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XCell Ion-X2 Assembly Manual

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X-Cell Ion-X
Assembly Manual
Version 1.0
Revision Date: 08/22/2007
Created: 8/25/2007
Copyright Miniature Aircraft US
This document may not be distributed without permission of Miniature Aircraft USA

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Summary of Contents for XCell Ion-X2

  • Page 1 X-Cell Ion-X Assembly Manual Version 1.0 Revision Date: 08/22/2007 Created: 8/25/2007 Copyright Miniature Aircraft US This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 2 XCell Ion-X Assembly Manual For More Information contact: Miniature Aircraft 31713 Long Acres Drive Sorrento, FL 32776 USA Phone 352-383-3201 352-383-3204 Email: minair@miniatureaircraftusa.com Page 2 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 3: Table Of Contents

    XCell Ion-X Assembly Manual Table of Contents REVISIONS TO THIS MANUAL................................. 5 ERRATA........................................5 I. KIT INTRODUCTION ..................................6 R/C H ..................................6 ELICOPTER AFETY R/C H ........................... 6 UIDELINES FOR ELICOPTER LIGHT X-CELL L ................................7 IMITED ARRANTY ..................................7...
  • Page 4 XCell Ion-X Assembly Manual 5B) Battery/Speed Control Mounts – Bag #5B..........................68 5B.1 – Mount Speed Controller ................................69 5B.2 – Prepare Battery Mounts ................................69 5C) Install Servos/Electronics – Bag #5C ............................71 5C.1 – Install Servos....................................71 5C.1.1 – Install Pitch Servo ..................................72 5C.1.2 –...

  • Page 5: Revisions To This Manual

    XCell Ion-X Assembly Manual Revisions to this Manual R1.0 • 08/12/07 – Revisions for final kitting modifications • 08/17/07 – Corrected document format errors • 08/22/07 - Initial Release For the most current version of this manual, please refer to www.miniatureaircraftusa.com, visit the Ion-X...

  • Page 6: Kit Introduction

    XCell Ion-X Assembly Manual I. Kit Introduction R/C Helicopter Safety A radio controlled model helicopter is a technically complex device that must be built and operated with care. It is also a fascinating and challenging part of the R/C sport, the mastery of which is very rewarding.

  • Page 7: X-Cell Limited Warranty

    XCell Ion-X Assembly Manual X-CELL Limited Warranty The warranty covers defects in material or workmanship or missing components to the original purchaser for 30 days from the date of purchase. Miniature Aircraft, USA will replace or repair, at our discretion, the defective or missing component.

  • Page 8: Kit Prerequisites

    XCell Ion-X Assembly Manual II. Kit Prerequisites In order to assemble this kit, you will need a number of additional supplies and tools to ensure the best final result. They are as follows: Supplies Needed for Assembly Blue Thread Red Thread...

  • Page 9: Tools Needed For Assembly

    XCell Ion-X Assembly Manual Tools Needed for Assembly M5 Nut Driver Needle Nose Pliers 8.0mm wrench M5.5 Nut Driver Phillips Screwdriver #1 5.5mm wrench M7 Nut Driver Flat Screwdriver 2.5mm 4.0mm wrench M4 Nut Driver Razor Knife (Xacto) 1.5mm allen driver 2.0mm allen driver...

  • Page 10: Additional Components Needed

    XCell Ion-X Assembly Manual Additional Components Needed Electronics Switch Receiver Gyro Battery – NiCad Servo NiMH/LiPo 1 each 800mah A or AA cells Cyclic Servos 3 each Gyro – Heading Hold Rotor Blades Main Rotor Blades 700-720mm 5mm blade bolt...

  • Page 11: Documentation

    XCell Ion-X Assembly Manual Power System Electronic Speed Control and motor – should be matched to the drive ratio and batteries you plan to use Main Batteries Documentation The most recent version of all of the documentation can be found on the website: www.miniatureaircraftusa.com...

  • Page 12: Kit Assembly Process

    XCell Ion-X Assembly Manual III. Kit Assembly Process Assembly Tips • Please note that this assembly manual consists of a photographic journal of the steps necessary to construct this helicopter. The builder is encouraged to pay close attention to the "building notes"...

  • Page 13: Fastener Guide

    XCell Ion-X Assembly Manual Fastener Guide The next two pages contain a list of all of the threaded fasteners in this kit. They will print at actual size. If it is not clear what the part number of a fastener is, simply find the fastener on the chart and match its part number and description Fasteners –...
  • Page 14 XCell Ion-X Assembly Manual Fasteners – Threaded Bolts Part # Description Actual Size 0059-1 M2.5 x 6 Socket Bolt ------------------- 0061 M3 x 8 Socket Bolt --------------------- 0060-1 M3 x 6 Socket Bolt --------------------- 0061 M3 x 8 Socket Bolt ---------------------...

  • Page 15: Assembly Components - Unbagged Parts

    Decal Sheet 1 each Canopy #124-98 Ion-X Canopy 1 each Kit Documentation #124-100 Ion-X2 Kit Documentation 1 CD Created: 8/25/2007 Page 15 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 16: Assembly Components - Long Parts Bag

    XCell Ion-X Assembly Manual Assembly Components – Long Parts Bag #120-15 33” Aluminum Tail Boom 1 Each #0867-15 Torque Tube T/R Drive 1 Each #0872-9 Tail Boom Supports 2 Each #0868-14 T/R Pushrod Graphite – 31-5/8” 1 Each #0566-1 Flybar – 18-5/8”...

  • Page 17: Step #1 - Locate Main Drive Components

    XCell Ion-X Assembly Manual Step #1 – Locate Main Drive Components 1A-S) Drive Train Components - Bag #1A – Single Gear #0865-93 93 tooth #124-160 main gear 7.75:1 Bearing Plate 1 each 1 each #124-172 12 tooth pinion gear 1 each...

  • Page 18: D) Drive Train Components - Bag #1A - Double Gear

    XCell Ion-X Assembly Manual 1A-D) Drive Train Components - Bag #1A – Double Gear #124-160 7.75:1 Bearing Plate 1 each #124-172 12 tooth pinion gear 1 each #124-166 7.75:1 Right Upper Ratio Plate 1 each #124-169 Assembled Ultimate 3D Autorotation...

  • Page 19: Primary Drive - Bag #1B

    XCell Ion-X Assembly Manual 1B) Primary Drive - Bag #1B Drive Belt #124-xxx - xxmm #124-xxx - xxmm 1 belt Drive Pulley (ratio dependent) Drive Pulley (ratio dependent) #124-216 – 6mm – 16 tooth #124-228 – 6mm – 28 tooth #124-216-8 –...

  • Page 20: Step #2 - Main Frame Assembly

    XCell Ion-X Assembly Manual Step #2 – Main Frame Assembly 2A) Major Frame Components - Bag #2A #124-134 G-10 Battery Main Plate 1 each #124-130 CF Left Main Frame 1 each #124-138 Vertical Rear Channel 1 each #124-142 Horizontal Upper...

  • Page 21: Chassis Components - Bag #2B

    XCell Ion-X Assembly Manual 2B) Chassis Components - Bag #2B #120-12 Upper Main Shaft Bearing Block 1 each #120-8 #127-65 Lower Main Shaft Bearing Block #126-55 Bearing Block w/ M6 Bearing Gyro Mounting 1 each 1 each Channel #124-144 1 each...

  • Page 22: - Assemble Left Frame

    XCell Ion-X Assembly Manual 2B.1 - Assemble Left Frame Parts Relationship Page 22 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 23 XCell Ion-X Assembly Manual 2B.1.a 2B.1.b #124-130 #0169 #0169 #0060-1 #0060-1 #0060-1 #0060-1 Standard 120° Optional 140° Bellcrank Layout Bellcrank Kit Layout 2B.1.c 2B.1.d Install here for 120° Bellcrank Position #115-20 Install here for optional 140° Swashplate Kit 2B.1.e 2B.1.f 2B.1.g...
  • Page 24 XCell Ion-X Assembly Manual 2B.1.h 2B.1.i 2B.1.j #124-144 #0019 (2) #124-136 #0003 (2) #0062 #124-13 2B.1.k 2B.1.l Building Notes: Note orientation and position of the vertical and horizontal rails #0061 (8) #124-142 #124-140 #124-136 2B.1.m 2B.1.n 2B.1.o #0061 #126-55 #0060-1...
  • Page 25 XCell Ion-X Assembly Manual 2B.1.P 2B.1.Q 2B.1.R Do Not Tighten These #0032 (2) #120-12 Until A Later Step #124-14 #0109 #120-8 #0061 2B.1.s 2B.1.t 2B.1.u #0874-1 #124-168 #0060-1 #0061 2B.1.v 2B.1.w #0063 (2) Building Notes: Do not tighten the front...

  • Page 26: Drive Train Components - Bag #2C

    XCell Ion-X Assembly Manual 2C) Drive Train Components - Bag #2C #0866-13 #0232 M14 x 20 x .1 15 tooth Shim #0866-5 Pinion Gear 1 Each 70 tooth 1 Each #0866-10 Crown Gear M14 x 20 x .2 1 Each...

  • Page 27: Assemble Constant Drive Unit

    XCell Ion-X Assembly Manual 2C.1 Assemble Constant Drive Unit 2C.1.1 Single Gear Constant Drive Parts Relationship #0866-5 #0866-6 #0088-2 (Qty 8) #0866-13 #0866-10 #0866-11 #0865-93 for 7.75 #0866-4 #0057 #0840-6 #0866-10 #0866-11 #0866-12 #0088 (Qty 4) Created: 8/25/2007 Page 27 of 123...
  • Page 28 XCell Ion-X Assembly Manual 2C.1.1.a 2C.1.1.b 2C1.1.c Round Edge #0866-6 #0866-5 #0865-93 #0866-4 #0088 (4) 2C.1.1.d 2C.1.1.e 2C1.1.f #0866-11 #0866-10 #0088-2 (8) #0866-13 2C.1.1.g 2C.1.1.h 2C1.1.i #0866-10 #0866-11 #0866-12 Page 28 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 29 XCell Ion-X Assembly Manual 2C.1.2 Double Gear Constant Drive Parts Relationship #0866-6 #0866-5 #0866-13 #0088-2 (Qty 8) #0866-10 #0866-11 #124-169 #0866-10 #0866-11 Pre-Assembled #0866-12 #0057 #0840-6 2C.1.1.a 2C.1.1.b 2C1.1.c #0866-5 #0866-6 #0088-2 (8) Created: 8/25/2007 Page 29 of 123 Copyright Miniature Aircraft USA...
  • Page 30 XCell Ion-X Assembly Manual 2C.1.1.d 2C.1.1.e 2C1.1.f #0866-11 #0866-10 #0866-10 #0866-13 2C.1.1.g 2C.1.1.h #0866-12 #0866-11 Page 30 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 31: Install Drive Train Components

    XCell Ion-X Assembly Manual 2C.2 Install Drive Train Components Parts Relationship #120-12 #0875-1 #0057 (2) #0059-1 #0875-1 #0057 (2) #0232 #123-87 #0059-1 #120-8 #120-9 #0866-15 #124-38 #0866-12 #0057 #0840-6 Created: 8/25/2007 Page 31 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 32 XCell Ion-X Assembly Manual 2C.2.a 2C.2.b 2C.2.c #0875-1 (2) #123-87 #0232 #0057 (2) #0059-1 (2) #0057 (2) 2C.2.d 2C.2.e 2C.2.f #0866-15 Building Notes: first clean the main shaft #123-87 and t/r input shaft to remove the protective lubricants Slide the main shaft into place as shown.
  • Page 33 XCell Ion-X Assembly Manual 2C.2.j 2C.2.k 2C.2.l #0866-12 #0840-6 #0057 Building Notes: align the holes in the main Building Notes: slide the pinion gear shaft, autorotation unit and retaining collar forward as shown and snug one of the set and slide the pin through them screws 2C.2.m...
  • Page 34 XCell Ion-X Assembly Manual Page 34 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 35 XCell Ion-X Assembly Manual Created: 8/25/2007 Page 35 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 36: Drive Train Components - Bag #2D

    XCell Ion-X Assembly Manual 2D) Drive Train Components - Bag #2D #0063 #0186 #0060-1 #0061 #0009 M3 x 10 Boom M3 x 6 M3 x 8 M3 Washer Socket Bolt Clamps Socket Bolt Socket Bolt Small 2 Each #0051 2 Each...

  • Page 37: Install Right Frame

    XCell Ion-X Assembly Manual 2D.1 Install Right Frame Parts Relationship #0032 (2) #0061 #0061 #0169 #0060-1 (3) #124-14 #0060-1 #0060-1 #0061 #0061 #124-166 #124-132 #0060-1 (4) #124-13 #0061 (2) #0003 (2) #124-146 #0060-1 (3) #0063 (2) #0060-1 #0061 (3) 2D.1.a 2D.1.b...
  • Page 38 XCell Ion-X Assembly Manual 2D.1.d 2D.1.e #0169 #0060-1 #0060-1 2D.1.f 2D.1.g 2D.1.h #0032 (2) #0003 #0060-1 #0169 #0061 #0063 Building Notes: Don’t tighten the two bolts for the front bearing block until step 4 2D.1.i 2D.1.j 2D.1.k #0061 #124-13 #124-146...
  • Page 39 XCell Ion-X Assembly Manual 2D.1.l 2D.1.m 2D.1.n #115-40 #0061 #0060-1 2D.1.o 2D.1.p 2D.1.q #0186 (2) #0061 #0061 2D.1.r 2D.1.s 2D.1.t #0077 (4) Created: 8/25/2007 Page 39 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 40 XCell Ion-X Assembly Manual 2D.1.u #0077 (4) Page 40 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 41 XCell Ion-X Assembly Manual Created: 8/25/2007 Page 41 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 42 XCell Ion-X Assembly Manual Page 42 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 43: Assemble Bellcranks

    XCell Ion-X Assembly Manual 2D.2 Assemble Bellcranks Parts Relationship #0099 Aileron #0171 #0051 #0009 #0159 #124-148 #0112 #122-28 #0159 #0105 #0169 #0159 #124-22 #0167 Elevator #0105 #0113 #0159 #0169 #0009 (2) #0159 #0159 #0167 #0597-3 #0112 #0009 #0107 Pitch #0019...
  • Page 44 XCell Ion-X Assembly Manual 2D.2.a 2D.2.b 2D.2.c #0159 Right Bellcrank #0159 #0167 2D.2.d 2D.2.e 2D.2.f #0112 Left Bellcrank Milled Flat #0107 2D.2.g 2D.2.h 2D.2.i #0105 #0159 #0159 #0112 Page 44 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 45: Install Bellcranks

    XCell Ion-X Assembly Manual 2D.2.j 2D.2.k 2D.2.l Front Bellcrank #0597-3 #0159 #0159 2D.2.m 2D.2.n 2D.2.o #0113 #0113 #0105 #0009 (2) 2D.3 Install Bellcranks 2D.3.a 2D.3.b 2D.3.c Right Bellcrank Left Bellcrank Created: 8/25/2007 Page 45 of 123 Copyright Miniature Aircraft USA...
  • Page 46 XCell Ion-X Assembly Manual 2D.3.d 2D.3.e 2D.3.f Front Bellcrank Installation Order 2D.3.g 2D.3.h 2D.3.i 2D.3.j Page 46 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 47: Step #3 - Skids/Battery Plate

    XCell Ion-X Assembly Manual Step #3 – Skids/Battery Plate 3A) Landing Gear - Bag #3A #124-150 Control Plate #127-53 G-10 Struts 1 each 2 each #124-152 CF Reinforcement plate 1 each #127-54 Skids 2 each #0872-8 Boom Support End 2 each...

  • Page 48: Assemble Landing Gear

    XCell Ion-X Assembly Manual 3A.1 Assemble Landing Gear Parts Relationship #127-54A #127-54 #0058-1 #127-54A #124-152 #0872-8 #127-53 #0058-1 #124-150 #0077 #0003 #0073 #0003 #0019 #0003 #0019 #127-53 #0058-1 #0872-8 #115-40 #127-54A #115-40 #0058-1 #127-54 #127-54A 3A.1.a 3A.1.b 3A.1.c #41 Drill...
  • Page 49 XCell Ion-X Assembly Manual 3A.1.d 3A.1.e 3A.1.f #127-54 Building Notes: Tighten only until set screw is flush with #0058-1 opening but doesn’t protrude into 3A.1.g 3A.1.h 3A.1.i #124-150 #0073 3A.1.j 3A.1.k 3A.1.l Wider #0077 #0003 #0003 #0019 #0019 Bolts Go This Way...
  • Page 50 XCell Ion-X Assembly Manual 3A.1.m 3A.1.n 3A.1.o #0003 #0019 #124-152 #0019 #127-54 3A.1.p 3A.1.q 3A.1.r #127-54A #127-53 3A.1.m 3A.1.n 30mm Building Notes: Slide skids in from front Page 50 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 51: Step #4 - Belt Drive/Motor Assembly

    XCell Ion-X Assembly Manual Step #4 – Belt Drive/Motor Assembly 4A) Belt Drive - Bag #4A #127-63 #0078-5 M8 x 14 Spacers M4 x 10 Socket Bolt #0084 #0083 8 each 4 each #0273 M4 x 35 M4 x 25 M6 x .011”...

  • Page 52: Assemble Primary Belt Drive

    XCell Ion-X Assembly Manual 4A.1 Assemble Primary Belt Drive Parts Relationship #0273 #124-172 #124-170 #0057 #0057 #124-2xx #127-63 (2) #127-63 (2) #0058 #0058 #0075 #0075 #0061 #0273 #0061 #0073 #0073 #0586-16 #0586-16 #0061 #0061 #0061 #124-160 #0061 #0061 #0061 #124-158...
  • Page 53 XCell Ion-X Assembly Manual 4A.1.a 4A.1.b 4A.1.c #0077 #0077 #0077 #0586-16 #124-160 #0077 #0073 #0073 #0586-16 #125-56 #0077 4A.1.d 4A.1.e 4A.1.f #0077 #125-63 (4) #0073 (2) 4A.1.g 4A.1.h 4A.1.i #124-172 #124-170 #0057 (2) Created: 8/25/2007 Page 53 of 123 Copyright Miniature Aircraft USA...
  • Page 54 XCell Ion-X Assembly Manual 4A.1.j 4A.1.k 4A.1.l #124-2xx Align one set screw with upper shaft flat. Tighten only lightly at this #0058 (2) time 4A.1.m 4A.1.n 4A.1.o Align one set screw with upper shaft flat. Tighten only lightly at this...
  • Page 55 XCell Ion-X Assembly Manual 4A.1.s 4A.1.t 4A.1.u #0077 #125-54 #125-63 (4) #0073 (2) 4A.1.v 4A.1.w 4A.1.x #0061 (2) Tighten Don’t fully Paper Strip tighten yet 4A.1.y 4A.1.z 4A.1.aa Tighten Building Notes: Tighten the set screw against the shaft flat WHILE pushing the...

  • Page 56: Assemble Motor Mount/Motor

    XCell Ion-X Assembly Manual 4A.1.bb 4A.1.cc Building Notes: Tighten the set screw against the shaft flat WHILE pushing the pulley down against the lower bearing 4A.2 Assemble Motor Mount/Motor 4A.2.a 4A.2.b 4A.2.c #0061 #0586-17 #0032 (2) #0061 #124-158 #0061 #0061 #0586-17 4A.2.d...
  • Page 57 XCell Ion-X Assembly Manual 4A.2.g 4A.2.h 4A.2.i 4A.2.j 4A.2.k 4A.2.l #124-2xx Flush #0058 (2) Building Notes: Align one set screw with the flat on the motor shaft. If there is no flat on the motor shaft use a grinding tool to cut one.

  • Page 58: Connect Esc

    XCell Ion-X Assembly Manual 4A.3 Connect ESC 4A.3.a 4A.2.b 4A.3.c Positive Match battery polarity to plug polarity Deans Female Connectors Optional Connector Kit Battery Side 4A.3.d 4A.3.e 4A.3.f Positive Negative Positive Battery Series Connector Follow manufacturers directions to connect Deans Male Connectors...

  • Page 59: Install Motor

    XCell Ion-X Assembly Manual 4A.4 Install Motor 4A.4.a 4A.4.b 4A.4.c Front #0003 (2) #0063 (2) 4A.4.d 4A.4.e 4A.4.f #124-157 #0084/0083 4A.4.g 4A.4.h Building Notes: Depending on the drive ratio, you may need the shorter or longer bolt to set the belt tension. Insert the...
  • Page 60 XCell Ion-X Assembly Manual 4A.4.i 4A.4.j 4A.4.k Building Notes: Using an allen driver, tighten the belt adjustment mechanism until the drive belt will deflect 1/16” or less when pushed from the side. 4A.4.l 4A.4.m Building Notes: Once the belt tension is...

  • Page 61: Step #5 - Control System/Canopy

    XCell Ion-X Assembly Manual Step #5 – Control System/Canopy 5A) Washout Mixer/Swashplate Assembly – Bag #5A #0159 #0051 #0869 #0221 #0219 M3 x 7 x 3 M3 x 3 Ball Washout Washout Washout Socket Set Screw Bearings Links Arms 4 each...
  • Page 62 XCell Ion-X Assembly Manual Parts Relationship #0869 #0109 #106-08 #106-07 #106-08 #0221 #0597-2 #0159 #0097 #0097 #0159 #0159 #0159 #0597-2 #0219 #0221 #0109 #106-08 #106-07 #106-08 #0133 #0133 #0869 #0107 #0369 #0109 #0112 #0217 #0107 #0112 #0109 #0107 #0597-4 #0133...

  • Page 63: - Assemble Swashplate

    XCell Ion-X Assembly Manual 5A.1 - Assemble Swashplate #0065 #0159 #0597-4 #0112 #0109 #0107 #0107 #0217 #0109 #0112 #0107 5A.1.a 5A.1.b 5A.1.c #0217-6 #0107 #0051 #0060-1 #0060-1 #0107 #0051 #0051 #0060 #0060 #0051 Building Notes: Thread set screws into Optional 140 degree CCPM kit – swashplate assembly as shown the bearing tension holes on the bottom of the swashplate.

  • Page 64: - Swashplate Control Rods

    XCell Ion-X Assembly Manual 5A.2 – Swashplate Control Rods 5A.2.a 5A.2.b #0133 #0133 #0133 #0369 20 mm 12 mm #0369 #0369 #0133 #0133 #0133 5A.2 - Assemble Washout Mixer Parts Relationship #0869 #106-07 #0221 #106-08 #106-08 #0109 #0597-2 #0219 #0159...
  • Page 65 XCell Ion-X Assembly Manual 5A.2.a 5A.2.b 5A.2.c #0221 #0159 #0109 #0597-2 5A.2.d 5A.2.e 5A.2.f #106-07 #106-08 #0159 5A.2.g 5A.2.h 5A.2.i Created: 8/25/2007 Page 65 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 66 XCell Ion-X Assembly Manual 5A.2.j 5A.2.k 5A.2.l #106-08 Building Notes: Heat Plastic with heat gun until hot and then move the link back and forth until it loosens up. Don’t Overheat. 5A.2.m #0219 #0097 Page 66 of 123 Created: 8/25/2007...

  • Page 67: - Install Swashplate/Washout Mixer

    XCell Ion-X Assembly Manual 5A.3 - Install Swashplate/Washout Mixer 5A.3.a 5A.3.b 5A.3.c 5A.3.d 5A.3.e 5A.3.f 5A.3.g 5A.3.h 5A.3.i Short Ball Created: 8/25/2007 Page 67 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 68: Created: 8/25/2007

    XCell Ion-X Assembly Manual Threaded Balls Used For Swashplate/Mixer Assembly Prints Actual Size #0113 #0109 #0103 #0107 #0112 5B) Battery/Speed Control Mounts – Bag #5B #124-176 Female Adhesive Back Velcro – 16” 1 each #124-178 Double Sided Velcro – 48”...

  • Page 69: - Mount Speed Controller

    XCell Ion-X Assembly Manual 5B.1 – Mount Speed Controller 5B.1.a 5B.1.b 5B.1.c 5B.1.d 5B.2 – Prepare Battery Mounts 5B.2.a 5B.2.b 5B.2.c Created: 8/25/2007 Page 69 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 70 XCell Ion-X Assembly Manual 5B.2.d 5B.2.e 5B.2.f 5B.2.g Page 70 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 71: Install Servos/Electronics - Bag #5C

    XCell Ion-X Assembly Manual 5C) Install Servos/Electronics – Bag #5C #0390 Wire Retainer 6 each #0133 #0367 Ball Link - Long M2 x 60 6 each Control Rod 2 each #0560-1 #0575-1 Servo Spacers – G10 Plastic Servo Blocks 2 each...

  • Page 72: 1.1 - Install Pitch Servo

    XCell Ion-X Assembly Manual 5C.1.1 – Install Pitch Servo Parts Relationship #0015 #0103 #0367 #0133 #0133 #0038 (2) #0038 (2) 5C.1.1.a 5C.1.1.b #0038 (4) Page 72 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 73: 1.2 - Install Elevator Servo

    XCell Ion-X Assembly Manual 5C.1.2 – Install Elevator Servo Parts Relationship #0039 (2) #0039 (2) #0560-1 #0560-1 #0337 #0133 #0133 #0103 #0015 5C.1.2.a 5C.1.2.b 5C.1.2.c #0560-1 #0039 (4) #0560-1 Created: 8/25/2007 Page 73 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 74: 1.3 - Install Aileron Servo

    XCell Ion-X Assembly Manual 5C.1.3 – Install Aileron Servo Parts Relationship #0038 (2) #0038 (2) #0133 #0133 #0367 #0103 #0015 5C.1.3.a 5C.1.3.b #0038 (4) Page 74 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 75: 1.4 - Install Rudder Servo

    XCell Ion-X Assembly Manual 5C.1.4 – Install Rudder Servo Parts Relationship #0039-1 (2) #0039-1 (2) #0575-1 #0575-1 #0015 #0103 5C.1.4.a 5C.1.4.b 5C.1.4.c #0039-1 (2) #0039-1 (2) #0575-1 Created: 8/25/2007 Page 75 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 76: 1.5 - Check Servo Orientation

    XCell Ion-X Assembly Manual 5C.1.5 – Check Servo Orientation 5C.1.5.a 5C.1.5.b 5C.1.5.c 140° Position Rudder Elevator Servo Servo Aileron Servo 120° 5C.1.5.d 140° Position Pitch Servo 120° Page 76 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 77: - Install Electronics

    XCell Ion-X Assembly Manual 5C.2 – Install Electronics 5C.2.a 5C.2.b 5C.2.c #0390 #0390 5C.2.d 5C.2.e 5C.2.f #0390 5C.2.g 5C.2.h 5C.2.i Created: 8/25/2007 Page 77 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 78: - Install Servo Control Rods

    XCell Ion-X Assembly Manual 5C.3 – Install Servo Control Rods 5C.3.a 5C.3.b 5C.3.c #0133 #0103 #0133 #0133 #0103 #0367 #0367 #0337 #0015 #0133 #0015 #0133 #0133 5C.3.d 5C.3.e 5C.3.f 44 mm 90° 90° 90° 90° 7 mm 5C.3.g 5C.3.h 90°...
  • Page 79 XCell Ion-X Assembly Manual Servo Control Rod Lengths #0367 Pitch #0133 #0133 Control 44 mm - 120° Swashplate Rods #0133 #0369 20 mm #0133 #0133 12 mm #0369 #0133 Aileron #0133 Control #0337 Rods 20 mm #0369 #0133 #0133 44 mm - 120° Swashplate...

  • Page 80: Install Canopy - Bag #5D

    XCell Ion-X Assembly Manual 5D) Install Canopy – Bag #5D #115-94 #122-99 Rubber Grommet - Small Canopy Knob 2 each 2 each #106-22 Rubber Grommet – Large 2 each 5D.1 – Prepare Canopy Page 80 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA...
  • Page 81 XCell Ion-X Assembly Manual 5D.1.a 5D.1.b 5D.1.c Drill this hole With #H drill .265” or 17/64” Drill this hole With #1 drill .225” Install grommets into canopy as shown 5D.1.d 5D.1.e #115-94 #106-22 Building Notes: At this point you can prepare the canopy by either painting it or applying canopies.

  • Page 82: Step #6 - Rotor Head

    XCell Ion-X Assembly Manual Step #6 – Rotor Head 6A) Assemble Rotor Head – Bag #6A #0848-2 #123-26 #0848-12 Circlips Aluminum Thrust 2 each Bell Bearings Mixers 2 each 2 each #0562-1 M3 x .003” Shim #0597-3 2 each #120-5 .187”...

  • Page 83: - Head Block Assembly

    XCell Ion-X Assembly Manual 6A.1 - Head Block Assembly 6A.1.a 6A.1.b #0509-1 #0065 #0065 (2) 6A.2 – Assemble Bell Mixer Parts Relationship #120-18 #106-02 #0597-3 #123-26 #0112 #0115 #106-02 #0562-1 #0093 Created: 8/25/2007 Page 83 of 123 Copyright Miniature Aircraft USA...
  • Page 84 XCell Ion-X Assembly Manual 6A.2.a 6A.2.b 6A.2.c #106-02 #0109 #0112 #0597-3 #123-26 6A.2.d #106-02 Page 84 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 85: - Install Bell Mixers

    XCell Ion-X Assembly Manual 6A.3 – Install Bell Mixers 6A.3.a 6A.3.b #0097 #0562-1 Outside hole Building Notes - Select the bell mixer with the inserted bolt and thread it into the rear hole on the blade grip tighten it until just before the assembly is fully tight.

  • Page 86: - Blade Arm Assembly

    XCell Ion-X Assembly Manual 6A.4 - Blade Arm Assembly Parts Relationship #120-5 #0319 #0840-12 #0324 #0331 #127-138 #0319 #0086 #0844-12 #0848-2 #0840-10 #0082-1 #0023 6A.4.1 – Assemble Blade Arms 6A.4.1a 6A.4.1.b 6A.4.1.c #0840-10 #0319 #0319 Page 86 of 123 Created: 8/25/2007...
  • Page 87 XCell Ion-X Assembly Manual 6A.4.1.d 6A.4.1.d 6A.4.1.d Locate Small Diameter Race #0840-12 Locate Large Large Diameter #0840-12 Diameter Middle Race Bearing 6A.4.1.e 6A.4.1.f 6A.4.1.g #0840-12 Rounded Seat In Small Edge Groove Diameter #0848-2 #0844-12 #120-05 6A.4.1.h 6A.4.1.i #0331 #0324 Created: 8/25/2007...

  • Page 88: - Install Blade Arms

    XCell Ion-X Assembly Manual 6A.5 – Install Blade Arms 6A.5.a 6A.5.b 6A.5.c Use Allen drivers to tighten – do not #127-138 overtighten #0086 6B) Assemble Flybar – Bag #6B #121-4 #0063 M3 x 30 Control Rod #0052 M3 x 10...

  • Page 89: - Assemble/Install Flybar Control System

    XCell Ion-X Assembly Manual Parts Relationship #0133-1 #0052 (2) #0052 (2) #0063 #0063 #126-88 #0053-5 #126-88 #0555-1 #0049-3 (3) #0049-3 (3) #0555-1 #0063 #126-88 #0053-5 #126-88 #126-90 #126-90 #0063 #0133-1 6B.1 – Assemble/Install Flybar Control System 6B.1.a 6B.1.b 6B.1.c #121-4...
  • Page 90 XCell Ion-X Assembly Manual 6B.1.d 6B.1.e 6B.1.f Bevel Towards Inside #126-88 #126-90 6B.1.g 6B.1.h 6BD.1.i #0063 #0049-3 #126-90 #0049-3 #126-90 6B.1.g 6B.1.h Insert flybar to align flybar controls #0566-1 Page 90 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 91: - Assemble/Install Flybar Bell Links

    XCell Ion-X Assembly Manual 6B.2 – Assemble/Install Flybar Bell Links 6B.2.a 6B.2.b Building Notes – snap one end of the #0135 assembled link onto the double ball on the bell mixer and the other onto the double ball on the flybar carrier. Repeat...

  • Page 92: - Install Flybar Paddles

    XCell Ion-X Assembly Manual 6B.4 – Install Flybar Paddles 6B.4.a 6B.4.b 6B.4.c 30 mm 6B.4.d Building Notes – make sure both flybar paddles are parallel to each other and the flybar control arms 6D.5 – Install Rotor Head 6D.5.a 6D.5.b 6D.5.c...
  • Page 93 XCell Ion-X Assembly Manual 6D.5.d 6D.5.e 6D.5.f #0057 #121-4 (2) 6D.5.g 6D.5.h 6D.5.i 61 mm #121-6 (2) #121-6 (2) #0133-1 Created: 8/25/2007 Page 93 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 94 XCell Ion-X Assembly Manual Rotor Head Control Rod Lengths Bell Mixer Bell Mixer Control Flybar Control Rods Control Rods Rods #0133-1 #0135 #0133-1 #0135 #0133-1 #0312 #0312 #0121-4 9 mm #0135 #0135 #0133-1 61 mm 61 mm #0133-1 9 mm...

  • Page 95: Step #7 - Tail Rotor

    XCell Ion-X Assembly Manual Step #7 – Tail Rotor 7A) Tail Rotor Hub – Bag #7A #0873-1 #122-65 T/R Blade Grips Tail Rotor 2 each 1 each #0446-4 M4 x .003” S/S Shim #120-39 2 each M5 x 10 Ball Bearings...

  • Page 96: - Assemble Tail Rotor Hub

    XCell Ion-X Assembly Manual 7A.1 – Assemble Tail Rotor Hub Parts Relationship #122-65 Small Small Inside Inside Diameter Diameter #0446-4 #0457 #120-39 #120-39 #0457 #0446-4 #0021 #0021 Large Large #0097 Inside Inside #0097 Diameter Diameter #0019 #0019 #0873-1 #0873-1 Page 96 of 123...
  • Page 97 XCell Ion-X Assembly Manual 7A.1.a 7A.1.b 7A.1.c Locate #0873-1 #0457 Large Bearing Diameter #120-39 Race Locate #0457 Small Large Diameter Diameter Race Race 7A.1.d 7A.1.e 7A.1.f #0457 #0446-4 Small #122-65 Diameter Race 7A.1.g 7A.1.h Building Notes: tighten the retaining nut #0021 carefully until it is snug.

  • Page 98: - Install Tail Rotor Blades

    XCell Ion-X Assembly Manual 7A.1.i 7A.2 – Install Tail Rotor Blades 7A.2.a 7A.2.b #0097 (2) #0019 (2) 7A.2.c Balance T/R using a balancing device Page 98 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 99: Tail Rotor Control - Bag #7B

    XCell Ion-X Assembly Manual 7B) Tail Rotor Control – Bag #7B #0015 #0056 #0019-1 M3 x 5 M3 Locknut – Thin M2 Hex Nut 3 Each Dog Point Set Screw 1 each 2 Each #0159 #0435 #120-14 #0439 M3 x 7 x 3...

  • Page 100: - Assemble Tr Pitch Yoke

    XCell Ion-X Assembly Manual 7B.1 – Assemble TR Pitch Yoke Parts Relationship #0439 #0101 #0435 #0437 #0439 #0443 (2) #120-14 #0015 #0015 #0859-16 #0859-16 #0049 (2) #0049 (2) 7B.1.a 7B.1.b 7B.1.c Round Edge #0439 (2) #0435 #0437 #0101 Insert this way...
  • Page 101 XCell Ion-X Assembly Manual 7B.1.d 7B.1.e 7B.1.f #0443 #120-14 Press until seated 7B.1.g 7B.1.h 7B.1.i #0443 #0015 #0049 Created: 8/25/2007 Page 101 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 102: - Assemble T/R Bellcrank

    XCell Ion-X Assembly Manual 7B.2 – Assemble T/R Bellcrank Parts Relationship #123-95 #0015 #0159 #0019-1 #0445 #0097 #0159 #0103 #0597-3 7B.2.a 7B.2.b 7B.2.c #0445 #0159 #0103 #0597-3 #0015 Page 102 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 103: - Install T/R Bellcrank

    XCell Ion-X Assembly Manual 7b.2.d #0159 7B.3 – Install T/R Bellcrank 7B.3.a 7B.3.b #0097 #0019-2 Created: 8/25/2007 Page 103 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 104: - Install T/R Pitch Yoke

    XCell Ion-X Assembly Manual 7B.3 – Install T/R Pitch Yoke 7BC.3.a 7B.3.b 7B.3.c #0056 7BC.3.a #0049 #0049 Page 104 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 105: Step #8 - Tail Boom

    XCell Ion-X Assembly Manual Step #8 – Tail Boom 8.1 – Install Tube Drive 8A.1.a Building Notes – before inserting the tube #120-15 drive into the tail boom as shown, spray inside the boom with a spray glass cleaner (like Windex®). This will make the tube...

  • Page 106: Tail Boom - Bag #8A

    XCell Ion-X Assembly Manual 8A) Tail Boom – Bag #8A #0027 #0016 #0868-4 #0868-5 #0015 M2.2 x 9.5 M3 Serrated Teflon Heat Push M2 Hex nut Shrink Phillips Lockwasher 2 Each Screw 2 Each 1 Each Guide 2 Each 1 Each...

  • Page 107: - Install Vertical Fin Mount/Fin

    XCell Ion-X Assembly Manual 8A.1 – Install Vertical Fin Mount/Fin Parts Relationship #0061 #0009 #0016 #0063 (2) #0063 #0032 #0017 #123-86A #0063 #0017 #0032 #0063 (2) #0017 (2) #124-180 #0017 #0063 #123-86B #0017 #0063 #0017 (2) #0016 #0009 #0061 #120-15...
  • Page 108 XCell Ion-X Assembly Manual 8A.1.a 8A.1.b 8A.1.c #123-86B #0017 (2) #0006 #0009 #0009 #0006 #123-86A #0017 (6) #0061 #0061 8A.1.d 8A.1.e 8A.1.f #0063 #0063 8A.1.g #0063 (4) Page 108 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 109: - Install Horizontal Fin Mount/Fin

    XCell Ion-X Assembly Manual 8A.2 – Install Horizontal Fin Mount/Fin Parts Relationship #0019 #0870-2 #0003 #0027 #0027 #0065 #124-182 8A.2.a 8A.2.b Front of tail boom #0589-5 Created: 8/25/2007 Page 109 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 110 XCell Ion-X Assembly Manual 8A.2.a 138.5 mm 8A.2.b 8a.2.c #0019 #0027 #0009 #0065 #124-182 Front 8A.2.d Page 110 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 111: - Install Tail Rotor

    XCell Ion-X Assembly Manual 8A.3 – Install Tail Rotor 8A.3.a 8A.3.b 8A.3.c Use inside Hole #0056 8A.3.d Created: 8/25/2007 Page 111 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 112: - Assemble/Install T/R Pushrod

    XCell Ion-X Assembly Manual 8A.4 – Assemble/Install T/R Pushrod #0868-5 Pushrod Guide 1 Each #0477 #121-5 #0868-4 #133-1 #0015 #0043 #0020 #0039 Guide M3 x 42 Teflon Heat Ball Link - Grey M2 Hex M2 x 10 M2.5 Hex M2.5 x 12...

  • Page 113: - Assemble/Install T/R Pushrod Guide

    XCell Ion-X Assembly Manual 8A.5 – Assemble/Install T/R Pushrod Guide 8A.5.a 8A.5.b Forward #0020 #0039 #0043 #0477 14-3/4” from front of tail boom To front of guide #0015 #0868-5 8A.6 – Install Tailboom 8A.6.a 8A.6.b 8A.6.c Insert 90° 8A.6.d Building Notes – Apply a small amount...

  • Page 114: - Assemble T/R Pushrod

    XCell Ion-X Assembly Manual 8A.7 – Assemble T/R Pushrod 8A.7.a 8A.7.b 8A.7.c #121-5 #133-1 Use sandpaper to remove the Front of pushrod paint from the exposed #0868-14 pushrods 8A.7.d 8A.7.e 8A.7.f #0868-14 20-5/8” from back of pushrod To center of sleeve...

  • Page 115: - Install T/R Pushrod

    XCell Ion-X Assembly Manual 8A.8 – Install T/R Pushrod 8A.8.a 8A.8.b 8A.8.c 90° 8A.8.d 90° Created: 8/25/2007 Page 115 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 116: - Assemble Tail Boom Supports

    XCell Ion-X Assembly Manual 8A.9 – Assemble Tail Boom Supports Parts Relationship #0077 #0081 #0003 #0004 #0048 #0048 #0872-7 #0872-7 #0872-9 #0003 #0019 #0870-2 #0019 #0003 #0872-9 #0872-7 #0872-7 #0048 #0048 #0003 #0004 #0081 #0077 Page 116 of 123 Created: 8/25/2007...
  • Page 117 XCell Ion-X Assembly Manual 8A.9.a 8A.9.b 8A.9.c #0872-9 #0048 8A.9.d 8A.9.e 8A.9.f Wider Bolts Go This Way 8A.9.g 8A.9.h 8A.9.i #0872-8 (2) #0081 #0004 #0048 Created: 8/25/2007 Page 117 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 118: 10 - Install Tail Boom Supports

    XCell Ion-X Assembly Manual 8A.10 – Install Tail Boom Supports 8A.10.a 8A.10.b 8A.10.c #0004 #0081 8A.10.d 8A.10.e 8A.10.f #0081 Page 118 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 119: 11 - Install Vertical Fin

    XCell Ion-X Assembly Manual 8A.11 – Install Vertical Fin 8A.11.a 8A.11.b #0039 (2) #124-180 8A.12 – Balance Model 8A.12.a 8A.12.b 8A.12.c #122-99 Install Canopy Install Batteries 8A.12.d 8A.12.e Building Notes – To determine the model #124-180 balance, mount the batteries and canopy and lift the model by the flybar.

  • Page 120: 13 - Install Main Rotor Blades

    XCell Ion-X Assembly Manual 8A.12.f 8A.12.g 8A.12.h 8A.12.i 8A.13 – Install Main Rotor Blades 8A.13.a 8A.13.b Building Notes – Tighten each blade #0082 equally. The blade should be tight enough to be hard to move in the blade holder. #0021...
  • Page 121 XCell Ion-X Assembly Manual Created: 8/25/2007 Page 121 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 122 XCell Ion-X Assembly Manual Page 122 of 123 Created: 8/25/2007 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 123 XCell Ion-X Assembly Manual Created: 8/25/2007 Page 123 of 123 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

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