THUNDER TIGER Raptor 50 V2 kit User Manual

ASSEMBLY & MAINTENANCE

50 Size 3D Heli

Version 2.0

0

NOTICE

This is an electronic duplicate of the Thunder Tiger Manual for the Raptor 50 V2 kit. In contrast
with the Raptor 30 manuals, a Raptor 50 manual has never been made available in electronic
form by Thunder Tiger. Therefore this manual was constructed partly by scanning in parts and by
manually creating the pages, and partly by copying and modifying the Raptor 30 V2 manual. I did
avery careful job in duplicating the manual, but of course I can not assume responsibility in case
of errors.
The duplicate has been kept as close as possible to the original manual, but at numerous places
errors and typos were corrected. At many places the English text was improved, as well as the
layout. Some part numbers have been corrected. A few sentences where correction would need
more than changing a few words were left unchanged.
The front page has been recreated in color, where the original manual is all black and white. A
colored front page is so much more inviting!

I hope you enjoy the use of this electronic manual.

June 2003
Wouter Pasman
Netherlands.

1

INTRODUCTION

Congratulations on your purchase of the Thunder Tiger Raptor 50 V2 helicopter. This model was
designed and engineered by the World-renowned Mr. Shgetada Taya. It combines elements of
his previously successful designs with today's advanced technologies.
Raptor 50: the best 50 class 3-D helicopter is now even better! The Raptor 50 V2 is the
cumulating result from all customers' feedback and tremendous research and development effort
by the Thunder Tiger design team. The Raptor 50 V2 is more rugged and has even better flying
performance than the original successful Raptor 50. The Raptor 50 V2 has the best power-to­weight ratio of any 50 class helicopter on the market. Buckle your seatbelt and get ready for
incredibly fast accelerations and climb rate. With the new main rotor, 3-D pilots will enjoy
executing crisp maneuvers like Climbing Tic-Toc, Chaos, Death Spirals, and any radical
maneuver that pilots can dream of. Key new features include stronger mainframes, bigger fuel
tank, reinforced pitch control arm, new main rotor with 6 mm spindle and bigger radial and thrust
bearings, and a fresh new look body. The V2 includes a constant drive auto rotation gear for
doing aerobatics during autorotation. Beginners and advanced 3-D fliers will be very impressed
with the new Raptor 50 V2.

CONTENTS

Introduction...............................................p.1

Contents ...................................................p.1

Warnings ..................................................p.1

Additional Items Needed...........................p.3

Tools Needed ...........................................p.3

Assembling Section.................................. p.4

Linkage Set-up Section ............................p.18

Blade Modification ....................................p.26

Parts List Section......................................p.28

WARNING

This radio controlled helicopter is not a toy. It is a sophisticated piece of equipment and is
designed for hobby use only. If not properly assembled and operated, it is capable of causing
property damage and bodily harm to both the operator and/or spectators. Thunder Tiger and its
duly authorized distributors assume no liability for damage that could occur from the assembly
and/or use/misuse of this product.

AMA INFORMATION

Operating a model helicopter requires a high degree of diligence and skill. If you are a newcomer
to the hobby, it is best to seek help and guidance from accomplished model helicopter pilots.
This will greatly speed up the learning process and have you flying successfully in a reasonable
time. We also would strongly urge you to join the Academy of Model Aeronautics. The AMA is a
non-profit organization that provides its members with a liability insurance plan as well as
monthly magazine entitled Model Aviation. All AMA charter aircraft clubs require all pilots to hold
acurrent AMA sporting license prior to operation of their models at club fields. For further
information, contact the AMA at:
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302
[phone]

2

FLIGHT SAFETY CHECKLIST

1. Make sure both the transmitter and receiver batteries are fully charged prior to operation the
helicopter.

2. Make sure all flight controls operate properly prior to flying.

3. Range check the radio before the first flight. The servos must operate properly with the
transmitter antenna collapsed at a range of at least 50 ft.(15 meters).

4. Check to make sure there is no radio interference on your radio channel before operating the
helicopter.

5. Use only the recommended engine fuel as specified by the engine manufacturer.

6. Make sure the transmitter and receiver are turned on before starting the engine.

7. The engine throttle must be in the idle position before starting the engine.

8. Model helicopter main and tail rotors operate at high RPM. Make sure nothing can come in
contact with the rotor blades during flight.

9. After starting the helicopter, maintain a safe distance during the flight.

10. Never operate the helicopter in rain or excessive wind conditions.

11. Always operate and fly your helicopter in a safe and responsible manner.

12. Never fly a model helicopter over other pilots, spectators or cars.

POST FLIGHT INSPECTION

1. Inspect the model thoroughly to insure no parts have come loose or become damaged during

the flight and landing. Replace damaged parts and tighten loose screws before flying again.

2. Pump out any remaining fuel from the fuel tank.

3. Wipe off excess oil and fuel from helicopter body and other exposed parts.

4. Lubricate all moving parts ensures smooth operation for the next time you fly.

5. Store model in a cool, dry place. Avoid storage in direct sunlight or near a source of heat.

Following these few, simple safety rules will allow you to enjoy the thrill of model helicopter flying
for many years to come.

SAFETY CHECKLIST

CAUTION: In the event the model has crashed, inspect the flybar, rotor shaft and the blade spindle to

make sure they are not bent at all. If any item is damaged, it must be replaced with a new part to ensure
safe operation. Do not glue any broken or damaged plastic part. Do not repair broken rotor blades. Always
inspect the following items immediately:
Engine starting shaft.
All the gears.
Main shaft, flybar and blade spindle.
Tail boom and support.
Vertical and horizontal fins.
Tail rotor shaft and control system.
Main and tail rotor blades.

3

TOOLS REQUIRED FOR ASSEMBLY

OTHER ITEMS REQUIRED

Receiver

Transmitter
(helicopter type only

6ormorechannels)

Servo x 5

Battery

1000mAh

Switch harness

Extended 6mm Hex

Starting Tool

Fuel Pump

HELI ENGINE(50-size)

Socket Drivers

Hex WrenchGrease

Blue Locktite

Instant Glue

Hobby Knife

Metric

4-way Wrench

ScissorsNipper5.5mm WrenchNeedle Nose PliersScrew Driver

Glow Plug Wrench

Gyro

Glow Fuel(15%-30%)

12V Battery

1.5V Glow starter
(1.2V~1.5V)

Rubber Band

Foam

RADIO SET

ENGINE

Glow Plug

12V Electric starter

7mm

5.5mm
7mm
8mm

5.5mm
7mm
8mm

10mm

Remote Glow Plug

Extension

Epoxy

Ball Link Pliers

4

ASSEMBLING SECTION

Most parts in the Raptor kit are packed according to the assembly steps. The part number and quantity contained
in each step are always shown in the square box on each page. Do not open all the bags at once. Open only the
bag that is needed for the current assembly step.

(3 )BK0463

(2 )BK0062

(5 )CB0363-1

(4 )BE1867

(1) BK0605

To Header Tank

(6) BB362-2

(6) BB362-2

To M uf f ler

5

2ClutchBellAssembly

1 Fuel Tank Assembly

(1)BK0605 Fuel Tank .....................1

(2)BK0062 Fuel Tank Grommet.......1

(3)BK0463 Fuel Tank Nipple .......... 1

(4)BE1867 Clunk.............................1

(5)CB0363-1 Silicone Fuel Tube.....1

(6)BB0362-2 Silicone Fuel Tube.....2

Note: After assembly, check to make sure the Fuel Tank
clunk can move from top to bottom without touching the
back of tank. Also, a fuel filter (available from any hobby
shop, TTR1164) should be placed between the fuel tank
and the carburetor.

(1) HMV1680 Bearing (d8xD16xW5).....1

(2) HMV1260Y Bearing (d6xD12xW4)...1

(3) BK0591 Clutch Bell..........................1

(4) BK0624 Drive Gear(Pinion 10T)......1

(5) BK0590 Clutch Liner........................1

(1) HMV1680

(4) BK0624

(3) BK0591

(2) HMV1260Y

(5) BK0590

The liner comes glued in the
clutch bell already

.

Connect the fuel tube to
header tank
(See Page 13 Step. 15)

(10) BK0600

(14) BK0594

(6) HME4-5B

(1) HSE3-12B

(2) HMV696Z

To pStarter Shaft
Bearing

(1) HSE3-12B

(8) BK0057

(15) Fuel Tank Ass'y

(16) Clutch Bell

Assembly

(13) BK0592

(3) HMV6800 Upper Main Shaft bearing

(4) BK0059 Main Frame Spacer(S)

(5) BK0058 Main Frame Spacer (L)

(11) BV0035

(1) HSE3-12B

(3) HMV6800

Lower Main Shaft Bearing

(9) BK0599

(7) BK0081

(12) BK0036

6

3MainFrame Assembly-Part1

(1) HSE3-12B Self Tapping Screw (M3x12).. 30

(2) HMV696Z Bearing (d6xD15xW5).......... 1

(3) HMV6800 Bearing (d10xD19xW5).......... 2

(4) BK0059 Frame Spacer (S)....................... 8

(5) BK0058 Frame Spacer (L)...................... 4

(6) HME4-5B Set Screw (M4x5)................... 2

(7) BK0081 Pin............................................. 2

(8) BK0057 Servo Frame.............................. 1

(9) BK0599 Main Frame Left Side.............. 1

(10) BK0600 Main Frame Right Side..........1

(11) BV0035 Guide Pulley.......................... 2

(12) BK0036 Pulley Collar.......................... 4

(13) BK0592 Starter Shaft.......................... 1

(14) BK0594 Starter Coupling.................... 1

(15) Fuel Tank Assembly

(16) Clutch Assembly

(17) HMS5 E-CLIP..................................... 1

(18) BK0584 Thrust Washer.......................1

Please insert the frame spacers, bearings, pulley and parts in the frames according the drawing below. Tighten the
screws snugly, but do not over torque them which could strip the plastic.
Insert starter shaft through the center of the clutch bell assembly, through the top starter shaft bearing and into the
starter coupling. Secure with the two set screws. Make sure this is tightly secured.

(17) HMS5

(18) BK0584

(3) HMV740ZZ

(4) BK0077

(5) BK0079

(6) BK0075

(7) BK0015

(8) BK0016

(9) BK0014

(1) HMJ2-10N

(2) HMC3-10B

(3) HMV740ZZ

(1) HMJ2-10N

(8) BK0016

(3) HMV740ZZ

(5) BK0079

(6) BK0075

(3) HMV740ZZ

(4) BK0077

(2) HMC3-10B

(7) BK0015

7

4Main Drive Gear Assembly

(1) HMC3-8B Socket Screw (M3x8)............. 4

(2) HMQ14 Snap Ring.................................... 2

(3) BV0033 One Way Clutch Housing.............1

(4) BK0148 Main Spur Gear 85T.....................1

(5) BK0610 Autorotation Tail Drive Pulley ..... 1

(6) BK0034 One Way Clutch Shaft..................1

5Washout Assembly

(1) HMJ2-10N Self Tapping Screw(M2x10).. 2

(2) HMC3-10B Socket Screw (M3x10)......... 2

(3) HMV740ZZ Bearing (d4xD7xW2.5)........ 4

(4) BK0077 Collar ........................................ 2

(5) BK0079 Pin............................................. 2

(6) BK0075 Linkage Ball.............................. 2

(7) BK0015 Flybar Control Lever.................. 2

(8) BK0016 Washout Linkage ..................... 2

(9) BK0014 Washout Base............................1

Make sure Linkage Balls are attached to the
inside hole of each stabilizer control lever.

(1) HMC3-8B

(6) BK0034

(2) HMQ14

(5) BK0610

(4) BK0148

(2) HMQ14

(3) BV0033

Add a drop of Blue Locktite on the
thread of each of these four screws.

Add some light
weight oil before
inserting this into
BV0033

8

6Main Frame Assembly-Part2

Add a drop of CA to the two screws at the pivoting point of the collective pitch control arm.
Attach the linkage rod to the parallel elevator linkage balls.

(1) HSE3-18B

(2) HSE3-12B

(3) HMJ3-22B

(4) HMJ2-14N

(5) HMJ2-10N

(6) HMV1280

(7) HMV740ZZ

(8) HMV840ZZ

(9) BK0076

(10) BK0078

(1) HSE3-18B

(12) BK0084

(13) BK0075

(14) BK0023

(15) BK0018

(16) BK0020

(17) BK0022

(18) BK0019

(20) BK0093

(21) BK0021

(22) BK0017

(14) BK0023

(7) HMV740ZZ

(5) HMJ2-10N

(13) BK0075

(8) HMV840ZZ

(10) BK0078
(11) BK0088
(7) HMV740ZZ

(13) BK0075

(7) HMV740ZZ

(9) BK0076

(6) HMV1280

(13) BK0075

(1) HSE3-18B

(5) HMJ2-10N

(7) HMV740ZZ

(5) HMJ2-10N

(13) BK0075

(7) HMV740ZZ

(9) BK0076

(1) HSE3-18B

(19) BK0086

Warning, do not over-torque the self-tapping screws.

(1) HSE3-18B Self Tapping Screw(M3x18)....4

(2) HSE3-12B Self Tapping Screw(M3x12)... 1

(3) HMJ3-22B Self Tapping Screw(M3x22)....1

(4) HMJ2-14N Self Tapping Screw(M2x14)... 1
(5) HMJ2-10N Self Tapping Screw(M2x10)... 6

(6) HMV1280 Bearing (d8xD12xW3.5)......... 2

(7) HMV740ZZ Bearing (d4xD7xW2.5)........ 6

(8) HMV840ZZ Bearing (d4xD8xW3)............ 2

(9) BK0076 Collar......................................... 3

(10) BK0078 Collar ...................................... 2

(11) BK0088 Flat Washer ......................... 1

(12) BK0084 Pin .......................................... 2

(13) BK0075 Linkage Ball..............................8

(14) BK0023 Elevator Control Arm Link........ 2

(15) BK0018 Elevator Control Arm................ 1

(16) BK0020 Elevator Arm Control Shaft.......1

(17) BK0022 Aileron Control Lever................ 2

(18) BK0019 Elevator Arm Parallel Lever...... 1

(19) BK0086 Ball Link....................................2

(20) BK0093 Linkage Rod ............................ 1

(21) BK0021 Elevator Control Lever..............1

(22) BK0017 Collective Pitch Control Arm.....1

66mm

7Main Frame Assembly-Part3

58mm

(1) BK0616 Socket Screw(M3x20)............1

(2) HMM3Z Lock Nut (M3)........................ 1

(3) HME4-5B Set Screw (M4x5)............... 2

(4) BK0086 Ball Link ................................ 4

(5) BK0092 Linkage Rod ......................... 2

(6) BK0030 Main Shaft Lock Ring............ 1

(7) BK0029 Main Shaft ............................ 1

(8) Wash Out Assembly

(9) BV0092 Swash Plate Assembly...........1

(10) Main Gear Assembly

Insert Main Shaft through the shaft bearings making sure that the end with the holes closest to the end is
pointed down. Next, slide main gear assembly into position on the shaft and line up the holes in the main
shaft with the holes in one way clutch shaft of the main gear assembly. Insert the socket head screw and
secure with the lock nut. Next, slide on the mainshaft lock ring on top of the main shaft bearing and secure
with the two set screws. Then slide on the swash plate assembly and attach the elevator and aileron
control linkages to the outside swash plate linkage balls. Next, slide on washout assembly and attach
washout linkage to the inner linkage balls of the swash plate.

(1) BK0616

(2) HMM3Z

(3) HME4-5B

(6) BK0030

(7) BK0029

(9) BV0092

(10) Main Gear Assembly

(8) Washout Assembly

(4) BK0086

(5) BK0092
(4) BK0086

8Engine Assembly

(1) HMC3-10B Socket Screw(M3x10)..... 2

(2) BV0589 Clutch Shoe..........................1

(3) BV0143 Cooling Fan.......................... 1

(4) No.9605 TT PRO-50H(R) Engine.......1

(5) BK0170 Shim.....................................1

Note: A piston lock (TTR1166P) purchased from your dealer will
make this a much easier task. You must replace the standard
throttlearm w/the extended throttle arm and attach the linkage
ball.

9

(1) HMC3-10B

(4) No.9605

(3) BV0143

(1) HMC3-10B

Add Blue Locktite

Linkage Ball to
throttle Arm

(2) BV0589

(5) BK0170

T

ighten the engine
nut securely by
grabbing the plastic
fan with a towel.

(5) BV0172

(6) Engine Ass'y.

(3) BK0087

(1) HMC3-14B

(2) HMC3-35B

Add Blue Locktite

(3) BK0087

Add Blue Locktite

Engine mount
Attachment

(1) HMC3-14B

(1)

(3) BK0087

(3) BK0087

(7) BA1579

HMC3-14B

Add Blue
Locktite

10

(1) HMC3-14B Socket Screw(M3x14)...... 8

(2) HMC3-35B Socket Screw(M3x35)..... 2

(3) BK0087 Flat Washer

........................... 4

(4) BK0144 Engine Mount........................ 1

(5) BV0172 Muffler ................................... 1

(6) Engine Assembly

(7) BA1579 Muffler Gasket.......................

Add blue Loctite to all metal to metal screw surfaces.

After installing the engine, connect the silicone fuel tube

to the carburator and muffler.

9MainFrame Assembly-Part4

10 Landing Skid Assembly

(1) HSE3-18B Self Tapping Screw(M3x18).4

(2) HME4-5B Set Screw(M4x5)..................4

(3) BK0066 Skid Brace...............................2

(4) BK0064 Skid Pipe.................................2

(5) BK0065 Skid Pipe End Cap..................4

(3) BK0066

(2) HME4-5B

(5) BK0065

(1) HSE3-18B

(4) BK0064

(2) HME4-5B

(3) BK0066

(2) HME4-5B

(1) HSE3-18B

(6) BK0525 Carbon Base Plate..................1

(5) BK0065

The engine mount furnished will accommodate the Thunder Tiger 46H,
50H, and the other heli engines. If you are installing a Thunder Tiger
engine, you will find the mount is wider than the engine crankcase. Two
spacers are furnished to accurately locate the engine while bolting it in
place.Remove thesespacers afterinstallation.

Engine Mount Notes:

Step1

Install the engine and
spacers into the engine
mount.

Step2

Install the 4 mount screws
and make sure the screws
are tightened firmly.

Step3

Remove the spacers.

(8) BK0179

(8) BK0179 Spacer...................................

1
2

(4) BK0144

(5) BK0525

(32) BK0584

(30) BK0595

(29) BK0587

(28) BK0012

(26) BV0085

(25) BK0007

(24) BK0583

(23) BK0596

(22) BK0006

(20) BK0005

(19) BK0002

(18) BK0010

(17) BK0067

(16) BK0088

(15) BK0581

(25) BK0007

(4) HME4-5B

(31) BK0075

(9) HMV740ZZ

(13) BK0076

(1) HMC3-14B

(31) BK0075

(9) HMV740ZZ
(3) HMJ2-10N

(11) HMX0612

(5) HME3-10B

(17) BK0067

(5) HME3-10B

(8) HMV830ZZ

(21) BK0004

(3) HMJ2-10N

(31) BK0075

(9) HMV740ZZ

(13) BK0076
(1) HMC3-14B

(22) BK0006

(10) HMV840ZZ

(14) BK0078

(2) HMC3-8B

(26) BV0085

(3) HMJ2-10N
(31) BK0075
(23) BK0596

(7) HMC4-8B

(12) HMV1360Z

(32) BK0584

(11) HMX0612

(27) BK0586

(7) HMC4-8B

(6) BK0435

(12) HMV1360Z

(6) BK0435

(12 ) HMV1360Z

(31) BK0075

(3) HMJ2-10N

11

11 Main Rotor Head Assembly

(1) HMC3-14B Socket Screw(M3x14)........... 2

(2) HMC3-8B Socket Screw(M3x8)................ 2

(3) HMJ2-10N Self Tapping Screw(M2x10).... 8

(4) HME4-5B Set Screw(M4x5)...................... 2

(5) HME3-10B Set Screw(M3x10).................. 2

(6) BK0435 Washer (d4xD11xW1.7)............ 2

(7) HMC4-8B Socket Screw (M4x8)............. 2

(8) HMV830ZZ Bearing (d3xD8xW4)............ 2

(9) HMV740ZZ Bearing (d4xD7xW2.5)......... 4

(10) HMV840ZZ Bearing (d4xD8xW3).......... 2

(11) HMX0612 Thrust Bearing...................... 2

(12) HMV1360Z Bearing (d6xD13xW5).......... 4

(13) BK0076 Collar..........................................2

(14) BK0078 Collar.......................................... 2

(15) BK0581 Flap Collar..................................2

(16) BK0088 Flat Washer................................ 2

(17) BK0067 Flybar Paddle............................ 2

(18) BK0010 Flybar Rod..................................1

(19) BK0002 Flybar Control Arm.................... 2

(20) BK0005 Flybar Arm Bushing................... 2

(21) BK0004 Flybar Seesaw Hub....................1

(22) BK0006 Mixing Lever.............................. 2

(23) BK0596 Main Rotor Pitch Housing...........

2

(24) BK0583 Feathering Shaft................ 1

(25) BK0007 Flybar Control Rod............. 2

(26) BV0085 Double Link ...................... 2

(27) BK0586 Flap Damper...................... 2

(28) BK0012 Pin..................................... 2

(29) BK0587 Main Rotor Hub Pin............1

(30) BK0595 Main Rotor Hub.................. 1

(31) BK0075 Ball Link............................. 8

(32) BK0584 Thrust Washer.................... 2

Assembly Hint: Start from the bottom of the main Rotor Hub and work your way up to the flybar assembly. When
screwing on the flybar paddles to the flybar, stop when you can see the rod in the window of the paddle. Then, lay
the assembly on a flat surface and align the paddles so they are exactly parallel. Insert and tighten the set screws.
Attach the flybar control rod to the flybar control arm and use the Double Link to connect the mixing lever (short side)
to the Main rotor Pitch Housing.

Diagram for Thrust Bearing Assembly

(11) HMX0612

Large Internal Diameter­always go toward the
Main Rotor Hub

Small Internal Diameter­always go toward the
Blade