 1
3 HMF2-8N Philip Machine Screw M2x8 1
No. Material No. Description Qty.
1 BK0882 Elevator Push Pull Lever 1
2 HMV840ZZY BRG d4xD8x3 2
3 BK0075 Link Ball
φ
4.8 3
4 HMJ2-8N Selfing-Tapping Screw M2x8 3
5 BK0410 Collar d3xD4x13 1
No. Material No. Description Qty.
1 HMS15 E Ring 4
2 BK0880 Elevator Link Shaft 2
3 BK0455 Metal Elevator Control Arm 1
4 BK0663 Elevator Arm Link 2
No. Material No. Description Qty.
1 BK0093 Link Rod 2x46 2
2 BK0086 Ball Link 4.8x2.0 4
3 BK0547 Hardened Main Shaft 1
4 BK0234 Lock Ring 1
5 HSA3-6B Button Head Socket Screw M3x6 2
No. Material No. DescriptionQty.
1 HMJ2-10N M2x10 Self-Tapping Screw2
2 HMC3-12B Socket Screw M3x122
3 HMV840ZZY BRG d4xD8x34
4 BK0088 Washer d3x5x0.52
5 BK0472 Washout base1
6 BK0342 Flybar Control Lever2
7 BK0343 Washout Link2
8 BK0075 Link Ball
φ
4.82
9 BK0409 Collar d3xD4x72
10 BK0487 Pin2
11 HMS15 E Ring2
No.Material No.DescriptionQty.
1BK0086Ball Link φ 4.84
2BK0292Link Rod 2.3x242
3BK0408Collar d3xD4x5.52
4BV0549Washout Base Guidance Ring1
No.Material No.DescriptionQty.
5HMC3-10BSocket Screw M3x102
6HMC3-12B Socket Screw M3x12 1
72-1-1Flybar Seesaw Subassembly1
82-1-2Metal Main Rotor Hub Subassembly1
No. Material No. Description Qty.
1 HMV740ZZ BRG d4xD7x2.5 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 HMJ2-8N Self-Tapping Screw M2x8 1
5 HMC3-10B Socket Screw M3x10 3
6 HMJ3-20N Self-Tapping Screw M3x20 1
7 HME3-4B Set Screw M3x4 1
8 HMM3Z Locknut M3 3
9 BK0075 Link Ball 4.8 1
No. Material No. Description Qty.
1 HMC3-30B Socket Screw M3x30 2
2 HMC3-14B Socket Screw M3x14 2
3 HMM3Z Locknut M3 4
4 BK0086 Ball Link 4.8x20 2
5 BK0278 Machined Washer 2
6 BK0403 Rod Guide 4
7 BK0404 Tail Rotor Blade 2
No. Material No. Description Qty.
8 BK0877 3D Vertical Fin 1
9 BK0650 Tail Boom 1
10 BK0707 Rear Servo Rod 1
11 BK0347 Tail Push Rod A 1
12 BK0653 Tail Push Rod B 1
13 3-1-1 Tail Transmission Subassembly 1
14 3-1-3 Tail Drive Shaft Subassembly 1
No. Material No. Description Qty.
1 BK0617 Bolt M4x25 1
2 BK0086 Ball Link 4.8x20 4
3 BK0318 Link Rod 2.3x95 2
4 HMM4Z Locknut M4 1
5 2-1 Rotor Head Assembly 1
No. Material No. Description Qty.
1 HME4-5B Set Screw M4x5 4
2 BK0397 Skid Brace 2
3 BK0398 Skid Pipe End Cap 4
4 BK0668 Skid Pipe 2
No.Material No.DescriptionQty.
15-4-1Body Subassembly1
No.Material No.DescriptionQty.
1HMJ2-6BM2x6 Self-Tapping Screw6
2HSE3-12BM3x12 Self-Tapping Screw2
3BK0102d3xD6x11Grommet2
4BK0098Body ClipA1
5BK0099Body Clip B1
6BK0429Body1
7BK0428Canopy1
8JV0186Decal1
9BK0473Body Support1
10BK0474Rubber CAP2
11HNLR6R Pin2
No.Material No.DescriptionQty.
1*****Main Rotor Blade2
2BK0446Rotor Bolt M5x352
3HMM5ZLocknut M52
TABLE OF CONTENTS
REPAIR AND REPLACEMENT PARTS
Purchase replacement parts from the hobby shop where you have purchased the Raptor 90!3D. Please contact
the Thunder Tiger distributor in your country, and the distributor can tell you where to obtain the parts. For example,
in the U.S, all Thunder Tiger products are distributed by Ace Hobby Distributors. On the web site www.acehobby.com,
there is a list of all the hobby shops in the USA that can order any Thunder Tiger parts from Ace for you. Technical
questions regarding the Raptor will be answered quickly by sending an email to [e-mail] or call
Technical Support at 949-833-7498. In Europe, Asia and Australia, please contact the distributor in your country.
WARNING
To ensure safety, please read the instruction manual thoroughly before assembly. Radio control helicopters are
sophisticated equipment, and not toys. Radio control model helicopters are capable of causing serious bodily injury
if not properly assembled or operated. The manufacturer and distributors assume no liability for damages that could
occur from the assembly or use of this product. This product is designed for hobby use only. Operating model
helicopters requires diligence and skill. The best way to ensure quick and successful learning is to seek help and
guidance from accomplished pilots. It is strongly recommended to join the appropriate radio control modeling governing
society in your country. For example, in the United States, it is strongly encouraged to join the Academy of Model
Aeronautics. AMA is a nonprofit organization that provides members in the United States with liability insurance
and monthly modeling magazines. For further information or to find a model helicopter club, please contact AMA
at:
Academy of Model aeronautics
515 East Memorial Drive
Muncie, IN 47302
USA
[phone]
We also encourage you to subscribe to different radio control helicopter magazines and learn about RC flying events,
new flying techniques, safety procedures, and hints. Rotory Modeler is a bi-monthly and Model Helicopter Techniques
is a quarterly newsletter published in the USA. Model Helicopter World is a month magazine published by Traplet
Publication in England and sold worldwide. Rotor is a monthly German magazine. Helico is a Swiss quarterly
magazine.
ATTENTION
We are unable to accept replacement or return of this model after it has been used or assembly has begun.
It is legally prohibited to duplicate or reprint this manual in any format without a written permission from the
manufacturer.
The manufacturer has the right to make changes to this model or instruction without notice.
We have done our best to the accuracy of information in this manual. If you are aware of any mistake, we welcome
you to notify us.
We will not accept any responsibility for any accident, breakdown, fault or trouble caused by improper usage of
this model. Please thoroughly inspect your model and range check the radio before flight. Please keep the model
in its best condition in order to enjoy it.
This model does not include all the items necessary for flying, such as engine, serevos, gyro...etc.
It is difficult for beginners to fly RC helicopters by themselves. It is highly recommended that beginners seek the
help of experienced RC helicopter pilots. We recommend beginners start with an inexpensive model such as the
Thunder Tiger Raptor 30 that is also designed by Mr. Taya.
RC helicopters are not toys. The manufacturer does not assume the liability for any property or bodily damage
caused by the model or the operator.
OTHER ITEMS REQUIRED
6
BODYSUPPORT INSTALLATION
Insert the aluminum support
tube through the servo frame.
Insert the "R" pins through the
two holes in the support tube
to prevent the tube from
moving in the servo frame.
Install two rubber ends onto
the support tube.The rubber
ends will dampen shake or
vibration generated by the
engine.
Glow Plug Wrench
12V Battery
1.5V Glow Starter
(1.2V~1.5V)
Rubber Band
(Included)
Foam
Remote Glow Plug
Extension
1-2-2 Cooling Fan Casing Subassembly
1-2-3 Fuel Tank Subassembly
No. Material No. Description Qty.
1 BK0062 Fuel Tank Stopper 1
2 BB0374 Silcon Tube (L=105mm) 1
3 BK0445 Fuel Plug 1
4 BK0463 Fuel Tank Nipple 1
5 BK0503-1 Fuel Tank 1
6 BE1867 Clunk Weight 1
1-5-5 Header Tank Subassembly
No. Material No. Description Qty.
1 HMC3-25B Socket Screw M3x25 1
2 BK0087 Washer d3xD8x1.4 1
3 BV0502 Header Tank 1
4 BK0506 Tank Mount 1
5 BK0698 Header Tank Supporter 1
The Raptor 90 3D kit includes a header fuel tank that can be
attached to the right of the side frame.
23
2-1-1 Flybar Seesaw Subassembly
24
2-1-2 Metal Main Rotor Hub Subassembly
2
4.Final Assembly ---------------------------------------------------------------------------------------------- 29
4-1 Installation of Rotor Head (Bag H)----------------------------------------------------------------------30
4-2 Installation of Engine --------------------------------------------------------------------------------------31
4-2-1 Engine Subassembly -------------------------------------------------------------------------------32
4-3 Installation of Landing Skid------------------------------------------------------------------------------- 33
4-3-1 Skid Subassembly -----------------------------------------------------------------------------------33
4-4 Installation of Tail Assembly ----------------------------------------------------------------------------- 34
4-4-1 Tail Support Subassembly------------------------------------------------------------------------ 34
5.Installation of Peripheral Equipment ----------------------------------------------------------- 35
5-1 Installation of Servo - Part 1 (Bag I) ------------------------------------------------------------------ 36
5-2 Installation of Servo - Part 2 (Bag I) ------------------------------------------------------------------ 37
5-3 Installation of Receiver and Gyro ---------------------------------------------------------------------- 38
5-4 Installation of Body (Bag J) ------------------------------------------------------------------------------39
5-4-1 Body Subassembly ----------------------------------------------------------------------------------39
5-5 Installation of Rotor Blades (Bag K) ------------------------------------------------------------------- 40
6.Settings --------------------------------------------------------------------------------------------------------- 41
6-1 Setting up Gear Backlash ------------------------------------------------------------------------------- 42
6-2 Setting up of Stabilizer Paddles ------------------------------------------------------------------------43
6-3 Setting up of Blade Pitch Angle ----------------------------------------------------------------------- 43
6-3-1 Collective Travel for Hovering ------------------------------------------------------------------ 44
6-3-2 Collective Travel for 3D --------------------------------------------------------------------------- 44
6-3-3 Configuring the Raptor 90 for 3D --------------------------------------------------------------- 45
Attention --------------------------------------------------------------------------------------------------------------46
7.Parts List Section -------------------------------------------------------------------------------------------49
Raptor 90 3D Exclusive Parts -------------------------------------------------------------------------------- 50
Raptor 90 3D Spare Parts List ------------------------------------------------------------------------------- 55
Raptor 90 3D Optional Parts List ---------------------------------------------------------------------------- 61
3
Thank you very much for purchasing the Thunder Tiger Raptor 90 3D R/C helicopter. The design of Raptor
90 3D is based on the original Raptor 90 series helicopter and modified for extreme aerobatics. It has all
needed must-have optional parts for 3D flying, such as metal main rotor hub, non-linear flapping damper,
metal BRG, 3D light paddles and so on. It also adopts the push-pull control system on collective pitch
and elevator to achieve the most precise control. The flybar ratio is changeable to fit all kinds of flying
style. Use of high quality material make the helicopter one tough machine that can handle everyday 3D
beating. Raptor 90 3D is born for 3D flying, and you don’t have to do any further modification for aggressive
3D maneuver. This is by far the best machine you have never seen. Just enjoy the model and have fun.
UNIQUE SIDEFRAME SYSTEM
Aluminum side plates are used in conjunction with molded material to construct the main structure. This
design produces minimum weight with maximum strength. If the sideframes were completely made of
molded material, then to achieve equal strength the plastic would have to be very thick and heavy. Using
molded material at the right place avoids using metal angle brackets or putting compound bends in metal
frames. Slots have been added in the frame design to permit the use of optional gear ratios to optimize
engine performance to suit any pilot's demand.
BELL-HIILLER MIXING CONTROL UNIT
Main rotor control geometry has been carefully engineered to minimize cross-coupling in collective and
cyclic commands. Blade pitch arms and the Bell-Hiller mixing arms are designed at an angle such that
the pushrod interlinking them are at 90 degrees when the blades are at 0 degree. The pilots will get the
symmetrical cyclic control feel and flybar authority either at +10 or -10 degrees of collective. We design
this system with the 3-D pilot in mind. We guarantee you this whole design philosophy provides a strong
and accurate control mechanism.
SHAFT DRIVE TAIL ROTOR
The Raptor 90 3D is designed with a constant drive tail rotor system to permit full tail rotor control during
autorotations. 180 autos, backward autos and pirouette autos are all within your reach now. It has the
same aluminum torque tube system as the Thunder Tiger/Taya Imperio helicopter. This allows obtaining
the maximum performance from any modern heading lock gyros.
3D CAD DESIGN
We use the latest 3D Computer Aided Design to design and manufacture the Raptor 90 3D. Our high-
tech CAD program allows simulation of all moving parts to ensure no interference. The analysis automatically
analyze the weight, the mass distribution, and inertia to help us pursue a design that will provide the high
level of maneuverability needed for all-out 3-D aerobatics.
INTRODUCTION
Socket Drivers
Hex WrenchGrease
Blue Loctite
Instant Glue
Hobby Knife
Metric
4-way Wrench
Scissors
Diagonal Pliers
Open End Wrench
5.5mm
Needle Nose PliersScrew Driver
7mm
5.5mm
7mm
8mm
5.5mm
7mm
8mm
10mm
Epoxy
Ball Link Pliers
No. Material No. Description Qty.
1 HMV6800ZZY BRG d10xD19x5 1
2 HME4-5B Set Screw M4x5 2
3 HMS5 E Ring M5x8 1
4 HMV696Z BRG d6xD15x5 1
5 BK0388 Clutch BRG Case 2
6 BK0659 Frame Space M 4
7 BK0594 Starter Coupling 1
8 BK0592 Starter Shaft 1
9 BK0422 Drive Pinion 11T 1
10 BK0366 Pinion Gear Nut 1
11 BV0522-2 Clutch Bell Set 1
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 2
2 HMC3-12B Socket Screw M3x12 4
3 BK0087 Washer d3xD8x1.4 6
4 BK0393 Pitch Frame Cross Member 1
5 BK0394 Pitch Frame Cross Member Nut 2
6 BK0375T Upper Frame 2
No. Material No. Description Qty.
1 HMM3Z Locknut M3 4
2 HMC3-25B Socket Screw M3x25 4
3 BK0820BL Landing Skid Damper 4
4 4-3-1 Skid Subassembly 1
No. Material No. DescriptionQty.
1 HMC3-8B Socket Screw M3x84
2 HMQ16 Retaining Ring1
3 BK0357 Tail Drive Spur Gear 83T1
4 BK0359 One Way Clutch Shaft1
5 BV0368 Auto Rotation Hub1
6 BK0356 Main Spur Gear 91T1
1-6-2 Main Gear Subassembly
(3)
(2)
(4)
(6)
(5)
(1)
The carbon rear servo plate is secured
by two Lower 3mm bolts from the plastic
tail boom bracket.
10
1-1-2 Pitch Guide L Subassembly
1-1-3 Pitch Guide R Subassembly
No. Material No. Description Qty.
1 BK0384 Pitch Guide Collar L 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
The side with a number should face
in because the opening on both sides
are differeent.
The hole on the plastic control arm has different
opening sizes on the two sides. Always snap the
bigger opening to the ball on swashplate gently and
afterward please check to make sure it is securely
attached and there is no damage or cracking.
INSTALLATION OF THE LINKS
Bigger Hole Face to Swashplate
Extended 6mm Hex
Starting Tool
Fuel Pump
Heli Engine (90size)
9609 PRO-90H(R)
Glow Fuel(15%-30%)
Glow Plug
Hi-torque 12V Electric starter
Receiver
Transmitter
(helicopter type, 6 or
more channels) High Speed/Torque Servo x 4
Rudder Servo x 1
Battery Switch harness
Heading Lock
Gyro
In order to enjoy a safe and enjoyable experience, please read the manual carefully and completely understand
the helicopter structure and operation before the first flight.
Read the warnings to avoid injuries to you and others.
WARNING – The following could cause heavy injury or death if used incorrectly.
Keep the model away from other people or animal when starting the engine.
Do not fly any model helicopter near or above people or cars. Models can sometimes lose
control due to pilot or mechanical failure.
WARNING – The following could also cause serious injury or death if not careful.
Take precaution with model fuel. Model engine glow fuel is highly flammable.
Please check the model carefully before each flight. Make sure that nothing has loosened up
or come apart.
Make sure everything moves freely without binding or excessive friction.
Do not operate the model in rain, snow, thunderstorm, or adverse weather.
WARNING – The following could also cause serious injury or death if not careful.
Please make sure that your radio frequency is not used before flight. If someone else is flying
with the same frequency as your radio, do not turn on your transmitter. Otherwise, it can cause
a crash and even bodily and property damages.
Please monitor the fuel level during flight and land before running out of fuel.
Before each flight, please check that all servos and controls move properly.
Do not modify any parts or use other than genuine Thunder Tiger parts.
Do not fly in places that are forbidden by law.
Use Loctite on screws that do not use a locknut.
When operating the model, please beware that no loose cloth or jewelry can get entangled in
the model helicopter.
Make sure the transmitter and receiver switches are on before starting the engine.
Do not touch the engine or the muffler right after flying because they are very hot.
Do not use this model for anything other than hobby.
WARNING – The following damages can happen to the model.
Do not leave the model in a car for a long time. The heat in the summer or the cold in the
winter and the humidity can cause damage to the model.
Be careful and watch the sharp edges and corners on the model.
BUILDING HINT – The instruction is divided into six assembly chapters:
Main Frame, Rotor Head, Tail Rotor, Final Assembly, Radio Installation, and Settings. There
are many major assembly steps in each chapter, please follow the instruction to do each "
Subassembly" first, then combine the subassemblies into a major assembly.
Upper Frame Assembly
Lower Frame Assembly
12
1-2-1 Tail Drive Unit Subassembly
No. Material No. Description Qty.
1 HME3-4B Set Screw M3x4 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 BK0362 Tail Drive Bevel Gear A 1
5 BK0363 Tail Drive Bevel Gear B 1
6 BK0364 Tail Drive Pinion 1
7 BK0365 Tail Drive Gear Shaft 1
8 BK0382 Tail Boom Bracket L 1
9 BK0383 Tail Boom Bracket R 1
10 BK0414 Pin 2x12 2
11 BK0660 Frame Spacer L 5
Main Frame Assembly Installation of Pitch Frame
No. Material No. Description Qty.
1 HMJ2-10N M2x10 Self-Tapping Screw 1
2 HMV840ZZY BRG d4xD8x3 2
3 HMV1280ZZY BRG d8xD12x3.5 2
4 BK0336 Pitch Frame 1
5 BK0075 Link Ball
φ
4.8 1
Optional: add a tiny drop of thick CA on the outside rim of the fovr ball
bearings before inserting them into the plastic Pitch Frame. Be careful
not to get any glue into the ball bearings. Add a tiny drop of thick CA
glue at the tip of the M2x10 self-tapping screw (No. 1) before
screwing it into the Pitch Frame.
32
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
Note:
The (3) spacer with threads is
supposed to be locate d at middle
position to fit the Body Fitting Post.
No. Material No. Description Qty.
1 BK0385 Pitch Guide Collar R 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
Tip: When setting up the phase
adjustment ring, the flybar and
the tail boom can be the
reference. When the flybar and
the tail boom are centered, the
inner balls of swashplate should
be aligned with the outer balls.
Tighten the socket screw on the
phase ring at this moment.
NOTE: Improper alignment will
cause unwanted mixing.
No. Material No. Description Qty.
1 ******** 90 Class Heli Engine 1
2 ******** Nut (Comes With the Engine) 1
3 HMC4-8B Socket Screw M4x8 2
4 HMC4-18B Socket Screw M4x18 4
No. Material No. Description Qty.
5 HMO10 Washer d9.5xD16x1 1
6 BK0349 Engine Mount 1
7 BV0380 Cooling Fan 1
8 BV0521 Heavy Duty Clutch 1
No. Material No. Description Qty.
1 BK0075 Link Ball φ 4.8 5
2 BK0086 Ball Link 4.8x20 8
3 BK0104 Servo Mounting Plate6
4 BK0105 Rod Joint 1
5 BK0318 Link Rod 2.3x95 2
6 BK0436 Link Rod 2.3x55 2
7 BK0833 Servo Block 4
8 HMC2516B Socket Screw M2.5x164
No.Material No.DescriptionQty.
9HMM25Lock Nut M2.54
10HML2Nut5
11HME4-5BSet Screw2
12HMF2-8NPhillips Machine Screw M2x85
13HSE2614NSelt-Tapping Screw4
14HSE2630NSelt-Tapping Screw4
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.87
2BK0086Ball Link 4.8x204
3BK0095Link Rod 2.3x761
4BK0104Servo Mounting Plate4
5BK0833Servo Block2
6BK0834Pitch Lever Fixed Plate1
7BK0839Link Rod 2.3x301
8BK0881Washer1
9BK0883Pitch Push Pull Lever1
No.Material No.DescriptionQty.
10BK0884Collar, d3xD4xW121
11BV0085Pitch Link Rod2
12HMC3-20BSocket Screw M3x201
13HMV840ZZYBearing d4xD8xW32
14HMF2-8NPhilip Maching Screw M2x84
15HMJ2-8NSelt-Tapping Screw M2x83
16HML2Nut4
17HSE2614NSelt-Tapping Screw M2.6x148
18HSE2620NSelt-Tapping Screw M2.6x204
No.Material No.DescriptionQty.
1****Switch1
2****Receiver Battery1
3****Receiver1
No.Material No.DescriptionQty.
4****Gyro
5BK0106Foam2
6 BE1052Antenna Pipe1
PV0517 ONEWAY BEARING GREASE
The hole on the Flybar Control Rod has different
opening on two sides.Always snap the bigger opening
to the link ball.
Bigger Hole
Face to ControlArm
10.5mm10.5mm
When installing pinion gear, add a small drop of Loctite to the
threads. Make sure not to get Loctite on lower clutch bell bearing.
Important:
For 90 class engine, we recommend the 11 teeth pinion for 3D
flying.
The servo tray and cooling fan shrouds on the Raptor 90 are different from the
Raptor 60 in order to accommodate the full head sink on the O.S 91. engine.
If using T.T 90, Y.S 91 or Webra 91 engine, make sure to install the fan shroud
baffle with two self-tapping screws. This will ensure optimal cooling of your engine
head.
Add CA glue Add CA glue
It is necessary to add grease inside the one way clutch before your
first flight. The clutch might lock up once grease is gone.The one
way clutch grease( PV0517) is recommended for this lubrication.
Make sure the inside ofAuto Rotation Hub is clean without any dirt
before you insert the one way clutch shaft.
Add Loctite
Add Loctite on
the threads
For 3D flying, it is recommended to use
lower flybar ratio setting.
Self-Tapping Screw, No. 10 Collar, and No. 11 Washer, with two
No. 1 Bearings. Attach a No. 9 Link Ball with a No. 4 Screw.
Upon finishing Step 3-1-1, make sure there are no extra parts
left on your workbench.
Elevator Control
Pushrod
Glue the two plastic halves of
the paddle with CAglue before
installation on flybar.
Add Loctite
the tail boom by tightening the four screws on the helicopter.
Visually check from the rear of the helicopter to make sure the
tail rotor output shaft is perpendicular to the main rotor shaft.
Add the tail boom supports.
Add Loctite
The thrust bearing washer with the
SMALLER inner hole should be closer to
the rotor blade.
The thrust bearing washer with the BIGGER
inner hole should be closer to the main rotor
shaft.
4-2-1 Engine Subassembly
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add CA Glue
Introduction -------------------------------------------------------------------------------------------------------- 3
Other Items Required -------------------------------------------------------------------------------------- 4
Warning --------------------------------------------------------------------------------------------------------------- 5
Assembly
1. Main Frame Assembly --------------------------------------------------------------------------------- 7
1-1 Upper Frame Assembly (Bag A) ---------------------------------------------------------------------- 8
1-1-1 Pinion Gear Subassembly ------------------------------------------------------------------------ 9
1-1-2 Pitch Guide Left Subassembly ------------------------------------------------------------------10
1-1-3 Pitch Guide Right Subassembly -----------------------------------------------------------------10
1-1-4 Elevator Control Arm Subassembly------------------------------------------------------------ 10
1-2 Lower Frame Assembly (Bag B) ----------------------------------------------------------------------11
1-2-1 Tail Drive Unit Subassembly ---------------------------------------------------------------------12
1-2-2 Cooling Fan Casing Subassembly -------------------------------------------------------------13
1-2-3 Fuel Tank Subassembly ------------------------------------------------------------------------13
1-3 Main Frame Assembly (Bag C) -------------------------------------------------------------------------14
1-3-1 Rod Guide Collar Subassembly-----------------------------------------------------------------14
1-4 Installation of Servo Frame (Bag C) ------------------------------------------------------------------- 15
1-5 Installation of Pitch Frame (Bag D) -------------------------------------------------------------------- 16
1-5-1 Aileron Lever Subassembly ---------------------------------------------------------------------17
1-5-2 Metal Elevator Parallel Lever Subassembly -------------------------------------------------17
1-5-3 Elevator Control Lever Subassembly --------------------------------------------------------- 17
1-5-4 Pitch Control Frame Subassembly -------------------------------------------------------------18
1-5-5 Header Tank Subassembly ----------------------------------------------------------------------18
1-6 Installation of Main Shaft (Bag E) ----------------------------------------------------------------------19
1-6-1 Wash Out Subassembly -------------------------------------------------------------------------20
1-6-2 Main Gear Subassembly -------------------------------------------------------------------------20
2. Rotor Head Assembly -----------------------------------------------------------------------------------21
2-1 Metal Rotor Head Assembly (Bag F) -----------------------------------------------------------------22
2-1-1 Flybar Seesaw Subassembly --------------------------------------------------------------------23
2-1-2 Metal Main Rotor Hub Subassembly ----------------------------------------------------------24
3.Tail Assembly -------------------------------------------------------------------------------------------------25
3-1 Tail Assembly (Bag G) ----------------------------------------------------------------------------------- 26
3-1-1 Tail Transmission Subassembly --------------------------------------------------------------- 27
3-1-2 Tail Rotor Subassembly --------------------------------------------------------------------------- 28
3-1-3 Tail Drive Shaft Subassembly -------------------------------------------------------------------28
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(6)
(4)
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(17)
(7)
(8)
(3)
(15)
(14)
The Liner is pre-glued on the
inside of clutch bell with 30 min
epoxy.
1-1 1-2 1-3
( 2 ) (1)
1-4
(1)
(2)
1-5 1-6
(7)
(1) (5)(4)
(9)
(3)
2-1
3-1 4-1
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(3)
(2)
(1)
4-3
(4)
(2)
4-4
(2)
(7)
(1)
(3)
(5)
(8)
4-2
(3)
(1)
(2)
5-1 5-2
5-3
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(6)
(1)
(3)
(2)
(5)
5-4
5-5
(2)
(3)
No. Material No. Description Qty.
8 BK0660 Frame Spacer L 3
9 BK0376T Lower Metal Frame 2
10 BV0870 Metal Lower BRG Block 1
11 1-2-1 Tail Drive Unit Subassembly 1
12 1-2-2 Cooling Fan Casing Subassembly 1
13 1-2-3 Fuel Tank Subassembly 1
No. Material No. Description Qty.
7 BK0659 Frame Spacer M 2
8 BV0869 Metal Upper BRG Block 1
9 1-1-1 Pinion Gear Subassembly 1
10 1-1-2 Pitch Guide L Subassembly 1
11 1-1-3 Pitch Guide R Subassembly 1
12 1-1-4 Elevator Control Arm Subassembly 1
(3)
No. Material No. Description Qty.
10 BK0093 Link Rod 2x46 1
11 BK0407 Collar d3xD4x4.5 2
12 BK0410 Collar d3xD4x13 2
13 1-5-1 Aileron Lever Subassembly 1
14 1-5-2 Metal Elevator Parallel Lever Subassembly 1
15 1-5-3 Elevator Control Lever Subassembly 1
16 1-5-4 Pitch Control Frame Subassembly 1
17 1-5-5 Header Tank Subassembly 1
No. Material No. Description Qty.
6 HMM4B Lucknut M4 1
7 BK0617 Bolt M4x25 1
8 BV0504 Metal Swashplate 1
9 1-6-1 Washout Subassembly 1
10 1-6-2 Main Gear Subassembly 1
No. Material No. Description Qty.
10 BK0076 Collar d3xD4x10 1
11 BK0088 Washer d3xD5x0.5 1
12 BK0346 Tail Pitch Control Lever 1
13 BK0370 Tail Case L 1
14 BK0371 Tail Case R 1
15 BK0372 Tail Input Bevel Gear 1
16 BK0373 Tail Output Bevel Gear 1
17 HMY2-12 Pin 2x12 1
18 3-1-2 Tail Rotor Subassembly 1
No. Material No. Description Qty.
1 HMM3Z Locknut M3 6
2 HMC3-16B Socket Screw M3x16 2
3 HMC3-20B Socket Screw M3x20 2
4 HMC3-25B Socket Screw M3x25 2
5 HMC3-30B Socket Screw M3x30 2
6 BK0087 Washer d3xD8x1.4 4
No. Material No. Description Qty.
1 HMJ2-8N Self-Tapping Screw M2x8 4
2 BK0447 Tail Support Rod End 4
3 BK0669 Tail Support Rod 2
No. Material No. Description Qty.
1 HMC4-42B Muffler Bolt M4x42 2
2 HMT4B Spring Washer 2
3 ******** Muffler ( 90 ) 1
4 4-2-1 Engine Subassembly 1
5 HMC4-12B Socket Screw M4x12 4
6 BK0435 Washer d4xD11xW1.7 4
BAG A
BAG B
BAG C BAG C BAG D
(L) (R)
BAG E
BAG F
BAG G
BAG H
BAG I
97.5mm
48mm
(3)
Throttle
Collective Pitch
(2)
BAG I
BAG J
BAG K
(11) (8)
(7)
(2)
(6)
(3)
(5)
(9)
(4)
Please complete subassembly steps 1-2-1 through 1-2-3 first. Then attach the subassemblies to the two Lower Frames. Note
that the Metal Lower BRG is installed with the bearing open side facing up. Please add a small drop of Loctite on every bolt
before screwing it into the aluminum hex spacer. Do not apply Loctite to the bolts which are going to secure the Lower BRG
Block at this moment.
Assemble the upper main frames by starting with the two Metal Upper Frames. The Pinion Gear Subassembly must be assembled
first according to Figure 1-1-1. Next insert three hex-shape frame spacers into the plastic Pitch Guide according to Figure 1-1-2
and 1-1-3. Assemble the Elevator Control Arm subassembly according to 1-1-4. Insert it in between the two Upper Frames. The
metal Elevator Control Arm is not symmetrical. The side with the longer profruding round knob should be on the right side of the
helicopter. Then attach the other subassemblies to the Upper Frames. Locate Hex Wrenches in BAG L which you need for
assembly.
Please add a tiny drop of non-permanent type Loctite on the tip of all bolts before screwing them into the hex shaped aluminum
frame spacers. Never use too much Loctite, otherwise it will become nearly impossible to remove later on for servicing. Only use
the non-permanent type of Loctite. If encountering difficulty in removing any bolt that was locked up by Loctite, heat up the head
of the screw or bolt with the tip of a hot soldering iron, it will help soften the cured Loctite.
For the kit, parts are bagged according to each major assembly and are labeled "Bag A, Bag
B, etc." The heading for each assembly indicates which bag to open. As a go od practice,
only open up the bag that you need for the particular assembly. Check the parts in that bag
against the parts list shown for each assembly as well as each sub-assembly to make sure
there are no missing parts. To prevent losing small hardware, please empty the small nuts
and bolts and parts into small plastic trays on your work table. At the end of each major
assembly, there should be no left over parts.
The fuel tank comes assembled from the factory because every tank has been
checked for leak. If you were to take the tank apart here is how to put it back
together. Install the silicone fuel line to the Fuel Nipple. Then add the rubber
fuel tank stopper and the clunk weight. The stock silicone fuel line is very soft
and thin which is designed to allow the clunk to pick up fuel easily during 3-D
aerobatics. The pickup line should be inspected and replaced if necessary every
month, otherwise when it becomes soggy it can break off. A thicker silicone line
maybe substituted but make sure the clunk will reach the bottom when moving
the fuel tank to all different orientations.
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(2)
(2)
(4)
(1)
(6)
(5)
As show in Figure 1-3-1, insert two hex
Frame Spacers S into the plastic Rod
Guide Collars. Then join the Upper
Frame Assembly to the Lower Frame
Assembly according to drawing 1-3.
Secure the Set Screws (No.1) to the
frames, and fit the Body Posts (No.4)
to the Set Screews. The two Body Posts
will be used to secure the canopy in the
future. Add Loctite on all bolts and
inside BK0103 threaded hole.
Install the one-piece servo frame with six self-tapping screws.
Do not use Loctite when attaching self-tapping screws to plastic
parts. Loctite is only for threading metal into metal parts. Assemble the constant drive Main Gear Subassembly according to Figure 1-6-2 first. Then build up the Wash Out Subassembly
according to 1-6-1. Insert the No.3 Main Shaft into the bearings and then add the No.4 Lock Ring and slide in the Main Gear
Subassembly. Add two M3x6 Button Head Screws to the Locking Ring, and the two screws are threaded into the holes on the
main rotor shaft.
The locking ring prevents the main shaft from sliding up. Line up the hole on the main gear and the main shaft, then insert M4x25
mm Bolt through them. Place a 4 mm M4 locknut on the other side of the autorotation hub, and then tighten the Bolt. Do not
over tighten the Bolt, otherwise the autorotation assembly will be distorted. Loosen the 3mm bolts holding the Upper and lower
bearing blocks for the 12mm main shaft. Wiggle the main shaft in the bearing blocks until the main shaft spins freely in the bearings.
This ensures the upper and lower bearing blocks are aligned. Push the lower bearing block up until the main shaft has no up
and down play. Then tighten the 3mm bolts for the upper and lower bearing blocks.
Insert the pin into the Washout Link.Add a tiny drop of Loctite on the inside
and outside of BK0409 Collar which will help give a completely slop free
control system. Do not let the Loctite seep into the bearing.Adjust the
tightness of the M3x12 bolts so the mixing arms can move freely but without
wobble or racheting the ball bearings.Add a tiny drop of thick CAglue at
the tip of the M2x10 self-tapping screw (No. 1) before screwing it into the
Flybar Control Levers (No. 6).
Make the two pushrods for controlling the blade pitch.The distance 43 mm is measured between the center of two pushrod holes.
Attach the Seesaw Hub of the Control PaddleAssembly to the Main Rotor Head with Socket Screws (M3x10).
Please add a small drop of Loctite along the entire length of the M3x10 Socket Screw (No.5) and on the outside of the collar
d3xD4x5.5 (No.3).Temporarily install the Washout Base Guidence Ring, but do not tighten the No.6 M3 Socket Screw yet.
Assemble the tail transmission subassembly according to 3-
1-1 and 3-1-2 first. And the tail drive shaft subassembly according
to 3-1-3.But do not close the two halves of the tail transmission
tightly. You will do this when you are ready to install the gearbox
onto the tail boom.
When installing the tail transmission, make sure the housings
match the hole on to the tail boom. Add Carbon Vertical Fin with
machined washer and Locknut, then tighten the five 3 mm bolts.
Add carbon Vertical Fin with Pom washer and Locknut.
Before inserting the finished tail drive shaft assembly into the
tail boom, add some flexible silicone glue or ZAP Goop glue
around the outside of the tail drive bearing housing. This will
prevent the bearing housing from spinning inside the tail boom.
(7)
Install bearings No. 2 and No.3 into the Tail Cases. Install No.
16 Tail Bevel Gear onto the Tail Shaft. Gently tap the No. 17
Pin into the Bevel Gear and Tail Shaft. Then secure the pin
with a No. 7 Set Screw with Loctite.
After installing the M3x4 set screws, try pushing on the 2x12
pin with a small Allen wrench to make sure the set screw has
locked the pin in place securely. Before closing the two halves
of the Tail Cases, please check the gear mesh between gears
No. 15 and No. 16. If the gears mesh too tight, then a 5 mm
i.d. washer should be added to move the gear No. 16 further
out. If there exists too much freeplay, then a 5 mm i.d. washer
to push gear No. 16 closer to gear No. 15.
Install the No. 12 Tail Pitch Control Lever as shown with No. 6
Slide four No. 6 Rod Guides onto the tail boom. Do not glue
them onto the tail boom yet. Add a tiny drop of CA glue to the
pushrod guide after you finish building the entire helicopter.
Before adding glue, make sure the tail pushrod is hooked up
to the servo and the rod travels in a straight line and moves
very smoothly.
Congratulation, we are almost done. Install the finished main
rotor head onto the 12 mm rotor main shaft. Secure it with a
M4x20 Bolt and M4 Locknut. Make up two 113.5 mm long
pushrods and attach them to the Bell-Hiller mixing arm.
Before installing the plastic end caps, please
add a drop of slow, thick CA glue on the
rim of the end caps and on the inside edge
of the aluminum skid.
Slide the finished tail boom into the helicopter. The four bolts
on the helicopter must be loose in order to insert the tail boom.
Make sure the tail drive shaft is inserted into the front receptacle
properly. Check this by turning the main rotor head. Secure
Secure the two ends to the rod with Epoxy, making sure the
two metal ends are perpendicular to each other.
(4)
Attach the engine into the side frames, with four M4x12 bolts and
four washers, but do not tighten until Section 6-1.
Install the muffler after you have building the entire helicopter.
Always add Loctite on the muffler bolts.
Install the servos and make up the pushrods according to the drawings.The distance between the steel ball and the center of
servo arm are shown in the drawing. Use them as a guide.These distances are used in conjunction with the servo travels (ATV
or End point) set to 100% for all the channels in the transmitter.Tune them later on to suit your personal flying style.
Attach the rudder servo to the rear mounted carbon plate with four 2.6mm bolts and four M2.6 locknut.
Make up the throttle and collective control pushrods according
to the drawing. Use the outermost hole on the carburetor throttle
control arm.Attach the steel ball on the throttle servo arm at
approximately the same distance as the steel ball on the throttle
arm.
Make up the throttle at 97.5mm long first, and then adjust the
pushrod length and throttle servoATV or Endpoint so full throttle
stick command will open the carburetor barrel fully.And full low
stick and low throttle trim will close the carburetor barrel completely.
Install the receiver and receiver battery. Even though the receiver and battery can be attached to the helicopter tray by using
double sided foam tape, but it is better to wrap the receiver and battery separately using half inch or 10 mm thickfoam. Then
secure them to the tray using six to eight rubberbands, or Velcro bands.
Carefully cut out the canopy (windshield) using scissors.The
best scissors to use are (TTR 1304) designed to cut RC car
bodies and Canopy. Install the canopy to the body using six
small screws. Drill small holes in the canopy and body for the
holes. Drill two more holes for the rubber grommets.
Refer to color box and apply the decals (In BAG M) .
Tools for Assembly
The Raptor 90 3D is designed for easy maintenance using standard hobby tools. Please only use genuine Thunder Tiger parts.
Please keep the model clean and well tuned. It will provide you with long lasting pleasure in return.
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(4)
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(3)(16)(8)
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Add Loctite
(Included)
Add a tiny drop of thick CA glue at the tip of the M2x10
self-tapping screw (No. 1) before screwing it into the
Aileron Levers.
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(10)
(11)
Make up the landing gear according to the
drawing.
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(3)
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(1)
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(5)
(8)
(3)
(1)
No. Material No. Description Qty.
1 HSE3-6B Self-Tapping Screw M3x6 2
2 BK0660 Frame Spacer L 4
3 BK0662 Cooling Fan Baffle 1
4 BK0665 Fan Casing L 1
5 BK0666 Fan Casing R 1
(2)
(1)
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(1)
(3)
(2)
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(3)
(2) (5)
(1)
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(5)
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Assemble the metal flybar control arms according to the drawings. Slide Flybar ControlArm onto the No.18 Flybar Rod. Slide
the flybar into the No.17 Seesaw Hub. Make sure the Flybar has equal protrusion from each side of the SeesawHub measure
them with a ruler, then install and tighten the No.8 HME4-5B set screws.Add the paddles. Make sure the two paddles and the
two flybar control arms are all parallel. Lock the paddles with No.6 set screws.
Assemble and install the No.10 Mixing Levers and No.5 Bearings according to the drawing using No.12 Collar andNo.9 d3xD5x0.5
washer.
Note:Before installing the Mixing Lever (No.10), please add a small drop of Loctite along the entire length of the M3x18 button
head socket screw (No.4) and on the outside of the collar d3xD4x13 (No.12). Be careful do not let the Loctite seep into the bear ings.
There are two choices of hole positions on the aluminum seesaw for attaching the mixing lever arm.The outside hole gives higher
Bell-Hiller mixing ratio. For aggressive 3D flying, you can attach the Bell-Hiller mixing arms to the inner hole which gives low er
flybar ratio.
(6)
No.Material No.DescriptionQty.
10BK0324Mixing Lever2
11BK0406LPaddle Root2
12BK0410Collar d3xD4x132
13BK0416Paddle Stopper2
14BK0432LFlybar Paddle2
15BK0633Flybar Control Frame2
16 BK0871 Longer StabilizerArm 2
17 BV0865 Longer Seesaw 1
18 BK0866 SUS Flybar 1
No.Material No.DescriptionQty.
1HMF2-8NPhillips Machine Screw M2x82
2HMJ2-10NSelfing-Tapping Screw M2x104
3HMC3-10BSocket Screw M3x102
4 HMC3-18B Socket Screw 2
5HMV840ZZYBRG d4xD8x34
6HME4-3BSet Screw M4x34
7HME4-5BSet Screw M4x52
8BK0075Link Ball
φ
4.86
9BK0088Washer d3xD5x0.52
Insert the aluminum Main Rotor Hub Pin and the Flap Dampers. (might need to apply silicone grease for easy installation). Push
the No.7 Feathering Spindle into the dampers and the rotor hub.Add No. 14 Flybar Control Rod. Slide both finished Main Rotor
Grip onto the feathering spindle and the secure with two M4x10 bolts and washers according to the drawing.Use two Allen
wrenches to tighten the two M4x10 bolts simultaneously.
Important Note:
The Raptor 90 3D kits come with non-linear flap damper for aggressive 3D flying.You may choose to experiment adding from
one up to three 0.4mm thick shim (No.10) washers between the washer (No.8) and bearing to further stiffen the main rotor flapping.
Stiffing the main rotor head will speed up the cyclic transient response, but may cause the helicopter fuselage to oscillate at arou nd
1600 RPM.This oscillation characteristic exists for all helicopters with hard 3D flap dampers.The inner dampers should be
replaced periodically if a lot of 3D flying has been done. When the dampers are worn, the main rotor blades canflap excessivel y
during some 3D maneuvers and risk touching the tail boom.
Add flexible silcone glue or ZAP
Goop glue around the outside
before insert ing into the tail
boom from the front side.
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(1)
(2)
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(3)
(2) (1)
(4)
180mm
25mm
(1)
(3)
(2) (3)
The optionalThunderTiger Remote Glow PlugAdaptor (#3803)
is recommended as shown, making starting easy without the
removal of your canopy.
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(3)
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(5)
(1)
(4)
(2)
Cut a hole at the
front air scoop for
backward flights.
(7)
No.Material No.DescriptionQty.
9BK0477Washer2
10BK0703Flap Damper Washer 0.4mm6
11BK0874Inner Damper2
12BK0875Outer Dampper2
13BK0075Ling Ball
φ
4.82
14BK0664Flybar Control Rod2
15BK0319Main Rotor Pitch Housing2
16BV0548-1Metal Main Rutor Hub1
No.Material No.DescriptionQty.
1HMC4-10BSocket Screw M4x102
2HMJ2-12NSelf-Tapping Screw M2x122
3HMV1680BRG d8xD16x54
4HMX0816Thrust Bearing d8xD16x52
5BK0330Main Rotor Hub Pin1
6 BK0325Thrust Washer 2
7BK0326Spindle1
8BK0435Washer2
Fiberglass or Carbon Rotor Blade
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(1)
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(1)
(5)
Add Loctite when setting up the
gearmesh in step 6-1.
(7)
No. Material No. Description Qty.
7 BK0539 Carbon Rear Servo Plate 1
8 BK0878 Bracket (Top) 1
9 BK0879 Bracket (Bottom) 1
10 3-1 Tail Assembly 1
11 4-4-1 Tail Support Subassembly 2
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(4)
Engine System
Use a high quality 90 size 2-stroke
model helicopter engine, such as the
Thunder Tiger TT PRO-90H, OS 91
SZ-H, YS 91 ST, Webra 91, or
equivalent. Please beware, some
engines may not fit because of their
shape and size. The Raptor 90 3D
kit comes with a cooling fan hub to fit
the TT PRO-90H, OS 91 SZ-H, Webra
91.
We recommend a high quality muffler
or tuned exhaust system designed to
fit on the left side of the model.
Rotor Blades
It is important to use main rotor blades
that are of high quality and suitable
for your flying style. If fiberglass or
carbon graphite blades are used, the
length should be between 680 and
710 mm. Blade weight should be
between 170 and 200 grams.
Starter System
To start the engine, it is necessary to
use an electric starter with a 6mm
shaft extension. The starter and the
6 mm extension are available from
Thunder Tiger, the part numbers are
No.2675 and No.3801.
Use a strong high torque 12 volt
electric starter which is designed for
models.
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(5) (8)
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(6)
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(4)
Add a small drop of Loctite.
Make sure it locks the pin.
Install BK0364 and BK0362 onto BK0365 Tail Gear Drive Shaft. Then insert the
two Pins and secure them with two M3x4 Set Screws. Add a tiny drop of Loctite
on the set screw thread before inserting them. Always use a very small amount
of Loctite liquid on the thread, otherwise it may be nearly impossible to remove
the set screws in the future for servicing. After installing the two M3x4 set screws
(No. 1), try to push on the 2x12 pins with a small Allen wrench to make sure the
set screws have locked the pins in place securely. Install the four ball bearings
and the hex shaped Frame Spacers according to the drawing. Before closing
the two halves of the Tail Boom Brackets, please check the gear mesh between
gears No. 4 and No. 5. If there exists too much freeplay, add some 5 mm i.d.
washers on top of gear No. 4. (The 5 mm i.d. washers are provided in BAG G).
Add a small drop of Loctite.
Make sure it locks the pin.
Shim Washer
(3)
(5)
(4)
(2)
(3)
(1)
Add CA Glue
Standard flybar ratio
Lower flybar ratio
Mild 3D Flying
Extreme 3D Flying
(3)
(8)
(2)
(7)
(5)
(1)
Attach the engine mount to the engine using four 4mm bolts and Loctite.
The cooling fan hub is threaded to fit the OS, TT or Webra only. Place the washer that came with your engine onto the engine
crankshaft first. Then screw the fan hub onto the engine. Add a tiny drop of Loctite on the engine nut. Do not use too much
Loctite. Tighten the engine nut using a socket head wrench while grabbing the fan with a towel. The nut should be tighten securely.
For 50-size or bigger engines, we do not recommend using a piston locking tool on the glow plug hole because that may damage
the engine. Attach the No. 8 Heavy Duty Clutch to the fan hub. Add a drop of Loctite on the threads of the M4x8 bolts. The
threads on the aluminum cooling fan hub are for the TT 70H, OS 61 SX, OS 61LX, OS 70H, TT 90H, OS 91 or Webra 91 engines.
If YS 61, 80 or 91 engines are used, the fan hub must be re-tapped by the modeler to M8x1mm thread size or purchase a optional
plastic fan hub with threads for the YS engine(PV0198YS) or the metal fan for the YS (PV0293YS).
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(4)
(1)
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(1)
(9)
(5)
Please complete subassemblies 1-5-1 through 1-5-5 first, then add them to the Main Frame. Fit the Pitch Control Frame
Subassembly. Attach the E Ring on the left side of the Metal Elevator Control Arm. Then fit the Elevator Control Lever to the
right side, insert the pin and fix it with a set screw. Secure the Pitch Control Frame with a M3*10 Socket Screw and a collar on
the left side. And attach the Elevator Push Pull Lever to the right side of the Pitch Control Frame as shown. Adjust the two bolts
so that the Pitch Control Frame can move freely without excessive play. Finally, add the two plastic Aileron Levers and the 66.5mm
elevator pushrod. Add the Washers (BK0088) to make sure that the Aileron Lever and the Metal Elevator Parallel Lever will not
touch each other during operation.
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Outer hole for standard.
Inner hole for extreme 3D.
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(3)
Add Loctite
Add Loctite
Add Loctite
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Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
30mm
(2)
Paddle
Flybar
A Arm
Phase
Adjustment
Ring
Swash
plate
Boom
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(11)
(18)
Pitch push-pull subassembly
(13)
(1)
(15)
(10)
(9)
(17)
(2)
(3)
Add Loctite
Add Epoxy
Add Epoxy
(13)
(14)
(17) (15)
(16)

1
5
7
MAIN FRAME ASSEMBLY
8 9
1-1-1 Pinion Gear Subassembly
11
13 14 15 16 17 18 19 20
21
22
25 26 27
29 30 33 34
36
3531
37
383940
4
1-3-1 Rod Guide Collar Subassembly
1-5-1 Aileron Lever Subassembly
1-5-2 Metal Elevator Parallel Lever Subassembly
1-5-3 Elevator Control Lever Subassembly
1-5-4 Pitch Control Frame Subassembly
1-1-4 Elevator Control Arm Subassembly
1-6-1 Wash Out Subassembly
ROTOR HEAD ASSEMBLY
TAIL ASSEMBLY
3-1-1 Tail Transmission Subassembly
FINAL ASSEMBLY
4-3-1 Skid Subassembly
4-4-1 Tail Support Subassembly
INSTALLATION OF PERIPHERAL EQUIPMENT
5-4-1 Body Subassembly
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 4
2 HMC3-12B Socket Screw M3x12 21
3 BK0087 Washer d3xD8x1.4 22
4 BK0274 Tank Rubber Grommets 4
5 BK0380 Rear Frame L 1
6 BK0381 Rear Frame R 1
7 BK0629 Washer 4
No. Material No. Description Qty.
1 HME3-18.5B Set Screw M3x18.5 2
2 HMC3-25B Socket Screw M3x25 10
3 BK0087 Washer d3xD8x1.4 10
4 BK0103 Body Fitting Post 2
5 BK0658 Frame Spacer S 2
6 1-1 Upper Frame Assembly 1
7 1-2 Lower Frame Assembly 1
8 1-3-1 Rod Guide Collar Subassembly 2
No. Material No. Description Qty.
1 BK0389 Rod Guide Collar 1
2 BK0658 Frame Spacer S 2
No. Material No. Description Qty.
1 BK0667 Servo Frame 1
2 HSE3-12B M3x12 Self-Tapping Screw 6
3 1-3 Main Frame Assembly 1
No. Material No. Description Qty.
1 HMC2-6B Socket Screw M2x6 1
2 HMC3-10B Socket Screw M3x10 1
3 HMC3-25B Socket Screw M3x25 1
4 HME3-3B Set Screw M3x3 1
5 HMJ3-20N Self-Tapping Screw M3x20 2
6 HMS4 E Ring 1
7 HMY2-10 Pin 2x10 1
8 BK0086 Ball link 4.8x20 2
9 BK0088 Washer d3xD5x0.5 3
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 BK0876 Elevator Control Arm 1
2 BK0075 Link Ball
φ
4.8 1
3 HMF2-8N Philip Machine Screw M2x8 1
No. Material No. Description Qty.
1 BK0882 Elevator Push Pull Lever 1
2 HMV840ZZY BRG d4xD8x3 2
3 BK0075 Link Ball
φ
4.8 3
4 HMJ2-8N Selfing-Tapping Screw M2x8 3
5 BK0410 Collar d3xD4x13 1
No. Material No. Description Qty.
1 HMS15 E Ring 4
2 BK0880 Elevator Link Shaft 2
3 BK0455 Metal Elevator Control Arm 1
4 BK0663 Elevator Arm Link 2
No. Material No. Description Qty.
1 BK0093 Link Rod 2x46 2
2 BK0086 Ball Link 4.8x2.0 4
3 BK0547 Hardened Main Shaft 1
4 BK0234 Lock Ring 1
5 HSA3-6B Button Head Socket Screw M3x6 2
No. Material No. Description Qty.
1 HMJ2-10N M2x10 Self-Tapping Screw 2
2 HMC3-12B Socket Screw M3x12 2
3 HMV840ZZY BRG d4xD8x3 4
4 BK0088 Washer d3x5x0.5 2
5 BK0472 Washout base 1
6 BK0342 Flybar Control Lever 2
7 BK0343 Washout Link 2
8 BK0075 Link Ball
φ
4.8 2
9 BK0409 Collar d3xD4x7 2
10 BK0487 Pin 2
11 HMS15 E Ring 2
No.Material No.DescriptionQty.
1BK0086Ball Link φ 4.84
2BK0292Link Rod 2.3x242
3BK0408Collar d3xD4x5.52
4BV0549Washout Base Guidance Ring1
No.Material No.DescriptionQty.
5HMC3-10BSocket Screw M3x102
6HMC3-12B Socket Screw M3x12 1
72-1-1Flybar Seesaw Subassembly1
82-1-2Metal Main Rotor Hub Subassembly1
No. Material No. Description Qty.
1 HMV740ZZ BRG d4xD7x2.5 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 HMJ2-8N Self-Tapping Screw M2x8 1
5 HMC3-10B Socket Screw M3x10 3
6 HMJ3-20N Self-Tapping Screw M3x20 1
7 HME3-4B Set Screw M3x4 1
8 HMM3Z Locknut M3 3
9 BK0075 Link Ball 4.8 1
No. Material No. Description Qty.
1 HMC3-30B Socket Screw M3x30 2
2 HMC3-14B Socket Screw M3x14 2
3 HMM3Z Locknut M3 4
4 BK0086 Ball Link 4.8x20 2
5 BK0278 Machined Washer 2
6 BK0403 Rod Guide 4
7 BK0404 Tail Rotor Blade 2
No. Material No. Description Qty.
8 BK0877 3D Vertical Fin 1
9 BK0650 Tail Boom 1
10 BK0707 Rear Servo Rod 1
11 BK0347 Tail Push Rod A 1
12 BK0653 Tail Push Rod B 1
13 3-1-1 Tail Transmission Subassembly 1
14 3-1-3 Tail Drive Shaft Subassembly 1
No. Material No. Description Qty.
1 BK0617 Bolt M4x25 1
2 BK0086 Ball Link 4.8x20 4
3 BK0318 Link Rod 2.3x95 2
4 HMM4Z Locknut M4 1
5 2-1 Rotor Head Assembly 1
No. Material No. Description Qty.
1 HME4-5B Set Screw M4x5 4
2 BK0397 Skid Brace 2
3 BK0398 Skid Pipe End Cap 4
4 BK0668 Skid Pipe 2
No.Material No.DescriptionQty.
15-4-1Body Subassembly1
No.Material No.DescriptionQty.
1HMJ2-6BM2x6 Self-Tapping Screw6
2HSE3-12BM3x12 Self-Tapping Screw2
3BK0102d3xD6x11Grommet2
4BK0098Body ClipA1
5BK0099Body Clip B1
6BK0429Body1
7BK0428Canopy1
8JV0186Decal1
9BK0473Body Support1
10BK0474Rubber CAP2
11HNLR6R Pin2
No.Material No.DescriptionQty.
1*****Main Rotor Blade2
2BK0446Rotor Bolt M5x352
3HMM5ZLocknut M52
TABLE OF CONTENTS
REPAIR AND REPLACEMENT PARTS
Purchase replacement parts from the hobby shop where you have purchased the Raptor 90!3D. Please contact
the Thunder Tiger distributor in your country, and the distributor can tell you where to obtain the parts. For example,
in the U.S, all Thunder Tiger products are distributed by Ace Hobby Distributors. On the web site www.acehobby.com,
there is a list of all the hobby shops in the USA that can order any Thunder Tiger parts from Ace for you. Technical
questions regarding the Raptor will be answered quickly by sending an email to [e-mail] or call
Technical Support at 949-833-7498. In Europe, Asia and Australia, please contact the distributor in your country.
WARNING
To ensure safety, please read the instruction manual thoroughly before assembly. Radio control helicopters are
sophisticated equipment, and not toys. Radio control model helicopters are capable of causing serious bodily injury
if not properly assembled or operated. The manufacturer and distributors assume no liability for damages that could
occur from the assembly or use of this product. This product is designed for hobby use only. Operating model
helicopters requires diligence and skill. The best way to ensure quick and successful learning is to seek help and
guidance from accomplished pilots. It is strongly recommended to join the appropriate radio control modeling governing
society in your country. For example, in the United States, it is strongly encouraged to join the Academy of Model
Aeronautics. AMA is a nonprofit organization that provides members in the United States with liability insurance
and monthly modeling magazines. For further information or to find a model helicopter club, please contact AMA
at:
Academy of Model aeronautics
515 East Memorial Drive
Muncie, IN 47302
USA
[phone]
We also encourage you to subscribe to different radio control helicopter magazines and learn about RC flying events,
new flying techniques, safety procedures, and hints. Rotory Modeler is a bi-monthly and Model Helicopter Techniques
is a quarterly newsletter published in the USA. Model Helicopter World is a month magazine published by Traplet
Publication in England and sold worldwide. Rotor is a monthly German magazine. Helico is a Swiss quarterly
magazine.
ATTENTION
We are unable to accept replacement or return of this model after it has been used or assembly has begun.
It is legally prohibited to duplicate or reprint this manual in any format without a written permission from the
manufacturer.
The manufacturer has the right to make changes to this model or instruction without notice.
We have done our best to the accuracy of information in this manual. If you are aware of any mistake, we welcome
you to notify us.
We will not accept any responsibility for any accident, breakdown, fault or trouble caused by improper usage of
this model. Please thoroughly inspect your model and range check the radio before flight. Please keep the model
in its best condition in order to enjoy it.
This model does not include all the items necessary for flying, such as engine, serevos, gyro...etc.
It is difficult for beginners to fly RC helicopters by themselves. It is highly recommended that beginners seek the
help of experienced RC helicopter pilots. We recommend beginners start with an inexpensive model such as the
Thunder Tiger Raptor 30 that is also designed by Mr. Taya.
RC helicopters are not toys. The manufacturer does not assume the liability for any property or bodily damage
caused by the model or the operator.
OTHER ITEMS REQUIRED
6
BODYSUPPORT INSTALLATION
Insert the aluminum support
tube through the servo frame.
Insert the "R" pins through the
two holes in the support tube
to prevent the tube from
moving in the servo frame.
Install two rubber ends onto
the support tube.The rubber
ends will dampen shake or
vibration generated by the
engine.
Glow Plug Wrench
12V Battery
1.5V Glow Starter
(1.2V~1.5V)
Rubber Band
(Included)
Foam
Remote Glow Plug
Extension
1-2-2 Cooling Fan Casing Subassembly
1-2-3 Fuel Tank Subassembly
No. Material No. Description Qty.
1 BK0062 Fuel Tank Stopper 1
2 BB0374 Silcon Tube (L=105mm) 1
3 BK0445 Fuel Plug 1
4 BK0463 Fuel Tank Nipple 1
5 BK0503-1 Fuel Tank 1
6 BE1867 Clunk Weight 1
1-5-5 Header Tank Subassembly
No. Material No. Description Qty.
1 HMC3-25B Socket Screw M3x25 1
2 BK0087 Washer d3xD8x1.4 1
3 BV0502 Header Tank 1
4 BK0506 Tank Mount 1
5 BK0698 Header Tank Supporter 1
The Raptor 90 3D kit includes a header fuel tank that can be
attached to the right of the side frame.
23
2-1-1 Flybar Seesaw Subassembly
24
2-1-2 Metal Main Rotor Hub Subassembly
2
4.Final Assembly ---------------------------------------------------------------------------------------------- 29
4-1 Installation of Rotor Head (Bag H)----------------------------------------------------------------------30
4-2 Installation of Engine --------------------------------------------------------------------------------------31
4-2-1 Engine Subassembly -------------------------------------------------------------------------------32
4-3 Installation of Landing Skid------------------------------------------------------------------------------- 33
4-3-1 Skid Subassembly -----------------------------------------------------------------------------------33
4-4 Installation of Tail Assembly ----------------------------------------------------------------------------- 34
4-4-1 Tail Support Subassembly------------------------------------------------------------------------ 34
5.Installation of Peripheral Equipment ----------------------------------------------------------- 35
5-1 Installation of Servo - Part 1 (Bag I) ------------------------------------------------------------------ 36
5-2 Installation of Servo - Part 2 (Bag I) ------------------------------------------------------------------ 37
5-3 Installation of Receiver and Gyro ---------------------------------------------------------------------- 38
5-4 Installation of Body (Bag J) ------------------------------------------------------------------------------39
5-4-1 Body Subassembly ----------------------------------------------------------------------------------39
5-5 Installation of Rotor Blades (Bag K) ------------------------------------------------------------------- 40
6.Settings --------------------------------------------------------------------------------------------------------- 41
6-1 Setting up Gear Backlash ------------------------------------------------------------------------------- 42
6-2 Setting up of Stabilizer Paddles ------------------------------------------------------------------------43
6-3 Setting up of Blade Pitch Angle ----------------------------------------------------------------------- 43
6-3-1 Collective Travel for Hovering ------------------------------------------------------------------ 44
6-3-2 Collective Travel for 3D --------------------------------------------------------------------------- 44
6-3-3 Configuring the Raptor 90 for 3D --------------------------------------------------------------- 45
Attention --------------------------------------------------------------------------------------------------------------46
7.Parts List Section -------------------------------------------------------------------------------------------49
Raptor 90 3D Exclusive Parts -------------------------------------------------------------------------------- 50
Raptor 90 3D Spare Parts List ------------------------------------------------------------------------------- 55
Raptor 90 3D Optional Parts List ---------------------------------------------------------------------------- 61
3
Thank you very much for purchasing the Thunder Tiger Raptor 90 3D R/C helicopter. The design of Raptor
90 3D is based on the original Raptor 90 series helicopter and modified for extreme aerobatics. It has all
needed must-have optional parts for 3D flying, such as metal main rotor hub, non-linear flapping damper,
metal BRG, 3D light paddles and so on. It also adopts the push-pull control system on collective pitch
and elevator to achieve the most precise control. The flybar ratio is changeable to fit all kinds of flying
style. Use of high quality material make the helicopter one tough machine that can handle everyday 3D
beating. Raptor 90 3D is born for 3D flying, and you don’t have to do any further modification for aggressive
3D maneuver. This is by far the best machine you have never seen. Just enjoy the model and have fun.
UNIQUE SIDEFRAME SYSTEM
Aluminum side plates are used in conjunction with molded material to construct the main structure. This
design produces minimum weight with maximum strength. If the sideframes were completely made of
molded material, then to achieve equal strength the plastic would have to be very thick and heavy. Using
molded material at the right place avoids using metal angle brackets or putting compound bends in metal
frames. Slots have been added in the frame design to permit the use of optional gear ratios to optimize
engine performance to suit any pilot's demand.
BELL-HIILLER MIXING CONTROL UNIT
Main rotor control geometry has been carefully engineered to minimize cross-coupling in collective and
cyclic commands. Blade pitch arms and the Bell-Hiller mixing arms are designed at an angle such that
the pushrod interlinking them are at 90 degrees when the blades are at 0 degree. The pilots will get the
symmetrical cyclic control feel and flybar authority either at +10 or -10 degrees of collective. We design
this system with the 3-D pilot in mind. We guarantee you this whole design philosophy provides a strong
and accurate control mechanism.
SHAFT DRIVE TAIL ROTOR
The Raptor 90 3D is designed with a constant drive tail rotor system to permit full tail rotor control during
autorotations. 180 autos, backward autos and pirouette autos are all within your reach now. It has the
same aluminum torque tube system as the Thunder Tiger/Taya Imperio helicopter. This allows obtaining
the maximum performance from any modern heading lock gyros.
3D CAD DESIGN
We use the latest 3D Computer Aided Design to design and manufacture the Raptor 90 3D. Our high-
tech CAD program allows simulation of all moving parts to ensure no interference. The analysis automatically
analyze the weight, the mass distribution, and inertia to help us pursue a design that will provide the high
level of maneuverability needed for all-out 3-D aerobatics.
INTRODUCTION
Socket Drivers
Hex WrenchGrease
Blue Loctite
Instant Glue
Hobby Knife
Metric
4-way Wrench
Scissors
Diagonal Pliers
Open End Wrench
5.5mm
Needle Nose PliersScrew Driver
7mm
5.5mm
7mm
8mm
5.5mm
7mm
8mm
10mm
Epoxy
Ball Link Pliers
No. Material No. Description Qty.
1 HMV6800ZZY BRG d10xD19x5 1
2 HME4-5B Set Screw M4x5 2
3 HMS5 E Ring M5x8 1
4 HMV696Z BRG d6xD15x5 1
5 BK0388 Clutch BRG Case 2
6 BK0659 Frame Space M 4
7 BK0594 Starter Coupling 1
8 BK0592 Starter Shaft 1
9 BK0422 Drive Pinion 11T 1
10 BK0366 Pinion Gear Nut 1
11 BV0522-2 Clutch Bell Set 1
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 2
2 HMC3-12B Socket Screw M3x12 4
3 BK0087 Washer d3xD8x1.4 6
4 BK0393 Pitch Frame Cross Member 1
5 BK0394 Pitch Frame Cross Member Nut 2
6 BK0375T Upper Frame 2
No. Material No. Description Qty.
1 HMM3Z Locknut M3 4
2 HMC3-25B Socket Screw M3x25 4
3 BK0820BL Landing Skid Damper 4
4 4-3-1 Skid Subassembly 1
No. Material No. Description Qty.
1 HMC3-8B Socket Screw M3x8 4
2 HMQ16 Retaining Ring 1
3 BK0357 Tail Drive Spur Gear 83T 1
4 BK0359 One Way Clutch Shaft 1
5 BV0368 Auto Rotation Hub 1
6 BK0356 Main Spur Gear 91T 1
1-6-2 Main Gear Subassembly
(3)
(2)
(4)
(6)
(5)
(1)
The carbon rear servo plate is secured
by two Lower 3mm bolts from the plastic
tail boom bracket.
10
1-1-2 Pitch Guide L Subassembly
1-1-3 Pitch Guide R Subassembly
No. Material No. Description Qty.
1 BK0384 Pitch Guide Collar L 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
The side with a number should face
in because the opening on both sides
are differeent.
The hole on the plastic control arm has different
opening sizes on the two sides. Always snap the
bigger opening to the ball on swashplate gently and
afterward please check to make sure it is securely
attached and there is no damage or cracking.
INSTALLATION OF THE LINKS
Bigger Hole Face to Swashplate
Extended 6mm Hex
Starting Tool
Fuel Pump
Heli Engine (90size)
9609 PRO-90H(R)
Glow Fuel(15%-30%)
Glow Plug
Hi-torque 12V Electric starter
Receiver
Transmitter
(helicopter type, 6 or
more channels) High Speed/Torque Servo x 4
Rudder Servo x 1
Battery Switch harness
Heading Lock
Gyro
In order to enjoy a safe and enjoyable experience, please read the manual carefully and completely understand
the helicopter structure and operation before the first flight.
Read the warnings to avoid injuries to you and others.
WARNING – The following could cause heavy injury or death if used incorrectly.
Keep the model away from other people or animal when starting the engine.
Do not fly any model helicopter near or above people or cars. Models can sometimes lose
control due to pilot or mechanical failure.
WARNING – The following could also cause serious injury or death if not careful.
Take precaution with model fuel. Model engine glow fuel is highly flammable.
Please check the model carefully before each flight. Make sure that nothing has loosened up
or come apart.
Make sure everything moves freely without binding or excessive friction.
Do not operate the model in rain, snow, thunderstorm, or adverse weather.
WARNING – The following could also cause serious injury or death if not careful.
Please make sure that your radio frequency is not used before flight. If someone else is flying
with the same frequency as your radio, do not turn on your transmitter. Otherwise, it can cause
a crash and even bodily and property damages.
Please monitor the fuel level during flight and land before running out of fuel.
Before each flight, please check that all servos and controls move properly.
Do not modify any parts or use other than genuine Thunder Tiger parts.
Do not fly in places that are forbidden by law.
Use Loctite on screws that do not use a locknut.
When operating the model, please beware that no loose cloth or jewelry can get entangled in
the model helicopter.
Make sure the transmitter and receiver switches are on before starting the engine.
Do not touch the engine or the muffler right after flying because they are very hot.
Do not use this model for anything other than hobby.
WARNING – The following damages can happen to the model.
Do not leave the model in a car for a long time. The heat in the summer or the cold in the
winter and the humidity can cause damage to the model.
Be careful and watch the sharp edges and corners on the model.
BUILDING HINT – The instruction is divided into six assembly chapters:
Main Frame, Rotor Head, Tail Rotor, Final Assembly, Radio Installation, and Settings. There
are many major assembly steps in each chapter, please follow the instruction to do each "
Subassembly" first, then combine the subassemblies into a major assembly.
Upper Frame Assembly
Lower Frame Assembly
12
1-2-1 Tail Drive Unit Subassembly
No. Material No. Description Qty.
1 HME3-4B Set Screw M3x4 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 BK0362 Tail Drive Bevel Gear A 1
5 BK0363 Tail Drive Bevel Gear B 1
6 BK0364 Tail Drive Pinion 1
7 BK0365 Tail Drive Gear Shaft 1
8 BK0382 Tail Boom Bracket L 1
9 BK0383 Tail Boom Bracket R 1
10 BK0414 Pin 2x12 2
11 BK0660 Frame Spacer L 5
Main Frame Assembly Installation of Pitch Frame
No. Material No. Description Qty.
1 HMJ2-10N M2x10 Self-Tapping Screw 1
2 HMV840ZZY BRG d4xD8x3 2
3 HMV1280ZZY BRG d8xD12x3.5 2
4 BK0336 Pitch Frame 1
5 BK0075 Link Ball
φ
4.8 1
Optional: add a tiny drop of thick CA on the outside rim of the fovr ball
bearings before inserting them into the plastic Pitch Frame. Be careful
not to get any glue into the ball bearings. Add a tiny drop of thick CA
glue at the tip of the M2x10 self-tapping screw (No. 1) before
screwing it into the Pitch Frame.
32
Note:
The (3) spacer with threads is
supposed to be locate d at middle
position to fit the Body Fitting Post.
Note:
The (3) spacer with threads is
supposed to be locate d at middle
position to fit the Body Fitting Post.
No. Material No. Description Qty.
1 BK0385 Pitch Guide Collar R 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
Tip: When setting up the phase
adjustment ring, the flybar and
the tail boom can be the
reference. When the flybar and
the tail boom are centered, the
inner balls of swashplate should
be aligned with the outer balls.
Tighten the socket screw on the
phase ring at this moment.
NOTE: Improper alignment will
cause unwanted mixing.
No. Material No. Description Qty.
1 ******** 90 Class Heli Engine 1
2 ******** Nut (Comes With the Engine) 1
3 HMC4-8B Socket Screw M4x8 2
4 HMC4-18B Socket Screw M4x18 4
No. Material No. Description Qty.
5 HMO10 Washer d9.5xD16x1 1
6 BK0349 Engine Mount 1
7 BV0380 Cooling Fan 1
8 BV0521 Heavy Duty Clutch 1
No. Material No. Description Qty.
1 BK0075 Link Ball φ 4.8 5
2 BK0086 Ball Link 4.8x20 8
3 BK0104 Servo Mounting Plate 6
4 BK0105 Rod Joint 1
5 BK0318 Link Rod 2.3x95 2
6 BK0436 Link Rod 2.3x55 2
7 BK0833 Servo Block 4
8 HMC2516B Socket Screw M2.5x16 4
No. Material No. Description Qty.
9 HMM25 Lock Nut M2.5 4
10 HML2 Nut 5
11 HME4-5B Set Screw 2
12 HMF2-8N Phillips Machine Screw M2x8 5
13 HSE2614N Selt-Tapping Screw 4
14 HSE2630N Selt-Tapping Screw 4
No. Material No. Description Qty.
1 BK0075 Link Ball φ 4.8 7
2 BK0086 Ball Link 4.8x20 4
3 BK0095 Link Rod 2.3x76 1
4 BK0104 Servo Mounting Plate4
5 BK0833 Servo Block 2
6 BK0834 Pitch Lever Fixed Plate1
7 BK0839 Link Rod 2.3x30 1
8 BK0881 Washer 1
9 BK0883 Pitch Push Pull Lever1
No.Material No.DescriptionQty.
10BK0884Collar, d3xD4xW121
11BV0085Pitch Link Rod2
12HMC3-20BSocket Screw M3x201
13HMV840ZZYBearing d4xD8xW32
14HMF2-8NPhilip Maching Screw M2x84
15HMJ2-8NSelt-Tapping Screw M2x83
16HML2Nut4
17HSE2614NSelt-Tapping Screw M2.6x148
18HSE2620NSelt-Tapping Screw M2.6x204
No.Material No.DescriptionQty.
1****Switch1
2****Receiver Battery1
3****Receiver1
No.Material No.DescriptionQty.
4****Gyro
5BK0106Foam2
6 BE1052Antenna Pipe1
PV0517 ONEWAY BEARING GREASE
The hole on the Flybar Control Rod has different
opening on two sides.Always snap the bigger opening
to the link ball.
Bigger Hole
Face to ControlArm
10.5mm 10.5mm
When installing pinion gear, add a small drop of Loctite to the
threads. Make sure not to get Loctite on lower clutch bell bearing.
Important:
For 90 class engine, we recommend the 11 teeth pinion for 3D
flying.
The servo tray and cooling fan shrouds on the Raptor 90 are different from the
Raptor 60 in order to accommodate the full head sink on the O.S 91. engine.
If using T.T 90, Y.S 91 or Webra 91 engine, make sure to install the fan shroud
baffle with two self-tapping screws. This will ensure optimal cooling of your engine
head.
Add CA glue Add CA glue
It is necessary to add grease inside the one way clutch before your
first flight. The clutch might lock up once grease is gone. The one
way clutch grease( PV0517) is recommended for this lubrication.
Make sure the inside of Auto Rotation Hub is clean without any dirt
before you insert the one way clutch shaft.
Add Loctite
Add Loctite on
the threads
For 3D flying, it is recommended to use
lower flybar ratio setting.
Self-Tapping Screw, No. 10 Collar, and No. 11 Washer, with two
No. 1 Bearings. Attach a No. 9 Link Ball with a No. 4 Screw.
Upon finishing Step 3-1-1, make sure there are no extra parts
left on your workbench.
Elevator Control
Pushrod
Glue the two plastic halves of
the paddle with CAglue before
installation on flybar.
Add Loctite
the tail boom by tightening the four screws on the helicopter.
Visually check from the rear of the helicopter to make sure the
tail rotor output shaft is perpendicular to the main rotor shaft.
Add the tail boom supports.
Add Loctite
The thrust bearing washer with the
SMALLER inner hole should be closer to
the rotor blade.
The thrust bearing washer with the BIGGER
inner hole should be closer to the main rotor
shaft.
4-2-1 Engine Subassembly
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add CA Glue
Introduction -------------------------------------------------------------------------------------------------------- 3
Other Items Required -------------------------------------------------------------------------------------- 4
Warning --------------------------------------------------------------------------------------------------------------- 5
Assembly
1. Main Frame Assembly --------------------------------------------------------------------------------- 7
1-1 Upper Frame Assembly (Bag A) ---------------------------------------------------------------------- 8
1-1-1 Pinion Gear Subassembly ------------------------------------------------------------------------ 9
1-1-2 Pitch Guide Left Subassembly ------------------------------------------------------------------10
1-1-3 Pitch Guide Right Subassembly -----------------------------------------------------------------10
1-1-4 Elevator Control Arm Subassembly------------------------------------------------------------ 10
1-2 Lower Frame Assembly (Bag B) ----------------------------------------------------------------------11
1-2-1 Tail Drive Unit Subassembly ---------------------------------------------------------------------12
1-2-2 Cooling Fan Casing Subassembly -------------------------------------------------------------13
1-2-3 Fuel Tank Subassembly ------------------------------------------------------------------------13
1-3 Main Frame Assembly (Bag C) -------------------------------------------------------------------------14
1-3-1 Rod Guide Collar Subassembly-----------------------------------------------------------------14
1-4 Installation of Servo Frame (Bag C) ------------------------------------------------------------------- 15
1-5 Installation of Pitch Frame (Bag D) -------------------------------------------------------------------- 16
1-5-1 Aileron Lever Subassembly ---------------------------------------------------------------------17
1-5-2 Metal Elevator Parallel Lever Subassembly -------------------------------------------------17
1-5-3 Elevator Control Lever Subassembly --------------------------------------------------------- 17
1-5-4 Pitch Control Frame Subassembly -------------------------------------------------------------18
1-5-5 Header Tank Subassembly ----------------------------------------------------------------------18
1-6 Installation of Main Shaft (Bag E) ----------------------------------------------------------------------19
1-6-1 Wash Out Subassembly -------------------------------------------------------------------------20
1-6-2 Main Gear Subassembly -------------------------------------------------------------------------20
2. Rotor Head Assembly -----------------------------------------------------------------------------------21
2-1 Metal Rotor Head Assembly (Bag F) -----------------------------------------------------------------22
2-1-1 Flybar Seesaw Subassembly --------------------------------------------------------------------23
2-1-2 Metal Main Rotor Hub Subassembly ----------------------------------------------------------24
3.Tail Assembly -------------------------------------------------------------------------------------------------25
3-1 Tail Assembly (Bag G) ----------------------------------------------------------------------------------- 26
3-1-1 Tail Transmission Subassembly --------------------------------------------------------------- 27
3-1-2 Tail Rotor Subassembly --------------------------------------------------------------------------- 28
3-1-3 Tail Drive Shaft Subassembly -------------------------------------------------------------------28
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(11)
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(12)
(6)
(4)
(16)
(17)
(7)
(8)
(3)
(15)
(14)
The Liner is pre-glued on the
inside of clutch bell with 30 min
epoxy.
1-1 1-2 1-3
( 2 ) (1)
1-4
(1)
(2)
1-5 1-6
(7)
(1) (5)(4)
(9)
(3)
2-1
3-1 4-1
(5)
(3)
(2)
(1)
4-3
(4)
(2)
4-4
(2)
(7)
(1)
(3)
(5)
(8)
4-2
(3)
(1)
(2)
5-1 5-2 5-3
(4)
(6)
(1)
(3)
(2)
(5)
5-4
5-5
(2)
(3)
No. Material No. Description Qty.
8 BK0660 Frame Spacer L 3
9 BK0376T Lower Metal Frame 2
10 BV0870 Metal Lower BRG Block 1
11 1-2-1 Tail Drive Unit Subassembly 1
12 1-2-2 Cooling Fan Casing Subassembly 1
13 1-2-3 Fuel Tank Subassembly 1
No. Material No. Description Qty.
7 BK0659 Frame Spacer M 2
8 BV0869 Metal Upper BRG Block 1
9 1-1-1 Pinion Gear Subassembly 1
10 1-1-2 Pitch Guide L Subassembly 1
11 1-1-3 Pitch Guide R Subassembly 1
12 1-1-4 Elevator Control Arm Subassembly 1
(3)
No. Material No. Description Qty.
10 BK0093 Link Rod 2x46 1
11 BK0407 Collar d3xD4x4.5 2
12 BK0410 Collar d3xD4x13 2
13 1-5-1 Aileron Lever Subassembly 1
14 1-5-2 Metal Elevator Parallel Lever Subassembly 1
15 1-5-3 Elevator Control Lever Subassembly 1
16 1-5-4 Pitch Control Frame Subassembly 1
17 1-5-5 Header Tank Subassembly 1
No. Material No. Description Qty.
6 HMM4B Lucknut M4 1
7 BK0617 Bolt M4x25 1
8 BV0504 Metal Swashplate 1
9 1-6-1 Washout Subassembly 1
10 1-6-2 Main Gear Subassembly 1
No. Material No. Description Qty.
10 BK0076 Collar d3xD4x10 1
11 BK0088 Washer d3xD5x0.5 1
12 BK0346 Tail Pitch Control Lever 1
13 BK0370 Tail Case L 1
14 BK0371 Tail Case R 1
15 BK0372 Tail Input Bevel Gear 1
16 BK0373 Tail Output Bevel Gear 1
17 HMY2-12 Pin 2x12 1
18 3-1-2 Tail Rotor Subassembly 1
No. Material No. Description Qty.
1 HMM3Z Locknut M3 6
2 HMC3-16B Socket Screw M3x16 2
3 HMC3-20B Socket Screw M3x20 2
4 HMC3-25B Socket Screw M3x25 2
5 HMC3-30B Socket Screw M3x30 2
6 BK0087 Washer d3xD8x1.4 4
No. Material No. Description Qty.
1 HMJ2-8N Self-Tapping Screw M2x8 4
2 BK0447 Tail Support Rod End 4
3 BK0669 Tail Support Rod 2
No. Material No. Description Qty.
1 HMC4-42B Muffler Bolt M4x42 2
2 HMT4B Spring Washer 2
3 ******** Muffler ( 90 ) 1
4 4-2-1 Engine Subassembly 1
5 HMC4-12B Socket Screw M4x12 4
6 BK0435 Washer d4xD11xW1.7 4
BAG A
BAG B
BAG C BAG C BAG D
(L) (R)
BAG E
BAG F
BAG G
BAG H
BAG I
97.5mm
48mm
(3)
Throttle
Collective Pitch
(2)
BAG I
BAG J
BAG K
(11) (8)
(7)
(2)
(6)
(3)
(5)
(9)
(4)
Please complete subassembly steps 1-2-1 through 1-2-3 first. Then attach the subassemblies to the two Lower Frames. Note
that the Metal Lower BRG is installed with the bearing open side facing up. Please add a small drop of Loctite on every bolt
before screwing it into the aluminum hex spacer. Do not apply Loctite to the bolts which are going to secure the Lower BRG
Block at this moment.
Assemble the upper main frames by starting with the two Metal Upper Frames. The Pinion Gear Subassembly must be assembled
first according to Figure 1-1-1. Next insert three hex-shape frame spacers into the plastic Pitch Guide according to Figure 1-1-2
and 1-1-3. Assemble the Elevator Control Arm subassembly according to 1-1-4. Insert it in between the two Upper Frames. The
metal Elevator Control Arm is not symmetrical. The side with the longer profruding round knob should be on the right side of the
helicopter. Then attach the other subassemblies to the Upper Frames. Locate Hex Wrenches in BAG L which you need for
assembly.
Please add a tiny drop of non-permanent type Loctite on the tip of all bolts before screwing them into the hex shaped aluminum
frame spacers. Never use too much Loctite, otherwise it will become nearly impossible to remove later on for servicing. Only use
the non-permanent type of Loctite. If encountering difficulty in removing any bolt that was locked up by Loctite, heat up the head
of the screw or bolt with the tip of a hot soldering iron, it will help soften the cured Loctite.
For the kit, parts are bagged according to each major assembly and are labeled "Bag A, Bag
B, etc." The heading for each assembly indicates which bag to open. As a go od practice,
only open up the bag that you need for the particular assembly. Check the parts in that bag
against the parts list shown for each assembly as well as each sub-assembly to make sure
there are no missing parts. To prevent losing small hardware, please empty the small nuts
and bolts and parts into small plastic trays on your work table. At the end of each major
assembly, there should be no left over parts.
The fuel tank comes assembled from the factory because every tank has been
checked for leak. If you were to take the tank apart here is how to put it back
together. Install the silicone fuel line to the Fuel Nipple. Then add the rubber
fuel tank stopper and the clunk weight. The stock silicone fuel line is very soft
and thin which is designed to allow the clunk to pick up fuel easily during 3-D
aerobatics. The pickup line should be inspected and replaced if necessary every
month, otherwise when it becomes soggy it can break off. A thicker silicone line
maybe substituted but make sure the clunk will reach the bottom when moving
the fuel tank to all different orientations.
(4)
(5)
(2)
(2)
(4)
(1)
(6)
(5)
As show in Figure 1-3-1, insert two hex
Frame Spacers S into the plastic Rod
Guide Collars. Then join the Upper
Frame Assembly to the Lower Frame
Assembly according to drawing 1-3.
Secure the Set Screws (No.1) to the
frames, and fit the Body Posts (No.4)
to the Set Screews. The two Body Posts
will be used to secure the canopy in the
future. Add Loctite on all bolts and
inside BK0103 threaded hole.
Install the one-piece servo frame with six self-tapping screws.
Do not use Loctite when attaching self-tapping screws to plastic
parts. Loctite is only for threading metal into metal parts. Assemble the constant drive Main Gear Subassembly according to Figure 1-6-2 first. Then build up the Wash Out Subassembly
according to 1-6-1. Insert the No.3 Main Shaft into the bearings and then add the No.4 Lock Ring and slide in the Main Gear
Subassembly. Add two M3x6 Button Head Screws to the Locking Ring, and the two screws are threaded into the holes on the
main rotor shaft.
The locking ring prevents the main shaft from sliding up. Line up the hole on the main gear and the main shaft, then insert M4x25
mm Bolt through them. Place a 4 mm M4 locknut on the other side of the autorotation hub, and then tighten the Bolt. Do not
over tighten the Bolt, otherwise the autorotation assembly will be distorted. Loosen the 3mm bolts holding the Upper and lower
bearing blocks for the 12mm main shaft. Wiggle the main shaft in the bearing blocks until the main shaft spins freely in the bearings.
This ensures the upper and lower bearing blocks are aligned. Push the lower bearing block up until the main shaft has no up
and down play. Then tighten the 3mm bolts for the upper and lower bearing blocks.
Insert the pin into the Washout Link. Add a tiny drop of Loctite on the inside
and outside of BK0409 Collar which will help give a completely slop free
control system. Do not let the Loctite seep into the bearing. Adjust the
tightness of the M3x12 bolts so the mixing arms can move freely but without
wobble or racheting the ball bearings. Add a tiny drop of thick CA glue at
the tip of the M2x10 self-tapping screw (No. 1) before screwing it into the
Flybar Control Levers (No. 6).
Make the two pushrods for controlling the blade pitch.The distance 43 mm is measured between the center of two pushrod holes.
Attach the Seesaw Hub of the Control PaddleAssembly to the Main Rotor Head with Socket Screws (M3x10).
Please add a small drop of Loctite along the entire length of the M3x10 Socket Screw (No.5) and on the outside of the collar
d3xD4x5.5 (No.3).Temporarily install the Washout Base Guidence Ring, but do not tighten the No.6 M3 Socket Screw yet.
Assemble the tail transmission subassembly according to 3-
1-1 and 3-1-2 first. And the tail drive shaft subassembly according
to 3-1-3.But do not close the two halves of the tail transmission
tightly. You will do this when you are ready to install the gearbox
onto the tail boom.
When installing the tail transmission, make sure the housings
match the hole on to the tail boom. Add Carbon Vertical Fin with
machined washer and Locknut, then tighten the five 3 mm bolts.
Add carbon Vertical Fin with Pom washer and Locknut.
Before inserting the finished tail drive shaft assembly into the
tail boom, add some flexible silicone glue or ZAP Goop glue
around the outside of the tail drive bearing housing. This will
prevent the bearing housing from spinning inside the tail boom.
(7)
Install bearings No. 2 and No.3 into the Tail Cases. Install No.
16 Tail Bevel Gear onto the Tail Shaft. Gently tap the No. 17
Pin into the Bevel Gear and Tail Shaft. Then secure the pin
with a No. 7 Set Screw with Loctite.
After installing the M3x4 set screws, try pushing on the 2x12
pin with a small Allen wrench to make sure the set screw has
locked the pin in place securely. Before closing the two halves
of the Tail Cases, please check the gear mesh between gears
No. 15 and No. 16. If the gears mesh too tight, then a 5 mm
i.d. washer should be added to move the gear No. 16 further
out. If there exists too much freeplay, then a 5 mm i.d. washer
to push gear No. 16 closer to gear No. 15.
Install the No. 12 Tail Pitch Control Lever as shown with No. 6
Slide four No. 6 Rod Guides onto the tail boom. Do not glue
them onto the tail boom yet. Add a tiny drop of CA glue to the
pushrod guide after you finish building the entire helicopter.
Before adding glue, make sure the tail pushrod is hooked up
to the servo and the rod travels in a straight line and moves
very smoothly.
Congratulation, we are almost done. Install the finished main
rotor head onto the 12 mm rotor main shaft. Secure it with a
M4x20 Bolt and M4 Locknut. Make up two 113.5 mm long
pushrods and attach them to the Bell-Hiller mixing arm.
Before installing the plastic end caps, please
add a drop of slow, thick CA glue on the
rim of the end caps and on the inside edge
of the aluminum skid.
Slide the finished tail boom into the helicopter. The four bolts
on the helicopter must be loose in order to insert the tail boom.
Make sure the tail drive shaft is inserted into the front receptacle
properly. Check this by turning the main rotor head. Secure
Secure the two ends to the rod with Epoxy, making sure the
two metal ends are perpendicular to each other.
(4)
Attach the engine into the side frames, with four M4x12 bolts and
four washers, but do not tighten until Section 6-1.
Install the muffler after you have building the entire helicopter.
Always add Loctite on the muffler bolts.
Install the servos and make up the pushrods according to the drawings. The distance between the steel ball and the center of
servo arm are shown in the drawing. Use them as a guide. These distances are used in conjunction with the servo travels (ATV
or End point) set to 100% for all the channels in the transmitter. Tune them later on to suit your personal flying style.
Attach the rudder servo to the rear mounted carbon plate with four 2.6mm bolts and four M2.6 locknut.
Make up the throttle and collective control pushrods according
to the drawing. Use the outermost hole on the carburetor throttle
control arm. Attach the steel ball on the throttle servo arm at
approximately the same distance as the steel ball on the throttle
arm.
Make up the throttle at 97.5mm long first, and then adjust the
pushrod length and throttle servo ATV or Endpoint so full throttle
stick command will open the carburetor barrel fully.And full low
stick and low throttle trim will close the carburetor barrel completely.
Install the receiver and receiver battery. Even though the receiver and battery can be attached to the helicopter tray by using
double sided foam tape, but it is better to wrap the receiver and battery separately using half inch or 10 mm thickfoam. Then
secure them to the tray using six to eight rubberbands, or Velcro bands.
Carefully cut out the canopy (windshield) using scissors.The
best scissors to use are (TTR 1304) designed to cut RC car
bodies and Canopy. Install the canopy to the body using six
small screws. Drill small holes in the canopy and body for the
holes. Drill two more holes for the rubber grommets.
Refer to color box and apply the decals (In BAG M) .
RADIO SET
ENGINE
TOOLS REQUIRED FOR ASSEMBLY
Tools for Assembly
The Raptor 90 3D is designed for easy maintenance using standard hobby tools. Please only use genuine Thunder Tiger parts.
Please keep the model clean and well tuned. It will provide you with long lasting pleasure in return.
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(2)
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(7)
(4)
(18)
(3)(16)(8)
(17)
Add Loctite
(Included)
Add a tiny drop of thick CA glue at the tip of the M2x10
self-tapping screw (No. 1) before screwing it into the
Aileron Levers.
(9)
(10)
(11)
Make up the landing gear according to the
drawing.
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(2)
(4)
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(9)
(3)
(10)
(1)
(11)
(5)
(8)
(3)
(1)
No. Material No. Description Qty.
1 HSE3-6B Self-Tapping Screw M3x6 2
2 BK0660 Frame Spacer L 4
3 BK0662 Cooling Fan Baffle 1
4 BK0665 Fan Casing L 1
5 BK0666 Fan Casing R 1
(2)
(1)
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(3)
(1)
(3)
(2)
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(4)
(3)
(2) (5)
(1)
(12)
(5)
(10)
(14)
Assemble the metal flybar control arms according to the drawings. Slide Flybar ControlArm onto the No.18 Flybar Rod. Slide
the flybar into the No.17 Seesaw Hub. Make sure the Flybar has equal protrusion from each side of the SeesawHub measure
them with a ruler, then install and tighten the No.8 HME4-5B set screws.Add the paddles. Make sure the two paddles and the
two flybar control arms are all parallel. Lock the paddles with No.6 set screws.
Assemble and install the No.10 Mixing Levers and No.5 Bearings according to the drawing using No.12 Collar andNo.9 d3xD5x0.5
washer.
Note:Before installing the Mixing Lever (No.10), please add a small drop of Loctite along the entire length of the M3x18 button
head socket screw (No.4) and on the outside of the collar d3xD4x13 (No.12). Be careful do not let the Loctite seep into the bear ings.
There are two choices of hole positions on the aluminum seesaw for attaching the mixing lever arm.The outside hole gives higher
Bell-Hiller mixing ratio. For aggressive 3D flying, you can attach the Bell-Hiller mixing arms to the inner hole which gives low er
flybar ratio.
(6)
No.Material No.DescriptionQty.
10BK0324Mixing Lever2
11BK0406LPaddle Root2
12BK0410Collar d3xD4x132
13BK0416Paddle Stopper2
14BK0432LFlybar Paddle2
15BK0633Flybar Control Frame2
16 BK0871 Longer StabilizerArm 2
17 BV0865 Longer Seesaw 1
18 BK0866 SUS Flybar 1
No.Material No.DescriptionQty.
1HMF2-8NPhillips Machine Screw M2x82
2HMJ2-10NSelfing-Tapping Screw M2x104
3HMC3-10BSocket Screw M3x102
4 HMC3-18B Socket Screw 2
5HMV840ZZYBRG d4xD8x34
6HME4-3BSet Screw M4x34
7HME4-5BSet Screw M4x52
8BK0075Link Ball
φ
4.86
9BK0088Washer d3xD5x0.52
Insert the aluminum Main Rotor Hub Pin and the Flap Dampers. (might need to apply silicone grease for easy installation). Push
the No.7 Feathering Spindle into the dampers and the rotor hub.Add No. 14 Flybar Control Rod. Slide both finished Main Rotor
Grip onto the feathering spindle and the secure with two M4x10 bolts and washers according to the drawing.Use two Allen
wrenches to tighten the two M4x10 bolts simultaneously.
Important Note:
The Raptor 90 3D kits come with non-linear flap damper for aggressive 3D flying.You may choose to experiment adding from
one up to three 0.4mm thick shim (No.10) washers between the washer (No.8) and bearing to further stiffen the main rotor flapping.
Stiffing the main rotor head will speed up the cyclic transient response, but may cause the helicopter fuselage to oscillate at arou nd
1600 RPM.This oscillation characteristic exists for all helicopters with hard 3D flap dampers.The inner dampers should be
replaced periodically if a lot of 3D flying has been done. When the dampers are worn, the main rotor blades canflap excessivel y
during some 3D maneuvers and risk touching the tail boom.
Add flexible silcone glue or ZAP
Goop glue around the outside
before insert ing into the tail
boom from the front side.
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(2)
(1)
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(3)
(1)
(2)
(5)
(3)
(2) (1)
(4)
180mm
25mm
(1)
(3)
(2) (3)
The optionalThunderTiger Remote Glow PlugAdaptor (#3803)
is recommended as shown, making starting easy without the
removal of your canopy.
(1)
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(3)
(7)
(5)
(1)
(4)
(2)
Cut a hole at the
front air scoop for
backward flights.
(7)
No.Material No.DescriptionQty.
9BK0477Washer2
10BK0703Flap Damper Washer 0.4mm6
11BK0874Inner Damper2
12BK0875Outer Dampper2
13BK0075Ling Ball
φ
4.82
14BK0664Flybar Control Rod2
15BK0319Main Rotor Pitch Housing2
16BV0548-1Metal Main Rutor Hub1
No.Material No.DescriptionQty.
1HMC4-10BSocket Screw M4x102
2HMJ2-12NSelf-Tapping Screw M2x122
3HMV1680BRG d8xD16x54
4HMX0816Thrust Bearing d8xD16x52
5BK0330Main Rotor Hub Pin1
6 BK0325Thrust Washer 2
7BK0326Spindle1
8BK0435Washer2
Fiberglass or Carbon Rotor Blade
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(15)
(1)
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(1)
(5)
Add Loctite when setting up the
gearmesh in step 6-1.
(7)
No. Material No. Description Qty.
7 BK0539 Carbon Rear Servo Plate 1
8 BK0878 Bracket (Top) 1
9 BK0879 Bracket (Bottom) 1
10 3-1 Tail Assembly 1
11 4-4-1 Tail Support Subassembly 2
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(1)
(2)
(1)
(2)
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(4)
(4)
Engine System
Use a high quality 90 size 2-stroke
model helicopter engine, such as the
Thunder Tiger TT PRO-90H, OS 91
SZ-H, YS 91 ST, Webra 91, or
equivalent. Please beware, some
engines may not fit because of their
shape and size. The Raptor 90 3D
kit comes with a cooling fan hub to fit
the TT PRO-90H, OS 91 SZ-H, Webra
91.
We recommend a high quality muffler
or tuned exhaust system designed to
fit on the left side of the model.
Rotor Blades
It is important to use main rotor blades
that are of high quality and suitable
for your flying style. If fiberglass or
carbon graphite blades are used, the
length should be between 680 and
710 mm. Blade weight should be
between 170 and 200 grams.
Starter System
To start the engine, it is necessary to
use an electric starter with a 6mm
shaft extension. The starter and the
6 mm extension are available from
Thunder Tiger, the part numbers are
No.2675 and No.3801.
Use a strong high torque 12 volt
electric starter which is designed for
models.
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(1)
(3)
(5) (8)
(10)
(6)
(7)
(11)
(4)
Add a small drop of Loctite.
Make sure it locks the pin.
Install BK0364 and BK0362 onto BK0365 Tail Gear Drive Shaft. Then insert the
two Pins and secure them with two M3x4 Set Screws. Add a tiny drop of Loctite
on the set screw thread before inserting them. Always use a very small amount
of Loctite liquid on the thread, otherwise it may be nearly impossible to remove
the set screws in the future for servicing. After installing the two M3x4 set screws
(No. 1), try to push on the 2x12 pins with a small Allen wrench to make sure the
set screws have locked the pins in place securely. Install the four ball bearings
and the hex shaped Frame Spacers according to the drawing. Before closing
the two halves of the Tail Boom Brackets, please check the gear mesh between
gears No. 4 and No. 5. If there exists too much freeplay, add some 5 mm i.d.
washers on top of gear No. 4. (The 5 mm i.d. washers are provided in BAG G).
Add a small drop of Loctite.
Make sure it locks the pin.
Shim Washer
(3)
(5)
(4)
(2)
(3)
(1)
Add CA Glue
Standard flybar ratio
Lower flybar ratio
Mild 3D Flying
Extreme 3D Flying
(3)
(8)
(2)
(7)
(5)
(1)
Attach the engine mount to the engine using four 4mm bolts and Loctite.
The cooling fan hub is threaded to fit the OS, TT or Webra only. Place the washer that came with your engine onto the engine
crankshaft first. Then screw the fan hub onto the engine. Add a tiny drop of Loctite on the engine nut. Do not use too much
Loctite. Tighten the engine nut using a socket head wrench while grabbing the fan with a towel. The nut should be tighten securely.
For 50-size or bigger engines, we do not recommend using a piston locking tool on the glow plug hole because that may damage
the engine. Attach the No. 8 Heavy Duty Clutch to the fan hub. Add a drop of Loctite on the threads of the M4x8 bolts. The
threads on the aluminum cooling fan hub are for the TT 70H, OS 61 SX, OS 61LX, OS 70H, TT 90H, OS 91 or Webra 91 engines.
If YS 61, 80 or 91 engines are used, the fan hub must be re-tapped by the modeler to M8x1mm thread size or purchase a optional
plastic fan hub with threads for the YS engine(PV0198YS) or the metal fan for the YS (PV0293YS).
(4)
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(1)
(2)
(4)
(1)
(3)
(3)
(2)
(3)
(6)
(10)
(8)
(1)
(9)
(5)
Please complete subassemblies 1-5-1 through 1-5-5 first, then add them to the Main Frame. Fit the Pitch Control Frame
Subassembly. Attach the E Ring on the left side of the Metal Elevator Control Arm. Then fit the Elevator Control Lever to the
right side, insert the pin and fix it with a set screw. Secure the Pitch Control Frame with a M3*10 Socket Screw and a collar on
the left side. And attach the Elevator Push Pull Lever to the right side of the Pitch Control Frame as shown. Adjust the two bolts
so that the Pitch Control Frame can move freely without excessive play. Finally, add the two plastic Aileron Levers and the 66.5mm
elevator pushrod. Add the Washers (BK0088) to make sure that the Aileron Lever and the Metal Elevator Parallel Lever will not
touch each other during operation.
(2)
(1)
(3)
(2)
(9) (3)
(10)
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(1)
(4)
(7)
(5)
(6)
(11)
(8)
(6)
(4)
Outer hole for standard.
Inner hole for extreme 3D.
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(2)
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(4)
(1) (7) (6)
(9) (12) (5)
(2)
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(3)
Add Loctite
Add Loctite
Add Loctite
(11)
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
30mm
(2)
Paddle
Flybar
A Arm
Phase
Adjustment
Ring
Swash
plate
Boom
(3)
(8)
(14)
(13) (9)
(1) (10) (12)
(7)
(11)
(12)
(2)(7)
(8)(6)
(5)
(4)
(1) (14) (16)
(11)
(18)
Pitch push-pull subassembly
(13)
(1)
(15)
(10) (9)
(17)
(2)
(3)
Add Loctite
Add Epoxy
Add Epoxy
(13)
(14)
(17) (15)
(16)

1
5
7
MAIN FRAME ASSEMBLY
8 9
1-1-1 Pinion Gear Subassembly
11
13 14 15 16 17 18 19 20
21 22
25 26 27
29 30 33 34
36
3531
37
383940
4
1-3-1 Rod Guide Collar Subassembly
1-5-1 Aileron Lever Subassembly
1-5-2 Metal Elevator Parallel Lever Subassembly
1-5-3 Elevator Control Lever Subassembly
1-5-4 Pitch Control Frame Subassembly
1-1-4 Elevator Control Arm Subassembly
1-6-1 Wash Out Subassembly
ROTOR HEAD ASSEMBLY
TAIL ASSEMBLY
3-1-1 Tail Transmission Subassembly
FINAL ASSEMBLY
4-3-1 Skid Subassembly
4-4-1 Tail Support Subassembly
INSTALLATION OF PERIPHERAL EQUIPMENT
5-4-1 Body Subassembly
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 4
2 HMC3-12B Socket Screw M3x12 21
3 BK0087 Washer d3xD8x1.4 22
4 BK0274 Tank Rubber Grommets 4
5 BK0380 Rear Frame L 1
6 BK0381 Rear Frame R 1
7 BK0629 Washer 4
No. Material No. Description Qty.
1 HME3-18.5B Set Screw M3x18.5 2
2 HMC3-25B Socket Screw M3x25 10
3 BK0087 Washer d3xD8x1.4 10
4 BK0103 Body Fitting Post 2
5 BK0658 Frame Spacer S 2
6 1-1 Upper Frame Assembly 1
7 1-2 Lower Frame Assembly 1
8 1-3-1 Rod Guide Collar Subassembly 2
No. Material No. Description Qty.
1 BK0389 Rod Guide Collar 1
2 BK0658 Frame Spacer S 2
No. Material No. Description Qty.
1 BK0667 Servo Frame 1
2 HSE3-12B M3x12 Self-Tapping Screw 6
3 1-3 Main Frame Assembly 1
No. Material No. Description Qty.
1 HMC2-6B Socket Screw M2x6 1
2 HMC3-10B Socket Screw M3x10 1
3 HMC3-25B Socket Screw M3x25 1
4 HME3-3B Set Screw M3x3 1
5 HMJ3-20N Self-Tapping Screw M3x20 2
6 HMS4 E Ring 1
7 HMY2-10 Pin 2x10 1
8 BK0086 Ball link 4.8x20 2
9 BK0088 Washer d3xD5x0.5 3
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 BK0876 Elevator Control Arm 1
2 BK0075 Link Ball
φ
4.8 1
3 HMF2-8N Philip Machine Screw M2x8 1
No. Material No. Description Qty.
1 BK0882 Elevator Push Pull Lever 1
2 HMV840ZZY BRG d4xD8x3 2
3 BK0075 Link Ball
φ
4.8 3
4 HMJ2-8N Selfing-Tapping Screw M2x8 3
5 BK0410 Collar d3xD4x13 1
No. Material No. Description Qty.
1 HMS15 E Ring 4
2 BK0880 Elevator Link Shaft 2
3 BK0455 Metal Elevator Control Arm 1
4 BK0663 Elevator Arm Link 2
No. Material No. Description Qty.
1 BK0093 Link Rod 2x46 2
2 BK0086 Ball Link 4.8x2.0 4
3 BK0547 Hardened Main Shaft 1
4 BK0234 Lock Ring 1
5 HSA3-6B Button Head Socket Screw M3x6 2
No. Material No. Description Qty.
1 HMJ2-10N M2x10 Self-Tapping Screw 2
2 HMC3-12B Socket Screw M3x12 2
3 HMV840ZZY BRG d4xD8x3 4
4 BK0088 Washer d3x5x0.5 2
5 BK0472 Washout base 1
6 BK0342 Flybar Control Lever 2
7 BK0343 Washout Link 2
8 BK0075 Link Ball
φ
4.8 2
9 BK0409 Collar d3xD4x7 2
10 BK0487 Pin 2
11 HMS15 E Ring 2
No. Material No. Description Qty.
1 BK0086 Ball Link φ 4.8 4
2 BK0292 Link Rod 2.3x24 2
3 BK0408 Collar d3xD4x5.5 2
4 BV0549 Washout Base Guidance Ring1
No.Material No.DescriptionQty.
5HMC3-10BSocket Screw M3x102
6HMC3-12B Socket Screw M3x12 1
72-1-1Flybar Seesaw Subassembly1
82-1-2Metal Main Rotor Hub Subassembly1
No. Material No. Description Qty.
1 HMV740ZZ BRG d4xD7x2.5 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 HMJ2-8N Self-Tapping Screw M2x8 1
5 HMC3-10B Socket Screw M3x10 3
6 HMJ3-20N Self-Tapping Screw M3x20 1
7 HME3-4B Set Screw M3x4 1
8 HMM3Z Locknut M3 3
9 BK0075 Link Ball 4.8 1
No. Material No. Description Qty.
1 HMC3-30B Socket Screw M3x30 2
2 HMC3-14B Socket Screw M3x14 2
3 HMM3Z Locknut M3 4
4 BK0086 Ball Link 4.8x20 2
5 BK0278 Machined Washer 2
6 BK0403 Rod Guide 4
7 BK0404 Tail Rotor Blade 2
No. Material No. Description Qty.
8 BK0877 3D Vertical Fin 1
9 BK0650 Tail Boom 1
10 BK0707 Rear Servo Rod 1
11 BK0347 Tail Push Rod A 1
12 BK0653 Tail Push Rod B 1
13 3-1-1 Tail Transmission Subassembly 1
14 3-1-3 Tail Drive Shaft Subassembly 1
No. Material No. Description Qty.
1 BK0617 Bolt M4x25 1
2 BK0086 Ball Link 4.8x20 4
3 BK0318 Link Rod 2.3x95 2
4 HMM4Z Locknut M4 1
5 2-1 Rotor Head Assembly 1
No. Material No. Description Qty.
1 HME4-5B Set Screw M4x5 4
2 BK0397 Skid Brace 2
3 BK0398 Skid Pipe End Cap 4
4 BK0668 Skid Pipe 2
No.Material No.DescriptionQty.
15-4-1Body Subassembly1
No.Material No.DescriptionQty.
1HMJ2-6BM2x6 Self-Tapping Screw6
2HSE3-12BM3x12 Self-Tapping Screw2
3BK0102d3xD6x11Grommet2
4BK0098Body ClipA1
5BK0099Body Clip B1
6BK0429Body1
7BK0428Canopy1
8JV0186Decal1
9BK0473Body Support1
10BK0474Rubber CAP2
11HNLR6R Pin2
No.Material No.DescriptionQty.
1*****Main Rotor Blade2
2BK0446Rotor Bolt M5x352
3HMM5ZLocknut M52
TABLE OF CONTENTS
REPAIR AND REPLACEMENT PARTS
Purchase replacement parts from the hobby shop where you have purchased the Raptor 90!3D. Please contact
the Thunder Tiger distributor in your country, and the distributor can tell you where to obtain the parts. For example,
in the U.S, all Thunder Tiger products are distributed by Ace Hobby Distributors. On the web site www.acehobby.com,
there is a list of all the hobby shops in the USA that can order any Thunder Tiger parts from Ace for you. Technical
questions regarding the Raptor will be answered quickly by sending an email to [e-mail] or call
Technical Support at 949-833-7498. In Europe, Asia and Australia, please contact the distributor in your country.
WARNING
To ensure safety, please read the instruction manual thoroughly before assembly. Radio control helicopters are
sophisticated equipment, and not toys. Radio control model helicopters are capable of causing serious bodily injury
if not properly assembled or operated. The manufacturer and distributors assume no liability for damages that could
occur from the assembly or use of this product. This product is designed for hobby use only. Operating model
helicopters requires diligence and skill. The best way to ensure quick and successful learning is to seek help and
guidance from accomplished pilots. It is strongly recommended to join the appropriate radio control modeling governing
society in your country. For example, in the United States, it is strongly encouraged to join the Academy of Model
Aeronautics. AMA is a nonprofit organization that provides members in the United States with liability insurance
and monthly modeling magazines. For further information or to find a model helicopter club, please contact AMA
at:
Academy of Model aeronautics
515 East Memorial Drive
Muncie, IN 47302
USA
[phone]
We also encourage you to subscribe to different radio control helicopter magazines and learn about RC flying events,
new flying techniques, safety procedures, and hints. Rotory Modeler is a bi-monthly and Model Helicopter Techniques
is a quarterly newsletter published in the USA. Model Helicopter World is a month magazine published by Traplet
Publication in England and sold worldwide. Rotor is a monthly German magazine. Helico is a Swiss quarterly
magazine.
ATTENTION
We are unable to accept replacement or return of this model after it has been used or assembly has begun.
It is legally prohibited to duplicate or reprint this manual in any format without a written permission from the
manufacturer.
The manufacturer has the right to make changes to this model or instruction without notice.
We have done our best to the accuracy of information in this manual. If you are aware of any mistake, we welcome
you to notify us.
We will not accept any responsibility for any accident, breakdown, fault or trouble caused by improper usage of
this model. Please thoroughly inspect your model and range check the radio before flight. Please keep the model
in its best condition in order to enjoy it.
This model does not include all the items necessary for flying, such as engine, serevos, gyro...etc.
It is difficult for beginners to fly RC helicopters by themselves. It is highly recommended that beginners seek the
help of experienced RC helicopter pilots. We recommend beginners start with an inexpensive model such as the
Thunder Tiger Raptor 30 that is also designed by Mr. Taya.
RC helicopters are not toys. The manufacturer does not assume the liability for any property or bodily damage
caused by the model or the operator.
OTHER ITEMS REQUIRED
6
BODYSUPPORT INSTALLATION
Insert the aluminum support
tube through the servo frame.
Insert the "R" pins through the
two holes in the support tube
to prevent the tube from
moving in the servo frame.
Install two rubber ends onto
the support tube.The rubber
ends will dampen shake or
vibration generated by the
engine.
Glow Plug Wrench
12V Battery
1.5V Glow Starter
(1.2V~1.5V)
Rubber Band
(Included)
Foam
Remote Glow Plug
Extension
1-2-2 Cooling Fan Casing Subassembly
1-2-3 Fuel Tank Subassembly
No. Material No. Description Qty.
1 BK0062 Fuel Tank Stopper 1
2 BB0374 Silcon Tube (L=105mm) 1
3 BK0445 Fuel Plug 1
4 BK0463 Fuel Tank Nipple 1
5 BK0503-1 Fuel Tank 1
6 BE1867 Clunk Weight 1
1-5-5 Header Tank Subassembly
No. Material No. Description Qty.
1 HMC3-25B Socket Screw M3x25 1
2 BK0087 Washer d3xD8x1.4 1
3 BV0502 Header Tank 1
4 BK0506 Tank Mount 1
5 BK0698 Header Tank Supporter 1
The Raptor 90 3D kit includes a header fuel tank that can be
attached to the right of the side frame.
23
2-1-1 Flybar Seesaw Subassembly
24
2-1-2 Metal Main Rotor Hub Subassembly
2
4.Final Assembly ---------------------------------------------------------------------------------------------- 29
4-1 Installation of Rotor Head (Bag H)----------------------------------------------------------------------30
4-2 Installation of Engine --------------------------------------------------------------------------------------31
4-2-1 Engine Subassembly -------------------------------------------------------------------------------32
4-3 Installation of Landing Skid------------------------------------------------------------------------------- 33
4-3-1 Skid Subassembly -----------------------------------------------------------------------------------33
4-4 Installation of Tail Assembly ----------------------------------------------------------------------------- 34
4-4-1 Tail Support Subassembly------------------------------------------------------------------------ 34
5.Installation of Peripheral Equipment ----------------------------------------------------------- 35
5-1 Installation of Servo - Part 1 (Bag I) ------------------------------------------------------------------ 36
5-2 Installation of Servo - Part 2 (Bag I) ------------------------------------------------------------------ 37
5-3 Installation of Receiver and Gyro ---------------------------------------------------------------------- 38
5-4 Installation of Body (Bag J) ------------------------------------------------------------------------------39
5-4-1 Body Subassembly ----------------------------------------------------------------------------------39
5-5 Installation of Rotor Blades (Bag K) ------------------------------------------------------------------- 40
6.Settings --------------------------------------------------------------------------------------------------------- 41
6-1 Setting up Gear Backlash ------------------------------------------------------------------------------- 42
6-2 Setting up of Stabilizer Paddles ------------------------------------------------------------------------43
6-3 Setting up of Blade Pitch Angle ----------------------------------------------------------------------- 43
6-3-1 Collective Travel for Hovering ------------------------------------------------------------------ 44
6-3-2 Collective Travel for 3D --------------------------------------------------------------------------- 44
6-3-3 Configuring the Raptor 90 for 3D --------------------------------------------------------------- 45
Attention --------------------------------------------------------------------------------------------------------------46
7.Parts List Section -------------------------------------------------------------------------------------------49
Raptor 90 3D Exclusive Parts -------------------------------------------------------------------------------- 50
Raptor 90 3D Spare Parts List ------------------------------------------------------------------------------- 55
Raptor 90 3D Optional Parts List ---------------------------------------------------------------------------- 61
3
Thank you very much for purchasing the Thunder Tiger Raptor 90 3D R/C helicopter. The design of Raptor
90 3D is based on the original Raptor 90 series helicopter and modified for extreme aerobatics. It has all
needed must-have optional parts for 3D flying, such as metal main rotor hub, non-linear flapping damper,
metal BRG, 3D light paddles and so on. It also adopts the push-pull control system on collective pitch
and elevator to achieve the most precise control. The flybar ratio is changeable to fit all kinds of flying
style. Use of high quality material make the helicopter one tough machine that can handle everyday 3D
beating. Raptor 90 3D is born for 3D flying, and you don’t have to do any further modification for aggressive
3D maneuver. This is by far the best machine you have never seen. Just enjoy the model and have fun.
UNIQUE SIDEFRAME SYSTEM
Aluminum side plates are used in conjunction with molded material to construct the main structure. This
design produces minimum weight with maximum strength. If the sideframes were completely made of
molded material, then to achieve equal strength the plastic would have to be very thick and heavy. Using
molded material at the right place avoids using metal angle brackets or putting compound bends in metal
frames. Slots have been added in the frame design to permit the use of optional gear ratios to optimize
engine performance to suit any pilot's demand.
BELL-HIILLER MIXING CONTROL UNIT
Main rotor control geometry has been carefully engineered to minimize cross-coupling in collective and
cyclic commands. Blade pitch arms and the Bell-Hiller mixing arms are designed at an angle such that
the pushrod interlinking them are at 90 degrees when the blades are at 0 degree. The pilots will get the
symmetrical cyclic control feel and flybar authority either at +10 or -10 degrees of collective. We design
this system with the 3-D pilot in mind. We guarantee you this whole design philosophy provides a strong
and accurate control mechanism.
SHAFT DRIVE TAIL ROTOR
The Raptor 90 3D is designed with a constant drive tail rotor system to permit full tail rotor control during
autorotations. 180 autos, backward autos and pirouette autos are all within your reach now. It has the
same aluminum torque tube system as the Thunder Tiger/Taya Imperio helicopter. This allows obtaining
the maximum performance from any modern heading lock gyros.
3D CAD DESIGN
We use the latest 3D Computer Aided Design to design and manufacture the Raptor 90 3D. Our high-
tech CAD program allows simulation of all moving parts to ensure no interference. The analysis automatically
analyze the weight, the mass distribution, and inertia to help us pursue a design that will provide the high
level of maneuverability needed for all-out 3-D aerobatics.
INTRODUCTION
Socket Drivers
Hex WrenchGrease
Blue Loctite
Instant Glue
Hobby Knife
Metric
4-way Wrench
Scissors
Diagonal Pliers
Open End Wrench
5.5mm
Needle Nose PliersScrew Driver
7mm
5.5mm
7mm
8mm
5.5mm
7mm
8mm
10mm
Epoxy
Ball Link Pliers
No. Material No. Description Qty.
1 HMV6800ZZY BRG d10xD19x5 1
2 HME4-5B Set Screw M4x5 2
3 HMS5 E Ring M5x8 1
4 HMV696Z BRG d6xD15x5 1
5 BK0388 Clutch BRG Case 2
6 BK0659 Frame Space M 4
7 BK0594 Starter Coupling 1
8 BK0592 Starter Shaft 1
9 BK0422 Drive Pinion 11T 1
10 BK0366 Pinion Gear Nut 1
11 BV0522-2 Clutch Bell Set 1
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 2
2 HMC3-12B Socket Screw M3x12 4
3 BK0087 Washer d3xD8x1.4 6
4 BK0393 Pitch Frame Cross Member 1
5 BK0394 Pitch Frame Cross Member Nut 2
6 BK0375T Upper Frame 2
No. Material No. Description Qty.
1 HMM3Z Locknut M3 4
2 HMC3-25B Socket Screw M3x25 4
3 BK0820BL Landing Skid Damper 4
4 4-3-1 Skid Subassembly 1
No. Material No. Description Qty.
1 HMC3-8B Socket Screw M3x8 4
2 HMQ16 Retaining Ring 1
3 BK0357 Tail Drive Spur Gear 83T 1
4 BK0359 One Way Clutch Shaft 1
5 BV0368 Auto Rotation Hub 1
6 BK0356 Main Spur Gear 91T 1
1-6-2 Main Gear Subassembly
(3)
(2)
(4)
(6)
(5)
(1)
The carbon rear servo plate is secured
by two Lower 3mm bolts from the plastic
tail boom bracket.
10
1-1-2 Pitch Guide L Subassembly
1-1-3 Pitch Guide R Subassembly
No. Material No. Description Qty.
1 BK0384 Pitch Guide Collar L 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
The side with a number should face
in because the opening on both sides
are differeent.
The hole on the plastic control arm has different
opening sizes on the two sides. Always snap the
bigger opening to the ball on swashplate gently and
afterward please check to make sure it is securely
attached and there is no damage or cracking.
INSTALLATION OF THE LINKS
Bigger Hole Face to Swashplate
Extended 6mm Hex
Starting Tool
Fuel Pump
Heli Engine (90size)
9609 PRO-90H(R)
Glow Fuel(15%-30%)
Glow Plug
Hi-torque 12V Electric starter
Receiver
Transmitter
(helicopter type, 6 or
more channels) High Speed/Torque Servo x 4
Rudder Servo x 1
Battery Switch harness
Heading Lock
Gyro
In order to enjoy a safe and enjoyable experience, please read the manual carefully and completely understand
the helicopter structure and operation before the first flight.
Read the warnings to avoid injuries to you and others.
WARNING – The following could cause heavy injury or death if used incorrectly.
Keep the model away from other people or animal when starting the engine.
Do not fly any model helicopter near or above people or cars. Models can sometimes lose
control due to pilot or mechanical failure.
WARNING – The following could also cause serious injury or death if not careful.
Take precaution with model fuel. Model engine glow fuel is highly flammable.
Please check the model carefully before each flight. Make sure that nothing has loosened up
or come apart.
Make sure everything moves freely without binding or excessive friction.
Do not operate the model in rain, snow, thunderstorm, or adverse weather.
WARNING – The following could also cause serious injury or death if not careful.
Please make sure that your radio frequency is not used before flight. If someone else is flying
with the same frequency as your radio, do not turn on your transmitter. Otherwise, it can cause
a crash and even bodily and property damages.
Please monitor the fuel level during flight and land before running out of fuel.
Before each flight, please check that all servos and controls move properly.
Do not modify any parts or use other than genuine Thunder Tiger parts.
Do not fly in places that are forbidden by law.
Use Loctite on screws that do not use a locknut.
When operating the model, please beware that no loose cloth or jewelry can get entangled in
the model helicopter.
Make sure the transmitter and receiver switches are on before starting the engine.
Do not touch the engine or the muffler right after flying because they are very hot.
Do not use this model for anything other than hobby.
WARNING – The following damages can happen to the model.
Do not leave the model in a car for a long time. The heat in the summer or the cold in the
winter and the humidity can cause damage to the model.
Be careful and watch the sharp edges and corners on the model.
BUILDING HINT – The instruction is divided into six assembly chapters:
Main Frame, Rotor Head, Tail Rotor, Final Assembly, Radio Installation, and Settings. There
are many major assembly steps in each chapter, please follow the instruction to do each "
Subassembly" first, then combine the subassemblies into a major assembly.
Upper Frame Assembly
Lower Frame Assembly
12
1-2-1 Tail Drive Unit Subassembly
No. Material No. Description Qty.
1 HME3-4B Set Screw M3x4 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 BK0362 Tail Drive Bevel Gear A 1
5 BK0363 Tail Drive Bevel Gear B 1
6 BK0364 Tail Drive Pinion 1
7 BK0365 Tail Drive Gear Shaft 1
8 BK0382 Tail Boom Bracket L 1
9 BK0383 Tail Boom Bracket R 1
10 BK0414 Pin 2x12 2
11 BK0660 Frame Spacer L 5
Main Frame Assembly Installation of Pitch Frame
No. Material No. Description Qty.
1 HMJ2-10N M2x10 Self-Tapping Screw 1
2 HMV840ZZY BRG d4xD8x3 2
3 HMV1280ZZY BRG d8xD12x3.5 2
4 BK0336 Pitch Frame 1
5 BK0075 Link Ball
φ
4.8 1
Optional: add a tiny drop of thick CA on the outside rim of the fovr ball
bearings before inserting them into the plastic Pitch Frame. Be careful
not to get any glue into the ball bearings. Add a tiny drop of thick CA
glue at the tip of the M2x10 self-tapping screw (No. 1) before
screwing it into the Pitch Frame.
32
Note:
The (3) spacer with threads is
supposed to be locate d at middle
position to fit the Body Fitting Post.
Note:
The (3) spacer with threads is
supposed to be locate d at middle
position to fit the Body Fitting Post.
No. Material No. Description Qty.
1 BK0385 Pitch Guide Collar R 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
Tip: When setting up the phase
adjustment ring, the flybar and
the tail boom can be the
reference. When the flybar and
the tail boom are centered, the
inner balls of swashplate should
be aligned with the outer balls.
Tighten the socket screw on the
phase ring at this moment.
NOTE: Improper alignment will
cause unwanted mixing.
No. Material No. Description Qty.
1 ******** 90 Class Heli Engine 1
2 ******** Nut (Comes With the Engine) 1
3 HMC4-8B Socket Screw M4x8 2
4 HMC4-18B Socket Screw M4x18 4
No. Material No. Description Qty.
5 HMO10 Washer d9.5xD16x1 1
6 BK0349 Engine Mount 1
7 BV0380 Cooling Fan 1
8 BV0521 Heavy Duty Clutch 1
No. Material No. Description Qty.
1 BK0075 Link Ball φ 4.8 5
2 BK0086 Ball Link 4.8x20 8
3 BK0104 Servo Mounting Plate 6
4 BK0105 Rod Joint 1
5 BK0318 Link Rod 2.3x95 2
6 BK0436 Link Rod 2.3x55 2
7 BK0833 Servo Block 4
8 HMC2516B Socket Screw M2.5x16 4
No. Material No. Description Qty.
9 HMM25 Lock Nut M2.5 4
10 HML2 Nut 5
11 HME4-5B Set Screw 2
12 HMF2-8N Phillips Machine Screw M2x8 5
13 HSE2614N Selt-Tapping Screw 4
14 HSE2630N Selt-Tapping Screw 4
No. Material No. Description Qty.
1 BK0075 Link Ball φ 4.8 7
2 BK0086 Ball Link 4.8x20 4
3 BK0095 Link Rod 2.3x76 1
4 BK0104 Servo Mounting Plate 4
5 BK0833 Servo Block 2
6 BK0834 Pitch Lever Fixed Plate 1
7 BK0839 Link Rod 2.3x30 1
8 BK0881 Washer 1
9 BK0883 Pitch Push Pull Lever 1
No. Material No. Description Qty.
10 BK0884 Collar, d3xD4xW12 1
11 BV0085 Pitch Link Rod 2
12 HMC3-20B Socket Screw M3x20 1
13 HMV840ZZY Bearing d4xD8xW3 2
14 HMF2-8N Philip Maching Screw M2x8 4
15 HMJ2-8N Selt-Tapping Screw M2x8 3
16 HML2 Nut 4
17 HSE2614N Selt-Tapping Screw M2.6x14 8
18 HSE2620N Selt-Tapping Screw M2.6x20 4
No. Material No. Description Qty.
1 **** Switch 1
2 **** Receiver Battery 1
3 **** Receiver 1
No.Material No.DescriptionQty.
4****Gyro
5BK0106Foam2
6 BE1052Antenna Pipe1
PV0517 ONEWAY BEARING GREASE
The hole on the Flybar Control Rod has different
opening on two sides. Always snap the bigger opening
to the link ball.
Bigger Hole
Face to Control Arm
10.5mm 10.5mm
When installing pinion gear, add a small drop of Loctite to the
threads. Make sure not to get Loctite on lower clutch bell bearing.
Important:
For 90 class engine, we recommend the 11 teeth pinion for 3D
flying.
The servo tray and cooling fan shrouds on the Raptor 90 are different from the
Raptor 60 in order to accommodate the full head sink on the O.S 91. engine.
If using T.T 90, Y.S 91 or Webra 91 engine, make sure to install the fan shroud
baffle with two self-tapping screws. This will ensure optimal cooling of your engine
head.
Add CA glue Add CA glue
It is necessary to add grease inside the one way clutch before your
first flight. The clutch might lock up once grease is gone. The one
way clutch grease( PV0517) is recommended for this lubrication.
Make sure the inside of Auto Rotation Hub is clean without any dirt
before you insert the one way clutch shaft.
Add Loctite
Add Loctite on
the threads
For 3D flying, it is recommended to use
lower flybar ratio setting.
Self-Tapping Screw, No. 10 Collar, and No. 11 Washer, with two
No. 1 Bearings. Attach a No. 9 Link Ball with a No. 4 Screw.
Upon finishing Step 3-1-1, make sure there are no extra parts
left on your workbench.
Elevator Control
Pushrod
Glue the two plastic halves of
the paddle with CAglue before
installation on flybar.
Add Loctite
the tail boom by tightening the four screws on the helicopter.
Visually check from the rear of the helicopter to make sure the
tail rotor output shaft is perpendicular to the main rotor shaft.
Add the tail boom supports.
Add Loctite
The thrust bearing washer with the
SMALLER inner hole should be closer to
the rotor blade.
The thrust bearing washer with the BIGGER
inner hole should be closer to the main rotor
shaft.
4-2-1 Engine Subassembly
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add CA Glue
Introduction -------------------------------------------------------------------------------------------------------- 3
Other Items Required -------------------------------------------------------------------------------------- 4
Warning --------------------------------------------------------------------------------------------------------------- 5
Assembly
1. Main Frame Assembly --------------------------------------------------------------------------------- 7
1-1 Upper Frame Assembly (Bag A) ---------------------------------------------------------------------- 8
1-1-1 Pinion Gear Subassembly ------------------------------------------------------------------------ 9
1-1-2 Pitch Guide Left Subassembly ------------------------------------------------------------------10
1-1-3 Pitch Guide Right Subassembly -----------------------------------------------------------------10
1-1-4 Elevator Control Arm Subassembly------------------------------------------------------------ 10
1-2 Lower Frame Assembly (Bag B) ----------------------------------------------------------------------11
1-2-1 Tail Drive Unit Subassembly ---------------------------------------------------------------------12
1-2-2 Cooling Fan Casing Subassembly -------------------------------------------------------------13
1-2-3 Fuel Tank Subassembly ------------------------------------------------------------------------13
1-3 Main Frame Assembly (Bag C) ------------------------------------------------------------------------- 14
1-3-1 Rod Guide Collar Subassembly----------------------------------------------------------------- 14
1-4 Installation of Servo Frame (Bag C) ------------------------------------------------------------------- 15
1-5 Installation of Pitch Frame (Bag D) -------------------------------------------------------------------- 16
1-5-1 Aileron Lever Subassembly ---------------------------------------------------------------------17
1-5-2 Metal Elevator Parallel Lever Subassembly -------------------------------------------------17
1-5-3 Elevator Control Lever Subassembly --------------------------------------------------------- 17
1-5-4 Pitch Control Frame Subassembly -------------------------------------------------------------18
1-5-5 Header Tank Subassembly ----------------------------------------------------------------------18
1-6 Installation of Main Shaft (Bag E) ----------------------------------------------------------------------19
1-6-1 Wash Out Subassembly -------------------------------------------------------------------------20
1-6-2 Main Gear Subassembly -------------------------------------------------------------------------20
2. Rotor Head Assembly -----------------------------------------------------------------------------------21
2-1 Metal Rotor Head Assembly (Bag F) -----------------------------------------------------------------22
2-1-1 Flybar Seesaw Subassembly --------------------------------------------------------------------23
2-1-2 Metal Main Rotor Hub Subassembly ----------------------------------------------------------24
3.Tail Assembly -------------------------------------------------------------------------------------------------25
3-1 Tail Assembly (Bag G) ----------------------------------------------------------------------------------- 26
3-1-1 Tail Transmission Subassembly --------------------------------------------------------------- 27
3-1-2 Tail Rotor Subassembly --------------------------------------------------------------------------- 28
3-1-3 Tail Drive Shaft Subassembly -------------------------------------------------------------------28
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The Liner is pre-glued on the
inside of clutch bell with 30 min
epoxy.
1-1 1-2 1-3
( 2 ) (1)
1-4
(1)
(2)
1-5 1-6
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(1) (5)(4)
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(3)
2-1
3-1 4-1
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(1)
4-3
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(2)
4-4
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(1)
(3)
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4-2
(3)
(1)
(2)
5-1 5-2 5-3
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5-4
5-5
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No. Material No. Description Qty.
8 BK0660 Frame Spacer L 3
9 BK0376T Lower Metal Frame 2
10 BV0870 Metal Lower BRG Block 1
11 1-2-1 Tail Drive Unit Subassembly 1
12 1-2-2 Cooling Fan Casing Subassembly 1
13 1-2-3 Fuel Tank Subassembly 1
No. Material No. Description Qty.
7 BK0659 Frame Spacer M 2
8 BV0869 Metal Upper BRG Block 1
9 1-1-1 Pinion Gear Subassembly 1
10 1-1-2 Pitch Guide L Subassembly 1
11 1-1-3 Pitch Guide R Subassembly 1
12 1-1-4 Elevator Control Arm Subassembly 1
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No. Material No. Description Qty.
10 BK0093 Link Rod 2x46 1
11 BK0407 Collar d3xD4x4.5 2
12 BK0410 Collar d3xD4x13 2
13 1-5-1 Aileron Lever Subassembly 1
14 1-5-2 Metal Elevator Parallel Lever Subassembly 1
15 1-5-3 Elevator Control Lever Subassembly 1
16 1-5-4 Pitch Control Frame Subassembly 1
17 1-5-5 Header Tank Subassembly 1
No. Material No. Description Qty.
6 HMM4B Lucknut M4 1
7 BK0617 Bolt M4x25 1
8 BV0504 Metal Swashplate 1
9 1-6-1 Washout Subassembly 1
10 1-6-2 Main Gear Subassembly 1
No. Material No. Description Qty.
10 BK0076 Collar d3xD4x10 1
11 BK0088 Washer d3xD5x0.5 1
12 BK0346 Tail Pitch Control Lever 1
13 BK0370 Tail Case L 1
14 BK0371 Tail Case R 1
15 BK0372 Tail Input Bevel Gear 1
16 BK0373 Tail Output Bevel Gear 1
17 HMY2-12 Pin 2x12 1
18 3-1-2 Tail Rotor Subassembly 1
No. Material No. Description Qty.
1 HMM3Z Locknut M3 6
2 HMC3-16B Socket Screw M3x16 2
3 HMC3-20B Socket Screw M3x20 2
4 HMC3-25B Socket Screw M3x25 2
5 HMC3-30B Socket Screw M3x30 2
6 BK0087 Washer d3xD8x1.4 4
No. Material No. Description Qty.
1 HMJ2-8N Self-Tapping Screw M2x8 4
2 BK0447 Tail Support Rod End 4
3 BK0669 Tail Support Rod 2
No. Material No. Description Qty.
1 HMC4-42B Muffler Bolt M4x42 2
2 HMT4B Spring Washer 2
3 ******** Muffler ( 90 ) 1
4 4-2-1 Engine Subassembly 1
5 HMC4-12B Socket Screw M4x12 4
6 BK0435 Washer d4xD11xW1.7 4
BAG A
BAG B
BAG C BAG C BAG D
(L) (R)
BAG E
BAG F
BAG G
BAG H
BAG I
97.5mm
48mm
(3)
Throttle
Collective Pitch
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BAG I
BAG J
BAG K
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Please complete subassembly steps 1-2-1 through 1-2-3 first. Then attach the subassemblies to the two Lower Frames. Note
that the Metal Lower BRG is installed with the bearing open side facing up. Please add a small drop of Loctite on every bolt
before screwing it into the aluminum hex spacer. Do not apply Loctite to the bolts which are going to secure the Lower BRG
Block at this moment.
Assemble the upper main frames by starting with the two Metal Upper Frames. The Pinion Gear Subassembly must be assembled
first according to Figure 1-1-1. Next insert three hex-shape frame spacers into the plastic Pitch Guide according to Figure 1-1-2
and 1-1-3. Assemble the Elevator Control Arm subassembly according to 1-1-4. Insert it in between the two Upper Frames. The
metal Elevator Control Arm is not symmetrical. The side with the longer profruding round knob should be on the right side of the
helicopter. Then attach the other subassemblies to the Upper Frames. Locate Hex Wrenches in BAG L which you need for
assembly.
Please add a tiny drop of non-permanent type Loctite on the tip of all bolts before screwing them into the hex shaped aluminum
frame spacers. Never use too much Loctite, otherwise it will become nearly impossible to remove later on for servicing. Only use
the non-permanent type of Loctite. If encountering difficulty in removing any bolt that was locked up by Loctite, heat up the head
of the screw or bolt with the tip of a hot soldering iron, it will help soften the cured Loctite.
For the kit, parts are bagged according to each major assembly and are labeled "Bag A, Bag
B, etc." The heading for each assembly indicates which bag to open. As a good practice,
only open up the bag that you need for the particular assembly. Check the parts in that bag
against the parts list shown for each assembly as well as each sub-assembly to make sure
there are no missing parts. To prevent losing small hardware, please empty the small nuts
and bolts and parts into small plastic trays on your work table. At the end of each major
assembly, there should be no left over parts.
The fuel tank comes assembled from the factory because every tank has been
checked for leak. If you were to take the tank apart here is how to put it back
together. Install the silicone fuel line to the Fuel Nipple. Then add the rubber
fuel tank stopper and the clunk weight. The stock silicone fuel line is very soft
and thin which is designed to allow the clunk to pick up fuel easily during 3-D
aerobatics. The pickup line should be inspected and replaced if necessary every
month, otherwise when it becomes soggy it can break off. A thicker silicone line
maybe substituted but make sure the clunk will reach the bottom when moving
the fuel tank to all different orientations.
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As show in Figure 1-3-1, insert two hex
Frame Spacers S into the plastic Rod
Guide Collars. Then join the Upper
Frame Assembly to the Lower Frame
Assembly according to drawing 1-3.
Secure the Set Screws (No.1) to the
frames, and fit the Body Posts (No.4)
to the Set Screews. The two Body Posts
will be used to secure the canopy in the
future. Add Loctite on all bolts and
inside BK0103 threaded hole.
Install the one-piece servo frame with six self-tapping screws.
Do not use Loctite when attaching self-tapping screws to plastic
parts. Loctite is only for threading metal into metal parts. Assemble the constant drive Main Gear Subassembly according to Figure 1-6-2 first. Then build up the Wash Out Subassembly
according to 1-6-1. Insert the No.3 Main Shaft into the bearings and then add the No.4 Lock Ring and slide in the Main Gear
Subassembly. Add two M3x6 Button Head Screws to the Locking Ring, and the two screws are threaded into the holes on the
main rotor shaft.
The locking ring prevents the main shaft from sliding up. Line up the hole on the main gear and the main shaft, then insert M4x25
mm Bolt through them. Place a 4 mm M4 locknut on the other side of the autorotation hub, and then tighten the Bolt. Do not
over tighten the Bolt, otherwise the autorotation assembly will be distorted. Loosen the 3mm bolts holding the Upper and lower
bearing blocks for the 12mm main shaft. Wiggle the main shaft in the bearing blocks until the main shaft spins freely in the bearings.
This ensures the upper and lower bearing blocks are aligned. Push the lower bearing block up until the main shaft has no up
and down play. Then tighten the 3mm bolts for the upper and lower bearing blocks.
Insert the pin into the Washout Link. Add a tiny drop of Loctite on the inside
and outside of BK0409 Collar which will help give a completely slop free
control system. Do not let the Loctite seep into the bearing. Adjust the
tightness of the M3x12 bolts so the mixing arms can move freely but without
wobble or racheting the ball bearings. Add a tiny drop of thick CA glue at
the tip of the M2x10 self-tapping screw (No. 1) before screwing it into the
Flybar Control Levers (No. 6).
Make the two pushrods for controlling the blade pitch.The distance 43 mm is measured between the center of two pushrod holes.
Attach the Seesaw Hub of the Control PaddleAssembly to the Main Rotor Head with Socket Screws (M3x10).
Please add a small drop of Loctite along the entire length of the M3x10 Socket Screw (No.5) and on the outside of the collar
d3xD4x5.5 (No.3). Temporarily install the Washout Base Guidence Ring, but do not tighten the No.6 M3 Socket Screw yet.
Assemble the tail transmission subassembly according to 3-
1-1 and 3-1-2 first. And the tail drive shaft subassembly according
to 3-1-3.But do not close the two halves of the tail transmission
tightly. You will do this when you are ready to install the gearbox
onto the tail boom.
When installing the tail transmission, make sure the housings
match the hole on to the tail boom. Add Carbon Vertical Fin with
machined washer and Locknut, then tighten the five 3 mm bolts.
Add carbon Vertical Fin with Pom washer and Locknut.
Before inserting the finished tail drive shaft assembly into the
tail boom, add some flexible silicone glue or ZAP Goop glue
around the outside of the tail drive bearing housing. This will
prevent the bearing housing from spinning inside the tail boom.
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Install bearings No. 2 and No.3 into the Tail Cases. Install No.
16 Tail Bevel Gear onto the Tail Shaft. Gently tap the No. 17
Pin into the Bevel Gear and Tail Shaft. Then secure the pin
with a No. 7 Set Screw with Loctite.
After installing the M3x4 set screws, try pushing on the 2x12
pin with a small Allen wrench to make sure the set screw has
locked the pin in place securely. Before closing the two halves
of the Tail Cases, please check the gear mesh between gears
No. 15 and No. 16. If the gears mesh too tight, then a 5 mm
i.d. washer should be added to move the gear No. 16 further
out. If there exists too much freeplay, then a 5 mm i.d. washer
to push gear No. 16 closer to gear No. 15.
Install the No. 12 Tail Pitch Control Lever as shown with No. 6
Slide four No. 6 Rod Guides onto the tail boom. Do not glue
them onto the tail boom yet. Add a tiny drop of CA glue to the
pushrod guide after you finish building the entire helicopter.
Before adding glue, make sure the tail pushrod is hooked up
to the servo and the rod travels in a straight line and moves
very smoothly.
Congratulation, we are almost done. Install the finished main
rotor head onto the 12 mm rotor main shaft. Secure it with a
M4x20 Bolt and M4 Locknut. Make up two 113.5 mm long
pushrods and attach them to the Bell-Hiller mixing arm.
Before installing the plastic end caps, please
add a drop of slow, thick CA glue on the
rim of the end caps and on the inside edge
of the aluminum skid.
Slide the finished tail boom into the helicopter. The four bolts
on the helicopter must be loose in order to insert the tail boom.
Make sure the tail drive shaft is inserted into the front receptacle
properly. Check this by turning the main rotor head. Secure
Secure the two ends to the rod with Epoxy, making sure the
two metal ends are perpendicular to each other.
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Attach the engine into the side frames, with four M4x12 bolts and
four washers, but do not tighten until Section 6-1.
Install the muffler after you have building the entire helicopter.
Always add Loctite on the muffler bolts.
Install the servos and make up the pushrods according to the drawings. The distance between the steel ball and the center of
servo arm are shown in the drawing. Use them as a guide. These distances are used in conjunction with the servo travels (ATV
or End point) set to 100% for all the channels in the transmitter. Tune them later on to suit your personal flying style.
Attach the rudder servo to the rear mounted carbon plate with four 2.6mm bolts and four M2.6 locknut.
Make up the throttle and collective control pushrods according
to the drawing. Use the outermost hole on the carburetor throttle
control arm. Attach the steel ball on the throttle servo arm at
approximately the same distance as the steel ball on the throttle
arm.
Make up the throttle at 97.5mm long first, and then adjust the
pushrod length and throttle servo ATV or Endpoint so full throttle
stick command will open the carburetor barrel fully. And full low
stick and low throttle trim will close the carburetor barrel completely.
Install the receiver and receiver battery. Even though the receiver and battery can be attached to the helicopter tray by using
double sided foam tape, but it is better to wrap the receiver and battery separately using half inch or 10 mm thick foam.Then
secure them to the tray using six to eight rubberbands, or Velcro bands.
Carefully cut out the canopy (windshield) using scissors.The
best scissors to use are (TTR 1304) designed to cut RC car
bodies and Canopy. Install the canopy to the body using six
small screws. Drill small holes in the canopy and body for the
holes. Drill two more holes for the rubber grommets.
Refer to color box and apply the decals (In BAG M) .
Tools for Assembly
The Raptor 90 3D is designed for easy maintenance using standard hobby tools. Please only use genuine Thunder Tiger parts.
Please keep the model clean and well tuned. It will provide you with long lasting pleasure in return.
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Add Loctite
(Included)
Add a tiny drop of thick CA glue at the tip of the M2x10
self-tapping screw (No. 1) before screwing it into the
Aileron Levers.
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Make up the landing gear according to the
drawing.
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No. Material No. Description Qty.
1 HSE3-6B Self-Tapping Screw M3x6 2
2 BK0660 Frame Spacer L 4
3 BK0662 Cooling Fan Baffle 1
4 BK0665 Fan Casing L 1
5 BK0666 Fan Casing R 1
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Assemble the metal flybar control arms according to the drawings. Slide Flybar ControlArm onto the No.18 Flybar Rod. Slide
the flybar into the No.17 Seesaw Hub. Make sure the Flybar has equal protrusion from each side of the SeesawHub measure
them with a ruler, then install and tighten the No.8 HME4-5B set screws.Add the paddles. Make sure the two paddles and the
two flybar control arms are all parallel. Lock the paddles with No.6 set screws.
Assemble and install the No.10 Mixing Levers and No.5 Bearings according to the drawing using No.12 Collar andNo.9 d3xD5x0.5
washer.
Note:Before installing the Mixing Lever (No.10), please add a small drop of Loctite along the entire length of the M3x18 button
head socket screw (No.4) and on the outside of the collar d3xD4x13 (No.12). Be careful do not let the Loctite seep into the bear ings.
There are two choices of hole positions on the aluminum seesaw for attaching the mixing lever arm.The outside hole gives higher
Bell-Hiller mixing ratio. For aggressive 3D flying, you can attach the Bell-Hiller mixing arms to the inner hole which gives low er
flybar ratio.
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No.Material No.DescriptionQty.
10BK0324Mixing Lever2
11BK0406LPaddle Root2
12BK0410Collar d3xD4x132
13BK0416Paddle Stopper2
14BK0432LFlybar Paddle2
15BK0633Flybar Control Frame2
16 BK0871 Longer StabilizerArm 2
17 BV0865 Longer Seesaw 1
18 BK0866 SUS Flybar 1
No.Material No.DescriptionQty.
1HMF2-8NPhillips Machine Screw M2x82
2HMJ2-10NSelfing-Tapping Screw M2x104
3HMC3-10BSocket Screw M3x102
4 HMC3-18B Socket Screw 2
5HMV840ZZYBRG d4xD8x34
6HME4-3BSet Screw M4x34
7HME4-5BSet Screw M4x52
8BK0075Link Ball
φ
4.86
9BK0088Washer d3xD5x0.52
Insert the aluminum Main Rotor Hub Pin and the Flap Dampers. (might need to apply silicone grease for easy installation). Push
the No.7 Feathering Spindle into the dampers and the rotor hub.Add No. 14 Flybar Control Rod. Slide both finished Main Rotor
Grip onto the feathering spindle and the secure with two M4x10 bolts and washers according to the drawing.Use two Allen
wrenches to tighten the two M4x10 bolts simultaneously.
Important Note:
The Raptor 90 3D kits come with non-linear flap damper for aggressive 3D flying.You may choose to experiment adding from
one up to three 0.4mm thick shim (No.10) washers between the washer (No.8) and bearing to further stiffen the main rotor flapping.
Stiffing the main rotor head will speed up the cyclic transient response, but may cause the helicopter fuselage to oscillate at arou nd
1600 RPM.This oscillation characteristic exists for all helicopters with hard 3D flap dampers.The inner dampers should be
replaced periodically if a lot of 3D flying has been done. When the dampers are worn, the main rotor blades canflap excessivel y
during some 3D maneuvers and risk touching the tail boom.
Add flexible silcone glue or ZAP
Goop glue around the outside
before insert ing into the tail
boom from the front side.
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180mm
25mm
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The optionalThunderTiger Remote Glow PlugAdaptor (#3803)
is recommended as shown, making starting easy without the
removal of your canopy.
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Cut a hole at the
front air scoop for
backward flights.
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No.Material No.DescriptionQty.
9BK0477Washer2
10BK0703Flap Damper Washer 0.4mm6
11BK0874Inner Damper2
12BK0875Outer Dampper2
13BK0075Ling Ball
φ
4.82
14BK0664Flybar Control Rod2
15BK0319Main Rotor Pitch Housing2
16BV0548-1Metal Main Rutor Hub1
No.Material No.DescriptionQty.
1HMC4-10BSocket Screw M4x102
2HMJ2-12NSelf-Tapping Screw M2x122
3HMV1680BRG d8xD16x54
4HMX0816Thrust Bearing d8xD16x52
5BK0330Main Rotor Hub Pin1
6 BK0325Thrust Washer 2
7BK0326Spindle1
8BK0435Washer2
Fiberglass or Carbon Rotor Blade
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Add Loctite when setting up the
gearmesh in step 6-1.
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No. Material No. Description Qty.
7 BK0539 Carbon Rear Servo Plate 1
8 BK0878 Bracket (Top) 1
9 BK0879 Bracket (Bottom) 1
10 3-1 Tail Assembly 1
11 4-4-1 Tail Support Subassembly 2
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Engine System
Use a high quality 90 size 2-stroke
model helicopter engine, such as the
Thunder Tiger TT PRO-90H, OS 91
SZ-H, YS 91 ST, Webra 91, or
equivalent . Please beware, some
engines may not fit because of their
shape and size. The Raptor 90 3D
kit comes with a cooling fan hub to fit
the TT PRO-90H, OS 91 SZ-H, Webra
91.
We recommend a high quality muffler
or tuned exhaust system designed to
fit on the left side of the model.
Rotor Blades
It is important to use main rotor blades
that are of high quality and suitable
for your flying style. If fiberglass or
carbon graphite blades are used, the
length should be between 680 and
710 mm. Blade weigh t should be
between 170 and 200 grams.
Starter System
To start the engine, it is necessary to
use an electric starter with a 6mm
shaft extension. The starter and the
6 mm extension are available from
Thunder Tiger, the part numbers are
No.2675 and No.3801.
Use a strong high torque 12 volt
electric starter which is designed for
models.
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Add a small drop of Loctite.
Make sure it locks the pin.
Install BK0364 and BK0362 onto BK0365 Tail Gear Drive Shaft. Then insert the
two Pins and secure them with two M3x4 Set Screws. Add a tiny drop of Loctite
on the set screw thread before inserting them. Always use a very small amount
of Loctite liquid on the thread, otherwise it may be nearly impossible to remove
the set screws in the future for servicing. After installing the two M3x4 set screws
(No. 1), try to push on the 2x12 pins with a small Allen wrench to make sure the
set screws have locked the pins in place securely. Install the four ball bearings
and the hex shaped Frame Spacers according to the drawing. Before closing
the two halves of the Tail Boom Brackets, please check the gear mesh between
gears No. 4 and No. 5. If there exists too much freeplay, add some 5 mm i.d.
washers on top of gear No. 4. (The 5 mm i.d. washers are provided in BAG G).
Add a small drop of Loctite.
Make sure it locks the pin.
Shim Washer
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Add CA Glue
Standard flybar ratio
Lower flybar ratio
Mild 3D Flying
Extreme 3D Flying
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Attach the engine mount to the engine using four 4mm bolts and Loctite.
The cooling fan hub is threaded to fit the OS, TT or Webra only. Place the washer that came with your engine onto the engine
crankshaft first. Then screw the fan hub onto the engine. Add a tiny drop of Loctite on the engine nut. Do not use too much
Loctite. Tighten the engine nut using a socket head wrench while grabbing the fan with a towel. The nut should be tighten securely.
For 50-size or bigger engines, we do not recommend using a piston locking tool on the glow plug hole because that may damage
the engine. Attach the No. 8 Heavy Duty Clutch to the fan hub. Add a drop of Loctite on the threads of the M4x8 bolts. The
threads on the aluminum cooling fan hub are for the TT 70H, OS 61 SX, OS 61LX, OS 70H, TT 90H, OS 91 or Webra 91 engines.
If YS 61, 80 or 91 engines are used, the fan hub must be re-tapped by the modeler to M8x1mm thread size or purchase a optional
plastic fan hub with threads for the YS engine(PV0198YS) or the metal fan for the YS (PV0293YS).
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Please complete subassemblies 1-5-1 through 1-5-5 first, then add them to the Main Frame. Fit the Pitch Control Frame
Subassembly. Attach the E Ring on the left side of the Metal Elevator Control Arm. Then fit the Elevator Control Lever to the
right side, insert the pin and fix it with a set screw. Secure the Pitch Control Frame with a M3*10 Socket Screw and a collar on
the left side. And attach the Elevator Push Pull Lever to the right side of the Pitch Control Frame as shown. Adjust the two bolts
so that the Pitch Control Frame can move freely without excessive play. Finally, add the two plastic Aileron Levers and the 66.5mm
elevator pushrod. Add the Washers (BK0088) to make sure that the Aileron Lever and the Metal Elevator Parallel Lever will not
touch each other during operation.
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Outer hole for standard.
Inner hole for extreme 3D.
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Add Loctite
Add Loctite
Add Loctite
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Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
30mm
(2)
Paddle
Flybar
A Arm
Phase
Adjustment
Ring
Swash
plate
Boom
(3)
(8)
(14)
(13) (9)
(1) (10) (12)
(7)
(11)
(12)
(2) (7)
(8)(6)
(5)
(4)
(1) (14) (16)
(11)
(18)
Pitch push-pull subassembly
(13)
(1)
(15)
(10) (9)
(17)
(2)
(3)
Add Loctite
Add Epoxy
Add Epoxy
(13)
(14)
(17) (15)
(16)

1
5
7
MAIN FRAME ASSEMBLY
8 9
1-1-1 Pinion Gear Subassembly
11
13 14 15 16 17 18 19 20
21 22
25 26 27
29 30 33 34
36
3531
37
38 3940
4
1-3-1 Rod Guide Collar Subassembly
1-5-1 Aileron Lever Subassembly
1-5-2 Metal Elevator Parallel Lever Subassembly
1-5-3 Elevator Control Lever Subassembly
1-5-4 Pitch Control Frame Subassembly
1-1-4 Elevator Control Arm Subassembly
1-6-1 Wash Out Subassembly
ROTOR HEAD ASSEMBLY
TAIL ASSEMBLY
3-1-1 Tail Transmission Subassembly
FINAL ASSEMBLY
4-3-1 Skid Subassembly
4-4-1 Tail Support Subassembly
INSTALLATION OF PERIPHERAL EQUIPMENT
5-4-1 Body Subassembly
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 4
2 HMC3-12B Socket Screw M3x12 21
3 BK0087 Washer d3xD8x1.4 22
4 BK0274 Tank Rubber Grommets 4
5 BK0380 Rear Frame L 1
6 BK0381 Rear Frame R 1
7 BK0629 Washer 4
No. Material No. Description Qty.
1 HME3-18.5B Set Screw M3x18.5 2
2 HMC3-25B Socket Screw M3x25 10
3 BK0087 Washer d3xD8x1.4 10
4 BK0103 Body Fitting Post 2
5 BK0658 Frame Spacer S 2
6 1-1 Upper Frame Assembly 1
7 1-2 Lower Frame Assembly 1
8 1-3-1 Rod Guide Collar Subassembly 2
No. Material No. Description Qty.
1 BK0389 Rod Guide Collar 1
2 BK0658 Frame Spacer S 2
No. Material No. Description Qty.
1 BK0667 Servo Frame 1
2 HSE3-12B M3x12 Self-Tapping Screw 6
3 1-3 Main Frame Assembly 1
No. Material No. Description Qty.
1 HMC2-6B Socket Screw M2x6 1
2 HMC3-10B Socket Screw M3x10 1
3 HMC3-25B Socket Screw M3x25 1
4 HME3-3B Set Screw M3x3 1
5 HMJ3-20N Self-Tapping Screw M3x20 2
6 HMS4 E Ring 1
7 HMY2-10 Pin 2x10 1
8 BK0086 Ball link 4.8x20 2
9 BK0088 Washer d3xD5x0.5 3
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 BK0876 Elevator Control Arm 1
2 BK0075 Link Ball
φ
4.8 1
3 HMF2-8N Philip Machine Screw M2x8 1
No. Material No. Description Qty.
1 BK0882 Elevator Push Pull Lever 1
2 HMV840ZZY BRG d4xD8x3 2
3 BK0075 Link Ball
φ
4.8 3
4 HMJ2-8N Selfing-Tapping Screw M2x8 3
5 BK0410 Collar d3xD4x13 1
No. Material No. Description Qty.
1 HMS15 E Ring 4
2 BK0880 Elevator Link Shaft 2
3 BK0455 Metal Elevator Control Arm 1
4 BK0663 Elevator Arm Link 2
No. Material No. Description Qty.
1 BK0093 Link Rod 2x46 2
2 BK0086 Ball Link 4.8x2.0 4
3 BK0547 Hardened Main Shaft 1
4 BK0234 Lock Ring 1
5 HSA3-6B Button Head Socket Screw M3x6 2
No. Material No. Description Qty.
1 HMJ2-10N M2x10 Self-Tapping Screw 2
2 HMC3-12B Socket Screw M3x12 2
3 HMV840ZZY BRG d4xD8x3 4
4 BK0088 Washer d3x5x0.5 2
5 BK0472 Washout base 1
6 BK0342 Flybar Control Lever 2
7 BK0343 Washout Link 2
8 BK0075 Link Ball
φ
4.8 2
9 BK0409 Collar d3xD4x7 2
10 BK0487 Pin 2
11 HMS15 E Ring 2
No. Material No. Description Qty.
1 BK0086 Ball Link φ 4.8 4
2 BK0292 Link Rod 2.3x24 2
3 BK0408 Collar d3xD4x5.5 2
4 BV0549 Washout Base Guidance Ring 1
No. Material No. Description Qty.
5 HMC3-10B Socket Screw M3x10 2
6 HMC3-12B Socket Screw M3x12 1
7 2-1-1 Flybar Seesaw Subassembly 1
8 2-1-2 Metal Main Rotor Hub Subassembly 1
No. Material No. Description Qty.
1 HMV740ZZ BRG d4xD7x2.5 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 HMJ2-8N Self-Tapping Screw M2x8 1
5 HMC3-10B Socket Screw M3x10 3
6 HMJ3-20N Self-Tapping Screw M3x20 1
7 HME3-4B Set Screw M3x4 1
8 HMM3Z Locknut M3 3
9 BK0075 Link Ball 4.8 1
No. Material No. Description Qty.
1 HMC3-30B Socket Screw M3x30 2
2 HMC3-14B Socket Screw M3x14 2
3 HMM3Z Locknut M3 4
4 BK0086 Ball Link 4.8x20 2
5 BK0278 Machined Washer 2
6 BK0403 Rod Guide 4
7 BK0404 Tail Rotor Blade 2
No. Material No. Description Qty.
8 BK0877 3D Vertical Fin 1
9 BK0650 Tail Boom 1
10 BK0707 Rear Servo Rod 1
11 BK0347 Tail Push Rod A 1
12 BK0653 Tail Push Rod B 1
13 3-1-1 Tail Transmission Subassembly 1
14 3-1-3 Tail Drive Shaft Subassembly 1
No. Material No. Description Qty.
1 BK0617 Bolt M4x25 1
2 BK0086 Ball Link 4.8x20 4
3 BK0318 Link Rod 2.3x95 2
4 HMM4Z Locknut M4 1
5 2-1 Rotor Head Assembly 1
No. Material No. Description Qty.
1 HME4-5B Set Screw M4x5 4
2 BK0397 Skid Brace 2
3 BK0398 Skid Pipe End Cap 4
4 BK0668 Skid Pipe 2
No. Material No. Description Qty.
1 5-4-1 Body Subassembly 1
No. Material No. Description Qty.
1 HMJ2-6B M2x6 Self-Tapping Screw 6
2 HSE3-12B M3x12 Self-Tapping Screw 2
3 BK0102 d3xD6x11Grommet 2
4 BK0098 Body Clip A 1
5 BK0099 Body Clip B 1
6 BK0429 Body 1
7 BK0428 Canopy 1
8 JV0186 Decal 1
9 BK0473 Body Support 1
10 BK0474 Rubber CAP 2
11 HNLR6 R Pin 2
No.Material No.DescriptionQty.
1*****Main Rotor Blade2
2BK0446Rotor Bolt M5x352
3HMM5ZLocknut M52
TABLE OF CONTENTS
REPAIR AND REPLACEMENT PARTS
Purchase replacement parts from the hobby shop where you have purchased the Raptor 90!3D. Please contact
the Thunder Tiger distributor in your country, and the distributor can tell you where to obtain the parts. For example,
in the U.S, all Thunder Tiger products are distributed by Ace Hobby Distributors. On the web site www.acehobby.com,
there is a list of all the hobby shops in the USA that can order any Thunder Tiger parts from Ace for you. Technical
questions regarding the Raptor will be answered quickly by sending an email to [e-mail] or call
Technical Support at 949-833-7498. In Europe, Asia and Australia, please contact the distributor in your country.
WARNING
To ensure safety, please read the instruction manual thoroughly before assembly. Radio control helicopters are
sophisticated equipment, and not toys. Radio control model helicopters are capable of causing serious bodily injury
if not properly assembled or operated. The manufacturer and distributors assume no liability for damages that could
occur from the assembly or use of this product. This product is designed for hobby use only. Operating model
helicopters requires diligence and skill. The best way to ensure quick and successful learning is to seek help and
guidance from accomplished pilots. It is strongly recommended to join the appropriate radio control modeling governing
society in your country. For example, in the United States, it is strongly encouraged to join the Academy of Model
Aeronautics. AMA is a nonprofit organization that provides members in the United States with liability insurance
and monthly modeling magazines. For further information or to find a model helicopter club, please contact AMA
at:
Academy of Model aeronautics
515 East Memorial Drive
Muncie, IN 47302
USA
[phone]
We also encourage you to subscribe to different radio control helicopter magazines and learn about RC flying events,
new flying techniques, safety procedures, and hints. Rotory Modeler is a bi-monthly and Model Helicopter Techniques
is a quarterly newsletter published in the USA. Model Helicopter World is a month magazine published by Traplet
Publication in England and sold worldwide. Rotor is a monthly German magazine. Helico is a Swiss quarterly
magazine.
ATTENTION
We are unable to accept replacement or return of this model after it has been used or assembly has begun.
It is legally prohibited to duplicate or reprint this manual in any format without a written permission from the
manufacturer.
The manufacturer has the right to make changes to this model or instruction without notice.
We have done our best to the accuracy of information in this manual. If you are aware of any mistake, we welcome
you to notify us.
We will not accept any responsibility for any accident, breakdown, fault or trouble caused by improper usage of
this model. Please thoroughly inspect your model and range check the radio before flight. Please keep the model
in its best condition in order to enjoy it.
This model does not include all the items necessary for flying, such as engine, serevos, gyro...etc.
It is difficult for beginners to fly RC helicopters by themselves. It is highly recommended that beginners seek the
help of experienced RC helicopter pilots. We recommend beginners start with an inexpensive model such as the
Thunder Tiger Raptor 30 that is also designed by Mr. Taya.
RC helicopters are not toys. The manufacturer does not assume the liability for any property or bodily damage
caused by the model or the operator.
OTHER ITEMS REQUIRED
6
BODY SUPPORT INSTALLATION
Insert the aluminum support
tube through the servo frame.
Insert the "R" pins through the
two holes in the support tube
to prevent the tube from
moving in the servo frame.
Install two rubber ends onto
the support tube. The rubber
ends will dampen shake or
vibration generated by the
engine.
Glow Plug Wrench
12V Battery
1.5V Glow Starter
(1.2V~1.5V)
Rubber Band
(Included)
Foam
Remote Glow Plug
Extension
1-2-2 Cooling Fan Casing Subassembly
1-2-3 Fuel Tank Subassembly
No. Material No. Description Qty.
1 BK0062 Fuel Tank Stopper 1
2 BB0374 Silcon Tube (L=105mm) 1
3 BK0445 Fuel Plug 1
4 BK0463 Fuel Tank Nipple 1
5 BK0503-1 Fuel Tank 1
6 BE1867 Clunk Weight 1
1-5-5 Header Tank Subassembly
No. Material No. Description Qty.
1 HMC3-25B Socket Screw M3x25 1
2 BK0087 Washer d3xD8x1.4 1
3 BV0502 Header Tank 1
4 BK0506 Tank Mount 1
5 BK0698 Header Tank Supporter 1
The Raptor 90 3D kit includes a header fuel tank that can be
attached to the right of the side frame.
23
2-1-1 Flybar Seesaw Subassembly
24
2-1-2 Metal Main Rotor Hub Subassembly
2
4.Final Assembly ---------------------------------------------------------------------------------------------- 29
4-1 Installation of Rotor Head (Bag H)----------------------------------------------------------------------30
4-2 Installation of Engine --------------------------------------------------------------------------------------31
4-2-1 Engine Subassembly -------------------------------------------------------------------------------32
4-3 Installation of Landing Skid------------------------------------------------------------------------------- 33
4-3-1 Skid Subassembly -----------------------------------------------------------------------------------33
4-4 Installation of Tail Assembly ----------------------------------------------------------------------------- 34
4-4-1 Tail Support Subassembly------------------------------------------------------------------------ 34
5.Installation of Peripheral Equipment ----------------------------------------------------------- 35
5-1 Installation of Servo - Part 1 (Bag I) ------------------------------------------------------------------ 36
5-2 Installation of Servo - Part 2 (Bag I) ------------------------------------------------------------------ 37
5-3 Installation of Receiver and Gyro ---------------------------------------------------------------------- 38
5-4 Installation of Body (Bag J) ------------------------------------------------------------------------------39
5-4-1 Body Subassembly ----------------------------------------------------------------------------------39
5-5 Installation of Rotor Blades (Bag K) ------------------------------------------------------------------- 40
6.Settings --------------------------------------------------------------------------------------------------------- 41
6-1 Setting up Gear Backlash ------------------------------------------------------------------------------- 42
6-2 Setting up of Stabilizer Paddles ------------------------------------------------------------------------43
6-3 Setting up of Blade Pitch Angle ----------------------------------------------------------------------- 43
6-3-1 Collective Travel for Hovering ------------------------------------------------------------------ 44
6-3-2 Collective Travel for 3D --------------------------------------------------------------------------- 44
6-3-3 Configuring the Raptor 90 for 3D --------------------------------------------------------------- 45
Attention --------------------------------------------------------------------------------------------------------------46
7.Parts List Section -------------------------------------------------------------------------------------------49
Raptor 90 3D Exclusive Parts -------------------------------------------------------------------------------- 50
Raptor 90 3D Spare Parts List ------------------------------------------------------------------------------- 55
Raptor 90 3D Optional Parts List ---------------------------------------------------------------------------- 61
3
Thank you very much for purchasing the Thunder Tiger Raptor 90 3D R/C helicopter. The design of Raptor
90 3D is based on the original Raptor 90 series helicopter and modified for extreme aerobatics. It has all
needed must-have optional parts for 3D flying, such as metal main rotor hub, non-linear flapping damper,
metal BRG, 3D light paddles and so on. It also adopts the push-pull control system on collective pitch
and elevator to achieve the most precise control. The flybar ratio is changeable to fit all kinds of flying
style. Use of high quality material make the helicopter one tough machine that can handle everyday 3D
beating. Raptor 90 3D is born for 3D flying, and you don’t have to do any further modification for aggressive
3D maneuver. This is by far the best machine you have never seen. Just enjoy the model and have fun.
UNIQUE SIDEFRAME SYSTEM
Aluminum side plates are used in conjunction with molded material to construct the main structure. This
design produces minimum weight with maximum strength. If the sideframes were completely made of
molded material, then to achieve equal strength the plastic would have to be very thick and heavy. Using
molded material at the right place avoids using metal angle brackets or putting compound bends in metal
frames. Slots have been added in the frame design to permit the use of optional gear ratios to optimize
engine performance to suit any pilot's demand.
BELL-HIILLER MIXING CONTROL UNIT
Main rotor control geometry has been carefully engineered to minimize cross-coupling in collective and
cyclic commands. Blade pitch arms and the Bell-Hiller mixing arms are designed at an angle such that
the pushrod interlinking them are at 90 degrees when the blades are at 0 degree. The pilots will get the
symmetrical cyclic control feel and flybar authority either at +10 or -10 degrees of collective. We design
this system with the 3-D pilot in mind. We guarantee you this whole design philosophy provides a strong
and accurate control mechanism.
SHAFT DRIVE TAIL ROTOR
The Raptor 90 3D is designed with a constant drive tail rotor system to permit full tail rotor control during
autorotations. 180 autos, backward autos and pirouette autos are all within your reach now. It has the
same aluminum torque tube system as the Thunder Tiger/Taya Imperio helicopter. This allows obtaining
the maximum performance from any modern heading lock gyros.
3D CAD DESIGN
We use the latest 3D Computer Aided Design to design and manufacture the Raptor 90 3D. Our high-
tech CAD program allows simulation of all moving parts to ensure no interference. The analysis automatically
analyze the weight, the mass distribution, and inertia to help us pursue a design that will provide the high
level of maneuverability needed for all-out 3-D aerobatics.
INTRODUCTION
Socket Drivers
Hex WrenchGrease
Blue Loctite
Instant Glue
Hobby Knife
Metric
4-way Wrench
Scissors
Diagonal Pliers
Open End Wrench
5.5mm
Needle Nose PliersScrew Driver
7mm
5.5mm
7mm
8mm
5.5mm
7mm
8mm
10mm
Epoxy
Ball Link Pliers
No. Material No. Description Qty.
1 HMV6800ZZY BRG d10xD19x5 1
2 HME4-5B Set Screw M4x5 2
3 HMS5 E Ring M5x8 1
4 HMV696Z BRG d6xD15x5 1
5 BK0388 Clutch BRG Case 2
6 BK0659 Frame Space M 4
7 BK0594 Starter Coupling 1
8 BK0592 Starter Shaft 1
9 BK0422 Drive Pinion 11T 1
10 BK0366 Pinion Gear Nut 1
11 BV0522-2 Clutch Bell Set 1
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 2
2 HMC3-12B Socket Screw M3x12 4
3 BK0087 Washer d3xD8x1.4 6
4 BK0393 Pitch Frame Cross Member 1
5 BK0394 Pitch Frame Cross Member Nut 2
6 BK0375T Upper Frame 2
No. Material No. Description Qty.
1 HMM3Z Locknut M3 4
2 HMC3-25B Socket Screw M3x25 4
3 BK0820BL Landing Skid Damper 4
4 4-3-1 Skid Subassembly 1
No. Material No. Description Qty.
1 HMC3-8B Socket Screw M3x8 4
2 HMQ16 Retaining Ring 1
3 BK0357 Tail Drive Spur Gear 83T 1
4 BK0359 One Way Clutch Shaft 1
5 BV0368 Auto Rotation Hub 1
6 BK0356 Main Spur Gear 91T 1
1-6-2 Main Gear Subassembly
(3)
(2)
(4)
(6)
(5)
(1)
The carbon rear servo plate is secured
by two Lower 3mm bolts from the plastic
tail boom bracket.
10
1-1-2 Pitch Guide L Subassembly
1-1-3 Pitch Guide R Subassembly
No. Material No. Description Qty.
1 BK0384 Pitch Guide Collar L 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
The side with a number should face
in because the opening on both sides
are differeent.
The hole on the plastic control arm has different
opening sizes on the two sides. Always snap the
bigger opening to the ball on swashplate gently and
afterward please check to make sure it is securely
attached and there is no damage or cracking.
INSTALLATION OF THE LINKS
Bigger Hole Face to Swashplate
Extended 6mm Hex
Starting Tool
Fuel Pump
Heli Engine (90size)
9609 PRO-90H(R)
Glow Fuel(15%-30%)
Glow Plug
Hi-torque 12V Electric starter
Receiver
Transmitter
(helicopter type, 6 or
more channels) High Speed/Torque Servo x 4
Rudder Servo x 1
Battery Switch harness
Heading Lock
Gyro
In order to enjoy a safe and enjoyable experience, please read the manual carefully and completely understand
the helicopter structure and operation before the first flight.
Read the warnings to avoid injuries to you and others.
WARNING – The following could cause heavy injury or death if used incorrectly.
Keep the model away from other people or animal when starting the engine.
Do not fly any model helicopter near or above people or cars. Models can sometimes lose
control due to pilot or mechanical failure.
WARNING – The following could also cause serious injury or death if not careful.
Take precaution with model fuel. Model engine glow fuel is highly flammable.
Please check the model carefully before each flight. Make sure that nothing has loosened up
or come apart.
Make sure everything moves freely without binding or excessive friction.
Do not operate the model in rain, snow, thunderstorm, or adverse weather.
WARNING – The following could also cause serious injury or death if not careful.
Please make sure that your radio frequency is not used before flight. If someone else is flying
with the same frequency as your radio, do not turn on your transmitter. Otherwise, it can cause
a crash and even bodily and property damages.
Please monitor the fuel level during flight and land before running out of fuel.
Before each flight, please check that all servos and controls move properly.
Do not modify any parts or use other than genuine Thunder Tiger parts.
Do not fly in places that are forbidden by law.
Use Loctite on screws that do not use a locknut.
When operating the model, please beware that no loose cloth or jewelry can get entangled in
the model helicopter.
Make sure the transmitter and receiver switches are on before starting the engine.
Do not touch the engine or the muffler right after flying because they are very hot.
Do not use this model for anything other than hobby.
WARNING – The following damages can happen to the model.
Do not leave the model in a car for a long time. The heat in the summer or the cold in the
winter and the humidity can cause damage to the model.
Be careful and watch the sharp edges and corners on the model.
BUILDING HINT – The instruction is divided into six assembly chapters:
Main Frame, Rotor Head, Tail Rotor, Final Assembly, Radio Installation, and Settings. There
are many major assembly steps in each chapter, please follow the instruction to do each "
Subassembly" first, then combine the subassemblies into a major assembly.
Upper Frame Assembly
Lower Frame Assembly
12
1-2-1 Tail Drive Unit Subassembly
No. Material No. Description Qty.
1 HME3-4B Set Screw M3x4 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 BK0362 Tail Drive Bevel Gear A 1
5 BK0363 Tail Drive Bevel Gear B 1
6 BK0364 Tail Drive Pinion 1
7 BK0365 Tail Drive Gear Shaft 1
8 BK0382 Tail Boom Bracket L 1
9 BK0383 Tail Boom Bracket R 1
10 BK0414 Pin 2x12 2
11 BK0660 Frame Spacer L 5
Main Frame Assembly Installation of Pitch Frame
No. Material No. Description Qty.
1 HMJ2-10N M2x10 Self-Tapping Screw 1
2 HMV840ZZY BRG d4xD8x3 2
3 HMV1280ZZY BRG d8xD12x3.5 2
4 BK0336 Pitch Frame 1
5 BK0075 Link Ball
φ
4.8 1
Optional: add a tiny drop of thick CA on the outside rim of the fovr ball
bearings before inserting them into the plastic Pitch Frame. Be careful
not to get any glue into the ball bearings. Add a tiny drop of thick CA
glue at the tip of the M2x10 self-tapping screw (No. 1) before
screwing it into the Pitch Frame.
32
Note:
The (3) spacer with threads is
supposed to be locate d at middle
position to fit the Body Fitting Post.
Note:
The (3) spacer with threads is
supposed to be locate d at middle
position to fit the Body Fitting Post.
No. Material No. Description Qty.
1 BK0385 Pitch Guide Collar R 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
Tip: When setting up the phase
adjustment ring, the flybar and
the tail boom can be the
reference. When the flybar and
the tail boom are centered, the
inner balls of swashplate should
be aligned with the outer balls.
Tighten the socket screw on the
phase ring at this moment.
NOTE: Improper alignment will
cause unwanted mixing.
No. Material No. Description Qty.
1 ******** 90 Class Heli Engine 1
2 ******** Nut (Comes With the Engine) 1
3 HMC4-8B Socket Screw M4x8 2
4 HMC4-18B Socket Screw M4x18 4
No. Material No. Description Qty.
5 HMO10 Washer d9.5xD16x1 1
6 BK0349 Engine Mount 1
7 BV0380 Cooling Fan 1
8 BV0521 Heavy Duty Clutch 1
No. Material No. Description Qty.
1 BK0075 Link Ball φ 4.8 5
2 BK0086 Ball Link 4.8x20 8
3 BK0104 Servo Mounting Plate 6
4 BK0105 Rod Joint 1
5 BK0318 Link Rod 2.3x95 2
6 BK0436 Link Rod 2.3x55 2
7 BK0833 Servo Block 4
8 HMC2516B Socket Screw M2.5x16 4
No. Material No. Description Qty.
9 HMM25 Lock Nut M2.5 4
10 HML2 Nut 5
11 HME4-5B Set Screw 2
12 HMF2-8N Phillips Machine Screw M2x8 5
13 HSE2614N Selt-Tapping Screw 4
14 HSE2630N Selt-Tapping Screw 4
No. Material No. Description Qty.
1 BK0075 Link Ball φ 4.8 7
2 BK0086 Ball Link 4.8x20 4
3 BK0095 Link Rod 2.3x76 1
4 BK0104 Servo Mounting Plate 4
5 BK0833 Servo Block 2
6 BK0834 Pitch Lever Fixed Plate 1
7 BK0839 Link Rod 2.3x30 1
8 BK0881 Washer 1
9 BK0883 Pitch Push Pull Lever 1
No. Material No. Description Qty.
10 BK0884 Collar, d3xD4xW12 1
11 BV0085 Pitch Link Rod 2
12 HMC3-20B Socket Screw M3x20 1
13 HMV840ZZY Bearing d4xD8xW3 2
14 HMF2-8N Philip Maching Screw M2x8 4
15 HMJ2-8N Selt-Tapping Screw M2x8 3
16 HML2 Nut 4
17 HSE2614N Selt-Tapping Screw M2.6x14 8
18 HSE2620N Selt-Tapping Screw M2.6x20 4
No. Material No. Description Qty.
1 **** Switch 1
2 **** Receiver Battery 1
3 **** Receiver 1
No. Material No. Description Qty.
4 **** Gyro
5 BK0106 Foam 2
6 BE1052 Antenna Pipe 1
PV0517 ONEWAY BEARING GREASE
The hole on the Flybar Control Rod has different
opening on two sides. Always snap the bigger opening
to the link ball.
Bigger Hole
Face to Control Arm
10.5mm 10.5mm
When installing pinion gear, add a small drop of Loctite to the
threads. Make sure not to get Loctite on lower clutch bell bearing.
Important:
For 90 class engine, we recommend the 11 teeth pinion for 3D
flying.
The servo tray and cooling fan shrouds on the Raptor 90 are different from the
Raptor 60 in order to accommodate the full head sink on the O.S 91. engine.
If using T.T 90, Y.S 91 or Webra 91 engine, make sure to install the fan shroud
baffle with two self-tapping screws. This will ensure optimal cooling of your engine
head.
Add CA glue Add CA glue
It is necessary to add grease inside the one way clutch before your
first flight. The clutch might lock up once grease is gone. The one
way clutch grease( PV0517) is recommended for this lubrication.
Make sure the inside of Auto Rotation Hub is clean without any dirt
before you insert the one way clutch shaft.
Add Loctite
Add Loctite on
the threads
For 3D flying, it is recommended to use
lower flybar ratio setting.
Self-Tapping Screw, No. 10 Collar, and No. 11 Washer, with two
No. 1 Bearings. Attach a No. 9 Link Ball with a No. 4 Screw.
Upon finishing Step 3-1-1, make sure there are no extra parts
left on your workbench.
Elevator Control
Pushrod
Glue the two plastic halves of
the paddle with CAglue before
installation on flybar.
Add Loctite
the tail boom by tightening the four screws on the helicopter.
Visually check from the rear of the helicopter to make sure the
tail rotor output shaft is perpendicular to the main rotor shaft.
Add the tail boom supports.
Add Loctite
The thrust bearing washer with the
SMALLER inner hole should be closer to
the rotor blade.
The thrust bearing washer with the BIGGER
inner hole should be closer to the main rotor
shaft.
4-2-1 Engine Subassembly
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add CA Glue
Introduction -------------------------------------------------------------------------------------------------------- 3
Other Items Required -------------------------------------------------------------------------------------- 4
Warning --------------------------------------------------------------------------------------------------------------- 5
Assembly
1. Main Frame Assembly --------------------------------------------------------------------------------- 7
1-1 Upper Frame Assembly (Bag A) ---------------------------------------------------------------------- 8
1-1-1 Pinion Gear Subassembly ------------------------------------------------------------------------ 9
1-1-2 Pitch Guide Left Subassembly ------------------------------------------------------------------10
1-1-3 Pitch Guide Right Subassembly -----------------------------------------------------------------10
1-1-4 Elevator Control Arm Subassembly------------------------------------------------------------ 10
1-2 Lower Frame Assembly (Bag B) ----------------------------------------------------------------------11
1-2-1 Tail Drive Unit Subassembly ---------------------------------------------------------------------12
1-2-2 Cooling Fan Casing Subassembly -------------------------------------------------------------13
1-2-3 Fuel Tank Subassembly ------------------------------------------------------------------------13
1-3 Main Frame Assembly (Bag C) -------------------------------------------------------------------------14
1-3-1 Rod Guide Collar Subassembly-----------------------------------------------------------------14
1-4 Installation of Servo Frame (Bag C) ------------------------------------------------------------------- 15
1-5 Installation of Pitch Frame (Bag D) -------------------------------------------------------------------- 16
1-5-1 Aileron Lever Subassembly ---------------------------------------------------------------------17
1-5-2 Metal Elevator Parallel Lever Subassembly -------------------------------------------------17
1-5-3 Elevator Control Lever Subassembly --------------------------------------------------------- 17
1-5-4 Pitch Control Frame Subassembly -------------------------------------------------------------18
1-5-5 Header Tank Subassembly ----------------------------------------------------------------------18
1-6 Installation of Main Shaft (Bag E) ----------------------------------------------------------------------19
1-6-1 Wash Out Subassembly -------------------------------------------------------------------------20
1-6-2 Main Gear Subassembly -------------------------------------------------------------------------20
2. Rotor Head Assembly -----------------------------------------------------------------------------------21
2-1 Metal Rotor Head Assembly (Bag F) -----------------------------------------------------------------22
2-1-1 Flybar Seesaw Subassembly --------------------------------------------------------------------23
2-1-2 Metal Main Rotor Hub Subassembly ----------------------------------------------------------24
3.Tail Assembly -------------------------------------------------------------------------------------------------25
3-1 Tail Assembly (Bag G) ----------------------------------------------------------------------------------- 26
3-1-1 Tail Transmission Subassembly --------------------------------------------------------------- 27
3-1-2 Tail Rotor Subassembly --------------------------------------------------------------------------- 28
3-1-3 Tail Drive Shaft Subassembly -------------------------------------------------------------------28
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The Liner is pre-glued on the
inside of clutch bell with 30 min
epoxy.
1-1 1-2 1-3
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1-4
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1-5 1-6
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(1) (5)(4)
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2-1
3-1 4-1
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4-3
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4-4
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4-2
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5-1 5-2 5-3
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5-4 5-5
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No. Material No. Description Qty.
8 BK0660 Frame Spacer L 3
9 BK0376T Lower Metal Frame 2
10 BV0870 Metal Lower BRG Block 1
11 1-2-1 Tail Drive Unit Subassembly 1
12 1-2-2 Cooling Fan Casing Subassembly 1
13 1-2-3 Fuel Tank Subassembly 1
No. Material No. Description Qty.
7 BK0659 Frame Spacer M 2
8 BV0869 Metal Upper BRG Block 1
9 1-1-1 Pinion Gear Subassembly 1
10 1-1-2 Pitch Guide L Subassembly 1
11 1-1-3 Pitch Guide R Subassembly 1
12 1-1-4 Elevator Control Arm Subassembly 1
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No. Material No. Description Qty.
10 BK0093 Link Rod 2x46 1
11 BK0407 Collar d3xD4x4.5 2
12 BK0410 Collar d3xD4x13 2
13 1-5-1 Aileron Lever Subassembly 1
14 1-5-2 Metal Elevator Parallel Lever Subassembly 1
15 1-5-3 Elevator Control Lever Subassembly 1
16 1-5-4 Pitch Control Frame Subassembly 1
17 1-5-5 Header Tank Subassembly 1
No. Material No. Description Qty.
6 HMM4B Lucknut M4 1
7 BK0617 Bolt M4x25 1
8 BV0504 Metal Swashplate 1
9 1-6-1 Washout Subassembly 1
10 1-6-2 Main Gear Subassembly 1
No. Material No. Description Qty.
10 BK0076 Collar d3xD4x10 1
11 BK0088 Washer d3xD5x0.5 1
12 BK0346 Tail Pitch Control Lever 1
13 BK0370 Tail Case L 1
14 BK0371 Tail Case R 1
15 BK0372 Tail Input Bevel Gear 1
16 BK0373 Tail Output Bevel Gear 1
17 HMY2-12 Pin 2x12 1
18 3-1-2 Tail Rotor Subassembly 1
No. Material No. Description Qty.
1 HMM3Z Locknut M3 6
2 HMC3-16B Socket Screw M3x16 2
3 HMC3-20B Socket Screw M3x20 2
4 HMC3-25B Socket Screw M3x25 2
5 HMC3-30B Socket Screw M3x30 2
6 BK0087 Washer d3xD8x1.4 4
No. Material No. Description Qty.
1 HMJ2-8N Self-Tapping Screw M2x8 4
2 BK0447 Tail Support Rod End 4
3 BK0669 Tail Support Rod 2
No. Material No. Description Qty.
1 HMC4-42B Muffler Bolt M4x42 2
2 HMT4B Spring Washer 2
3 ******** Muffler ( 90 ) 1
4 4-2-1 Engine Subassembly 1
5 HMC4-12B Socket Screw M4x12 4
6 BK0435 Washer d4xD11xW1.7 4
BAG A
BAG B
BAG C BAG C BAG D
(L) (R)
BAG E
BAG F
BAG G
BAG H
BAG I
97.5mm
48mm
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Throttle
Collective Pitch
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BAG I
BAG J
BAG K
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Please complete subassembly steps 1-2-1 through 1-2-3 first. Then attach the subassemblies to the two Lower Frames. Note
that the Metal Lower BRG is installed with the bearing open side facing up. Please add a small drop of Loctite on every bolt
before screwing it into the aluminum hex spacer. Do not apply Loctite to the bolts which are going to secure the Lower BRG
Block at this moment.
Assemble the upper main frames by starting with the two Metal Upper Frames. The Pinion Gear Subassembly must be assembled
first according to Figure 1-1-1. Next insert three hex-shape frame spacers into the plastic Pitch Guide according to Figure 1-1-2
and 1-1-3. Assemble the Elevator Control Arm subassembly according to 1-1-4. Insert it in between the two Upper Frames. The
metal Elevator Control Arm is not symmetrical. The side with the longer profruding round knob should be on the right side of the
helicopter. Then attach the other subassemblies to the Upper Frames. Locate Hex Wrenches in BAG L which you need for
assembly.
Please add a tiny drop of non-permanent type Loctite on the tip of all bolts before screwing them into the hex shaped aluminum
frame spacers. Never use too much Loctite, otherwise it will become nearly impossible to remove later on for servicing. Only use
the non-permanent type of Loctite. If encountering difficulty in removing any bolt that was locked up by Loctite, heat up the head
of the screw or bolt with the tip of a hot soldering iron, it will help soften the cured Loctite.
For the kit, parts are bagged according to each major assembly and are labeled "Bag A, Bag
B, etc." The heading for each assembly indicates which bag to open. As a good practice,
only open up the bag that you need for the particular assembly. Check the parts in that bag
against the parts list shown for each assembly as well as each sub-assembly to make sure
there are no missing parts. To prevent losing small hardware, please empty the small nuts
and bolts and parts into small plastic trays on your work table. At the end of each major
assembly, there should be no left over parts.
The fuel tank comes assembled from the factory because every tank has been
checked for leak. If you were to take the tank apart here is how to put it back
together. Install the silicone fuel line to the Fuel Nipple. Then add the rubber
fuel tank stopper and the clunk weight. The stock silicone fuel line is very soft
and thin which is designed to allow the clunk to pick up fuel easily during 3-D
aerobatics. The pickup line should be inspected and replaced if necessary every
month, otherwise when it becomes soggy it can break off. A thicker silicone line
maybe substituted but make sure the clunk will reach the bottom when moving
the fuel tank to all different orientations.
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As show in Figure 1-3-1, insert two hex
Frame Spacers S into the plastic Rod
Guide Collars. Then join the Upper
Frame Assembly to the Lower Frame
Assembly according to drawing 1-3.
Secure the Set Screws (No.1) to the
frames, and fit the Body Posts (No.4)
to the Set Screews. The two Body Posts
will be used to secure the canopy in the
future. Add Loctite on all bolts and
inside BK0103 threaded hole.
Install the one-piece servo frame with six self-tapping screws.
Do not use Loctite when attaching self-tapping screws to plastic
parts. Loctite is only for threading metal into metal parts. Assemble the constant drive Main Gear Subassembly according to Figure 1-6-2 first. Then build up the Wash Out Subassembly
according to 1-6-1. Insert the No.3 Main Shaft into the bearings and then add the No.4 Lock Ring and slide in the Main Gear
Subassembly. Add two M3x6 Button Head Screws to the Locking Ring, and the two screws are threaded into the holes on the
main rotor shaft.
The locking ring prevents the main shaft from sliding up. Line up the hole on the main gear and the main shaft, then insert M4x25
mm Bolt through them. Place a 4 mm M4 locknut on the other side of the autorotation hub, and then tighten the Bolt. Do not
over tighten the Bolt, otherwise the autorotation assembly will be distorted. Loosen the 3mm bolts holding the Upper and lower
bearing blocks for the 12mm main shaft. Wiggle the main shaft in the bearing blocks until the main shaft spins freely in the bearings.
This ensures the upper and lower bearing blocks are aligned. Push the lower bearing block up until the main shaft has no up
and down play. Then tighten the 3mm bolts for the upper and lower bearing blocks.
Insert the pin into the Washout Link. Add a tiny drop of Loctite on the inside
and outside of BK0409 Collar which will help give a completely slop free
control system. Do not let the Loctite seep into the bearing. Adjust the
tightness of the M3x12 bolts so the mixing arms can move freely but without
wobble or racheting the ball bearings. Add a tiny drop of thick CA glue at
the tip of the M2x10 self-tapping screw (No. 1) before screwing it into the
Flybar Control Levers (No. 6).
Make the two pushrods for controlling the blade pitch. The distance 43 mm is measured between the center of two pushrod holes.
Attach the Seesaw Hub of the Control Paddle Assembly to the Main Rotor Head with Socket Screws (M3x10).
Please add a small drop of Loctite along the entire length of the M3x10 Socket Screw (No.5) and on the outside of the collar
d3xD4x5.5 (No.3). Temporarily install the Washout Base Guidence Ring, but do not tighten the No.6 M3 Socket Screw yet.
Assemble the tail transmission subassembly according to 3-
1-1 and 3-1-2 first. And the tail drive shaft subassembly according
to 3-1-3.But do not close the two halves of the tail transmission
tightly. You will do this when you are ready to install the gearbox
onto the tail boom.
When installing the tail transmission, make sure the housings
match the hole on to the tail boom. Add Carbon Vertical Fin with
machined washer and Locknut, then tighten the five 3 mm bolts.
Add carbon Vertical Fin with Pom washer and Locknut.
Before inserting the finished tail drive shaft assembly into the
tail boom, add some flexible silicone glue or ZAP Goop glue
around the outside of the tail drive bearing housing. This will
prevent the bearing housing from spinning inside the tail boom.
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Install bearings No. 2 and No.3 into the Tail Cases. Install No.
16 Tail Bevel Gear onto the Tail Shaft. Gently tap the No. 17
Pin into the Bevel Gear and Tail Shaft. Then secure the pin
with a No. 7 Set Screw with Loctite.
After installing the M3x4 set screws, try pushing on the 2x12
pin with a small Allen wrench to make sure the set screw has
locked the pin in place securely. Before closing the two halves
of the Tail Cases, please check the gear mesh between gears
No. 15 and No. 16. If the gears mesh too tight, then a 5 mm
i.d. washer should be added to move the gear No. 16 further
out. If there exists too much freeplay, then a 5 mm i.d. washer
to push gear No. 16 closer to gear No. 15.
Install the No. 12 Tail Pitch Control Lever as shown with No. 6
Slide four No. 6 Rod Guides onto the tail boom. Do not glue
them onto the tail boom yet. Add a tiny drop of CA glue to the
pushrod guide after you finish building the entire helicopter.
Before adding glue, make sure the tail pushrod is hooked up
to the servo and the rod travels in a straight line and moves
very smoothly.
Congratulation, we are almost done. Install the finished main
rotor head onto the 12 mm rotor main shaft. Secure it with a
M4x20 Bolt and M4 Locknut. Make up two 113.5 mm long
pushrods and attach them to the Bell-Hiller mixing arm.
Before installing the plastic end caps, please
add a drop of slow, thick CA glue on the
rim of the end caps and on the inside edge
of the aluminum skid.
Slide the finished tail boom into the helicopter. The four bolts
on the helicopter must be loose in order to insert the tail boom.
Make sure the tail drive shaft is inserted into the front receptacle
properly. Check this by turning the main rotor head. Secure
Secure the two ends to the rod with Epoxy, making sure the
two metal ends are perpendicular to each other.
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Attach the engine into the side frames, with four M4x12 bolts and
four washers, but do not tighten until Section 6-1.
Install the muffler after you have building the entire helicopter.
Always add Loctite on the muffler bolts.
Install the servos and make up the pushrods according to the drawings. The distance between the steel ball and the center of
servo arm are shown in the drawing. Use them as a guide. These distances are used in conjunction with the servo travels (ATV
or End point) set to 100% for all the channels in the transmitter. Tune them later on to suit your personal flying style.
Attach the rudder servo to the rear mounted carbon plate with four 2.6mm bolts and four M2.6 locknut.
Make up the throttle and collective control pushrods according
to the drawing. Use the outermost hole on the carburetor throttle
control arm. Attach the steel ball on the throttle servo arm at
approximately the same distance as the steel ball on the throttle
arm.
Make up the throttle at 97.5mm long first, and then adjust the
pushrod length and throttle servo ATV or Endpoint so full throttle
stick command will open the carburetor barrel fully. And full low
stick and low throttle trim will close the carburetor barrel completely.
Install the receiver and receiver battery. Even though the receiver and battery can be attached to the helicopter tray by using
double sided foam tape, but it is better to wrap the receiver and battery separately using half inch or 10 mm thick foam. Then
secure them to the tray using six to eight rubberbands, or Velcro bands.
Carefully cut out the canopy (windshield) using scissors. The
best scissors to use are (TTR 1304) designed to cut RC car
bodies and Canopy. Install the canopy to the body using six
small screws. Drill small holes in the canopy and body for the
holes. Drill two more holes for the rubber grommets.
Refer to color box and apply the decals (In BAG M) .
Tools for Assembly
The Raptor 90 3D is designed for easy maintenance using standard hobby tools. Please only use genuine Thunder Tiger parts.
Please keep the model clean and well tuned. It will provide you with long lasting pleasure in return.
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Add Loctite
(Included)
Add a tiny drop of thick CA glue at the tip of the M2x10
self-tapping screw (No. 1) before screwing it into the
Aileron Levers.
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Make up the landing gear according to the
drawing.
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No. Material No. Description Qty.
1 HSE3-6B Self-Tapping Screw M3x6 2
2 BK0660 Frame Spacer L 4
3 BK0662 Cooling Fan Baffle 1
4 BK0665 Fan Casing L 1
5 BK0666 Fan Casing R 1
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Assemble the metal flybar control arms according to the drawings. Slide Flybar ControlArm onto the No.18 Flybar Rod. Slide
the flybar into the No.17 Seesaw Hub. Make sure the Flybar has equal protrusion from each side of the Seesaw Hub measure
them with a ruler, then install and tighten the No.8 HME4-5B set screws.Add the paddles. Make sure the two paddles and the
two flybar control arms are all parallel. Lock the paddles with No.6 set screws.
Assemble and install the No.10 Mixing Levers and No.5 Bearings according to the drawing using No.12 Collar and No.9 d3xD5x0.5
washer.
Note: Before installing the Mixing Lever (No.10), please add a small drop of Loctite along the entire length of the M3x18 button
head socket screw (No.4) and on the outside of the collar d3xD4x13 (No.12). Be careful do not let the Loctite seep into the bearings.
There are two choices of hole positions on the aluminum seesaw for attaching the mixing lever arm.The outside hole gives higher
Bell-Hiller mixing ratio. For aggressive 3D flying, you can attach the Bell-Hiller mixing arms to the inner hole which gives lower
flybar ratio.
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No.Material No.DescriptionQty.
10BK0324Mixing Lever2
11BK0406LPaddle Root2
12BK0410Collar d3xD4x132
13BK0416Paddle Stopper2
14BK0432LFlybar Paddle2
15BK0633Flybar Control Frame2
16 BK0871 Longer StabilizerArm 2
17 BV0865 Longer Seesaw 1
18 BK0866 SUS Flybar 1
No. Material No. Description Qty.
1 HMF2-8N Phillips Machine Screw M2x8 2
2 HMJ2-10N Selfing-Tapping Screw M2x10 4
3 HMC3-10B Socket Screw M3x10 2
4 HMC3-18B Socket Screw 2
5 HMV840ZZY BRG d4xD8x3 4
6 HME4-3B Set Screw M4x3 4
7 HME4-5B Set Screw M4x5 2
8 BK0075 Link Ball
φ
4.8 6
9 BK0088 Washer d3xD5x0.5 2
Insert the aluminum Main Rotor Hub Pin and the Flap Dampers. (might need to apply silicone grease for easy installation). Push
the No.7 Feathering Spindle into the dampers and the rotor hub.Add No. 14 Flybar Control Rod. Slide both finished Main Rotor
Grip onto the feathering spindle and the secure with two M4x10 bolts and washers according to the drawing.Use two Allen
wrenches to tighten the two M4x10 bolts simultaneously.
Important Note:
The Raptor 90 3D kits come with non-linear flap damper for aggressive 3D flying.You may choose to experiment adding from
one up to three 0.4mm thick shim (No.10) washers between the washer (No.8) and bearing to further stiffen the main rotor flapping.
Stiffing the main rotor head will speed up the cyclic transient response, but may cause the helicopter fuselage to oscillate at arou nd
1600 RPM.This oscillation characteristic exists for all helicopters with hard 3D flap dampers.The inner dampers should be
replaced periodically if a lot of 3D flying has been done. When the dampers are worn, the main rotor blades canflap excessivel y
during some 3D maneuvers and risk touching the tail boom.
Add flexible silcone glue or ZAP
Goop glue around the outside
before insert ing into the tail
boom from the front side.
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180mm
25mm
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The optional Thunder Tiger Remote Glow Plug Adaptor (#3803)
is recommended as shown, making starting easy without the
removal of your canopy.
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Cut a hole at the
front air scoop for
backward flights.
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No.Material No.DescriptionQty.
9BK0477Washer2
10BK0703Flap Damper Washer 0.4mm6
11BK0874Inner Damper2
12BK0875Outer Dampper2
13BK0075Ling Ball
φ
4.82
14BK0664Flybar Control Rod2
15BK0319Main Rotor Pitch Housing2
16BV0548-1Metal Main Rutor Hub1
No.Material No.DescriptionQty.
1HMC4-10BSocket Screw M4x102
2HMJ2-12NSelf-Tapping Screw M2x122
3HMV1680BRG d8xD16x54
4HMX0816Thrust Bearing d8xD16x52
5BK0330Main Rotor Hub Pin1
6 BK0325Thrust Washer 2
7BK0326Spindle1
8BK0435Washer2
Fiberglass or Carbon Rotor Blade
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Add Loctite when setting up the
gearmesh in step 6-1.
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No. Material No. Description Qty.
7 BK0539 Carbon Rear Servo Plate 1
8 BK0878 Bracket (Top) 1
9 BK0879 Bracket (Bottom) 1
10 3-1 Tail Assembly 1
11 4-4-1 Tail Support Subassembly 2
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Engine System
Use a high quality 90 size 2-stroke
model helicopter engine, such as the
Thunder Tiger TT PRO-90H, OS 91
SZ-H, YS 91 ST, Webra 91, or
equivalent . Please beware, some
engines may not fit because of their
shape and size. The Raptor 90 3D
kit comes with a cooling fan hub to fit
the TT PRO-90H, OS 91 SZ-H, Webra
91.
We recommend a high quality muffler
or tuned exhaust system designed to
fit on the left side of the model.
Rotor Blades
It is important to use main rotor blades
that are of high quality and suitable
for your flying style. If fiberglass or
carbon graphite blades are used, the
length should be between 680 and
710 mm. Blade weigh t should be
between 170 and 200 grams.
Starter System
To start the engine, it is necessary to
use an electric starter with a 6mm
shaft extension. The starter and the
6 mm extension are available from
Thunder Tiger, the part numbers are
No.2675 and No.3801.
Use a strong high torque 12 volt
electric starter which is designed for
models.
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Add a small drop of Loctite.
Make sure it locks the pin.
Install BK0364 and BK0362 onto BK0365 Tail Gear Drive Shaft. Then insert the
two Pins and secure them with two M3x4 Set Screws. Add a tiny drop of Loctite
on the set screw thread before inserting them. Always use a very small amount
of Loctite liquid on the thread, otherwise it may be nearly impossible to remove
the set screws in the future for servicing. After installing the two M3x4 set screws
(No. 1), try to push on the 2x12 pins with a small Allen wrench to make sure the
set screws have locked the pins in place securely. Install the four ball bearings
and the hex shaped Frame Spacers according to the drawing. Before closing
the two halves of the Tail Boom Brackets, please check the gear mesh between
gears No. 4 and No. 5. If there exists too much freeplay, add some 5 mm i.d.
washers on top of gear No. 4. (The 5 mm i.d. washers are provided in BAG G).
Add a small drop of Loctite.
Make sure it locks the pin.
Shim Washer
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Add CA Glue
Standard flybar ratio
Lower flybar ratio
Mild 3D Flying
Extreme 3D Flying
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Attach the engine mount to the engine using four 4mm bolts and Loctite.
The cooling fan hub is threaded to fit the OS, TT or Webra only. Place the washer that came with your engine onto the engine
crankshaft first. Then screw the fan hub onto the engine. Add a tiny drop of Loctite on the engine nut. Do not use too much
Loctite. Tighten the engine nut using a socket head wrench while grabbing the fan with a towel. The nut should be tighten securely.
For 50-size or bigger engines, we do not recommend using a piston locking tool on the glow plug hole because that may damage
the engine. Attach the No. 8 Heavy Duty Clutch to the fan hub. Add a drop of Loctite on the threads of the M4x8 bolts. The
threads on the aluminum cooling fan hub are for the TT 70H, OS 61 SX, OS 61LX, OS 70H, TT 90H, OS 91 or Webra 91 engines.
If YS 61, 80 or 91 engines are used, the fan hub must be re-tapped by the modeler to M8x1mm thread size or purchase a optional
plastic fan hub with threads for the YS engine(PV0198YS) or the metal fan for the YS (PV0293YS).
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Please complete subassemblies 1-5-1 through 1-5-5 first, then add them to the Main Frame. Fit the Pitch Control Frame
Subassembly. Attach the E Ring on the left side of the Metal Elevator Control Arm. Then fit the Elevator Control Lever to the
right side, insert the pin and fix it with a set screw. Secure the Pitch Control Frame with a M3*10 Socket Screw and a collar on
the left side. And attach the Elevator Push Pull Lever to the right side of the Pitch Control Frame as shown. Adjust the two bolts
so that the Pitch Control Frame can move freely without excessive play. Finally, add the two plastic Aileron Levers and the 66.5mm
elevator pushrod. Add the Washers (BK0088) to make sure that the Aileron Lever and the Metal Elevator Parallel Lever will not
touch each other during operation.
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Outer hole for standard.
Inner hole for extreme 3D.
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(4)
(1) (7) (6)
(9) (12) (5)
(2)
(11)
(3)
Add Loctite
Add Loctite
Add Loctite
(11)
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
30mm
(2)
Paddle
Flybar
A Arm
Phase
Adjustment
Ring
Swash
plate
Boom
(3)
(8)
(14)
(13) (9)
(1) (10) (12)
(7)
(11)
(12)
(2) (7)
(8)(6)
(5)
(4)
(1) (14) (16)
(11)
(18)
Pitch push-pull subassembly
(13)
(1)
(15)
(10) (9)
(17)
(2)
(3)
Add Loctite
Add Epoxy
Add Epoxy
(13)
(14)
(17) (15)
(16)

1
5
7
MAIN FRAME ASSEMBLY
8 9
1-1-1 Pinion Gear Subassembly
11
13 14 15 16 17181920
21
22
25 26 27
29 30 3334
36
3531
37
383940
4
1-3-1 Rod Guide Collar Subassembly
1-5-1Aileron Lever Subassembly
1-5-2 Metal Elevator Parallel Lever Subassembly
1-5-3 Elevator Control Lever Subassembly
1-5-4 Pitch Control Frame Subassembly
1-1-4 Elevator Control Arm Subassembly
1-6-1 Wash Out Subassembly
ROTOR HEAD ASSEMBLY
TAIL ASSEMBLY
3-1-1 Tail Transmission Subassembly
FINAL ASSEMBLY
4-3-1 Skid Subassembly
4-4-1 Tail Support Subassembly
INSTALLATION OF PERIPHERAL EQUIPMENT
5-4-1 Body Subassembly
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 4
2 HMC3-12B Socket Screw M3x12 21
3 BK0087 Washer d3xD8x1.4 22
4 BK0274 Tank Rubber Grommets 4
5 BK0380 Rear Frame L 1
6 BK0381 Rear Frame R 1
7 BK0629 Washer 4
No. Material No. Description Qty.
1 HME3-18.5B Set Screw M3x18.5 2
2 HMC3-25B Socket Screw M3x25 10
3 BK0087 Washer d3xD8x1.4 10
4 BK0103 Body Fitting Post 2
5 BK0658 Frame Spacer S 2
6 1-1 Upper Frame Assembly 1
7 1-2 Lower Frame Assembly 1
8 1-3-1 Rod Guide Collar Subassembly 2
No. Material No. Description Qty.
1 BK0389 Rod Guide Collar 1
2 BK0658 Frame Spacer S 2
No. Material No. Description Qty.
1 BK0667 Servo Frame 1
2 HSE3-12B M3x12 Self-Tapping Screw 6
3 1-3 Main Frame Assembly 1
No. Material No. Description Qty.
1 HMC2-6B Socket Screw M2x6 1
2 HMC3-10B Socket Screw M3x10 1
3 HMC3-25B Socket Screw M3x25 1
4 HME3-3B Set Screw M3x3 1
5 HMJ3-20N Self-Tapping Screw M3x20 2
6 HMS4 E Ring 1
7 HMY2-10 Pin 2x10 1
8 BK0086 Ball link 4.8x20 2
9 BK0088 Washer d3xD5x0.5 3
No.Material No.DescriptionQty.
1HMJ2-10NSelf-Tapping Screw M2x102
2HMV840ZZYBRG d4xD8X32
3BK0075Link Ball 4.82
4BK0340Aileron ControlArm1
No.Material No.DescriptionQty.
1HMJ2-10NSelf-Tapping Screw M2x102
2HMV840ZZYBRG d4xD8X32
3BK0075Link Ball 4.82
4BK0340Aileron ControlArm1
No.Material No.DescriptionQty.
1BK0876Elevator ControlArm1
2BK0075Link Ball
φ
4.81
3HMF2-8NPhilip Machine Screw M2x81
No.Material No.DescriptionQty.
1BK0882Elevator Push Pull Lever1
2HMV840ZZYBRG d4xD8x32
3BK0075Link Ball
φ
4.83
4HMJ2-8NSelfing-Tapping Screw M2x83
5 BK0410Collar d3xD4x131
No. Material No. Description Qty.
1 HMS15 E Ring 4
2 BK0880 Elevator Link Shaft 2
3 BK0455 Metal Elevator Control Arm 1
4 BK0663 Elevator Arm Link 2
No.Material No.DescriptionQty.
1BK0093Link Rod 2x462
2BK0086Ball Link 4.8x2.04
3BK0547Hardened Main Shaft1
4BK0234Lock Ring1
5HSA3-6BButton Head Socket Screw M3x62
No.Material No.DescriptionQty.
1HMJ2-10NM2x10 Self-Tapping Screw2
2HMC3-12BSocket Screw M3x122
3HMV840ZZYBRG d4xD8x34
4BK0088Washer d3x5x0.52
5BK0472Washout base1
6BK0342Flybar Control Lever2
7BK0343Washout Link2
8BK0075Link Ball
φ
4.82
9BK0409Collar d3xD4x72
10BK0487Pin2
11 HMS15 E Ring2
No.Material No.DescriptionQty.
1BK0086Ball Link φ 4.84
2BK0292Link Rod 2.3x242
3BK0408Collar d3xD4x5.52
4BV0549Washout Base Guidance Ring1
No.Material No.DescriptionQty.
5HMC3-10BSocket Screw M3x102
6HMC3-12B Socket Screw M3x12 1
72-1-1Flybar Seesaw Subassembly1
82-1-2Metal Main Rotor Hub Subassembly1
No. Material No. Description Qty.
1 HMV740ZZ BRG d4xD7x2.5 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 HMJ2-8N Self-Tapping Screw M2x8 1
5 HMC3-10B Socket Screw M3x10 3
6 HMJ3-20N Self-Tapping Screw M3x20 1
7 HME3-4B Set Screw M3x4 1
8 HMM3Z Locknut M3 3
9 BK0075 Link Ball 4.8 1
No. Material No. Description Qty.
1 HMC3-30B Socket Screw M3x30 2
2 HMC3-14B Socket Screw M3x14 2
3 HMM3Z Locknut M3 4
4 BK0086 Ball Link 4.8x20 2
5 BK0278 Machined Washer 2
6 BK0403 Rod Guide 4
7 BK0404 Tail Rotor Blade 2
No. Material No. Description Qty.
8 BK0877 3D Vertical Fin 1
9 BK0650 Tail Boom 1
10 BK0707 Rear Servo Rod 1
11 BK0347 Tail Push Rod A 1
12 BK0653 Tail Push Rod B 1
13 3-1-1 Tail Transmission Subassembly 1
14 3-1-3 Tail Drive Shaft Subassembly 1
No. Material No. Description Qty.
1 BK0617 Bolt M4x25 1
2 BK0086 Ball Link 4.8x20 4
3 BK0318 Link Rod 2.3x95 2
4 HMM4Z Locknut M4 1
5 2-1 Rotor Head Assembly 1
No.Material No.DescriptionQty.
1HME4-5BSet Screw M4x54
2BK0397Skid Brace2
3BK0398Skid Pipe End Cap4
4 BK0668 Skid Pipe 2
No.Material No.DescriptionQty.
15-4-1Body Subassembly1
No.Material No.DescriptionQty.
1HMJ2-6BM2x6 Self-Tapping Screw6
2HSE3-12BM3x12 Self-Tapping Screw2
3BK0102d3xD6x11Grommet2
4BK0098Body ClipA1
5BK0099Body Clip B1
6BK0429Body1
7BK0428Canopy1
8JV0186Decal1
9BK0473Body Support1
10BK0474Rubber CAP2
11HNLR6R Pin2
No.Material No.DescriptionQty.
1*****Main Rotor Blade2
2BK0446Rotor Bolt M5x352
3HMM5ZLocknut M52
TABLE OF CONTENTS
REPAIR AND REPLACEMENT PARTS
Purchase replacement parts from the hobby shop where you have purchased the Raptor 90!3D. Please contact
the Thunder Tiger distributor in your country, and the distributor can tell you where to obtain the parts. For example,
in the U.S, all Thunder Tiger products are distributed by Ace Hobby Distributors. On the web site www.acehobby.com,
there is a list of all the hobby shops in the USA that can order any Thunder Tiger parts from Ace for you. Technical
questions regarding the Raptor will be answered quickly by sending an email to [e-mail] or call
Technical Support at 949-833-7498. In Europe, Asia and Australia, please contact the distributor in your country.
WARNING
To ensure safety, please read the instruction manual thoroughly before assembly. Radio control helicopters are
sophisticated equipment, and not toys. Radio control model helicopters are capable of causing serious bodily injury
if not properly assembled or operated. The manufacturer and distributors assume no liability for damages that could
occur from the assembly or use of this product. This product is designed for hobby use only. Operating model
helicopters requires diligence and skill. The best way to ensure quick and successful learning is to seek help and
guidance from accomplished pilots. It is strongly recommended to join the appropriate radio control modeling governing
society in your country. For example, in the United States, it is strongly encouraged to join the Academy of Model
Aeronautics. AMA is a nonprofit organization that provides members in the United States with liability insurance
and monthly modeling magazines. For further information or to find a model helicopter club, please contact AMA
at:
Academy of Model aeronautics
515 East Memorial Drive
Muncie, IN 47302
USA
[phone]
We also encourage you to subscribe to different radio control helicopter magazines and learn about RC flying events,
new flying techniques, safety procedures, and hints. Rotory Modeler is a bi-monthly and Model Helicopter Techniques
is a quarterly newsletter published in the USA. Model Helicopter World is a month magazine published by Traplet
Publication in England and sold worldwide. Rotor is a monthly German magazine. Helico is a Swiss quarterly
magazine.
ATTENTION
We are unable to accept replacement or return of this model after it has been used or assembly has begun.
It is legally prohibited to duplicate or reprint this manual in any format without a written permission from the
manufacturer.
The manufacturer has the right to make changes to this model or instruction without notice.
We have done our best to the accuracy of information in this manual. If you are aware of any mistake, we welcome
you to notify us.
We will not accept any responsibility for any accident, breakdown, fault or trouble caused by improper usage of
this model. Please thoroughly inspect your model and range check the radio before flight. Please keep the model
in its best condition in order to enjoy it.
This model does not include all the items necessary for flying, such as engine, serevos, gyro...etc.
It is difficult for beginners to fly RC helicopters by themselves. It is highly recommended that beginners seek the
help of experienced RC helicopter pilots. We recommend beginners start with an inexpensive model such as the
Thunder Tiger Raptor 30 that is also designed by Mr. Taya.
RC helicopters are not toys. The manufacturer does not assume the liability for any property or bodily damage
caused by the model or the operator.
OTHER ITEMS REQUIRED
6
BODYSUPPORT INSTALLATION
Insert the aluminum support
tube through the servo frame.
Insert the "R" pins through the
two holes in the support tube
to prevent the tube from
moving in the servo frame.
Install two rubber ends onto
the support tube.The rubber
ends will dampen shake or
vibration generated by the
engine.
Glow Plug Wrench
12V Battery
1.5V Glow Starter
(1.2V~1.5V)
Rubber Band
(Included)
Foam
Remote Glow Plug
Extension
1-2-2 Cooling Fan Casing Subassembly
1-2-3 Fuel Tank Subassembly
No. Material No. Description Qty.
1 BK0062 Fuel Tank Stopper 1
2 BB0374 Silcon Tube (L=105mm) 1
3 BK0445 Fuel Plug 1
4 BK0463 Fuel Tank Nipple 1
5 BK0503-1 Fuel Tank 1
6 BE1867 Clunk Weight 1
1-5-5 Header Tank Subassembly
No.Material No.DescriptionQty.
1HMC3-25BSocket Screw M3x251
2BK0087Washer d3xD8x1.41
3BV0502HeaderTank1
4BK0506Tank Mount1
5BK0698HeaderTank Supporter1
The Raptor 90 3D kit includes a header fuel tank that can be
attached to the right of the side frame.
23
2-1-1 Flybar Seesaw Subassembly
24
2-1-2 Metal Main Rotor Hub Subassembly
2
4.Final Assembly ---------------------------------------------------------------------------------------------- 29
4-1 Installation of Rotor Head (Bag H)----------------------------------------------------------------------30
4-2 Installation of Engine --------------------------------------------------------------------------------------31
4-2-1 Engine Subassembly -------------------------------------------------------------------------------32
4-3 Installation of Landing Skid------------------------------------------------------------------------------- 33
4-3-1 Skid Subassembly -----------------------------------------------------------------------------------33
4-4 Installation of Tail Assembly ----------------------------------------------------------------------------- 34
4-4-1 Tail Support Subassembly------------------------------------------------------------------------ 34
5.Installation of Peripheral Equipment ----------------------------------------------------------- 35
5-1 Installation of Servo - Part 1 (Bag I) ------------------------------------------------------------------ 36
5-2 Installation of Servo - Part 2 (Bag I) ------------------------------------------------------------------ 37
5-3 Installation of Receiver and Gyro ---------------------------------------------------------------------- 38
5-4 Installation of Body (Bag J) ------------------------------------------------------------------------------39
5-4-1 Body Subassembly ----------------------------------------------------------------------------------39
5-5 Installation of Rotor Blades (Bag K) ------------------------------------------------------------------- 40
6.Settings --------------------------------------------------------------------------------------------------------- 41
6-1 Setting up Gear Backlash ------------------------------------------------------------------------------- 42
6-2 Setting up of Stabilizer Paddles ------------------------------------------------------------------------43
6-3 Setting up of Blade Pitch Angle ----------------------------------------------------------------------- 43
6-3-1 Collective Travel for Hovering ------------------------------------------------------------------ 44
6-3-2 Collective Travel for 3D --------------------------------------------------------------------------- 44
6-3-3 Configuring the Raptor 90 for 3D --------------------------------------------------------------- 45
Attention --------------------------------------------------------------------------------------------------------------46
7.Parts List Section -------------------------------------------------------------------------------------------49
Raptor 90 3D Exclusive Parts -------------------------------------------------------------------------------- 50
Raptor 90 3D Spare Parts List ------------------------------------------------------------------------------- 55
Raptor 90 3D Optional Parts List ---------------------------------------------------------------------------- 61
3
Thank you very much for purchasing the Thunder Tiger Raptor 90 3D R/C helicopter. The design of Raptor
90 3D is based on the original Raptor 90 series helicopter and modified for extreme aerobatics. It has all
needed must-have optional parts for 3D flying, such as metal main rotor hub, non-linear flapping damper,
metal BRG, 3D light paddles and so on. It also adopts the push-pull control system on collective pitch
and elevator to achieve the most precise control. The flybar ratio is changeable to fit all kinds of flying
style. Use of high quality material make the helicopter one tough machine that can handle everyday 3D
beating. Raptor 90 3D is born for 3D flying, and you don’t have to do any further modification for aggressive
3D maneuver. This is by far the best machine you have never seen. Just enjoy the model and have fun.
UNIQUE SIDEFRAME SYSTEM
Aluminum side plates are used in conjunction with molded material to construct the main structure. This
design produces minimum weight with maximum strength. If the sideframes were completely made of
molded material, then to achieve equal strength the plastic would have to be very thick and heavy. Using
molded material at the right place avoids using metal angle brackets or putting compound bends in metal
frames. Slots have been added in the frame design to permit the use of optional gear ratios to optimize
engine performance to suit any pilot's demand.
BELL-HIILLER MIXING CONTROL UNIT
Main rotor control geometry has been carefully engineered to minimize cross-coupling in collective and
cyclic commands. Blade pitch arms and the Bell-Hiller mixing arms are designed at an angle such that
the pushrod interlinking them are at 90 degrees when the blades are at 0 degree. The pilots will get the
symmetrical cyclic control feel and flybar authority either at +10 or -10 degrees of collective. We design
this system with the 3-D pilot in mind. We guarantee you this whole design philosophy provides a strong
and accurate control mechanism.
SHAFT DRIVE TAIL ROTOR
The Raptor 90 3D is designed with a constant drive tail rotor system to permit full tail rotor control during
autorotations. 180 autos, backward autos and pirouette autos are all within your reach now. It has the
same aluminum torque tube system as the Thunder Tiger/Taya Imperio helicopter. This allows obtaining
the maximum performance from any modern heading lock gyros.
3D CAD DESIGN
We use the latest 3D Computer Aided Design to design and manufacture the Raptor 90 3D. Our high-
tech CAD program allows simulation of all moving parts to ensure no interference. The analysis automatically
analyze the weight, the mass distribution, and inertia to help us pursue a design that will provide the high
level of maneuverability needed for all-out 3-D aerobatics.
INTRODUCTION
Socket Drivers
Hex WrenchGrease
Blue Loctite
Instant Glue
Hobby Knife
Metric
4-way Wrench
Scissors
Diagonal Pliers
Open End Wrench
5.5mm
Needle Nose PliersScrew Driver
7mm
5.5mm
7mm
8mm
5.5mm
7mm
8mm
10mm
Epoxy
Ball Link Pliers
No. Material No. Description Qty.
1 HMV6800ZZY BRG d10xD19x5 1
2 HME4-5B Set Screw M4x5 2
3 HMS5 E Ring M5x8 1
4 HMV696Z BRG d6xD15x5 1
5 BK0388 Clutch BRG Case 2
6 BK0659 Frame Space M 4
7 BK0594 Starter Coupling 1
8 BK0592 Starter Shaft 1
9 BK0422 Drive Pinion 11T 1
10 BK0366 Pinion Gear Nut 1
11 BV0522-2 Clutch Bell Set 1
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 2
2 HMC3-12B Socket Screw M3x12 4
3 BK0087 Washer d3xD8x1.4 6
4 BK0393 Pitch Frame Cross Member 1
5 BK0394 Pitch Frame Cross Member Nut 2
6 BK0375T Upper Frame 2
No.Material No.DescriptionQty.
1HMM3ZLocknut M34
2HMC3-25BSocket Screw M3x254
3BK0820BLLanding Skid Damper4
44-3-1Skid Subassembly1
No.Material No.DescriptionQty.
1HMC3-8BSocket Screw M3x84
2HMQ16Retaining Ring1
3BK0357Tail Drive Spur Gear 83T1
4BK0359One Way Clutch Shaft1
5BV0368Auto Rotation Hub1
6BK0356Main Spur Gear 91T1
1-6-2 Main Gear Subassembly
(3)
(2)
(4)
(6)
(5)
(1)
The carbon rear servo plate is secured
by two Lower 3mm bolts from the plastic
tail boom bracket.
10
1-1-2 Pitch Guide L Subassembly
1-1-3 Pitch Guide R Subassembly
No. Material No. Description Qty.
1 BK0384 Pitch Guide Collar L 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
The side with a number should face
in because the opening on both sides
are differeent.
The hole on the plastic control arm has different
opening sizes on the two sides.Always snap the
bigger opening to the ball on swashplate gently and
afterward please check to make sure it is securely
attached and there is no damage or cracking.
INSTALLATION OF THE LINKS
Bigger Hole Face to Swashplate
Extended 6mm Hex
Starting Tool
Fuel Pump
Heli Engine (90size)
9609 PRO-90H(R)
Glow Fuel(15%-30%)
Glow Plug
Hi-torque 12V Electric starter
Receiver
Transmitter
(helicopter type, 6 or
more channels) High Speed/Torque Servo x 4
Rudder Servo x 1
Battery Switch harness
Heading Lock
Gyro
In order to enjoy a safe and enjoyable experience, please read the manual carefully and completely understand
the helicopter structure and operation before the first flight.
Read the warnings to avoid injuries to you and others.
WARNING – The following could cause heavy injury or death if used incorrectly.
Keep the model away from other people or animal when starting the engine.
Do not fly any model helicopter near or above people or cars. Models can sometimes lose
control due to pilot or mechanical failure.
WARNING – The following could also cause serious injury or death if not careful.
Take precaution with model fuel. Model engine glow fuel is highly flammable.
Please check the model carefully before each flight. Make sure that nothing has loosened up
or come apart.
Make sure everything moves freely without binding or excessive friction.
Do not operate the model in rain, snow, thunderstorm, or adverse weather.
WARNING – The following could also cause serious injury or death if not careful.
Please make sure that your radio frequency is not used before flight. If someone else is flying
with the same frequency as your radio, do not turn on your transmitter. Otherwise, it can cause
a crash and even bodily and property damages.
Please monitor the fuel level during flight and land before running out of fuel.
Before each flight, please check that all servos and controls move properly.
Do not modify any parts or use other than genuine Thunder Tiger parts.
Do not fly in places that are forbidden by law.
Use Loctite on screws that do not use a locknut.
When operating the model, please beware that no loose cloth or jewelry can get entangled in
the model helicopter.
Make sure the transmitter and receiver switches are on before starting the engine.
Do not touch the engine or the muffler right after flying because they are very hot.
Do not use this model for anything other than hobby.
WARNING – The following damages can happen to the model.
Do not leave the model in a car for a long time. The heat in the summer or the cold in the
winter and the humidity can cause damage to the model.
Be careful and watch the sharp edges and corners on the model.
BUILDING HINT – The instruction is divided into six assembly chapters:
Main Frame, Rotor Head, Tail Rotor, Final Assembly, Radio Installation, and Settings. There
are many major assembly steps in each chapter, please follow the instruction to do each "
Subassembly" first, then combine the subassemblies into a major assembly.
Upper Frame Assembly
Lower Frame Assembly
12
1-2-1 Tail Drive Unit Subassembly
No. Material No. Description Qty.
1 HME3-4B Set Screw M3x4 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 BK0362 Tail Drive Bevel Gear A 1
5 BK0363 Tail Drive Bevel Gear B 1
6 BK0364 Tail Drive Pinion 1
7 BK0365 Tail Drive Gear Shaft 1
8 BK0382 Tail Boom Bracket L 1
9 BK0383 Tail Boom Bracket R 1
10 BK0414 Pin 2x12 2
11 BK0660 Frame Spacer L 5
Main Frame Assembly Installation of Pitch Frame
No.Material No.DescriptionQty.
1HMJ2-10NM2x10 Self-Tapping Screw1
2HMV840ZZYBRG d4xD8x32
3HMV1280ZZYBRG d8xD12x3.52
4BK0336Pitch Frame1
5BK0075Link Ball
φ
4.81
Optional: add a tiny drop of thick CAon the outside rim of the fovr ball
bearings before inserting them into the plastic Pitch Frame. Be careful
not to get any glue into the ball bearings.Add a tiny drop of thick CA
glue at the tip of the M2x10 self-tapping screw (No. 1) before
screwing it into the Pitch Frame.
32
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
No. Material No. Description Qty.
1 BK0385 Pitch Guide Collar R 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
Tip: When setting up the phase
adjustment ring, the flybar and
the tail boom can be the
reference. When the flybar and
the tail boom are centered, the
inner balls of swashplate should
be aligned with the outer balls.
Tighten the socket screw on the
phase ring at this moment.
NOTE: Improper alignment will
cause unwanted mixing.
No. Material No. Description Qty.
1 ******** 90 Class Heli Engine 1
2 ******** Nut (Comes With the Engine) 1
3 HMC4-8B Socket Screw M4x8 2
4 HMC4-18B Socket Screw M4x18 4
No. Material No. Description Qty.
5 HMO10 Washer d9.5xD16x1 1
6 BK0349 Engine Mount 1
7 BV0380 Cooling Fan 1
8 BV0521 Heavy Duty Clutch 1
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.85
2BK0086Ball Link 4.8x208
3BK0104Servo Mounting Plate6
4BK0105Rod Joint1
5BK0318Link Rod 2.3x952
6BK0436Link Rod 2.3x552
7BK0833Servo Block4
8HMC2516BSocket Screw M2.5x164
No.Material No.DescriptionQty.
9HMM25Lock Nut M2.54
10HML2Nut5
11HME4-5BSet Screw2
12HMF2-8NPhillips Machine Screw M2x85
13HSE2614NSelt-Tapping Screw4
14HSE2630NSelt-Tapping Screw4
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.87
2BK0086Ball Link 4.8x204
3BK0095Link Rod 2.3x761
4BK0104Servo Mounting Plate4
5BK0833Servo Block2
6BK0834Pitch Lever Fixed Plate1
7BK0839Link Rod 2.3x301
8BK0881Washer1
9BK0883Pitch Push Pull Lever1
No.Material No.DescriptionQty.
10BK0884Collar, d3xD4xW121
11BV0085Pitch Link Rod2
12HMC3-20BSocket Screw M3x201
13HMV840ZZYBearing d4xD8xW32
14HMF2-8NPhilip Maching Screw M2x84
15HMJ2-8NSelt-Tapping Screw M2x83
16HML2Nut4
17HSE2614NSelt-Tapping Screw M2.6x148
18HSE2620NSelt-Tapping Screw M2.6x204
No.Material No.DescriptionQty.
1****Switch1
2****Receiver Battery1
3****Receiver1
No.Material No.DescriptionQty.
4****Gyro
5BK0106Foam2
6 BE1052Antenna Pipe1
PV0517ONEWAYBEARING GREASE
The hole on the Flybar Control Rod has different
opening on two sides.Always snap the bigger opening
to the link ball.
Bigger Hole
Face to ControlArm
10.5mm10.5mm
When installing pinion gear, add a small drop of Loctite to the
threads. Make sure not to get Loctite on lower clutch bell bearing.
Important:
For 90 class engine, we recommend the 11 teeth pinion for 3D
flying.
The servo tray and cooling fan shrouds on the Raptor 90 are different from the
Raptor 60 in order to accommodate the full head sink on the O.S 91. engine.
If using T.T 90, Y.S 91 or Webra 91 engine, make sure to install the fan shroud
baffle with two self-tapping screws. This will ensure optimal cooling of your engine
head.
Add CAglue
Add CAglue
It is necessary to add grease inside the one way clutch before your
first flight.The clutch might lock up once grease is gone.The one
way clutch grease( PV0517) is recommended for this lubrication.
Make sure the inside ofAuto Rotation Hub is clean without any dirt
before you insert the one way clutch shaft.
Add Loctite
Add Loctite on
the threads
For 3D flying, it is recommended to use
lower flybar ratio setting.
Self-Tapping Screw, No. 10 Collar, and No. 11 Washer, with two
No. 1 Bearings. Attach a No. 9 Link Ball with a No. 4 Screw.
Upon finishing Step 3-1-1, make sure there are no extra parts
left on your workbench.
Elevator Control
Pushrod
Glue the two plastic halves of
the paddle with CAglue before
installation on flybar.
Add Loctite
the tail boom by tightening the four screws on the helicopter.
Visually check from the rear of the helicopter to make sure the
tail rotor output shaft is perpendicular to the main rotor shaft.
Add the tail boom supports.
Add Loctite
The thrust bearing washer with the
SMALLER inner hole should be closer to
the rotor blade.
The thrust bearing washer with the BIGGER
inner hole should be closer to the main rotor
shaft.
4-2-1 Engine Subassembly
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add CAGlue
Introduction -------------------------------------------------------------------------------------------------------- 3
Other Items Required -------------------------------------------------------------------------------------- 4
Warning --------------------------------------------------------------------------------------------------------------- 5
Assembly
1. Main Frame Assembly --------------------------------------------------------------------------------- 7
1-1 Upper Frame Assembly (Bag A) ---------------------------------------------------------------------- 8
1-1-1 Pinion Gear Subassembly ------------------------------------------------------------------------ 9
1-1-2 Pitch Guide Left Subassembly ------------------------------------------------------------------10
1-1-3 Pitch Guide Right Subassembly -----------------------------------------------------------------10
1-1-4 Elevator Control Arm Subassembly------------------------------------------------------------ 10
1-2 Lower Frame Assembly (Bag B) ----------------------------------------------------------------------11
1-2-1 Tail Drive Unit Subassembly ---------------------------------------------------------------------12
1-2-2 Cooling Fan Casing Subassembly -------------------------------------------------------------13
1-2-3 Fuel Tank Subassembly ------------------------------------------------------------------------13
1-3 Main Frame Assembly (Bag C) -------------------------------------------------------------------------14
1-3-1 Rod Guide Collar Subassembly----------------------------------------------------------------- 14
1-4 Installation of Servo Frame (Bag C) ------------------------------------------------------------------- 15
1-5 Installation of Pitch Frame (Bag D) -------------------------------------------------------------------- 16
1-5-1 Aileron Lever Subassembly ---------------------------------------------------------------------17
1-5-2 Metal Elevator Parallel Lever Subassembly -------------------------------------------------17
1-5-3 Elevator Control Lever Subassembly --------------------------------------------------------- 17
1-5-4 Pitch Control Frame Subassembly -------------------------------------------------------------18
1-5-5 Header Tank Subassembly ----------------------------------------------------------------------18
1-6 Installation of Main Shaft (Bag E) ----------------------------------------------------------------------19
1-6-1 Wash Out Subassembly -------------------------------------------------------------------------20
1-6-2 Main Gear Subassembly -------------------------------------------------------------------------20
2. Rotor Head Assembly -----------------------------------------------------------------------------------21
2-1 Metal Rotor Head Assembly (Bag F) -----------------------------------------------------------------22
2-1-1 Flybar Seesaw Subassembly --------------------------------------------------------------------23
2-1-2 Metal Main Rotor Hub Subassembly ----------------------------------------------------------24
3.Tail Assembly -------------------------------------------------------------------------------------------------25
3-1 Tail Assembly (Bag G) ----------------------------------------------------------------------------------- 26
3-1-1 Tail Transmission Subassembly --------------------------------------------------------------- 27
3-1-2 Tail Rotor Subassembly --------------------------------------------------------------------------- 28
3-1-3 Tail Drive Shaft Subassembly -------------------------------------------------------------------28
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The Liner is pre-glued on the
inside of clutch bell with 30 min
epoxy.
1-1
1
1-2 1-3
( 2 ) (1)
1-4
(1)
(2)
1-5 1-6
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(1)
(5)(4)
(9)
(3)
2-1
3-1 4-1
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(3)
(2)
(1)
4-3
(4)
(2)
4-4
(2)
(7)
(1)
(3)
(5)
(8)
4-2
(3)
(1)
(2)
5-15-2
5-3
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(1)
(3)
(2)
(5)
5-4
5-5
(2)
(3)
No. Material No. Description Qty.
8 BK0660 Frame Spacer L 3
9 BK0376T Lower Metal Frame 2
10 BV0870 Metal Lower BRG Block 1
11 1-2-1 Tail Drive Unit Subassembly 1
12 1-2-2 Cooling Fan Casing Subassembly 1
13 1-2-3 Fuel Tank Subassembly 1
No. Material No. Description Qty.
7 BK0659 Frame Spacer M 2
8 BV0869 Metal Upper BRG Block 1
9 1-1-1 Pinion Gear Subassembly 1
10 1-1-2 Pitch Guide L Subassembly 1
11 1-1-3 Pitch Guide R Subassembly 1
12 1-1-4 Elevator Control Arm Subassembly 1
(3)
No. Material No. Description Qty.
10 BK0093 Link Rod 2x46 1
11 BK0407 Collar d3xD4x4.5 2
12 BK0410 Collar d3xD4x13 2
13 1-5-1 Aileron Lever Subassembly 1
14 1-5-2 Metal Elevator Parallel Lever Subassembly 1
15 1-5-3 Elevator Control Lever Subassembly 1
16 1-5-4 Pitch Control Frame Subassembly 1
17 1-5-5 Header Tank Subassembly 1
No.Material No.DescriptionQty.
6HMM4BLucknut M41
7BK0617Bolt M4x251
8BV0504Metal Swashplate1
91-6-1Washout Subassembly1
101-6-2Main Gear Subassembly1
No. Material No. Description Qty.
10 BK0076 Collar d3xD4x10 1
11 BK0088 Washer d3xD5x0.5 1
12 BK0346 Tail Pitch Control Lever 1
13 BK0370 Tail Case L 1
14 BK0371 Tail Case R 1
15 BK0372 Tail Input Bevel Gear 1
16 BK0373 Tail Output Bevel Gear 1
17 HMY2-12 Pin 2x12 1
18 3-1-2 Tail Rotor Subassembly 1
No.Material No.DescriptionQty.
1HMM3ZLocknut M36
2HMC3-16BSocket Screw M3x162
3HMC3-20BSocket Screw M3x202
4HMC3-25BSocket Screw M3x252
5HMC3-30BSocket Screw M3x302
6BK0087Washer d3xD8x1.44
No.Material No.DescriptionQty.
1 HMJ2-8N Self-Tapping Screw M2x8 4
2BK0447Tail Support Rod End4
3BK0669Tail Support Rod2
No. Material No. Description Qty.
1 HMC4-42B Muffler Bolt M4x42 2
2 HMT4B Spring Washer 2
3 ******** Muffler ( 90 ) 1
4 4-2-1 Engine Subassembly 1
5 HMC4-12B Socket Screw M4x12 4
6 BK0435 Washer d4xD11xW1.7 4
BAG A
BAG B
BAG C BAG C BAG D
(L)
(R)
BAG E
BAG F
BAG G
BAG H
BAG I
97.5mm
48mm
(3)
Throttle
Collective Pitch
(2)
BAG I
BAG J
BAG K
(11) (8)
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(2)
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(5)
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(4)
Please complete subassembly steps 1-2-1 through 1-2-3 first. Then attach the subassemblies to the two Lower Frames. Note
that the Metal Lower BRG is installed with the bearing open side facing up. Please add a small drop of Loctite on every bolt
before screwing it into the aluminum hex spacer. Do not apply Loctite to the bolts which are going to secure the Lower BRG
Block at this moment.
Assemble the upper main frames by starting with the two Metal Upper Frames. The Pinion Gear Subassembly must be assembled
first according to Figure 1-1-1. Next insert three hex-shape frame spacers into the plastic Pitch Guide according to Figure 1-1-2
and 1-1-3. Assemble the Elevator Control Arm subassembly according to 1-1-4. Insert it in between the two Upper Frames. The
metal Elevator Control Arm is not symmetrical. The side with the longer profruding round knob should be on the right side of the
helicopter. Then attach the other subassemblies to the Upper Frames. Locate Hex Wrenches in BAG L which you need for
assembly.
Please add a tiny drop of non-permanent type Loctite on the tip of all bolts before screwing them into the hex shaped aluminum
frame spacers. Never use too much Loctite, otherwise it will become nearly impossible to remove later on for servicing. Only use
the non-permanent type of Loctite. If encountering difficulty in removing any bolt that was locked up by Loctite, heat up the head
of the screw or bolt with the tip of a hot soldering iron, it will help soften the cured Loctite.
For the kit, parts are bagged according to each major assembly and are labeled "Bag A, Bag
B, etc." The heading for each assembly indicates which bag to open. As a good practice,
only open up the bag that you need for the particular assembly. Check the parts in that bag
against the parts list shown for each assembly as well as each sub-assembly to make sure
there are no missing parts. To prevent losing small hardware, please empty the small nuts
and bolts and parts into small plastic trays on your work table. At the end of each major
assembly, there should be no left over parts.
The fuel tank comes assembled from the factory because every tank has been
checked for leak. If you were to take the tank apart here is how to put it back
together. Install the silicone fuel line to the Fuel Nipple. Then add the rubber
fuel tank stopper and the clunk weight. The stock silicone fuel line is very soft
and thin which is designed to allow the clunk to pick up fuel easily during 3-D
aerobatics. The pickup line should be inspected and replaced if necessary every
month, otherwise when it becomes soggy it can break off. A thicker silicone line
maybe substituted but make sure the clunk will reach the bottom when moving
the fuel tank to all different orientations.
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As show in Figure 1-3-1, insert two hex
Frame Spacers S into the plastic Rod
Guide Collars. Then join the Upper
Frame Assembly to the Lower Frame
Assembly according to drawing 1-3.
Secure the Set Screws (No.1) to the
frames, and fit the Body Posts (No.4)
to the Set Screews. The two Body Posts
will be used to secure the canopy in the
future. Add Loctite on all bolts and
inside BK0103 threaded hole.
Install the one-piece servo frame with six self-tapping screws.
Do not use Loctite when attaching self-tapping screws to plastic
parts. Loctite is only for threading metal into metal parts. Assemble the constant drive Main Gear Subassembly according to Figure 1-6-2 first.Then build up the Wash Out Subassembly
according to 1-6-1. Insert the No.3 Main Shaft into the bearings and then add the No.4 Lock Ring and slide in the Main Gear
Subassembly.Add two M3x6 Button Head Screws to the Locking Ring, and the two screws are threaded into the holes on the
main rotor shaft.
The locking ring prevents the main shaft from sliding up. Line up the hole on the main gear and the main shaft, then insert M4x2 5
mm Bolt through them. Place a 4 mm M4 locknut on the other side of the autorotation hub, and then tighten the Bolt. Do not
over tighten the Bolt, otherwise the autorotation assembly will be distorted. Loosen the 3mm bolts holding the Upper and lower
bearing blocks for the 12mm main shaft. Wiggle the main shaft in the bearing blocks until the main shaft spins freelyin the bea rings.
This ensures the upper and lower bearing blocks are aligned. Push the lower bearing block up until the mainshaft has no up
and down play.Then tighten the 3mm bolts for the upper and lower bearing blocks.
Insert the pin into the Washout Link.Add a tiny drop of Loctite on the inside
and outside of BK0409 Collar which will help give a completely slop free
control system. Do not let the Loctite seep into the bearing.Adjust the
tightness of the M3x12 bolts so the mixing arms can move freely but without
wobble or racheting the ball bearings.Add a tiny drop of thick CAglue at
the tip of the M2x10 self-tapping screw (No. 1) before screwing it into the
Flybar Control Levers (No. 6).
Make the two pushrods for controlling the blade pitch.The distance 43 mm is measured between the center of two pushrod holes.
Attach the Seesaw Hub of the Control PaddleAssembly to the Main Rotor Head with Socket Screws (M3x10).
Please add a small drop of Loctite along the entire length of the M3x10 Socket Screw (No.5) and on the outside of the collar
d3xD4x5.5 (No.3).Temporarily install the Washout Base Guidence Ring, but do not tighten the No.6 M3 Socket Screw yet.
Assemble the tail transmission subassembly according to 3-
1-1 and 3-1-2 first. And the tail drive shaft subassembly according
to 3-1-3.But do not close the two halves of the tail transmission
tightly. You will do this when you are ready to install the gearbox
onto the tail boom.
When installing the tail transmission, make sure the housings
match the hole on to the tail boom. Add Carbon Vertical Fin with
machined washer and Locknut, then tighten the five 3 mm bolts.
Add carbon Vertical Fin with Pom washer and Locknut.
Before inserting the finished tail drive shaft assembly into the
tail boom, add some flexible silicone glue or ZAP Goop glue
around the outside of the tail drive bearing housing. This will
prevent the bearing housing from spinning inside the tail boom.
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Install bearings No. 2 and No.3 into the Tail Cases. Install No.
16 Tail Bevel Gear onto the Tail Shaft. Gently tap the No. 17
Pin into the Bevel Gear and Tail Shaft. Then secure the pin
with a No. 7 Set Screw with Loctite.
After installing the M3x4 set screws, try pushing on the 2x12
pin with a small Allen wrench to make sure the set screw has
locked the pin in place securely. Before closing the two halves
of the Tail Cases, please check the gear mesh between gears
No. 15 and No. 16. If the gears mesh too tight, then a 5 mm
i.d. washer should be added to move the gear No. 16 further
out. If there exists too much freeplay, then a 5 mm i.d. washer
to push gear No. 16 closer to gear No. 15.
Install the No. 12 Tail Pitch Control Lever as shown with No. 6
Slide four No. 6 Rod Guides onto the tail boom. Do not glue
them onto the tail boom yet. Add a tiny drop of CA glue to the
pushrod guide after you finish building the entire helicopter.
Before adding glue, make sure the tail pushrod is hooked up
to the servo and the rod travels in a straight line and moves
very smoothly.
Congratulation, we are almost done. Install the finished main
rotor head onto the 12 mm rotor main shaft. Secure it with a
M4x20 Bolt and M4 Locknut. Make up two 113.5 mm long
pushrods and attach them to the Bell-Hiller mixing arm.
Before installing the plastic end caps, please
add a drop of slow, thick CAglue on the
rim of the end caps and on the inside edge
of the aluminum skid.
Slide the finished tail boom into the helicopter.The four bolts
on the helicopter must be loose in order to insert the tail boom.
Make sure the tail drive shaft is inserted into the front receptacle
properly. Check this by turning the main rotor head. Secure
Secure the two ends to the rod with Epoxy, making sure the
two metal ends are perpendicular to each other.
(4)
Attach the engine into the side frames, with four M4x12 bolts and
four washers, but do not tighten until Section 6-1.
Install the muffler after you have building the entire helicopter.
Always add Loctite on the muffler bolts.
Install the servos and make up the pushrods according to the drawings.The distance between the steel ball and the center of
servo arm are shown in the drawing. Use them as a guide.These distances are used in conjunction with the servo travels (ATV
or End point) set to 100% for all the channels in the transmitter.Tune them later on to suit your personal flying style.
Attach the rudder servo to the rear mounted carbon plate with four 2.6mm bolts and four M2.6 locknut.
Make up the throttle and collective control pushrods according
to the drawing. Use the outermost hole on the carburetor throttle
control arm.Attach the steel ball on the throttle servo arm at
approximately the same distance as the steel ball on the throttle
arm.
Make up the throttle at 97.5mm long first, and then adjust the
pushrod length and throttle servoATV or Endpoint so full throttle
stick command will open the carburetor barrel fully.And full low
stick and low throttle trim will close the carburetor barrel completely.
Install the receiver and receiver battery. Even though the receiver and battery can be attached to the helicopter tray by using
double sided foam tape, but it is better to wrap the receiver and battery separately using half inch or 10 mm thickfoam. Then
secure them to the tray using six to eight rubberbands, or Velcro bands.
Carefully cut out the canopy (windshield) using scissors.The
best scissors to use are (TTR 1304) designed to cut RC car
bodies and Canopy. Install the canopy to the body using six
small screws. Drill small holes in the canopy and body for the
holes. Drill two more holes for the rubber grommets.
Refer to color box and apply the decals (In BAG M) .
Tools for Assembly
The Raptor 90 3D is designed for easy maintenance using standard hobby tools. Please only use genuine Thunder Tiger parts.
Please keep the model clean and well tuned. It will provide you with long lasting pleasure in return.
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Add Loctite
(Included)
Add a tiny drop of thick CAglue at the tip of the M2x10
self-tapping screw (No. 1) before screwing it into the
Aileron Levers.
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Make up the landing gear according to the
drawing.
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No. Material No. Description Qty.
1 HSE3-6B Self-Tapping Screw M3x6 2
2 BK0660 Frame Spacer L 4
3 BK0662 Cooling Fan Baffle 1
4 BK0665 Fan Casing L 1
5 BK0666 Fan Casing R 1
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Assemble the metal flybar control arms according to the drawings. Slide Flybar ControlArm onto the No.18 Flybar Rod. Slide
the flybar into the No.17 Seesaw Hub. Make sure the Flybar has equal protrusion from each side of the SeesawHub measure
them with a ruler, then install and tighten the No.8 HME4-5B set screws.Add the paddles. Make sure the two paddles and the
two flybar control arms are all parallel. Lock the paddles with No.6 set screws.
Assemble and install the No.10 Mixing Levers and No.5 Bearings according to the drawing using No.12 Collar andNo.9 d3xD5x0.5
washer.
Note:Before installing the Mixing Lever (No.10), please add a small drop of Loctite along the entire length of the M3x18 button
head socket screw (No.4) and on the outside of the collar d3xD4x13 (No.12). Be careful do not let the Loctite seep into the bear ings.
There are two choices of hole positions on the aluminum seesaw for attaching the mixing lever arm.The outside hole gives higher
Bell-Hiller mixing ratio. For aggressive 3D flying, you can attach the Bell-Hiller mixing arms to the inner hole which gives low er
flybar ratio.
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No.Material No.DescriptionQty.
10BK0324Mixing Lever2
11BK0406LPaddle Root2
12BK0410Collar d3xD4x132
13BK0416Paddle Stopper2
14BK0432LFlybar Paddle2
15BK0633Flybar Control Frame2
16 BK0871 Longer StabilizerArm 2
17 BV0865 Longer Seesaw 1
18 BK0866 SUS Flybar 1
No.Material No.DescriptionQty.
1HMF2-8NPhillips Machine Screw M2x82
2HMJ2-10NSelfing-Tapping Screw M2x104
3HMC3-10BSocket Screw M3x102
4 HMC3-18B Socket Screw 2
5HMV840ZZYBRG d4xD8x34
6HME4-3BSet Screw M4x34
7HME4-5BSet Screw M4x52
8BK0075Link Ball
φ
4.86
9BK0088Washer d3xD5x0.52
Insert the aluminum Main Rotor Hub Pin and the Flap Dampers. (might need to apply silicone grease for easy installation). Push
the No.7 Feathering Spindle into the dampers and the rotor hub.Add No. 14 Flybar Control Rod. Slide both finished Main Rotor
Grip onto the feathering spindle and the secure with two M4x10 bolts and washers according to the drawing.Use two Allen
wrenches to tighten the two M4x10 bolts simultaneously.
Important Note:
The Raptor 90 3D kits come with non-linear flap damper for aggressive 3D flying.You may choose to experiment adding from
one up to three 0.4mm thick shim (No.10) washers between the washer (No.8) and bearing to further stiffen the main rotor flapping.
Stiffing the main rotor head will speed up the cyclic transient response, but may cause the helicopter fuselage to oscillate at arou nd
1600 RPM.This oscillation characteristic exists for all helicopters with hard 3D flap dampers.The inner dampers should be
replaced periodically if a lot of 3D flying has been done. When the dampers are worn, the main rotor blades canflap excessivel y
during some 3D maneuvers and risk touching the tail boom.
Add flexible silcone glue or ZAP
Goop glue around the outside
before inserting into the tail
boom from the front side.
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180mm
25mm
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The optionalThunderTiger Remote Glow PlugAdaptor (#3803)
is recommended as shown, making starting easy without the
removal of your canopy.
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Cut a hole at the
front air scoop for
backward flights.
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No.Material No.DescriptionQty.
9BK0477Washer2
10BK0703Flap Damper Washer 0.4mm6
11BK0874Inner Damper2
12BK0875Outer Dampper2
13BK0075Ling Ball
φ
4.82
14BK0664Flybar Control Rod2
15BK0319Main Rotor Pitch Housing2
16BV0548-1Metal Main Rutor Hub1
No.Material No.DescriptionQty.
1HMC4-10BSocket Screw M4x102
2HMJ2-12NSelf-Tapping Screw M2x122
3HMV1680BRG d8xD16x54
4HMX0816Thrust Bearing d8xD16x52
5BK0330Main Rotor Hub Pin1
6 BK0325Thrust Washer 2
7BK0326Spindle1
8BK0435Washer2
Fiberglass or Carbon Rotor Blade
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Add Loctite when setting up the
gearmesh in step 6-1.
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No.Material No.DescriptionQty.
7BK0539Carbon Rear Servo Plate1
8BK0878Bracket (Top)1
9BK0879Bracket (Bottom)1
103-1TailAssembly1
114-4-1Tail Support Subassembly2
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Engine System
Use a high quality 90 size 2-stroke
model helicopter engine, such as the
Thunder Tiger TT PRO-90H, OS 91
SZ-H, YS 91 ST, Webra 91, or
equivalent. Please beware, some
engines may not fit because of their
shape and size. The Raptor 90 3D
kit comes with a cooling fan hub to fit
the TT PRO-90H, OS 91 SZ-H, Webra
91.
We recommend a high quality muffler
or tuned exhaust system designed to
fit on the left side of the model.
Rotor Blades
It is important to use main rotor blades
that are of high quality and suitable
for your flying style. If fiberglass or
carbon graphite blades are used, the
length should be between 680 and
710 mm. Blade weight should be
between 170 and 200 grams.
Starter System
To start the engine, it is necessary to
use an electric starter with a 6mm
shaft extension. The starter and the
6 mm extension are available from
Thunder Tiger, the part numbers are
No.2675 and No.3801.
Use a strong high torque 12 volt
electric starter which is designed for
models.
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Add a small drop of Loctite.
Make sure it locks the pin.
Install BK0364 and BK0362 onto BK0365 Tail Gear Drive Shaft. Then insert the
two Pins and secure them with two M3x4 Set Screws. Add a tiny drop of Loctite
on the set screw thread before inserting them. Always use a very small amount
of Loctite liquid on the thread, otherwise it may be nearly impossible to remove
the set screws in the future for servicing. After installing the two M3x4 set screws
(No. 1), try to push on the 2x12 pins with a small Allen wrench to make sure the
set screws have locked the pins in place securely. Install the four ball bearings
and the hex shaped Frame Spacers according to the drawing. Before closing
the two halves of the Tail Boom Brackets, please check the gear mesh between
gears No. 4 and No. 5. If there exists too much freeplay, add some 5 mm i.d.
washers on top of gear No. 4. (The 5 mm i.d. washers are provided in BAG G).
Add a small drop of Loctite.
Make sure it locks the pin.
Shim Washer
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(1)
Add CAGlue
Standard flybar ratio
Lower flybar ratio
Mild 3D Flying
Extreme 3D Flying
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(1)
Attach the engine mount to the engine using four 4mm bolts and Loctite.
The cooling fan hub is threaded to fit the OS, TT or Webra only. Place the washer that came with your engine onto the engine
crankshaft first. Then screw the fan hub onto the engine. Add a tiny drop of Loctite on the engine nut. Do not use too much
Loctite. Tighten the engine nut using a socket head wrench while grabbing the fan with a towel. The nut should be tighten securely.
For 50-size or bigger engines, we do not recommend using a piston locking tool on the glow plug hole because that may damage
the engine. Attach the No. 8 Heavy Duty Clutch to the fan hub. Add a drop of Loctite on the threads of the M4x8 bolts. The
threads on the aluminum cooling fan hub are for the TT 70H, OS 61 SX, OS 61LX, OS 70H, TT 90H, OS 91 or Webra 91 engines.
If YS 61, 80 or 91 engines are used, the fan hub must be re-tapped by the modeler to M8x1mm thread size or purchase a optional
plastic fan hub with threads for the YS engine(PV0198YS) or the metal fan for the YS (PV0293YS).
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Please complete subassemblies 1-5-1 through 1-5-5 first, then add them to the Main Frame. Fit the Pitch Control Frame
Subassembly. Attach the E Ring on the left side of the Metal Elevator Control Arm. Then fit the Elevator Control Lever to the
right side, insert the pin and fix it with a set screw. Secure the Pitch Control Frame with a M3*10 Socket Screw and a collar on
the left side. And attach the Elevator Push Pull Lever to the right side of the Pitch Control Frame as shown. Adjust the two bolts
so that the Pitch Control Frame can move freely without excessive play. Finally, add the two plastic Aileron Levers and the 66.5mm
elevator pushrod. Add the Washers (BK0088) to make sure that the Aileron Lever and the Metal Elevator Parallel Lever will not
touch each other during operation.
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Outer hole for standard.
Inner hole for extreme 3D.
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Add Loctite
Add Loctite
Add Loctite
(11)
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
30mm
(2)
Paddle
Flybar
A Arm
Phase
Adjustment
Ring
Swash
plate
Boom
(3)
(8)
(14)
(13)
(9)
(1) (10) (12)
(7)
(11)
(12)
(2)(7)
(8)(6)
(5)
(4)
(1) (14) (16)
(11)
(18)
Pitch push-pull subassembly
(13)
(1)
(15)
(10)
(9)
(17)
(2)
(3)
Add Loctite
Add Epoxy
Add Epoxy
(13)
(14)
(17) (15)
(16)

1
5
7
MAIN FRAME ASSEMBLY
8 9
1-1-1 Pinion Gear Subassembly
11
13 14 15 16 17 181920
21
22
25 26 27
29 30 33 34
36
3531
37
383940
4
1-3-1 Rod Guide Collar Subassembly
1-5-1 Aileron Lever Subassembly
1-5-2 Metal Elevator Parallel Lever Subassembly
1-5-3 Elevator Control Lever Subassembly
1-5-4 Pitch Control Frame Subassembly
1-1-4 Elevator Control Arm Subassembly
1-6-1 Wash Out Subassembly
ROTOR HEAD ASSEMBLY
TAIL ASSEMBLY
3-1-1 Tail Transmission Subassembly
FINAL ASSEMBLY
4-3-1 Skid Subassembly
4-4-1 Tail Support Subassembly
INSTALLATION OF PERIPHERAL EQUIPMENT
5-4-1 Body Subassembly
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 4
2 HMC3-12B Socket Screw M3x12 21
3 BK0087 Washer d3xD8x1.4 22
4 BK0274 Tank Rubber Grommets 4
5 BK0380 Rear Frame L 1
6 BK0381 Rear Frame R 1
7 BK0629 Washer 4
No. Material No. Description Qty.
1 HME3-18.5B Set Screw M3x18.5 2
2 HMC3-25B Socket Screw M3x25 10
3 BK0087 Washer d3xD8x1.4 10
4 BK0103 Body Fitting Post 2
5 BK0658 Frame Spacer S 2
6 1-1 Upper Frame Assembly 1
7 1-2 Lower Frame Assembly 1
8 1-3-1 Rod Guide Collar Subassembly 2
No. Material No. Description Qty.
1 BK0389 Rod Guide Collar 1
2 BK0658 Frame Spacer S 2
No. Material No. Description Qty.
1 BK0667 Servo Frame 1
2 HSE3-12B M3x12 Self-Tapping Screw 6
3 1-3 Main Frame Assembly 1
No. Material No. Description Qty.
1 HMC2-6B Socket Screw M2x6 1
2 HMC3-10B Socket Screw M3x10 1
3 HMC3-25B Socket Screw M3x25 1
4 HME3-3B Set Screw M3x3 1
5 HMJ3-20N Self-Tapping Screw M3x20 2
6 HMS4 E Ring 1
7 HMY2-10 Pin 2x10 1
8 BK0086 Ball link 4.8x20 2
9 BK0088 Washer d3xD5x0.5 3
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 BK0876 Elevator Control Arm 1
2 BK0075 Link Ball
φ
4.8 1
3 HMF2-8N Philip Machine Screw M2x8 1
No. Material No. Description Qty.
1 BK0882 Elevator Push Pull Lever 1
2 HMV840ZZY BRG d4xD8x3 2
3 BK0075 Link Ball
φ
4.8 3
4 HMJ2-8N Selfing-Tapping Screw M2x8 3
5 BK0410 Collar d3xD4x13 1
No. Material No. Description Qty.
1 HMS15 E Ring 4
2 BK0880 Elevator Link Shaft 2
3 BK0455 Metal Elevator Control Arm 1
4 BK0663 Elevator Arm Link 2
No.Material No.DescriptionQty.
1BK0093Link Rod 2x462
2BK0086Ball Link 4.8x2.04
3BK0547Hardened Main Shaft1
4BK0234Lock Ring1
5HSA3-6BButton Head Socket Screw M3x62
No.Material No.DescriptionQty.
1HMJ2-10NM2x10 Self-Tapping Screw2
2HMC3-12BSocket Screw M3x122
3HMV840ZZYBRG d4xD8x34
4BK0088Washer d3x5x0.52
5BK0472Washout base1
6BK0342Flybar Control Lever2
7BK0343Washout Link2
8BK0075Link Ball
φ
4.82
9BK0409Collar d3xD4x72
10BK0487Pin2
11 HMS15 E Ring2
No.Material No.DescriptionQty.
1BK0086Ball Link φ 4.84
2BK0292Link Rod 2.3x242
3BK0408Collar d3xD4x5.52
4BV0549Washout Base Guidance Ring1
No.Material No.DescriptionQty.
5HMC3-10BSocket Screw M3x102
6HMC3-12B Socket Screw M3x12 1
72-1-1Flybar Seesaw Subassembly1
82-1-2Metal Main Rotor Hub Subassembly1
No. Material No. Description Qty.
1 HMV740ZZ BRG d4xD7x2.5 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 HMJ2-8N Self-Tapping Screw M2x8 1
5 HMC3-10B Socket Screw M3x10 3
6 HMJ3-20N Self-Tapping Screw M3x20 1
7 HME3-4B Set Screw M3x4 1
8 HMM3Z Locknut M3 3
9 BK0075 Link Ball 4.8 1
No. Material No. Description Qty.
1 HMC3-30B Socket Screw M3x30 2
2 HMC3-14B Socket Screw M3x14 2
3 HMM3Z Locknut M3 4
4 BK0086 Ball Link 4.8x20 2
5 BK0278 Machined Washer 2
6 BK0403 Rod Guide 4
7 BK0404 Tail Rotor Blade 2
No. Material No. Description Qty.
8 BK0877 3D Vertical Fin 1
9 BK0650 Tail Boom 1
10 BK0707 Rear Servo Rod 1
11 BK0347 Tail Push Rod A 1
12 BK0653 Tail Push Rod B 1
13 3-1-1 Tail Transmission Subassembly 1
14 3-1-3 Tail Drive Shaft Subassembly 1
No. Material No. Description Qty.
1 BK0617 Bolt M4x25 1
2 BK0086 Ball Link 4.8x20 4
3 BK0318 Link Rod 2.3x95 2
4 HMM4Z Locknut M4 1
5 2-1 Rotor Head Assembly 1
No. Material No. Description Qty.
1 HME4-5B Set Screw M4x5 4
2 BK0397 Skid Brace 2
3 BK0398 Skid Pipe End Cap 4
4 BK0668 Skid Pipe 2
No.Material No.DescriptionQty.
15-4-1Body Subassembly1
No.Material No.DescriptionQty.
1HMJ2-6BM2x6 Self-Tapping Screw6
2HSE3-12BM3x12 Self-Tapping Screw2
3BK0102d3xD6x11Grommet2
4BK0098Body ClipA1
5BK0099Body Clip B1
6BK0429Body1
7BK0428Canopy1
8JV0186Decal1
9BK0473Body Support1
10BK0474Rubber CAP2
11HNLR6R Pin2
No.Material No.DescriptionQty.
1*****Main Rotor Blade2
2BK0446Rotor Bolt M5x352
3HMM5ZLocknut M52
TABLE OF CONTENTS
REPAIR AND REPLACEMENT PARTS
Purchase replacement parts from the hobby shop where you have purchased the Raptor 90!3D. Please contact
the Thunder Tiger distributor in your country, and the distributor can tell you where to obtain the parts. For example,
in the U.S, all Thunder Tiger products are distributed by Ace Hobby Distributors. On the web site www.acehobby.com,
there is a list of all the hobby shops in the USA that can order any Thunder Tiger parts from Ace for you. Technical
questions regarding the Raptor will be answered quickly by sending an email to [e-mail] or call
Technical Support at 949-833-7498. In Europe, Asia and Australia, please contact the distributor in your country.
WARNING
To ensure safety, please read the instruction manual thoroughly before assembly. Radio control helicopters are
sophisticated equipment, and not toys. Radio control model helicopters are capable of causing serious bodily injury
if not properly assembled or operated. The manufacturer and distributors assume no liability for damages that could
occur from the assembly or use of this product. This product is designed for hobby use only. Operating model
helicopters requires diligence and skill. The best way to ensure quick and successful learning is to seek help and
guidance from accomplished pilots. It is strongly recommended to join the appropriate radio control modeling governing
society in your country. For example, in the United States, it is strongly encouraged to join the Academy of Model
Aeronautics. AMA is a nonprofit organization that provides members in the United States with liability insurance
and monthly modeling magazines. For further information or to find a model helicopter club, please contact AMA
at:
Academy of Model aeronautics
515 East Memorial Drive
Muncie, IN 47302
USA
[phone]
We also encourage you to subscribe to different radio control helicopter magazines and learn about RC flying events,
new flying techniques, safety procedures, and hints. Rotory Modeler is a bi-monthly and Model Helicopter Techniques
is a quarterly newsletter published in the USA. Model Helicopter World is a month magazine published by Traplet
Publication in England and sold worldwide. Rotor is a monthly German magazine. Helico is a Swiss quarterly
magazine.
ATTENTION
We are unable to accept replacement or return of this model after it has been used or assembly has begun.
It is legally prohibited to duplicate or reprint this manual in any format without a written permission from the
manufacturer.
The manufacturer has the right to make changes to this model or instruction without notice.
We have done our best to the accuracy of information in this manual. If you are aware of any mistake, we welcome
you to notify us.
We will not accept any responsibility for any accident, breakdown, fault or trouble caused by improper usage of
this model. Please thoroughly inspect your model and range check the radio before flight. Please keep the model
in its best condition in order to enjoy it.
This model does not include all the items necessary for flying, such as engine, serevos, gyro...etc.
It is difficult for beginners to fly RC helicopters by themselves. It is highly recommended that beginners seek the
help of experienced RC helicopter pilots. We recommend beginners start with an inexpensive model such as the
Thunder Tiger Raptor 30 that is also designed by Mr. Taya.
RC helicopters are not toys. The manufacturer does not assume the liability for any property or bodily damage
caused by the model or the operator.
OTHER ITEMS REQUIRED
6
BODYSUPPORT INSTALLATION
Insert the aluminum support
tube through the servo frame.
Insert the "R" pins through the
two holes in the support tube
to prevent the tube from
moving in the servo frame.
Install two rubber ends onto
the support tube.The rubber
ends will dampen shake or
vibration generated by the
engine.
Glow Plug Wrench
12V Battery
1.5V Glow Starter
(1.2V~1.5V)
Rubber Band
(Included)
Foam
Remote Glow Plug
Extension
1-2-2 Cooling Fan Casing Subassembly
1-2-3 Fuel Tank Subassembly
No. Material No. Description Qty.
1 BK0062 Fuel Tank Stopper 1
2 BB0374 Silcon Tube (L=105mm) 1
3 BK0445 Fuel Plug 1
4 BK0463 Fuel Tank Nipple 1
5 BK0503-1 Fuel Tank 1
6 BE1867 Clunk Weight 1
1-5-5 Header Tank Subassembly
No.Material No.DescriptionQty.
1HMC3-25BSocket Screw M3x251
2BK0087Washer d3xD8x1.41
3BV0502HeaderTank1
4BK0506Tank Mount1
5BK0698HeaderTank Supporter1
The Raptor 90 3D kit includes a header fuel tank that can be
attached to the right of the side frame.
23
2-1-1 Flybar Seesaw Subassembly
24
2-1-2 Metal Main Rotor Hub Subassembly
2
4.Final Assembly ---------------------------------------------------------------------------------------------- 29
4-1 Installation of Rotor Head (Bag H)---------------------------------------------------------------------- 30
4-2 Installation of Engine --------------------------------------------------------------------------------------31
4-2-1 Engine Subassembly -------------------------------------------------------------------------------32
4-3 Installation of Landing Skid------------------------------------------------------------------------------- 33
4-3-1 Skid Subassembly -----------------------------------------------------------------------------------33
4-4 Installation of Tail Assembly ----------------------------------------------------------------------------- 34
4-4-1 Tail Support Subassembly------------------------------------------------------------------------ 34
5.Installation of Peripheral Equipment ----------------------------------------------------------- 35
5-1 Installation of Servo - Part 1 (Bag I) ------------------------------------------------------------------ 36
5-2 Installation of Servo - Part 2 (Bag I) ------------------------------------------------------------------ 37
5-3 Installation of Receiver and Gyro ---------------------------------------------------------------------- 38
5-4 Installation of Body (Bag J) ------------------------------------------------------------------------------39
5-4-1 Body Subassembly ----------------------------------------------------------------------------------39
5-5 Installation of Rotor Blades (Bag K) ------------------------------------------------------------------- 40
6.Settings --------------------------------------------------------------------------------------------------------- 41
6-1 Setting up Gear Backlash ------------------------------------------------------------------------------- 42
6-2 Setting up of Stabilizer Paddles ------------------------------------------------------------------------43
6-3 Setting up of Blade Pitch Angle ----------------------------------------------------------------------- 43
6-3-1 Collective Travel for Hovering ------------------------------------------------------------------ 44
6-3-2 Collective Travel for 3D --------------------------------------------------------------------------- 44
6-3-3 Configuring the Raptor 90 for 3D --------------------------------------------------------------- 45
Attention --------------------------------------------------------------------------------------------------------------46
7.Parts List Section -------------------------------------------------------------------------------------------49
Raptor 90 3D Exclusive Parts -------------------------------------------------------------------------------- 50
Raptor 90 3D Spare Parts List ------------------------------------------------------------------------------- 55
Raptor 90 3D Optional Parts List ---------------------------------------------------------------------------- 61
3
Thank you very much for purchasing the Thunder Tiger Raptor 90 3D R/C helicopter. The design of Raptor
90 3D is based on the original Raptor 90 series helicopter and modified for extreme aerobatics. It has all
needed must-have optional parts for 3D flying, such as metal main rotor hub, non-linear flapping damper,
metal BRG, 3D light paddles and so on. It also adopts the push-pull control system on collective pitch
and elevator to achieve the most precise control. The flybar ratio is changeable to fit all kinds of flying
style. Use of high quality material make the helicopter one tough machine that can handle everyday 3D
beating. Raptor 90 3D is born for 3D flying, and you don’t have to do any further modification for aggressive
3D maneuver. This is by far the best machine you have never seen. Just enjoy the model and have fun.
UNIQUE SIDEFRAME SYSTEM
Aluminum side plates are used in conjunction with molded material to construct the main structure. This
design produces minimum weight with maximum strength. If the sideframes were completely made of
molded material, then to achieve equal strength the plastic would have to be very thick and heavy. Using
molded material at the right place avoids using metal angle brackets or putting compound bends in metal
frames. Slots have been added in the frame design to permit the use of optional gear ratios to optimize
engine performance to suit any pilot's demand.
BELL-HIILLER MIXING CONTROL UNIT
Main rotor control geometry has been carefully engineered to minimize cross-coupling in collective and
cyclic commands. Blade pitch arms and the Bell-Hiller mixing arms are designed at an angle such that
the pushrod interlinking them are at 90 degrees when the blades are at 0 degree. The pilots will get the
symmetrical cyclic control feel and flybar authority either at +10 or -10 degrees of collective. We design
this system with the 3-D pilot in mind. We guarantee you this whole design philosophy provides a strong
and accurate control mechanism.
SHAFT DRIVE TAIL ROTOR
The Raptor 90 3D is designed with a constant drive tail rotor system to permit full tail rotor control during
autorotations. 180 autos, backward autos and pirouette autos are all within your reach now. It has the
same aluminum torque tube system as the Thunder Tiger/Taya Imperio helicopter. This allows obtaining
the maximum performance from any modern heading lock gyros.
3D CAD DESIGN
We use the latest 3D Computer Aided Design to design and manufacture the Raptor 90 3D. Our high-
tech CAD program allows simulation of all moving parts to ensure no interference. The analysis automatically
analyze the weight, the mass distribution, and inertia to help us pursue a design that will provide the high
level of maneuverability needed for all-out 3-D aerobatics.
INTRODUCTION
Socket Drivers
Hex WrenchGrease
Blue Loctite
Instant Glue
Hobby Knife
Metric
4-way Wrench
Scissors
Diagonal Pliers
Open End Wrench
5.5mm
Needle Nose PliersScrew Driver
7mm
5.5mm
7mm
8mm
5.5mm
7mm
8mm
10mm
Epoxy
Ball Link Pliers
No. Material No. Description Qty.
1 HMV6800ZZY BRG d10xD19x5 1
2 HME4-5B Set Screw M4x5 2
3 HMS5 E Ring M5x8 1
4 HMV696Z BRG d6xD15x5 1
5 BK0388 Clutch BRG Case 2
6 BK0659 Frame Space M 4
7 BK0594 Starter Coupling 1
8 BK0592 Starter Shaft 1
9 BK0422 Drive Pinion 11T 1
10 BK0366 Pinion Gear Nut 1
11 BV0522-2 Clutch Bell Set 1
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 2
2 HMC3-12B Socket Screw M3x12 4
3 BK0087 Washer d3xD8x1.4 6
4 BK0393 Pitch Frame Cross Member 1
5 BK0394 Pitch Frame Cross Member Nut 2
6 BK0375T Upper Frame 2
No. Material No. Description Qty.
1 HMM3Z Locknut M3 4
2 HMC3-25B Socket Screw M3x25 4
3 BK0820BL Landing Skid Damper 4
4 4-3-1 Skid Subassembly 1
No.Material No.DescriptionQty.
1HMC3-8BSocket Screw M3x84
2HMQ16Retaining Ring1
3BK0357Tail Drive Spur Gear 83T1
4BK0359One Way Clutch Shaft1
5BV0368Auto Rotation Hub1
6BK0356Main Spur Gear 91T1
1-6-2 Main Gear Subassembly
(3)
(2)
(4)
(6)
(5)
(1)
The carbon rear servo plate is secured
by two Lower 3mm bolts from the plastic
tail boom bracket.
10
1-1-2 Pitch Guide L Subassembly
1-1-3 Pitch Guide R Subassembly
No. Material No. Description Qty.
1 BK0384 Pitch Guide Collar L 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
The side with a number should face
in because the opening on both sides
are differeent.
The hole on the plastic control arm has different
opening sizes on the two sides.Always snap the
bigger opening to the ball on swashplate gently and
afterward please check to make sure it is securely
attached and there is no damage or cracking.
INSTALLATION OF THE LINKS
Bigger Hole Face to Swashplate
Extended 6mm Hex
Starting Tool
Fuel Pump
Heli Engine (90size)
9609 PRO-90H(R)
Glow Fuel(15%-30%)
Glow Plug
Hi-torque 12V Electric starter
Receiver
Transmitter
(helicopter type, 6 or
more channels) High Speed/Torque Servo x 4
Rudder Servo x 1
Battery Switch harness
Heading Lock
Gyro
In order to enjoy a safe and enjoyable experience, please read the manual carefully and completely understand
the helicopter structure and operation before the first flight.
Read the warnings to avoid injuries to you and others.
WARNING – The following could cause heavy injury or death if used incorrectly.
Keep the model away from other people or animal when starting the engine.
Do not fly any model helicopter near or above people or cars. Models can sometimes lose
control due to pilot or mechanical failure.
WARNING – The following could also cause serious injury or death if not careful.
Take precaution with model fuel. Model engine glow fuel is highly flammable.
Please check the model carefully before each flight. Make sure that nothing has loosened up
or come apart.
Make sure everything moves freely without binding or excessive friction.
Do not operate the model in rain, snow, thunderstorm, or adverse weather.
WARNING – The following could also cause serious injury or death if not careful.
Please make sure that your radio frequency is not used before flight. If someone else is flying
with the same frequency as your radio, do not turn on your transmitter. Otherwise, it can cause
a crash and even bodily and property damages.
Please monitor the fuel level during flight and land before running out of fuel.
Before each flight, please check that all servos and controls move properly.
Do not modify any parts or use other than genuine Thunder Tiger parts.
Do not fly in places that are forbidden by law.
Use Loctite on screws that do not use a locknut.
When operating the model, please beware that no loose cloth or jewelry can get entangled in
the model helicopter.
Make sure the transmitter and receiver switches are on before starting the engine.
Do not touch the engine or the muffler right after flying because they are very hot.
Do not use this model for anything other than hobby.
WARNING – The following damages can happen to the model.
Do not leave the model in a car for a long time. The heat in the summer or the cold in the
winter and the humidity can cause damage to the model.
Be careful and watch the sharp edges and corners on the model.
BUILDING HINT – The instruction is divided into six assembly chapters:
Main Frame, Rotor Head, Tail Rotor, Final Assembly, Radio Installation, and Settings. There
are many major assembly steps in each chapter, please follow the instruction to do each "
Subassembly" first, then combine the subassemblies into a major assembly.
Upper Frame Assembly
Lower Frame Assembly
12
1-2-1 Tail Drive Unit Subassembly
No. Material No. Description Qty.
1 HME3-4B Set Screw M3x4 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 BK0362 Tail Drive Bevel Gear A 1
5 BK0363 Tail Drive Bevel Gear B 1
6 BK0364 Tail Drive Pinion 1
7 BK0365 Tail Drive Gear Shaft 1
8 BK0382 Tail Boom Bracket L 1
9 BK0383 Tail Boom Bracket R 1
10 BK0414 Pin 2x12 2
11 BK0660 Frame Spacer L 5
Main Frame Assembly Installation of Pitch Frame
No.Material No.DescriptionQty.
1HMJ2-10NM2x10 Self-Tapping Screw1
2HMV840ZZYBRG d4xD8x32
3HMV1280ZZYBRG d8xD12x3.52
4BK0336Pitch Frame1
5BK0075Link Ball
φ
4.81
Optional: add a tiny drop of thick CAon the outside rim of the fovr ball
bearings before inserting them into the plastic Pitch Frame. Be careful
not to get any glue into the ball bearings.Add a tiny drop of thick CA
glue at the tip of the M2x10 self-tapping screw (No. 1) before
screwing it into the Pitch Frame.
32
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
No. Material No. Description Qty.
1 BK0385 Pitch Guide Collar R 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
Tip: When setting up the phase
adjustment ring, the flybar and
the tail boom can be the
reference. When the flybar and
the tail boom are centered, the
inner balls of swashplate should
be aligned with the outer balls.
Tighten the socket screw on the
phase ring at this moment.
NOTE: Improper alignment will
cause unwanted mixing.
No. Material No. Description Qty.
1 ******** 90 Class Heli Engine 1
2 ******** Nut (Comes With the Engine) 1
3 HMC4-8B Socket Screw M4x8 2
4 HMC4-18B Socket Screw M4x18 4
No. Material No. Description Qty.
5 HMO10 Washer d9.5xD16x1 1
6 BK0349 Engine Mount 1
7 BV0380 Cooling Fan 1
8 BV0521 Heavy Duty Clutch 1
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.85
2BK0086Ball Link 4.8x208
3BK0104Servo Mounting Plate6
4BK0105Rod Joint1
5BK0318Link Rod 2.3x952
6BK0436Link Rod 2.3x552
7BK0833Servo Block4
8HMC2516BSocket Screw M2.5x164
No.Material No.DescriptionQty.
9HMM25Lock Nut M2.54
10HML2Nut5
11HME4-5BSet Screw2
12HMF2-8NPhillips Machine Screw M2x85
13HSE2614NSelt-Tapping Screw4
14HSE2630NSelt-Tapping Screw4
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.87
2BK0086Ball Link 4.8x204
3BK0095Link Rod 2.3x761
4BK0104Servo Mounting Plate4
5BK0833Servo Block2
6BK0834Pitch Lever Fixed Plate1
7BK0839Link Rod 2.3x301
8BK0881Washer1
9BK0883Pitch Push Pull Lever1
No.Material No.DescriptionQty.
10BK0884Collar, d3xD4xW121
11BV0085Pitch Link Rod2
12HMC3-20BSocket Screw M3x201
13HMV840ZZYBearing d4xD8xW32
14HMF2-8NPhilip Maching Screw M2x84
15HMJ2-8NSelt-Tapping Screw M2x83
16HML2Nut4
17HSE2614NSelt-Tapping Screw M2.6x148
18HSE2620NSelt-Tapping Screw M2.6x204
No.Material No.DescriptionQty.
1****Switch1
2****Receiver Battery1
3****Receiver1
No.Material No.DescriptionQty.
4****Gyro
5BK0106Foam2
6 BE1052Antenna Pipe1
PV0517ONEWAYBEARING GREASE
The hole on the Flybar Control Rod has different
opening on two sides.Always snap the bigger opening
to the link ball.
Bigger Hole
Face to ControlArm
10.5mm10.5mm
When installing pinion gear, add a small drop of Loctite to the
threads. Make sure not to get Loctite on lower clutch bell bearing.
Important:
For 90 class engine, we recommend the 11 teeth pinion for 3D
flying.
The servo tray and cooling fan shrouds on the Raptor 90 are different from the
Raptor 60 in order to accommodate the full head sink on the O.S 91. engine.
If using T.T 90, Y.S 91 or Webra 91 engine, make sure to install the fan shroud
baffle with two self-tapping screws. This will ensure optimal cooling of your engine
head.
Add CA glue Add CA glue
It is necessary to add grease inside the one way clutch before your
first flight.The clutch might lock up once grease is gone.The one
way clutch grease( PV0517) is recommended for this lubrication.
Make sure the inside ofAuto Rotation Hub is clean without any dirt
before you insert the one way clutch shaft.
Add Loctite
Add Loctite on
the threads
For 3D flying, it is recommended to use
lower flybar ratio setting.
Self-Tapping Screw, No. 10 Collar, and No. 11 Washer, with two
No. 1 Bearings. Attach a No. 9 Link Ball with a No. 4 Screw.
Upon finishing Step 3-1-1, make sure there are no extra parts
left on your workbench.
Elevator Control
Pushrod
Glue the two plastic halves of
the paddle with CAglue before
installation on flybar.
Add Loctite
the tail boom by tightening the four screws on the helicopter.
Visually check from the rear of the helicopter to make sure the
tail rotor output shaft is perpendicular to the main rotor shaft.
Add the tail boom supports.
Add Loctite
The thrust bearing washer with the
SMALLER inner hole should be closer to
the rotor blade.
The thrust bearing washer with the BIGGER
inner hole should be closer to the main rotor
shaft.
4-2-1 Engine Subassembly
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add CA Glue
Introduction -------------------------------------------------------------------------------------------------------- 3
Other Items Required -------------------------------------------------------------------------------------- 4
Warning --------------------------------------------------------------------------------------------------------------- 5
Assembly
1. Main Frame Assembly --------------------------------------------------------------------------------- 7
1-1 Upper Frame Assembly (Bag A) ---------------------------------------------------------------------- 8
1-1-1 Pinion Gear Subassembly ------------------------------------------------------------------------ 9
1-1-2 Pitch Guide Left Subassembly ------------------------------------------------------------------10
1-1-3 Pitch Guide Right Subassembly -----------------------------------------------------------------10
1-1-4 Elevator Control Arm Subassembly------------------------------------------------------------ 10
1-2 Lower Frame Assembly (Bag B) ----------------------------------------------------------------------11
1-2-1 Tail Drive Unit Subassembly ---------------------------------------------------------------------12
1-2-2 Cooling Fan Casing Subassembly -------------------------------------------------------------13
1-2-3 Fuel Tank Subassembly ------------------------------------------------------------------------13
1-3 Main Frame Assembly (Bag C) -------------------------------------------------------------------------14
1-3-1 Rod Guide Collar Subassembly----------------------------------------------------------------- 14
1-4 Installation of Servo Frame (Bag C) ------------------------------------------------------------------- 15
1-5 Installation of Pitch Frame (Bag D) -------------------------------------------------------------------- 16
1-5-1 Aileron Lever Subassembly ---------------------------------------------------------------------17
1-5-2 Metal Elevator Parallel Lever Subassembly -------------------------------------------------17
1-5-3 Elevator Control Lever Subassembly --------------------------------------------------------- 17
1-5-4 Pitch Control Frame Subassembly -------------------------------------------------------------18
1-5-5 Header Tank Subassembly ----------------------------------------------------------------------18
1-6 Installation of Main Shaft (Bag E) ----------------------------------------------------------------------19
1-6-1 Wash Out Subassembly -------------------------------------------------------------------------20
1-6-2 Main Gear Subassembly -------------------------------------------------------------------------20
2. Rotor Head Assembly -----------------------------------------------------------------------------------21
2-1 Metal Rotor Head Assembly (Bag F) -----------------------------------------------------------------22
2-1-1 Flybar Seesaw Subassembly --------------------------------------------------------------------23
2-1-2 Metal Main Rotor Hub Subassembly ----------------------------------------------------------24
3.Tail Assembly -------------------------------------------------------------------------------------------------25
3-1 Tail Assembly (Bag G) ----------------------------------------------------------------------------------- 26
3-1-1 Tail Transmission Subassembly --------------------------------------------------------------- 27
3-1-2 Tail Rotor Subassembly --------------------------------------------------------------------------- 28
3-1-3 Tail Drive Shaft Subassembly -------------------------------------------------------------------28
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The Liner is pre-glued on the
inside of clutch bell with 30 min
epoxy.
1-1 1-2 1-3
( 2 ) (1)
1-4
(1)
(2)
1-5 1-6
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(1)
(5)(4)
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(3)
2-1
3-1 4-1
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(2)
(1)
4-3
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(2)
4-4
(2)
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(1)
(3)
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4-2
(3)
(1)
(2)
5-15-2
5-3
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5-4
5-5
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No. Material No. Description Qty.
8 BK0660 Frame Spacer L 3
9 BK0376T Lower Metal Frame 2
10 BV0870 Metal Lower BRG Block 1
11 1-2-1 Tail Drive Unit Subassembly 1
12 1-2-2 Cooling Fan Casing Subassembly 1
13 1-2-3 Fuel Tank Subassembly 1
No. Material No. Description Qty.
7 BK0659 Frame Spacer M 2
8 BV0869 Metal Upper BRG Block 1
9 1-1-1 Pinion Gear Subassembly 1
10 1-1-2 Pitch Guide L Subassembly 1
11 1-1-3 Pitch Guide R Subassembly 1
12 1-1-4 Elevator Control Arm Subassembly 1
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No. Material No. Description Qty.
10 BK0093 Link Rod 2x46 1
11 BK0407 Collar d3xD4x4.5 2
12 BK0410 Collar d3xD4x13 2
13 1-5-1 Aileron Lever Subassembly 1
14 1-5-2 Metal Elevator Parallel Lever Subassembly 1
15 1-5-3 Elevator Control Lever Subassembly 1
16 1-5-4 Pitch Control Frame Subassembly 1
17 1-5-5 Header Tank Subassembly 1
No.Material No.DescriptionQty.
6HMM4BLucknut M41
7BK0617Bolt M4x251
8BV0504Metal Swashplate1
91-6-1Washout Subassembly1
101-6-2Main Gear Subassembly1
No. Material No. Description Qty.
10 BK0076 Collar d3xD4x10 1
11 BK0088 Washer d3xD5x0.5 1
12 BK0346 Tail Pitch Control Lever 1
13 BK0370 Tail Case L 1
14 BK0371 Tail Case R 1
15 BK0372 Tail Input Bevel Gear 1
16 BK0373 Tail Output Bevel Gear 1
17 HMY2-12 Pin 2x12 1
18 3-1-2 Tail Rotor Subassembly 1
No.Material No.DescriptionQty.
1HMM3ZLocknut M36
2HMC3-16BSocket Screw M3x162
3HMC3-20BSocket Screw M3x202
4HMC3-25BSocket Screw M3x252
5HMC3-30BSocket Screw M3x302
6BK0087Washer d3xD8x1.44
No.Material No.DescriptionQty.
1 HMJ2-8N Self-Tapping Screw M2x8 4
2BK0447Tail Support Rod End4
3BK0669Tail Support Rod2
No. Material No. Description Qty.
1 HMC4-42B Muffler Bolt M4x42 2
2 HMT4B Spring Washer 2
3 ******** Muffler ( 90 ) 1
4 4-2-1 Engine Subassembly 1
5 HMC4-12B Socket Screw M4x12 4
6 BK0435 Washer d4xD11xW1.7 4
BAG A
BAG B
BAG C BAG C BAG D
(L) (R)
BAG E
BAG F
BAG G
BAG H
BAG I
97.5mm
48mm
(3)
Throttle
Collective Pitch
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BAG I
BAG J
BAG K
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Please complete subassembly steps 1-2-1 through 1-2-3 first. Then attach the subassemblies to the two Lower Frames. Note
that the Metal Lower BRG is installed with the bearing open side facing up. Please add a small drop of Loctite on every bolt
before screwing it into the aluminum hex spacer. Do not apply Loctite to the bolts which are going to secure the Lower BRG
Block at this moment.
Assemble the upper main frames by starting with the two Metal Upper Frames. The Pinion Gear Subassembly must be assembled
first according to Figure 1-1-1. Next insert three hex-shape frame spacers into the plastic Pitch Guide according to Figure 1-1-2
and 1-1-3. Assemble the Elevator Control Arm subassembly according to 1-1-4. Insert it in between the two Upper Frames. The
metal Elevator Control Arm is not symmetrical. The side with the longer profruding round knob should be on the right side of the
helicopter. Then attach the other subassemblies to the Upper Frames. Locate Hex Wrenches in BAG L which you need for
assembly.
Please add a tiny drop of non-permanent type Loctite on the tip of all bolts before screwing them into the hex shaped aluminum
frame spacers. Never use too much Loctite, otherwise it will become nearly impossible to remove later on for servicing. Only use
the non-permanent type of Loctite. If encountering difficulty in removing any bolt that was locked up by Loctite, heat up the head
of the screw or bolt with the tip of a hot soldering iron, it will help soften the cured Loctite.
For the kit, parts are bagged according to each major assembly and are labeled "Bag A, Bag
B, etc." The heading for each assembly indicates which bag to open. As a go od practice,
only open up the bag that you need for the particular assembly. Check the parts in that bag
against the parts list shown for each assembly as well as each sub-assembly to make sure
there are no missing parts. To prevent losing small hardware, please empty the small nuts
and bolts and parts into small plastic trays on your work table. At the end of each major
assembly, there should be no left over parts.
The fuel tank comes assembled from the factory because every tank has been
checked for leak. If you were to take the tank apart here is how to put it back
together. Install the silicone fuel line to the Fuel Nipple. Then add the rubber
fuel tank stopper and the clunk weight. The stock silicone fuel line is very soft
and thin which is designed to allow the clunk to pick up fuel easily during 3-D
aerobatics. The pickup line should be inspected and replaced if necessary every
month, otherwise when it becomes soggy it can break off. A thicker silicone line
maybe substituted but make sure the clunk will reach the bottom when moving
the fuel tank to all different orientations.
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As show in Figure 1-3-1, insert two hex
Frame Spacers S into the plastic Rod
Guide Collars. Then join the Upper
Frame Assembly to the Lower Frame
Assembly according to drawing 1-3.
Secure the Set Screws (No.1) to the
frames, and fit the Body Posts (No.4)
to the Set Screews. The two Body Posts
will be used to secure the canopy in the
future. Add Loctite on all bolts and
inside BK0103 threaded hole.
Install the one-piece servo frame with six self-tapping screws.
Do not use Loctite when attaching self-tapping screws to plastic
parts. Loctite is only for threading metal into metal parts. Assemble the constant drive Main Gear Subassembly according to Figure 1-6-2 first.Then build up the Wash Out Subassembly
according to 1-6-1. Insert the No.3 Main Shaft into the bearings and then add the No.4 Lock Ring and slide in the Main Gear
Subassembly.Add two M3x6 Button Head Screws to the Locking Ring, and the two screws are threaded into the holes on the
main rotor shaft.
The locking ring prevents the main shaft from sliding up. Line up the hole on the main gear and the main shaft, then insert M4x2 5
mm Bolt through them. Place a 4 mm M4 locknut on the other side of the autorotation hub, and then tighten the Bolt. Do not
over tighten the Bolt, otherwise the autorotation assembly will be distorted. Loosen the 3mm bolts holding the Upper and lower
bearing blocks for the 12mm main shaft. Wiggle the main shaft in the bearing blocks until the main shaft spins freelyin the bea rings.
This ensures the upper and lower bearing blocks are aligned. Push the lower bearing block up until the mainshaft has no up
and down play.Then tighten the 3mm bolts for the upper and lower bearing blocks.
Insert the pin into the Washout Link.Add a tiny drop of Loctite on the inside
and outside of BK0409 Collar which will help give a completely slop free
control system. Do not let the Loctite seep into the bearing.Adjust the
tightness of the M3x12 bolts so the mixing arms can move freely but without
wobble or racheting the ball bearings.Add a tiny drop of thick CAglue at
the tip of the M2x10 self-tapping screw (No. 1) before screwing it into the
Flybar Control Levers (No. 6).
Make the two pushrods for controlling the blade pitch.The distance 43 mm is measured between the center of two pushrod holes.
Attach the Seesaw Hub of the Control PaddleAssembly to the Main Rotor Head with Socket Screws (M3x10).
Please add a small drop of Loctite along the entire length of the M3x10 Socket Screw (No.5) and on the outside of the collar
d3xD4x5.5 (No.3).Temporarily install the Washout Base Guidence Ring, but do not tighten the No.6 M3 Socket Screw yet.
Assemble the tail transmission subassembly according to 3-
1-1 and 3-1-2 first. And the tail drive shaft subassembly according
to 3-1-3.But do not close the two halves of the tail transmission
tightly. You will do this when you are ready to install the gearbox
onto the tail boom.
When installing the tail transmission, make sure the housings
match the hole on to the tail boom. Add Carbon Vertical Fin with
machined washer and Locknut, then tighten the five 3 mm bolts.
Add carbon Vertical Fin with Pom washer and Locknut.
Before inserting the finished tail drive shaft assembly into the
tail boom, add some flexible silicone glue or ZAP Goop glue
around the outside of the tail drive bearing housing. This will
prevent the bearing housing from spinning inside the tail boom.
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Install bearings No. 2 and No.3 into the Tail Cases. Install No.
16 Tail Bevel Gear onto the Tail Shaft. Gently tap the No. 17
Pin into the Bevel Gear and Tail Shaft. Then secure the pin
with a No. 7 Set Screw with Loctite.
After installing the M3x4 set screws, try pushing on the 2x12
pin with a small Allen wrench to make sure the set screw has
locked the pin in place securely. Before closing the two halves
of the Tail Cases, please check the gear mesh between gears
No. 15 and No. 16. If the gears mesh too tight, then a 5 mm
i.d. washer should be added to move the gear No. 16 further
out. If there exists too much freeplay, then a 5 mm i.d. washer
to push gear No. 16 closer to gear No. 15.
Install the No. 12 Tail Pitch Control Lever as shown with No. 6
Slide four No. 6 Rod Guides onto the tail boom. Do not glue
them onto the tail boom yet. Add a tiny drop of CA glue to the
pushrod guide after you finish building the entire helicopter.
Before adding glue, make sure the tail pushrod is hooked up
to the servo and the rod travels in a straight line and moves
very smoothly.
Congratulation, we are almost done. Install the finished main
rotor head onto the 12 mm rotor main shaft. Secure it with a
M4x20 Bolt and M4 Locknut. Make up two 113.5 mm long
pushrods and attach them to the Bell-Hiller mixing arm.
Before installing the plastic end caps, please
add a drop of slow, thick CA glue on the
rim of the end caps and on the inside edge
of the aluminum skid.
Slide the finished tail boom into the helicopter.The four bolts
on the helicopter must be loose in order to insert the tail boom.
Make sure the tail drive shaft is inserted into the front receptacle
properly. Check this by turning the main rotor head. Secure
Secure the two ends to the rod with Epoxy, making sure the
two metal ends are perpendicular to each other.
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Attach the engine into the side frames, with four M4x12 bolts and
four washers, but do not tighten until Section 6-1.
Install the muffler after you have building the entire helicopter.
Always add Loctite on the muffler bolts.
Install the servos and make up the pushrods according to the drawings.The distance between the steel ball and the center of
servo arm are shown in the drawing. Use them as a guide.These distances are used in conjunction with the servo travels (ATV
or End point) set to 100% for all the channels in the transmitter.Tune them later on to suit your personal flying style.
Attach the rudder servo to the rear mounted carbon plate with four 2.6mm bolts and four M2.6 locknut.
Make up the throttle and collective control pushrods according
to the drawing. Use the outermost hole on the carburetor throttle
control arm.Attach the steel ball on the throttle servo arm at
approximately the same distance as the steel ball on the throttle
arm.
Make up the throttle at 97.5mm long first, and then adjust the
pushrod length and throttle servoATV or Endpoint so full throttle
stick command will open the carburetor barrel fully.And full low
stick and low throttle trim will close the carburetor barrel completely.
Install the receiver and receiver battery. Even though the receiver and battery can be attached to the helicopter tray by using
double sided foam tape, but it is better to wrap the receiver and battery separately using half inch or 10 mm thickfoam. Then
secure them to the tray using six to eight rubberbands, or Velcro bands.
Carefully cut out the canopy (windshield) using scissors.The
best scissors to use are (TTR 1304) designed to cut RC car
bodies and Canopy. Install the canopy to the body using six
small screws. Drill small holes in the canopy and body for the
holes. Drill two more holes for the rubber grommets.
Refer to color box and apply the decals (In BAG M) .
Tools for Assembly
The Raptor 90 3D is designed for easy maintenance using standard hobby tools. Please only use genuine Thunder Tiger parts.
Please keep the model clean and well tuned. It will provide you with long lasting pleasure in return.
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Add Loctite
(Included)
Add a tiny drop of thick CA glue at the tip of the M2x10
self-tapping screw (No. 1) before screwing it into the
Aileron Levers.
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Make up the landing gear according to the
drawing.
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No. Material No. Description Qty.
1 HSE3-6B Self-Tapping Screw M3x6 2
2 BK0660 Frame Spacer L 4
3 BK0662 Cooling Fan Baffle 1
4 BK0665 Fan Casing L 1
5 BK0666 Fan Casing R 1
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Assemble the metal flybar control arms according to the drawings. Slide Flybar ControlArm onto the No.18 Flybar Rod. Slide
the flybar into the No.17 Seesaw Hub. Make sure the Flybar has equal protrusion from each side of the SeesawHub measure
them with a ruler, then install and tighten the No.8 HME4-5B set screws.Add the paddles. Make sure the two paddles and the
two flybar control arms are all parallel. Lock the paddles with No.6 set screws.
Assemble and install the No.10 Mixing Levers and No.5 Bearings according to the drawing using No.12 Collar andNo.9 d3xD5x0.5
washer.
Note:Before installing the Mixing Lever (No.10), please add a small drop of Loctite along the entire length of the M3x18 button
head socket screw (No.4) and on the outside of the collar d3xD4x13 (No.12). Be careful do not let the Loctite seep into the bear ings.
There are two choices of hole positions on the aluminum seesaw for attaching the mixing lever arm.The outside hole gives higher
Bell-Hiller mixing ratio. For aggressive 3D flying, you can attach the Bell-Hiller mixing arms to the inner hole which gives low er
flybar ratio.
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No.Material No.DescriptionQty.
10BK0324Mixing Lever2
11BK0406LPaddle Root2
12BK0410Collar d3xD4x132
13BK0416Paddle Stopper2
14BK0432LFlybar Paddle2
15BK0633Flybar Control Frame2
16 BK0871 Longer StabilizerArm 2
17 BV0865 Longer Seesaw 1
18 BK0866 SUS Flybar 1
No.Material No.DescriptionQty.
1HMF2-8NPhillips Machine Screw M2x82
2HMJ2-10NSelfing-Tapping Screw M2x104
3HMC3-10BSocket Screw M3x102
4 HMC3-18B Socket Screw 2
5HMV840ZZYBRG d4xD8x34
6HME4-3BSet Screw M4x34
7HME4-5BSet Screw M4x52
8BK0075Link Ball
φ
4.86
9BK0088Washer d3xD5x0.52
Insert the aluminum Main Rotor Hub Pin and the Flap Dampers. (might need to apply silicone grease for easy installation). Push
the No.7 Feathering Spindle into the dampers and the rotor hub.Add No. 14 Flybar Control Rod. Slide both finished Main Rotor
Grip onto the feathering spindle and the secure with two M4x10 bolts and washers according to the drawing.Use two Allen
wrenches to tighten the two M4x10 bolts simultaneously.
Important Note:
The Raptor 90 3D kits come with non-linear flap damper for aggressive 3D flying.You may choose to experiment adding from
one up to three 0.4mm thick shim (No.10) washers between the washer (No.8) and bearing to further stiffen the main rotor flapping.
Stiffing the main rotor head will speed up the cyclic transient response, but may cause the helicopter fuselage to oscillate at arou nd
1600 RPM.This oscillation characteristic exists for all helicopters with hard 3D flap dampers.The inner dampers should be
replaced periodically if a lot of 3D flying has been done. When the dampers are worn, the main rotor blades canflap excessivel y
during some 3D maneuvers and risk touching the tail boom.
Add flexible silcone glue or ZAP
Goop glue around the outside
before inserting into the tail
boom from the front side.
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180mm
25mm
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The optionalThunderTiger Remote Glow PlugAdaptor (#3803)
is recommended as shown, making starting easy without the
removal of your canopy.
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Cut a hole at the
front air scoop for
backward flights.
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No.Material No.DescriptionQty.
9BK0477Washer2
10BK0703Flap Damper Washer 0.4mm6
11BK0874Inner Damper2
12BK0875Outer Dampper2
13BK0075Ling Ball
φ
4.82
14BK0664Flybar Control Rod2
15BK0319Main Rotor Pitch Housing2
16BV0548-1Metal Main Rutor Hub1
No.Material No.DescriptionQty.
1HMC4-10BSocket Screw M4x102
2HMJ2-12NSelf-Tapping Screw M2x122
3HMV1680BRG d8xD16x54
4HMX0816Thrust Bearing d8xD16x52
5BK0330Main Rotor Hub Pin1
6 BK0325Thrust Washer 2
7BK0326Spindle1
8BK0435Washer2
Fiberglass or Carbon Rotor Blade
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Add Loctite when setting up the
gearmesh in step 6-1.
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No.Material No.DescriptionQty.
7BK0539Carbon Rear Servo Plate1
8BK0878Bracket (Top)1
9BK0879Bracket (Bottom)1
103-1TailAssembly1
114-4-1Tail Support Subassembly2
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Engine System
Use a high quality 90 size 2-stroke
model helicopter engine, such as the
Thunder Tiger TT PRO-90H, OS 91
SZ-H, YS 91 ST, Webra 91, or
equivalent. Please beware, some
engines may not fit because of their
shape and size. The Raptor 90 3D
kit comes with a cooling fan hub to fit
the TT PRO-90H, OS 91 SZ-H, Webra
91.
We recommend a high quality muffler
or tuned exhaust system designed to
fit on the left side of the model.
Rotor Blades
It is important to use main rotor blades
that are of high quality and suitable
for your flying style. If fiberglass or
carbon graphite blades are used, the
length should be between 680 and
710 mm. Blade weight should be
between 170 and 200 grams.
Starter System
To start the engine, it is necessary to
use an electric starter with a 6mm
shaft extension. The starter and the
6 mm extension are available from
Thunder Tiger, the part numbers are
No.2675 and No.3801.
Use a strong high torque 12 volt
electric starter which is designed for
models.
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Add a small drop of Loctite.
Make sure it locks the pin.
Install BK0364 and BK0362 onto BK0365 Tail Gear Drive Shaft. Then insert the
two Pins and secure them with two M3x4 Set Screws. Add a tiny drop of Loctite
on the set screw thread before inserting them. Always use a very small amount
of Loctite liquid on the thread, otherwise it may be nearly impossible to remove
the set screws in the future for servicing. After installing the two M3x4 set screws
(No. 1), try to push on the 2x12 pins with a small Allen wrench to make sure the
set screws have locked the pins in place securely. Install the four ball bearings
and the hex shaped Frame Spacers according to the drawing. Before closing
the two halves of the Tail Boom Brackets, please check the gear mesh between
gears No. 4 and No. 5. If there exists too much freeplay, add some 5 mm i.d.
washers on top of gear No. 4. (The 5 mm i.d. washers are provided in BAG G).
Add a small drop of Loctite.
Make sure it locks the pin.
Shim Washer
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Add CAGlue
Standard flybar ratio
Lower flybar ratio
Mild 3D Flying
Extreme 3D Flying
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Attach the engine mount to the engine using four 4mm bolts and Loctite.
The cooling fan hub is threaded to fit the OS, TT or Webra only. Place the washer that came with your engine onto the engine
crankshaft first. Then screw the fan hub onto the engine. Add a tiny drop of Loctite on the engine nut. Do not use too much
Loctite. Tighten the engine nut using a socket head wrench while grabbing the fan with a towel. The nut should be tighten securely.
For 50-size or bigger engines, we do not recommend using a piston locking tool on the glow plug hole because that may damage
the engine. Attach the No. 8 Heavy Duty Clutch to the fan hub. Add a drop of Loctite on the threads of the M4x8 bolts. The
threads on the aluminum cooling fan hub are for the TT 70H, OS 61 SX, OS 61LX, OS 70H, TT 90H, OS 91 or Webra 91 engines.
If YS 61, 80 or 91 engines are used, the fan hub must be re-tapped by the modeler to M8x1mm thread size or purchase a optional
plastic fan hub with threads for the YS engine(PV0198YS) or the metal fan for the YS (PV0293YS).
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Please complete subassemblies 1-5-1 through 1-5-5 first, then add them to the Main Frame. Fit the Pitch Control Frame
Subassembly. Attach the E Ring on the left side of the Metal Elevator Control Arm. Then fit the Elevator Control Lever to the
right side, insert the pin and fix it with a set screw. Secure the Pitch Control Frame with a M3*10 Socket Screw and a collar on
the left side. And attach the Elevator Push Pull Lever to the right side of the Pitch Control Frame as shown. Adjust the two bolts
so that the Pitch Control Frame can move freely without excessive play. Finally, add the two plastic Aileron Levers and the 66.5mm
elevator pushrod. Add the Washers (BK0088) to make sure that the Aileron Lever and the Metal Elevator Parallel Lever will not
touch each other during operation.
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Outer hole for standard.
Inner hole for extreme 3D.
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Add Loctite
Add Loctite
Add Loctite
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Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
30mm
(2)
Paddle
Flybar
A Arm
Phase
Adjustment
Ring
Swash
plate
Boom
(3)
(8)
(14)
(13)
(9)
(1) (10) (12)
(7)
(11)
(12)
(2)(7)
(8)(6)
(5)
(4)
(1) (14) (16)
(11)
(18)
Pitch push-pull subassembly
(13)
(1)
(15)
(10)
(9)
(17)
(2)
(3)
Add Loctite
Add Epoxy
Add Epoxy
(13)
(14)
(17) (15)
(16)

1
5
7
MAIN FRAME ASSEMBLY
8 9
1-1-1 Pinion Gear Subassembly
11
13 14 15 16 17 18 1920
21
22
25 26 27
29 30 33 34
36
3531
37
383940
4
1-3-1 Rod Guide Collar Subassembly
1-5-1 Aileron Lever Subassembly
1-5-2 Metal Elevator Parallel Lever Subassembly
1-5-3 Elevator Control Lever Subassembly
1-5-4 Pitch Control Frame Subassembly
1-1-4 Elevator Control Arm Subassembly
1-6-1 Wash Out Subassembly
ROTOR HEAD ASSEMBLY
TAIL ASSEMBLY
3-1-1 Tail Transmission Subassembly
FINAL ASSEMBLY
4-3-1 Skid Subassembly
4-4-1 Tail Support Subassembly
INSTALLATION OF PERIPHERAL EQUIPMENT
5-4-1 Body Subassembly
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 4
2 HMC3-12B Socket Screw M3x12 21
3 BK0087 Washer d3xD8x1.4 22
4 BK0274 Tank Rubber Grommets 4
5 BK0380 Rear Frame L 1
6 BK0381 Rear Frame R 1
7 BK0629 Washer 4
No. Material No. Description Qty.
1 HME3-18.5B Set Screw M3x18.5 2
2 HMC3-25B Socket Screw M3x25 10
3 BK0087 Washer d3xD8x1.4 10
4 BK0103 Body Fitting Post 2
5 BK0658 Frame Spacer S 2
6 1-1 Upper Frame Assembly 1
7 1-2 Lower Frame Assembly 1
8 1-3-1 Rod Guide Collar Subassembly 2
No. Material No. Description Qty.
1 BK0389 Rod Guide Collar 1
2 BK0658 Frame Spacer S 2
No. Material No. Description Qty.
1 BK0667 Servo Frame 1
2 HSE3-12B M3x12 Self-Tapping Screw 6
3 1-3 Main Frame Assembly 1
No. Material No. Description Qty.
1 HMC2-6B Socket Screw M2x6 1
2 HMC3-10B Socket Screw M3x10 1
3 HMC3-25B Socket Screw M3x25 1
4 HME3-3B Set Screw M3x3 1
5 HMJ3-20N Self-Tapping Screw M3x20 2
6 HMS4 E Ring 1
7 HMY2-10 Pin 2x10 1
8 BK0086 Ball link 4.8x20 2
9 BK0088 Washer d3xD5x0.5 3
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 HMJ2-10N Self-Tapping Screw M2x10 2
2 HMV840ZZY BRG d4xD8X3 2
3 BK0075 Link Ball 4.8 2
4 BK0340 Aileron Control Arm 1
No. Material No. Description Qty.
1 BK0876 Elevator Control Arm 1
2 BK0075 Link Ball
φ
4.8 1
3 HMF2-8N Philip Machine Screw M2x8 1
No. Material No. Description Qty.
1 BK0882 Elevator Push Pull Lever 1
2 HMV840ZZY BRG d4xD8x3 2
3 BK0075 Link Ball
φ
4.8 3
4 HMJ2-8N Selfing-Tapping Screw M2x8 3
5 BK0410 Collar d3xD4x13 1
No. Material No. Description Qty.
1 HMS15 E Ring 4
2 BK0880 Elevator Link Shaft 2
3 BK0455 Metal Elevator Control Arm 1
4 BK0663 Elevator Arm Link 2
No.Material No.DescriptionQty.
1BK0093Link Rod 2x462
2BK0086Ball Link 4.8x2.04
3BK0547Hardened Main Shaft1
4BK0234Lock Ring1
5HSA3-6BButton Head Socket Screw M3x62
No.Material No.DescriptionQty.
1HMJ2-10NM2x10 Self-Tapping Screw2
2HMC3-12BSocket Screw M3x122
3HMV840ZZYBRG d4xD8x34
4BK0088Washer d3x5x0.52
5BK0472Washout base1
6BK0342Flybar Control Lever2
7BK0343Washout Link2
8BK0075Link Ball
φ
4.82
9BK0409Collar d3xD4x72
10BK0487Pin2
11 HMS15 E Ring2
No.Material No.DescriptionQty.
1BK0086Ball Link φ 4.84
2BK0292Link Rod 2.3x242
3BK0408Collar d3xD4x5.52
4BV0549Washout Base Guidance Ring1
No.Material No.DescriptionQty.
5HMC3-10BSocket Screw M3x102
6HMC3-12B Socket Screw M3x12 1
72-1-1Flybar Seesaw Subassembly1
82-1-2Metal Main Rotor Hub Subassembly1
No. Material No. Description Qty.
1 HMV740ZZ BRG d4xD7x2.5 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 HMJ2-8N Self-Tapping Screw M2x8 1
5 HMC3-10B Socket Screw M3x10 3
6 HMJ3-20N Self-Tapping Screw M3x20 1
7 HME3-4B Set Screw M3x4 1
8 HMM3Z Locknut M3 3
9 BK0075 Link Ball 4.8 1
No. Material No. Description Qty.
1 HMC3-30B Socket Screw M3x30 2
2 HMC3-14B Socket Screw M3x14 2
3 HMM3Z Locknut M3 4
4 BK0086 Ball Link 4.8x20 2
5 BK0278 Machined Washer 2
6 BK0403 Rod Guide 4
7 BK0404 Tail Rotor Blade 2
No. Material No. Description Qty.
8 BK0877 3D Vertical Fin 1
9 BK0650 Tail Boom 1
10 BK0707 Rear Servo Rod 1
11 BK0347 Tail Push Rod A 1
12 BK0653 Tail Push Rod B 1
13 3-1-1 Tail Transmission Subassembly 1
14 3-1-3 Tail Drive Shaft Subassembly 1
No. Material No. Description Qty.
1 BK0617 Bolt M4x25 1
2 BK0086 Ball Link 4.8x20 4
3 BK0318 Link Rod 2.3x95 2
4 HMM4Z Locknut M4 1
5 2-1 Rotor Head Assembly 1
No. Material No. Description Qty.
1 HME4-5B Set Screw M4x5 4
2 BK0397 Skid Brace 2
3 BK0398 Skid Pipe End Cap 4
4 BK0668 Skid Pipe 2
No.Material No.DescriptionQty.
15-4-1Body Subassembly1
No.Material No.DescriptionQty.
1HMJ2-6BM2x6 Self-Tapping Screw6
2HSE3-12BM3x12 Self-Tapping Screw2
3BK0102d3xD6x11Grommet2
4BK0098Body ClipA1
5BK0099Body Clip B1
6BK0429Body1
7BK0428Canopy1
8JV0186Decal1
9BK0473Body Support1
10BK0474Rubber CAP2
11HNLR6R Pin2
No.Material No.DescriptionQty.
1*****Main Rotor Blade2
2BK0446Rotor Bolt M5x352
3HMM5ZLocknut M52
TABLE OF CONTENTS
REPAIR AND REPLACEMENT PARTS
Purchase replacement parts from the hobby shop where you have purchased the Raptor 90!3D. Please contact
the Thunder Tiger distributor in your country, and the distributor can tell you where to obtain the parts. For example,
in the U.S, all Thunder Tiger products are distributed by Ace Hobby Distributors. On the web site www.acehobby.com,
there is a list of all the hobby shops in the USA that can order any Thunder Tiger parts from Ace for you. Technical
questions regarding the Raptor will be answered quickly by sending an email to [e-mail] or call
Technical Support at 949-833-7498. In Europe, Asia and Australia, please contact the distributor in your country.
WARNING
To ensure safety, please read the instruction manual thoroughly before assembly. Radio control helicopters are
sophisticated equipment, and not toys. Radio control model helicopters are capable of causing serious bodily injury
if not properly assembled or operated. The manufacturer and distributors assume no liability for damages that could
occur from the assembly or use of this product. This product is designed for hobby use only. Operating model
helicopters requires diligence and skill. The best way to ensure quick and successful learning is to seek help and
guidance from accomplished pilots. It is strongly recommended to join the appropriate radio control modeling governing
society in your country. For example, in the United States, it is strongly encouraged to join the Academy of Model
Aeronautics. AMA is a nonprofit organization that provides members in the United States with liability insurance
and monthly modeling magazines. For further information or to find a model helicopter club, please contact AMA
at:
Academy of Model aeronautics
515 East Memorial Drive
Muncie, IN 47302
USA
[phone]
We also encourage you to subscribe to different radio control helicopter magazines and learn about RC flying events,
new flying techniques, safety procedures, and hints. Rotory Modeler is a bi-monthly and Model Helicopter Techniques
is a quarterly newsletter published in the USA. Model Helicopter World is a month magazine published by Traplet
Publication in England and sold worldwide. Rotor is a monthly German magazine. Helico is a Swiss quarterly
magazine.
ATTENTION
We are unable to accept replacement or return of this model after it has been used or assembly has begun.
It is legally prohibited to duplicate or reprint this manual in any format without a written permission from the
manufacturer.
The manufacturer has the right to make changes to this model or instruction without notice.
We have done our best to the accuracy of information in this manual. If you are aware of any mistake, we welcome
you to notify us.
We will not accept any responsibility for any accident, breakdown, fault or trouble caused by improper usage of
this model. Please thoroughly inspect your model and range check the radio before flight. Please keep the model
in its best condition in order to enjoy it.
This model does not include all the items necessary for flying, such as engine, serevos, gyro...etc.
It is difficult for beginners to fly RC helicopters by themselves. It is highly recommended that beginners seek the
help of experienced RC helicopter pilots. We recommend beginners start with an inexpensive model such as the
Thunder Tiger Raptor 30 that is also designed by Mr. Taya.
RC helicopters are not toys. The manufacturer does not assume the liability for any property or bodily damage
caused by the model or the operator.
OTHER ITEMS REQUIRED
6
BODYSUPPORT INSTALLATION
Insert the aluminum support
tube through the servo frame.
Insert the "R" pins through the
two holes in the support tube
to prevent the tube from
moving in the servo frame.
Install two rubber ends onto
the support tube.The rubber
ends will dampen shake or
vibration generated by the
engine.
Glow Plug Wrench
12V Battery
1.5V Glow Starter
(1.2V~1.5V)
Rubber Band
(Included)
Foam
Remote Glow Plug
Extension
1-2-2 Cooling Fan Casing Subassembly
1-2-3 Fuel Tank Subassembly
No. Material No. Description Qty.
1 BK0062 Fuel Tank Stopper 1
2 BB0374 Silcon Tube (L=105mm) 1
3 BK0445 Fuel Plug 1
4 BK0463 Fuel Tank Nipple 1
5 BK0503-1 Fuel Tank 1
6 BE1867 Clunk Weight 1
1-5-5 Header Tank Subassembly
No. Material No. Description Qty.
1 HMC3-25B Socket Screw M3x25 1
2 BK0087 Washer d3xD8x1.4 1
3 BV0502 Header Tank 1
4 BK0506 Tank Mount 1
5 BK0698 Header Tank Supporter 1
The Raptor 90 3D kit includes a header fuel tank that can be
attached to the right of the side frame.
23
2-1-1 Flybar Seesaw Subassembly
24
2-1-2 Metal Main Rotor Hub Subassembly
2
4.Final Assembly ---------------------------------------------------------------------------------------------- 29
4-1 Installation of Rotor Head (Bag H)---------------------------------------------------------------------- 30
4-2 Installation of Engine --------------------------------------------------------------------------------------31
4-2-1 Engine Subassembly -------------------------------------------------------------------------------32
4-3 Installation of Landing Skid------------------------------------------------------------------------------- 33
4-3-1 Skid Subassembly -----------------------------------------------------------------------------------33
4-4 Installation of Tail Assembly ----------------------------------------------------------------------------- 34
4-4-1 Tail Support Subassembly------------------------------------------------------------------------ 34
5.Installation of Peripheral Equipment ----------------------------------------------------------- 35
5-1 Installation of Servo - Part 1 (Bag I) ------------------------------------------------------------------ 36
5-2 Installation of Servo - Part 2 (Bag I) ------------------------------------------------------------------ 37
5-3 Installation of Receiver and Gyro ---------------------------------------------------------------------- 38
5-4 Installation of Body (Bag J) ------------------------------------------------------------------------------39
5-4-1 Body Subassembly ----------------------------------------------------------------------------------39
5-5 Installation of Rotor Blades (Bag K) ------------------------------------------------------------------- 40
6.Settings --------------------------------------------------------------------------------------------------------- 41
6-1 Setting up Gear Backlash ------------------------------------------------------------------------------- 42
6-2 Setting up of Stabilizer Paddles ------------------------------------------------------------------------43
6-3 Setting up of Blade Pitch Angle ----------------------------------------------------------------------- 43
6-3-1 Collective Travel for Hovering ------------------------------------------------------------------ 44
6-3-2 Collective Travel for 3D --------------------------------------------------------------------------- 44
6-3-3 Configuring the Raptor 90 for 3D --------------------------------------------------------------- 45
Attention --------------------------------------------------------------------------------------------------------------46
7.Parts List Section -------------------------------------------------------------------------------------------49
Raptor 90 3D Exclusive Parts -------------------------------------------------------------------------------- 50
Raptor 90 3D Spare Parts List ------------------------------------------------------------------------------- 55
Raptor 90 3D Optional Parts List ---------------------------------------------------------------------------- 61
3
Thank you very much for purchasing the Thunder Tiger Raptor 90 3D R/C helicopter. The design of Raptor
90 3D is based on the original Raptor 90 series helicopter and modified for extreme aerobatics. It has all
needed must-have optional parts for 3D flying, such as metal main rotor hub, non-linear flapping damper,
metal BRG, 3D light paddles and so on. It also adopts the push-pull control system on collective pitch
and elevator to achieve the most precise control. The flybar ratio is changeable to fit all kinds of flying
style. Use of high quality material make the helicopter one tough machine that can handle everyday 3D
beating. Raptor 90 3D is born for 3D flying, and you don’t have to do any further modification for aggressive
3D maneuver. This is by far the best machine you have never seen. Just enjoy the model and have fun.
UNIQUE SIDEFRAME SYSTEM
Aluminum side plates are used in conjunction with molded material to construct the main structure. This
design produces minimum weight with maximum strength. If the sideframes were completely made of
molded material, then to achieve equal strength the plastic would have to be very thick and heavy. Using
molded material at the right place avoids using metal angle brackets or putting compound bends in metal
frames. Slots have been added in the frame design to permit the use of optional gear ratios to optimize
engine performance to suit any pilot's demand.
BELL-HIILLER MIXING CONTROL UNIT
Main rotor control geometry has been carefully engineered to minimize cross-coupling in collective and
cyclic commands. Blade pitch arms and the Bell-Hiller mixing arms are designed at an angle such that
the pushrod interlinking them are at 90 degrees when the blades are at 0 degree. The pilots will get the
symmetrical cyclic control feel and flybar authority either at +10 or -10 degrees of collective. We design
this system with the 3-D pilot in mind. We guarantee you this whole design philosophy provides a strong
and accurate control mechanism.
SHAFT DRIVE TAIL ROTOR
The Raptor 90 3D is designed with a constant drive tail rotor system to permit full tail rotor control during
autorotations. 180 autos, backward autos and pirouette autos are all within your reach now. It has the
same aluminum torque tube system as the Thunder Tiger/Taya Imperio helicopter. This allows obtaining
the maximum performance from any modern heading lock gyros.
3D CAD DESIGN
We use the latest 3D Computer Aided Design to design and manufacture the Raptor 90 3D. Our high-
tech CAD program allows simulation of all moving parts to ensure no interference. The analysis automatically
analyze the weight, the mass distribution, and inertia to help us pursue a design that will provide the high
level of maneuverability needed for all-out 3-D aerobatics.
INTRODUCTION
Socket Drivers
Hex WrenchGrease
Blue Loctite
Instant Glue
Hobby Knife
Metric
4-way Wrench
Scissors
Diagonal Pliers
Open End Wrench
5.5mm
Needle Nose PliersScrew Driver
7mm
5.5mm
7mm
8mm
5.5mm
7mm
8mm
10mm
Epoxy
Ball Link Pliers
No. Material No. Description Qty.
1 HMV6800ZZY BRG d10xD19x5 1
2 HME4-5B Set Screw M4x5 2
3 HMS5 E Ring M5x8 1
4 HMV696Z BRG d6xD15x5 1
5 BK0388 Clutch BRG Case 2
6 BK0659 Frame Space M 4
7 BK0594 Starter Coupling 1
8 BK0592 Starter Shaft 1
9 BK0422 Drive Pinion 11T 1
10 BK0366 Pinion Gear Nut 1
11 BV0522-2 Clutch Bell Set 1
No. Material No. Description Qty.
1 HMC3-10B Socket Screw M3x10 2
2 HMC3-12B Socket Screw M3x12 4
3 BK0087 Washer d3xD8x1.4 6
4 BK0393 Pitch Frame Cross Member 1
5 BK0394 Pitch Frame Cross Member Nut 2
6 BK0375T Upper Frame 2
No. Material No. Description Qty.
1 HMM3Z Locknut M3 4
2 HMC3-25B Socket Screw M3x25 4
3 BK0820BL Landing Skid Damper 4
4 4-3-1 Skid Subassembly 1
No.Material No.DescriptionQty.
1HMC3-8BSocket Screw M3x84
2HMQ16Retaining Ring1
3BK0357Tail Drive Spur Gear 83T1
4BK0359One Way Clutch Shaft1
5BV0368Auto Rotation Hub1
6BK0356Main Spur Gear 91T1
1-6-2 Main Gear Subassembly
(3)
(2)
(4)
(6)
(5)
(1)
The carbon rear servo plate is secured
by two Lower 3mm bolts from the plastic
tail boom bracket.
10
1-1-2 Pitch Guide L Subassembly
1-1-3 Pitch Guide R Subassembly
No. Material No. Description Qty.
1 BK0384 Pitch Guide Collar L 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
The side with a number should face
in because the opening on both sides
are differeent.
The hole on the plastic control arm has different
opening sizes on the two sides.Always snap the
bigger opening to the ball on swashplate gently and
afterward please check to make sure it is securely
attached and there is no damage or cracking.
INSTALLATION OF THE LINKS
Bigger Hole Face to Swashplate
Extended 6mm Hex
Starting Tool
Fuel Pump
Heli Engine (90size)
9609 PRO-90H(R)
Glow Fuel(15%-30%)
Glow Plug
Hi-torque 12V Electric starter
Receiver
Transmitter
(helicopter type, 6 or
more channels) High Speed/Torque Servo x 4
Rudder Servo x 1
Battery Switch harness
Heading Lock
Gyro
In order to enjoy a safe and enjoyable experience, please read the manual carefully and completely understand
the helicopter structure and operation before the first flight.
Read the warnings to avoid injuries to you and others.
WARNING – The following could cause heavy injury or death if used incorrectly.
Keep the model away from other people or animal when starting the engine.
Do not fly any model helicopter near or above people or cars. Models can sometimes lose
control due to pilot or mechanical failure.
WARNING – The following could also cause serious injury or death if not careful.
Take precaution with model fuel. Model engine glow fuel is highly flammable.
Please check the model carefully before each flight. Make sure that nothing has loosened up
or come apart.
Make sure everything moves freely without binding or excessive friction.
Do not operate the model in rain, snow, thunderstorm, or adverse weather.
WARNING – The following could also cause serious injury or death if not careful.
Please make sure that your radio frequency is not used before flight. If someone else is flying
with the same frequency as your radio, do not turn on your transmitter. Otherwise, it can cause
a crash and even bodily and property damages.
Please monitor the fuel level during flight and land before running out of fuel.
Before each flight, please check that all servos and controls move properly.
Do not modify any parts or use other than genuine Thunder Tiger parts.
Do not fly in places that are forbidden by law.
Use Loctite on screws that do not use a locknut.
When operating the model, please beware that no loose cloth or jewelry can get entangled in
the model helicopter.
Make sure the transmitter and receiver switches are on before starting the engine.
Do not touch the engine or the muffler right after flying because they are very hot.
Do not use this model for anything other than hobby.
WARNING – The following damages can happen to the model.
Do not leave the model in a car for a long time. The heat in the summer or the cold in the
winter and the humidity can cause damage to the model.
Be careful and watch the sharp edges and corners on the model.
BUILDING HINT – The instruction is divided into six assembly chapters:
Main Frame, Rotor Head, Tail Rotor, Final Assembly, Radio Installation, and Settings. There
are many major assembly steps in each chapter, please follow the instruction to do each "
Subassembly" first, then combine the subassemblies into a major assembly.
Upper Frame Assembly
Lower Frame Assembly
12
1-2-1 Tail Drive Unit Subassembly
No. Material No. Description Qty.
1 HME3-4B Set Screw M3x4 2
2 HMV1350 BRG d5xD13x4 2
3 HMV6701ZZY BRG d12xD18x4 2
4 BK0362 Tail Drive Bevel Gear A 1
5 BK0363 Tail Drive Bevel Gear B 1
6 BK0364 Tail Drive Pinion 1
7 BK0365 Tail Drive Gear Shaft 1
8 BK0382 Tail Boom Bracket L 1
9 BK0383 Tail Boom Bracket R 1
10 BK0414 Pin 2x12 2
11 BK0660 Frame Spacer L 5
Main Frame Assembly Installation of Pitch Frame
No. Material No. Description Qty.
1 HMJ2-10N M2x10 Self-Tapping Screw 1
2 HMV840ZZY BRG d4xD8x3 2
3 HMV1280ZZY BRG d8xD12x3.5 2
4 BK0336 Pitch Frame 1
5 BK0075 Link Ball
φ
4.8 1
Optional: add a tiny drop of thick CA on the outside rim of the fovr ball
bearings before inserting them into the plastic Pitch Frame. Be careful
not to get any glue into the ball bearings. Add a tiny drop of thick CA
glue at the tip of the M2x10 self-tapping screw (No. 1) before
screwing it into the Pitch Frame.
32
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
Note:
The (3) spacer with threads is
supposed to be located at middle
position to fit the Body Fitting Post.
No. Material No. Description Qty.
1 BK0385 Pitch Guide Collar R 1
2 BK0658 Frame Spacer S 2
3 BK0693 Cross Member 1
Tip: When setting up the phase
adjustment ring, the flybar and
the tail boom can be the
reference. When the flybar and
the tail boom are centered, the
inner balls of swashplate should
be aligned with the outer balls.
Tighten the socket screw on the
phase ring at this moment.
NOTE: Improper alignment will
cause unwanted mixing.
No. Material No. Description Qty.
1 ******** 90 Class Heli Engine 1
2 ******** Nut (Comes With the Engine) 1
3 HMC4-8B Socket Screw M4x8 2
4 HMC4-18B Socket Screw M4x18 4
No. Material No. Description Qty.
5 HMO10 Washer d9.5xD16x1 1
6 BK0349 Engine Mount 1
7 BV0380 Cooling Fan 1
8 BV0521 Heavy Duty Clutch 1
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.85
2BK0086Ball Link 4.8x208
3BK0104Servo Mounting Plate6
4BK0105Rod Joint1
5BK0318Link Rod 2.3x952
6BK0436Link Rod 2.3x552
7BK0833Servo Block4
8HMC2516BSocket Screw M2.5x164
No.Material No.DescriptionQty.
9HMM25Lock Nut M2.54
10HML2Nut5
11HME4-5BSet Screw2
12HMF2-8NPhillips Machine Screw M2x85
13HSE2614NSelt-Tapping Screw4
14HSE2630NSelt-Tapping Screw4
No.Material No.DescriptionQty.
1BK0075Link Ball φ 4.87
2BK0086Ball Link 4.8x204
3BK0095Link Rod 2.3x761
4BK0104Servo Mounting Plate4
5BK0833Servo Block2
6BK0834Pitch Lever Fixed Plate1
7BK0839Link Rod 2.3x301
8BK0881Washer1
9BK0883Pitch Push Pull Lever1
No.Material No.DescriptionQty.
10BK0884Collar, d3xD4xW121
11BV0085Pitch Link Rod2
12HMC3-20BSocket Screw M3x201
13HMV840ZZYBearing d4xD8xW32
14HMF2-8NPhilip Maching Screw M2x84
15HMJ2-8NSelt-Tapping Screw M2x83
16HML2Nut4
17HSE2614NSelt-Tapping Screw M2.6x148
18HSE2620NSelt-Tapping Screw M2.6x204
No.Material No.DescriptionQty.
1****Switch1
2****Receiver Battery1
3****Receiver1
No.Material No.DescriptionQty.
4****Gyro
5BK0106Foam2
6 BE1052Antenna Pipe1
PV0517ONEWAYBEARING GREASE
The hole on the Flybar Control Rod has different
opening on two sides.Always snap the bigger opening
to the link ball.
Bigger Hole
Face to ControlArm
10.5mm10.5mm
When installing pinion gear, add a small drop of Loctite to the
threads. Make sure not to get Loctite on lower clutch bell bearing.
Important:
For 90 class engine, we recommend the 11 teeth pinion for 3D
flying.
The servo tray and cooling fan shrouds on the Raptor 90 are different from the
Raptor 60 in order to accommodate the full head sink on the O.S 91. engine.
If using T.T 90, Y.S 91 or Webra 91 engine, make sure to install the fan shroud
baffle with two self-tapping screws. This will ensure optimal cooling of your engine
head.
Add CA glue Add CA glue
It is necessary to add grease inside the one way clutch before your
first flight.The clutch might lock up once grease is gone.The one
way clutch grease( PV0517) is recommended for this lubrication.
Make sure the inside ofAuto Rotation Hub is clean without any dirt
before you insert the one way clutch shaft.
Add Loctite
Add Loctite on
the threads
For 3D flying, it is recommended to use
lower flybar ratio setting.
Self-Tapping Screw, No. 10 Collar, and No. 11 Washer, with two
No. 1 Bearings. Attach a No. 9 Link Ball with a No. 4 Screw.
Upon finishing Step 3-1-1, make sure there are no extra parts
left on your workbench.
Elevator Control
Pushrod
Glue the two plastic halves of
the paddle with CAglue before
installation on flybar.
Add Loctite
the tail boom by tightening the four screws on the helicopter.
Visually check from the rear of the helicopter to make sure the
tail rotor output shaft is perpendicular to the main rotor shaft.
Add the tail boom supports.
Add Loctite
The thrust bearing washer with the
SMALLER inner hole should be closer to
the rotor blade.
The thrust bearing washer with the BIGGER
inner hole should be closer to the main rotor
shaft.
4-2-1 Engine Subassembly
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add CA Glue
Introduction -------------------------------------------------------------------------------------------------------- 3
Other Items Required -------------------------------------------------------------------------------------- 4
Warning --------------------------------------------------------------------------------------------------------------- 5
Assembly
1. Main Frame Assembly --------------------------------------------------------------------------------- 7
1-1 Upper Frame Assembly (Bag A) ---------------------------------------------------------------------- 8
1-1-1 Pinion Gear Subassembly ------------------------------------------------------------------------ 9
1-1-2 Pitch Guide Left Subassembly ------------------------------------------------------------------10
1-1-3 Pitch Guide Right Subassembly -----------------------------------------------------------------10
1-1-4 Elevator Control Arm Subassembly------------------------------------------------------------ 10
1-2 Lower Frame Assembly (Bag B) ----------------------------------------------------------------------11
1-2-1 Tail Drive Unit Subassembly ---------------------------------------------------------------------12
1-2-2 Cooling Fan Casing Subassembly -------------------------------------------------------------13
1-2-3 Fuel Tank Subassembly ------------------------------------------------------------------------13
1-3 Main Frame Assembly (Bag C) -------------------------------------------------------------------------14
1-3-1 Rod Guide Collar Subassembly-----------------------------------------------------------------14
1-4 Installation of Servo Frame (Bag C) ------------------------------------------------------------------- 15
1-5 Installation of Pitch Frame (Bag D) -------------------------------------------------------------------- 16
1-5-1 Aileron Lever Subassembly ---------------------------------------------------------------------17
1-5-2 Metal Elevator Parallel Lever Subassembly -------------------------------------------------17
1-5-3 Elevator Control Lever Subassembly --------------------------------------------------------- 17
1-5-4 Pitch Control Frame Subassembly -------------------------------------------------------------18
1-5-5 Header Tank Subassembly ----------------------------------------------------------------------18
1-6 Installation of Main Shaft (Bag E) ----------------------------------------------------------------------19
1-6-1 Wash Out Subassembly -------------------------------------------------------------------------20
1-6-2 Main Gear Subassembly -------------------------------------------------------------------------20
2. Rotor Head Assembly -----------------------------------------------------------------------------------21
2-1 Metal Rotor Head Assembly (Bag F) -----------------------------------------------------------------22
2-1-1 Flybar Seesaw Subassembly --------------------------------------------------------------------23
2-1-2 Metal Main Rotor Hub Subassembly ----------------------------------------------------------24
3.Tail Assembly -------------------------------------------------------------------------------------------------25
3-1 Tail Assembly (Bag G) ----------------------------------------------------------------------------------- 26
3-1-1 Tail Transmission Subassembly --------------------------------------------------------------- 27
3-1-2 Tail Rotor Subassembly --------------------------------------------------------------------------- 28
3-1-3 Tail Drive Shaft Subassembly -------------------------------------------------------------------28
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The Liner is pre-glued on the
inside of clutch bell with 30 min
epoxy.
1-1 1-2 1-3
( 2 ) (1)
1-4
(1)
(2)
1-5 1-6
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(1)
(5)(4)
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(3)
2-1
3-1 4-1
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(2)
(1)
4-3
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(2)
4-4
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4-2
(3)
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5-15-2
5-3
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5-4
5-5
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No. Material No. Description Qty.
8 BK0660 Frame Spacer L 3
9 BK0376T Lower Metal Frame 2
10 BV0870 Metal Lower BRG Block 1
11 1-2-1 Tail Drive Unit Subassembly 1
12 1-2-2 Cooling Fan Casing Subassembly 1
13 1-2-3 Fuel Tank Subassembly 1
No. Material No. Description Qty.
7 BK0659 Frame Spacer M 2
8 BV0869 Metal Upper BRG Block 1
9 1-1-1 Pinion Gear Subassembly 1
10 1-1-2 Pitch Guide L Subassembly 1
11 1-1-3 Pitch Guide R Subassembly 1
12 1-1-4 Elevator Control Arm Subassembly 1
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No. Material No. Description Qty.
10 BK0093 Link Rod 2x46 1
11 BK0407 Collar d3xD4x4.5 2
12 BK0410 Collar d3xD4x13 2
13 1-5-1 Aileron Lever Subassembly 1
14 1-5-2 Metal Elevator Parallel Lever Subassembly 1
15 1-5-3 Elevator Control Lever Subassembly 1
16 1-5-4 Pitch Control Frame Subassembly 1
17 1-5-5 Header Tank Subassembly 1
No.Material No.DescriptionQty.
6HMM4BLucknut M41
7BK0617Bolt M4x251
8BV0504Metal Swashplate1
91-6-1Washout Subassembly1
101-6-2Main Gear Subassembly1
No. Material No. Description Qty.
10 BK0076 Collar d3xD4x10 1
11 BK0088 Washer d3xD5x0.5 1
12 BK0346 Tail Pitch Control Lever 1
13 BK0370 Tail Case L 1
14 BK0371 Tail Case R 1
15 BK0372 Tail Input Bevel Gear 1
16 BK0373 Tail Output Bevel Gear 1
17 HMY2-12 Pin 2x12 1
18 3-1-2 Tail Rotor Subassembly 1
No. Material No. Description Qty.
1 HMM3Z Locknut M3 6
2 HMC3-16B Socket Screw M3x16 2
3 HMC3-20B Socket Screw M3x20 2
4 HMC3-25B Socket Screw M3x25 2
5 HMC3-30B Socket Screw M3x30 2
6 BK0087 Washer d3xD8x1.4 4
No. Material No. Description Qty.
1 HMJ2-8N Self-Tapping Screw M2x8 4
2 BK0447 Tail Support Rod End 4
3 BK0669 Tail Support Rod 2
No. Material No. Description Qty.
1 HMC4-42B Muffler Bolt M4x42 2
2 HMT4B Spring Washer 2
3 ******** Muffler ( 90 ) 1
4 4-2-1 Engine Subassembly 1
5 HMC4-12B Socket Screw M4x12 4
6 BK0435 Washer d4xD11xW1.7 4
BAG A
BAG B
BAG C BAG C BAG D
(L) (R)
BAG E
BAG F
BAG G
BAG H
BAG I
97.5mm
48mm
(3)
Throttle
Collective Pitch
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BAG I
BAG J
BAG K
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Please complete subassembly steps 1-2-1 through 1-2-3 first. Then attach the subassemblies to the two Lower Frames. Note
that the Metal Lower BRG is installed with the bearing open side facing up. Please add a small drop of Loctite on every bolt
before screwing it into the aluminum hex spacer. Do not apply Loctite to the bolts which are going to secure the Lower BRG
Block at this moment.
Assemble the upper main frames by starting with the two Metal Upper Frames. The Pinion Gear Subassembly must be assembled
first according to Figure 1-1-1. Next insert three hex-shape frame spacers into the plastic Pitch Guide according to Figure 1-1-2
and 1-1-3. Assemble the Elevator Control Arm subassembly according to 1-1-4. Insert it in between the two Upper Frames. The
metal Elevator Control Arm is not symmetrical. The side with the longer profruding round knob should be on the right side of the
helicopter. Then attach the other subassemblies to the Upper Frames. Locate Hex Wrenches in BAG L which you need for
assembly.
Please add a tiny drop of non-permanent type Loctite on the tip of all bolts before screwing them into the hex shaped aluminum
frame spacers. Never use too much Loctite, otherwise it will become nearly impossible to remove later on for servicing. Only use
the non-permanent type of Loctite. If encountering difficulty in removing any bolt that was locked up by Loctite, heat up the head
of the screw or bolt with the tip of a hot soldering iron, it will help soften the cured Loctite.
For the kit, parts are bagged according to each major assembly and are labeled "Bag A, Bag
B, etc." The heading for each assembly indicates which bag to open. As a go od practice,
only open up the bag that you need for the particular assembly. Check the parts in that bag
against the parts list shown for each assembly as well as each sub-assembly to make sure
there are no missing parts. To prevent losing small hardware, please empty the small nuts
and bolts and parts into small plastic trays on your work table. At the end of each major
assembly, there should be no left over parts.
The fuel tank comes assembled from the factory because every tank has been
checked for leak. If you were to take the tank apart here is how to put it back
together. Install the silicone fuel line to the Fuel Nipple. Then add the rubber
fuel tank stopper and the clunk weight. The stock silicone fuel line is very soft
and thin which is designed to allow the clunk to pick up fuel easily during 3-D
aerobatics. The pickup line should be inspected and replaced if necessary every
month, otherwise when it becomes soggy it can break off. A thicker silicone line
maybe substituted but make sure the clunk will reach the bottom when moving
the fuel tank to all different orientations.
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As show in Figure 1-3-1, insert two hex
Frame Spacers S into the plastic Rod
Guide Collars. Then join the Upper
Frame Assembly to the Lower Frame
Assembly according to drawing 1-3.
Secure the Set Screws (No.1) to the
frames, and fit the Body Posts (No.4)
to the Set Screews. The two Body Posts
will be used to secure the canopy in the
future. Add Loctite on all bolts and
inside BK0103 threaded hole.
Install the one-piece servo frame with six self-tapping screws.
Do not use Loctite when attaching self-tapping screws to plastic
parts. Loctite is only for threading metal into metal parts. Assemble the constant drive Main Gear Subassembly according to Figure 1-6-2 first.Then build up the Wash Out Subassembly
according to 1-6-1. Insert the No.3 Main Shaft into the bearings and then add the No.4 Lock Ring and slide in the Main Gear
Subassembly.Add two M3x6 Button Head Screws to the Locking Ring, and the two screws are threaded into the holes on the
main rotor shaft.
The locking ring prevents the main shaft from sliding up. Line up the hole on the main gear and the main shaft, then insert M4x2 5
mm Bolt through them. Place a 4 mm M4 locknut on the other side of the autorotation hub, and then tighten the Bolt. Do not
over tighten the Bolt, otherwise the autorotation assembly will be distorted. Loosen the 3mm bolts holding the Upper and lower
bearing blocks for the 12mm main shaft. Wiggle the main shaft in the bearing blocks until the main shaft spins freelyin the bea rings.
This ensures the upper and lower bearing blocks are aligned. Push the lower bearing block up until the mainshaft has no up
and down play.Then tighten the 3mm bolts for the upper and lower bearing blocks.
Insert the pin into the Washout Link.Add a tiny drop of Loctite on the inside
and outside of BK0409 Collar which will help give a completely slop free
control system. Do not let the Loctite seep into the bearing.Adjust the
tightness of the M3x12 bolts so the mixing arms can move freely but without
wobble or racheting the ball bearings.Add a tiny drop of thick CAglue at
the tip of the M2x10 self-tapping screw (No. 1) before screwing it into the
Flybar Control Levers (No. 6).
Make the two pushrods for controlling the blade pitch.The distance 43 mm is measured between the center of two pushrod holes.
Attach the Seesaw Hub of the Control PaddleAssembly to the Main Rotor Head with Socket Screws (M3x10).
Please add a small drop of Loctite along the entire length of the M3x10 Socket Screw (No.5) and on the outside of the collar
d3xD4x5.5 (No.3).Temporarily install the Washout Base Guidence Ring, but do not tighten the No.6 M3 Socket Screw yet.
Assemble the tail transmission subassembly according to 3-
1-1 and 3-1-2 first. And the tail drive shaft subassembly according
to 3-1-3.But do not close the two halves of the tail transmission
tightly. You will do this when you are ready to install the gearbox
onto the tail boom.
When installing the tail transmission, make sure the housings
match the hole on to the tail boom. Add Carbon Vertical Fin with
machined washer and Locknut, then tighten the five 3 mm bolts.
Add carbon Vertical Fin with Pom washer and Locknut.
Before inserting the finished tail drive shaft assembly into the
tail boom, add some flexible silicone glue or ZAP Goop glue
around the outside of the tail drive bearing housing. This will
prevent the bearing housing from spinning inside the tail boom.
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Install bearings No. 2 and No.3 into the Tail Cases. Install No.
16 Tail Bevel Gear onto the Tail Shaft. Gently tap the No. 17
Pin into the Bevel Gear and Tail Shaft. Then secure the pin
with a No. 7 Set Screw with Loctite.
After installing the M3x4 set screws, try pushing on the 2x12
pin with a small Allen wrench to make sure the set screw has
locked the pin in place securely. Before closing the two halves
of the Tail Cases, please check the gear mesh between gears
No. 15 and No. 16. If the gears mesh too tight, then a 5 mm
i.d. washer should be added to move the gear No. 16 further
out. If there exists too much freeplay, then a 5 mm i.d. washer
to push gear No. 16 closer to gear No. 15.
Install the No. 12 Tail Pitch Control Lever as shown with No. 6
Slide four No. 6 Rod Guides onto the tail boom. Do not glue
them onto the tail boom yet. Add a tiny drop of CA glue to the
pushrod guide after you finish building the entire helicopter.
Before adding glue, make sure the tail pushrod is hooked up
to the servo and the rod travels in a straight line and moves
very smoothly.
Congratulation, we are almost done. Install the finished main
rotor head onto the 12 mm rotor main shaft. Secure it with a
M4x20 Bolt and M4 Locknut. Make up two 113.5 mm long
pushrods and attach them to the Bell-Hiller mixing arm.
Before installing the plastic end caps, please
add a drop of slow, thick CA glue on the
rim of the end caps and on the inside edge
of the aluminum skid.
Slide the finished tail boom into the helicopter. The four bolts
on the helicopter must be loose in order to insert the tail boom.
Make sure the tail drive shaft is inserted into the front receptacle
properly. Check this by turning the main rotor head. Secure
Secure the two ends to the rod with Epoxy, making sure the
two metal ends are perpendicular to each other.
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Attach the engine into the side frames, with four M4x12 bolts and
four washers, but do not tighten until Section 6-1.
Install the muffler after you have building the entire helicopter.
Always add Loctite on the muffler bolts.
Install the servos and make up the pushrods according to the drawings.The distance between the steel ball and the center of
servo arm are shown in the drawing. Use them as a guide.These distances are used in conjunction with the servo travels (ATV
or End point) set to 100% for all the channels in the transmitter.Tune them later on to suit your personal flying style.
Attach the rudder servo to the rear mounted carbon plate with four 2.6mm bolts and four M2.6 locknut.
Make up the throttle and collective control pushrods according
to the drawing. Use the outermost hole on the carburetor throttle
control arm.Attach the steel ball on the throttle servo arm at
approximately the same distance as the steel ball on the throttle
arm.
Make up the throttle at 97.5mm long first, and then adjust the
pushrod length and throttle servoATV or Endpoint so full throttle
stick command will open the carburetor barrel fully.And full low
stick and low throttle trim will close the carburetor barrel completely.
Install the receiver and receiver battery. Even though the receiver and battery can be attached to the helicopter tray by using
double sided foam tape, but it is better to wrap the receiver and battery separately using half inch or 10 mm thickfoam. Then
secure them to the tray using six to eight rubberbands, or Velcro bands.
Carefully cut out the canopy (windshield) using scissors.The
best scissors to use are (TTR 1304) designed to cut RC car
bodies and Canopy. Install the canopy to the body using six
small screws. Drill small holes in the canopy and body for the
holes. Drill two more holes for the rubber grommets.
Refer to color box and apply the decals (In BAG M) .
Tools for Assembly
The Raptor 90 3D is designed for easy maintenance using standard hobby tools. Please only use genuine Thunder Tiger parts.
Please keep the model clean and well tuned. It will provide you with long lasting pleasure in return.
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Add Loctite
(Included)
Add a tiny drop of thick CA glue at the tip of the M2x10
self-tapping screw (No. 1) before screwing it into the
Aileron Levers.
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Make up the landing gear according to the
drawing.
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No. Material No. Description Qty.
1 HSE3-6B Self-Tapping Screw M3x6 2
2 BK0660 Frame Spacer L 4
3 BK0662 Cooling Fan Baffle 1
4 BK0665 Fan Casing L 1
5 BK0666 Fan Casing R 1
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Assemble the metal flybar control arms according to the drawings. Slide Flybar ControlArm onto the No.18 Flybar Rod. Slide
the flybar into the No.17 Seesaw Hub. Make sure the Flybar has equal protrusion from each side of the SeesawHub measure
them with a ruler, then install and tighten the No.8 HME4-5B set screws.Add the paddles. Make sure the two paddles and the
two flybar control arms are all parallel. Lock the paddles with No.6 set screws.
Assemble and install the No.10 Mixing Levers and No.5 Bearings according to the drawing using No.12 Collar andNo.9 d3xD5x0.5
washer.
Note:Before installing the Mixing Lever (No.10), please add a small drop of Loctite along the entire length of the M3x18 button
head socket screw (No.4) and on the outside of the collar d3xD4x13 (No.12). Be careful do not let the Loctite seep into the bear ings.
There are two choices of hole positions on the aluminum seesaw for attaching the mixing lever arm.The outside hole gives higher
Bell-Hiller mixing ratio. For aggressive 3D flying, you can attach the Bell-Hiller mixing arms to the inner hole which gives low er
flybar ratio.
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No.Material No.DescriptionQty.
10BK0324Mixing Lever2
11BK0406LPaddle Root2
12BK0410Collar d3xD4x132
13BK0416Paddle Stopper2
14BK0432LFlybar Paddle2
15BK0633Flybar Control Frame2
16 BK0871 Longer StabilizerArm 2
17 BV0865 Longer Seesaw 1
18 BK0866 SUS Flybar 1
No.Material No.DescriptionQty.
1HMF2-8NPhillips Machine Screw M2x82
2HMJ2-10NSelfing-Tapping Screw M2x104
3HMC3-10BSocket Screw M3x102
4 HMC3-18B Socket Screw 2
5HMV840ZZYBRG d4xD8x34
6HME4-3BSet Screw M4x34
7HME4-5BSet Screw M4x52
8BK0075Link Ball
φ
4.86
9BK0088Washer d3xD5x0.52
Insert the aluminum Main Rotor Hub Pin and the Flap Dampers. (might need to apply silicone grease for easy installation). Push
the No.7 Feathering Spindle into the dampers and the rotor hub.Add No. 14 Flybar Control Rod. Slide both finished Main Rotor
Grip onto the feathering spindle and the secure with two M4x10 bolts and washers according to the drawing.Use two Allen
wrenches to tighten the two M4x10 bolts simultaneously.
Important Note:
The Raptor 90 3D kits come with non-linear flap damper for aggressive 3D flying.You may choose to experiment adding from
one up to three 0.4mm thick shim (No.10) washers between the washer (No.8) and bearing to further stiffen the main rotor flapping.
Stiffing the main rotor head will speed up the cyclic transient response, but may cause the helicopter fuselage to oscillate at arou nd
1600 RPM.This oscillation characteristic exists for all helicopters with hard 3D flap dampers.The inner dampers should be
replaced periodically if a lot of 3D flying has been done. When the dampers are worn, the main rotor blades canflap excessivel y
during some 3D maneuvers and risk touching the tail boom.
Add flexible silcone glue or ZAP
Goop glue around the outside
before inserting into the tail
boom from the front side.
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180mm
25mm
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The optionalThunderTiger Remote Glow PlugAdaptor (#3803)
is recommended as shown, making starting easy without the
removal of your canopy.
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Cut a hole at the
front air scoop for
backward flights.
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No.Material No.DescriptionQty.
9BK0477Washer2
10BK0703Flap Damper Washer 0.4mm6
11BK0874Inner Damper2
12BK0875Outer Dampper2
13BK0075Ling Ball
φ
4.82
14BK0664Flybar Control Rod2
15BK0319Main Rotor Pitch Housing2
16BV0548-1Metal Main Rutor Hub1
No.Material No.DescriptionQty.
1HMC4-10BSocket Screw M4x102
2HMJ2-12NSelf-Tapping Screw M2x122
3HMV1680BRG d8xD16x54
4HMX0816Thrust Bearing d8xD16x52
5BK0330Main Rotor Hub Pin1
6 BK0325Thrust Washer 2
7BK0326Spindle1
8BK0435Washer2
Fiberglass or Carbon Rotor Blade
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Add Loctite when setting up the
gearmesh in step 6-1.
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No. Material No. Description Qty.
7 BK0539 Carbon Rear Servo Plate 1
8 BK0878 Bracket (Top) 1
9 BK0879 Bracket (Bottom) 1
10 3-1 Tail Assembly 1
11 4-4-1 Tail Support Subassembly 2
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Engine System
Use a high quality 90 size 2-stroke
model helicopter engine, such as the
Thunder Tiger TT PRO-90H, OS 91
SZ-H, YS 91 ST, Webra 91, or
equivalent. Please beware, some
engines may not fit because of their
shape and size. The Raptor 90 3D
kit comes with a cooling fan hub to fit
the TT PRO-90H, OS 91 SZ-H, Webra
91.
We recommend a high quality muffler
or tuned exhaust system designed to
fit on the left side of the model.
Rotor Blades
It is important to use main rotor blades
that are of high quality and suitable
for your flying style. If fiberglass or
carbon graphite blades are used, the
length should be between 680 and
710 mm. Blade weight should be
between 170 and 200 grams.
Starter System
To start the engine, it is necessary to
use an electric starter with a 6mm
shaft extension. The starter and the
6 mm extension are available from
Thunder Tiger, the part numbers are
No.2675 and No.3801.
Use a strong high torque 12 volt
electric starter which is designed for
models.
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Add a small drop of Loctite.
Make sure it locks the pin.
Install BK0364 and BK0362 onto BK0365 Tail Gear Drive Shaft. Then insert the
two Pins and secure them with two M3x4 Set Screws. Add a tiny drop of Loctite
on the set screw thread before inserting them. Always use a very small amount
of Loctite liquid on the thread, otherwise it may be nearly impossible to remove
the set screws in the future for servicing. After installing the two M3x4 set screws
(No. 1), try to push on the 2x12 pins with a small Allen wrench to make sure the
set screws have locked the pins in place securely. Install the four ball bearings
and the hex shaped Frame Spacers according to the drawing. Before closing
the two halves of the Tail Boom Brackets, please check the gear mesh between
gears No. 4 and No. 5. If there exists too much freeplay, add some 5 mm i.d.
washers on top of gear No. 4. (The 5 mm i.d. washers are provided in BAG G).
Add a small drop of Loctite.
Make sure it locks the pin.
Shim Washer
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Add CA Glue
Standard flybar ratio
Lower flybar ratio
Mild 3D Flying
Extreme 3D Flying
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Attach the engine mount to the engine using four 4mm bolts and Loctite.
The cooling fan hub is threaded to fit the OS, TT or Webra only. Place the washer that came with your engine onto the engine
crankshaft first. Then screw the fan hub onto the engine. Add a tiny drop of Loctite on the engine nut. Do not use too much
Loctite. Tighten the engine nut using a socket head wrench while grabbing the fan with a towel. The nut should be tighten securely.
For 50-size or bigger engines, we do not recommend using a piston locking tool on the glow plug hole because that may damage
the engine. Attach the No. 8 Heavy Duty Clutch to the fan hub. Add a drop of Loctite on the threads of the M4x8 bolts. The
threads on the aluminum cooling fan hub are for the TT 70H, OS 61 SX, OS 61LX, OS 70H, TT 90H, OS 91 or Webra 91 engines.
If YS 61, 80 or 91 engines are used, the fan hub must be re-tapped by the modeler to M8x1mm thread size or purchase a optional
plastic fan hub with threads for the YS engine(PV0198YS) or the metal fan for the YS (PV0293YS).
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Please complete subassemblies 1-5-1 through 1-5-5 first, then add them to the Main Frame. Fit the Pitch Control Frame
Subassembly. Attach the E Ring on the left side of the Metal Elevator Control Arm. Then fit the Elevator Control Lever to the
right side, insert the pin and fix it with a set screw. Secure the Pitch Control Frame with a M3*10 Socket Screw and a collar on
the left side. And attach the Elevator Push Pull Lever to the right side of the Pitch Control Frame as shown. Adjust the two bolts
so that the Pitch Control Frame can move freely without excessive play. Finally, add the two plastic Aileron Levers and the 66.5mm
elevator pushrod. Add the Washers (BK0088) to make sure that the Aileron Lever and the Metal Elevator Parallel Lever will not
touch each other during operation.
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Outer hole for standard.
Inner hole for extreme 3D.
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Add Loctite
Add Loctite
Add Loctite
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Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
Add Loctite
30mm
(2)
Paddle
Flybar
A Arm
Phase
Adjustment
Ring
Swash
plate
Boom
(3)
(8)
(14)
(13)
(9)
(1) (10) (12)
(7)
(11)
(12)
(2)(7)
(8)(6)
(5)
(4)
(1) (14) (16)
(11)
(18)
Pitch push-pull subassembly
(13)
(1)
(15)
(10)
(9)
(17)
(2)
(3)
Add Loctite
Add Epoxy
Add Epoxy
(13)
(14)
(17) (15)
(16)