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miniature aircraft X-CELL Spectra-G Instruction Manual

Radio controlled model helicopter
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  • Page 2 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. A model helicopter must be built exactly in accordance with the building instructions.
  • Page 3 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. Defective components must be returned to us prior to replacement.
  • Page 4 X-CELL Spectra G-3D (with Tempest head) INTRODUCTION These instructions apply to the Spectra G-3D Kit #1025 Congratulations! You have purchased a quick assembling, high quality helicopter kit ideally suited for beginner through expert pilots. Please pay particular attention to each assembly step. SYSTEM REQUIREMENTS A minimum five channel “helicopter”...
  • Page 5 Small hammer Vinyl two-sided tape - 1/8" thick (M.A./USA p/n 3869) Slow and fast setting Cyanoacrylate (CA) adhesive Heat gun High quality synthetic grease (M.A./USA p/n 4707) Light oil (teflon type M.A./USA p/n 4801) Canopy finishing materials (described elsewhere in this document) “C”...
  • Page 6 refer to the addition of Blue Locktite thread locker (included). Any position using steel hardware into plastic will refer to the addition of slow Cyanoacrylate (CA) (not included) as a thread locker. Always clean the threads with alcohol and use the locking material sparingly. For individuals wishing to know, the following maximum torque values apply to metal-to-metal positions on the model.
  • Page 7 Pre-flight information Starting and stopping procedure XVII First flight adjustments XVIII Troubleshooting guide I. BUILDING THE ROTOR HEAD Bags required: #1A, #1B, #1C, #1D, #1E, #1F, #1G and bag #9A Tools or materials required: Small Phillips screwdriver Small hammer Solvent (thinner or alcohol) Loctite-Blue or Green Slow cyanoacrylate glue (CA) M1.3, 1.5, 2.5 and 4.0mm (2 each) Allen tools...
  • Page 8 #0051 M3X3 Socket set screws Refer to drawings #1A and #1B A) Select two #122-03 flybar control arms, two #0063 M3X10 socket head bolts, two #122-18 threaded s/s spacers, two #0572-7 aluminum standoffs and two #0109 M3X8 threaded balls. Assemble each flybar control arm per the drawing. Tighten securely using blue loctite. B) Note: Each flybar control arm #122-03 contains three optional positions.
  • Page 9 #0091 M3X16 Phillips bolt #0562-1 M3X0.09 Shim washer #123-26 Bell Hiller mixers Refer to drawing #1C A) Press one #106-02 M3X7X3 flanged ball bearing into each #123-26 bell mixer. It is recommended that the bearing be installed first in the same side of each mixer. A light amount of green loctite is mandatory on the outer race of each bearing.
  • Page 10 Bell mixer mounting Flybar tube control ball location location Inside hole Outside hole Position 1 1:0.61 1:0.56 Position 2 1:0.62 1:0.58 Table 1: Head input mixing ratios Pitch arms: Each pitch arm has three threaded hole positions for mounting the Bell mixers. The center hole is zero offset.
  • Page 11 #122-17 Head button #0064 M3X8 Button head bolt #0062 M3X10 Flat head bolt Pre-assembled lower head block from step 1 #0687 M3 X 0.086" X 0.158" steel spacer Refer to drawing #1D A. The upper head block #122-14 is symmetrical by design, therefore it may be installed on either side.
  • Page 12 #0844-2 70-D Rubber O-rings #0848-4 Aluminum retainer sleeves #0848-3 M8X12X2 Hinge ring #122-02 Head axle #122-11 Machined main blade mounts #122-12 M5 Main blade bolts #122-13 M5 Fiber blade spacers Refer to drawings #1E and #1F Note: Two different hardnesses of O-ring dampeners and three sets of shim thicknesses are provided.
  • Page 13 the remaining small I.D. outer ring into position with the grooved side facing the ball cage. 6) One #0848-10 M8X12X0.8 Spacer 7) One #0319 M8X16X5 Ball bearing 8) One #0011 M5 Washer 9) One M5X12 Flanged socket head bolt Note: Sparingly apply blue loctite to the threads and install into the head axel. Tighten only finger tight at this time.
  • Page 14 for a paddle locking device, allowing sufficient cure time to simplify aligning the component. Install each paddle as indicated and remove the tape. If all steps were accurately performed, then it should be evident that by holding the head vertical and releasing the flybar, the paddles will appear balanced.
  • Page 15 #125-33 Rear doubler plate strip #122-27 Rear canopy mount #0862-1 Rudder bell crank pivot stud #115-18 Main shaft bearing block #0089-1 M3X8 Hex bolt #125-15 Left main frame #120-10 Main shaft #125-30 Throttle servo plate #106-41 Front Canopy Mount SPECIAL NOTES: 1) This kit allows the motor to be mounted such that the cylinder is either forward facing or rearward.
  • Page 16 B) Select one #0169 bell crank pivot stud and one #115-20 frame spacer. Note the position of the pivot stud outside the frame. Using loctite, install the pivot stud with the frame spacer on the inside and tighten securely. C) Install the #125-30 throttle servo plate or the #125-32 doubler plate strip “A” to the outside of the left frame using two #0061 M3X8 socket bolts and two #115-20 frame spacers.
  • Page 17 III. INSTALLING THE MAIN SHAFT, MAIN GEAR AND FRONT TAIL DRIVE Bags required: #3A, #3B, #3C, #3D Tools or materials required: M1.5, 2.0 and 2.5 allen tools M5.5 flat wrench Tri-flow #4801 or automatic transmission fluid (ATF) (optional) feeler gauge Step 1: Installing the front tail rotor drive gear and shaft Parts required: Part number...
  • Page 18 for final positioning. Final gear position can be determined after the main gear is installed, observing the rule that the bevel gear be centered within the main gear. Which ever method is utilized, always remember to install the remaining #0051 M3X3 socket set screw with blue loctite then remove and loctite the first set screw and double check the contact within the flat provided.
  • Page 19 A) Select four #0088 bolts and prepare with blue loctite. Select the outer main gear and note the four countersunk holes on the upper surface. Only the countersunk holes will be utilized. Press the gear atop the upper housing, align the countersunk holes, install the four bolts and tighten with light torque.
  • Page 20 Refer to drawing #3D A) Select the #120-10 main shaft. Note: the main shaft must be installed per the drawing. Apply a little light oil to a cloth a briskly wipe down the shaft. This will remove the protective coating. It is suggested that a trial fit of the main shaft be performed prior to assembling the main shaft components.
  • Page 21 The pin may not fully insert due to an obstruction within the collar. Remove the collar and trial fit the pin. Look for any metal debris lodged in the “small hole” side of the collar. If any exists, use a 1.5mm allen tool to push it out. The pin may not insert fully sue to a misalignment of the holes in the related parts.
  • Page 22 Parts required: Part number Part description Found in bag #0003 M3 washer #0019-1 M3 locknut-low profile #106-41 Front canopy standoff #122-28 Brass sleeve .187" X .125" X .079" #0053-5 M3X16 Socket set screw #0089-1 M3X8 Hex head bolt #0099 M3X30 Phillips bolt #0105 M3X45 Threaded ball #0113...
  • Page 23 done in step 2. C) Study the drawing for proper orientation of the assembly of the elevator bellcrank #125- 18. Install one #0105 threaded ball, one #0113 threaded ball and one #122-28 brass spacer. Use a small dab of slow CA on the threaded portion of each ball. D) Press one #106-02 flanged ball bearing into one hole of the bellcrank.
  • Page 24 A) Install the following hardware into the following positions as per the drawing. Use blue loctite on all the threaded parts except the #0019 locknut positions. * Two #0063 M3X10 socket bolts into the upper main shaft bearing block #120-12. * Two #0061 M3X8 socket bolts and one #0060-1 M3X6 socket bolt into the #120-8 center main shaft bearing block.
  • Page 25 * One #0019 M3 locknut * One #0063 M3X10 socket bolt * One #0061 M3X8 socket bolt * One #0060-1 M3X6 socket bolt Tighten securely using blue loctite except on the positions where locknuts are used. Step 3: Installing the left and right bellcranks and gyro brackets Bags required: 4D Parts required: Part number...
  • Page 26 (A) gyro bracket and one #0595-2 type (B) gyro bracket. Install the brackets as shown, making sure they are securely tightened and aligned to form a uniform flat top surface. Step 4: Assembly and installation of the rudder bellcrank Bags required: 4E Parts required: Part number Part description...
  • Page 27 Check for smooth movement of the bellcrank. Step 5: Final main shaft adjustment The main shaft should rotate freely and have no vertical free play. Re-check the gear mesh between the crown gear and the tail drive pinion. If needed, readjust the main shaft collars and the #0232 gear.
  • Page 28 D) Install the #121-8 clutch/clutch bell unit in place between the frames. Examine the drawing and note the position of the #0061 M3X8 socket head bolts and the #0063 M3X10 socket head bolts through the doubler plates and into the clutch unit. Lay one graphite doubler plat in position on the left main frame.
  • Page 29 securely. V. BUILDING THE LOWER PLATE AND INSTALLING THE LANDING GEAR Step 1: Preparing the engine unit Tools and materials required: M2.0, 2.5, 3.0, 4.0 and 5.0 Allen wrench’s Electric drill Dial indicator and mounting base 5.5mm open end wrench 3/32"...
  • Page 30 #0086-5 M6X15 Socket head bolt #0078-5 M4X10 Socket head bolts #0546-21 Fan assembly tool #0004 M4 Washers #125-10 RF Shield #4694 4" Tie wraps #0064-3 M3X6 Button head bolt #0032-1 M2.9X13 Phillips bolt #0078 M4X12 Socket head bolts Refer to drawing #5A, 5B, 5B-1, 5B-2 A) Remove the carburetor and the lower aluminum pull starter plate provided on the Zenoah 231H engine.
  • Page 31 RF noise being emitted from the engines ignition system. If you elect to use this part, follow steps 1 through 5 below. Note: For even greater RF shielding, Miniature Aircraft USA offers a 5K ohm resistor spark plug cap. Order P/N #115-112.
  • Page 32 Slide one of the pieces of heat shrink tubing up to the coil as far as it will go and shrink in place. Re-enforce with one #4694 4" tie wrap. 3) The shield braid needs to cover the spark plug wire to within 1/4" of the hole in the spark plug wire.
  • Page 33 #0003 M3 washers (large) #0019 M3 Locknut #0067 M3X14 Socket head bolts #0069 M3X16 Socket head bolts #0058-1 M4X6 Socket set screws #0075 M3X25 Socket head bolts #125-40 Aluminum ladder supports #3937-1 Skid plugs #3933 White struts #3937 Skids #125-43 Secondary engine plate #125-41 Graphite base plate...
  • Page 34 C) If you elected to use the Zenoah pull starter, assemble and trial fit the unit at this time. Select the pull starter from your Zenoah engine package, four #0017-3 M4 hex nuts, four #0078-6 M4X16 tapered bolts and four #125-29 .300" spacers. Assemble as shown using blue loctite until the thread of each bolt is flush with the hex nut.
  • Page 35 Part number Part description Found in bag #0063 M3X10 Socket head bolts #0009 M3 Washers (small) Refer to drawing #5D, 5D-1 and 5D-2 A) Slide the pre-assembled upper frame unit down onto the assembled lower base unit. Align the clutch driver pins with the holes in the dampers already installed in the fan hub. Firmly press the two units together until the bolts may be installed through the main frames and into the ladder supports #125-40.
  • Page 36 Qty Part number Part description Found in bag #125-24 Fuel tank #125-20 Inner fuel line #125-22 Filtered fuel clunk #0405 Fuel vents #0011 M5 Washer #0013 M5 Nut #0408 Fuel pick-up fitting #0409 90 Degree external tank fitting #4691 Tie wraps 17" #105-100 Main fuel line 31"...
  • Page 37 other end fully onto the #125-22 filtered fuel clunk. Do not shorten the fuel line, it is supposed to loop around the base of the fuel tank when installed. D) Insert the prepared fuel pick-up tube, clunk and fitting out through the hole in the tank cap and secure with one #0409 ninety degree external tank fitting.
  • Page 38 Tools and materials required: M1.5 and 2.5 Allen tools Medium phillips screwdriver Small good quality pliers Small flat screwdriver Step 1: Assembling the swashplate Parts required: Part number Part description Found in bag #0009 M3 Flat washer (small) #0051 M3X3 Socket set screws #0065 M3X12 Socket head bolt #0107...
  • Page 39 M3X6 threaded balls. Prepare each with blue loctite and install in each position previously indicated. C) Slide the swashplate down the main shaft. Rotate it so that one outer control ball is pointed rearward and the remaining two balls are pointing forward at an angle on each side of the mechanics.
  • Page 40 the #0107 threaded ball on each arm. Apply a small amount of slow CA adhesive to the threads of each ball and install one ball in each arm as shown. Press one ball bearing into each arm (noting that when fully inserted, each will protrude approximately 0.75mm) and install one #0597-1 brass spacer in the opposite side of the arm against the bearing.
  • Page 41 with the “chamfered end” first. Once the dowel pin is properly fitted, secure it with the #0057 M4X4 set screw and a small amount of blue loctite. Apply blue loctite sparingly and only to the set screw to avoid contacting the dowel pin and making later servicing more difficult.
  • Page 42 one bearing into each tail blade mount towards the control arm side. The bearing should be flush with the outer surface of the tail blade mount. B) Select two #0457 thrust bearings. Each is made up of a ball cage (with balls) and two grooved outer races.
  • Page 43 freely. The proper balance method is called a “four point balance”. Two steps are involved. At first, no blades will be installed on the assembly, just the #0097 bolts and #0019 locknuts. Always orient the blade mounts with the threaded control arms in opposite directions (as they would be on the model).
  • Page 44 #120-14 Tail rotor pitch yoke #0439 Ball bearings #0437 Plastic pitch ring Refer to drawing: 8B A) Select one #0101 M2X5 threaded ball an one #0437 plastic pitch ring. Install the threaded ball into the plastic pitch ring using a small amount of slow CA adhesive on the threads of the ball.
  • Page 45 assembled, each pitch link plate will be “captured” between the bearing flange and the mounting surface. This is important as a security if any bearing would fail. The same is true for the later connection to each tail blade grip. Step 3: Final assembly of the tail rotor gearbox Tools and materials required: 1.5 and 2.5mm allen tools...
  • Page 46 shaft with it’s control ball pointing downward. Press this control ball into the hole provided in the top of the tail rotor bellcrank and position the bearings of the bellcrank directly under the mounting hole in the #123-84 bellcrank support. Select one M3X22 special phillips bolt and insert it through the bearings in the bellcrank from the bottom side of the bellcrank and thread into the #123-84 bellcrank support.
  • Page 47 Small phillips screwdriver Hand drill with 1.3mm (.055") drill bit Heat gun “J-B Weld” epoxy adhesive Small piece of 180 to 220 grit sandpaper Light oil or “Vaseline” petroleum jelly Step 1: Installing the tube drive and push rod guides Part number Part description Found in bag...
  • Page 48 #0867-15 Torque tube #0017 M3 Hex nuts #123-88 gear case alignment shim #123-86 Rear transmission clamp (A & B) #120-15 33" metal tail boom Refer to drawing #9A, 9A-1, 9A-2 and 9A-3 A) Select the #0867-15 heavy duty torque tube assembly. The ball bearings at the center are surrounded by plastic housings which require the addition of two O-rings #0800-5.
  • Page 49 from the raised portion of each clamp half. A very slight amount of the tail boom will protrude out of the clamp, approximately 0.013". E) Apply a small amount of grease to the torque tube drive end. Position the #123-88 gearbox alignment shim onto the end of the tail boom and simultaneously press the gearbox fully into the tail boom so as to completely engage the clamp.
  • Page 50 Parts required: Qty Part number Part description Found in bag #0004 M4 Washer #0021 M4 Lock nuts #0048 M3.5X25 Socket set screw #0081 M4X16 Socket head bolts #0872-7 Molded “ball & socket” end... M4 hole #0872-9 Graphite tubes #0087 M4X20 Socket head bolts Refer to drawing #9B A) Select four #0048 M3.5X25 socket set screws and two #0872-9 graphite tubes.
  • Page 51 assembly steps while the slow CA adhesive will allow only a minimal amount of working time...be prepared if you choose CA adhesives. D) Apply a liberal amount of your chosen adhesive to the threads exposed on the brace end and inside the graphite tube end. Insert one tube into one brace end until it stops (about 9.5 to 10mm) and secure it from moving while the glue sets.
  • Page 52 Step 3: Installing the graphite tail rotor push rod Parts required: Part number Part description Found in bag #0133-1 Grey ball link #0868-4 Heat shrinkable teflon tubes #122-94 M3 X 97 Control Rod #121-5 M3X42 Control Rod #0868-20 Sleeve #0868-11 Graphite pushrod 31"...
  • Page 53 threaded end which has no ball link installed) through each previously installed push-rod guide. Select one #0133-1 grey ball link and thread it onto the pushrod to a depth of about 7mm. Adjustments will ONLY be made at the rear ball link. Connect one link to the front bellcrank and the other to the rear bellcrank.
  • Page 54 #0037 M2.5X25 Phillips bolt #115-30 Velcro 34" #0389 Wire retainer (small) #0390 Wire retainer (large) #0044 M2X12 Slotted screws #0065 M3X12 Socket head bolt Refer to drawings #10A, #10A-1 and #10A-2 A) All servos (except throttle) mount using #0038 M2.5X10 phillips machine screws into threaded steel inserts (factory installed “PEM”...
  • Page 55 Fourth from top of left main frame Rudder Rudder bell crank spline facing rearward Throttle plate #125-30 spline Throttle Carburetor facing motor Examine the drawings to be sure each servo is in the correct front/rear position. B) Select your battery pack (1800mAHr or greater). Apply two strips of thick foam tape to the battery pack.
  • Page 56 Install the velcro around the receiver and amplifier box’s. D) Install the gyro sensor onto the gyro shelf being sure to follow the instructions included with the unit. E) Install the switch on to the upper front side of the #125-41 bottom plate as shown. Install two #125-48 rubber grommets between the main switch body and the graphite plate and secure using the longer screws provided (#0043 or #0063).
  • Page 57 All servos must be in the “neutral” position, i.e. the half way point in their travel, before proceeding. If you are a beginner, the amount of negative pitch that you will not be using can be eliminated electronically within your radios pitch curve prior to flight. Servos #1, #2 and #3 are set at neutral positions by placing the throttle stick at the center of it’s travel and verifying that all trims for aileron, elevator and collective are centered.
  • Page 58 screw is chosen (make sure to neutralize the servo). Servo #2 utilizes the control ball to the inside of the servo wheel. Select and install one #0015 hex nut and one #0103 control ball with blue loctite. Snap the prepared pushrod in place connecting the servo to the left cyclic bellcrank.
  • Page 59 tightening it fully against the graphite tube. Align each link in the same orientation and wipe away any excess glue. Snap the assembled rod in place. Servo #5 Parts required: Part number Part description Found in bag #0015 M2 Hex nut #0103 M2X5 Threaded ball #0133-1...
  • Page 60 #0313 M2X10 Pushrods #0133-1 Ball links (long, grey) #0337 M2X27 Pushrods Refer to drawing: # 10D A) Select six #0133 ball links and three #0227 pushrods. Install two links on each pushrod, adjusting each until approximately 26mm (if calipers are used, make them 25.2mm each) of pushrod is exposed between the links.
  • Page 61 Step 1: Installing mounting hardware and fitting the canopy Parts required: Qty Part number Part description Found in bag #106-22 Rubber grommet (large) #122-90 Canopy #125-80 Decal sheet #122-99 Canopy retaining knobs #0053-5 M3X16 Set screw Refer to drawing: #11 Note: Depending on the motor position selected, the canopy will require minor trimming.
  • Page 62 3/4" masking tape Strong detergent Masking paper or newspaper Alcohol or paint prep solvent (such as Dupont #3919 Prep-sol) “Tack” cloth Paint selection: Paint must be chosen that is fuel proof or compatible with fuel proof clear coats. Automotive poly-urethanes are best but modelers epoxy or urethane can also be used. Always apply a light coat first, allowing 15 to 30 minute set-up time, before final gloss coats.
  • Page 63 XII. ROTOR BLADE SELECTION It is recommended that a blade length of 700 to 710mm be used. A good quality rotor blade is suggested. Miniature Aircraft USA offers a variety of high quality rotor blades suitable for this model. XIII. FINAL MECHANICAL AND ELECTRONIC SET-UP Note: The following procedures will be described using a pitch gauge, flybar lock and paddle gauges.
  • Page 64 Read the pitch at the blade (the exact value in degrees does not matter at this stage). The pitch reading should not change as you rotate the head, checking it at 90 degrees points, fore, aft, right and left. Miniature Aircraft USA offers an excellent tool for leveling the swashplate, order #0513.
  • Page 65 * Percentages shown are approximate throttle settings H) Switch your radio into Idle-up 2 and move the collective/throttle stick to exactly half stick. Adjust the #0335 pushrod (from the swashplate to the bell mixer) so that the blade reads exactly zero degrees of pitch. Repeat for the opposite blade. Move the stick to full up and down positions, reading the pitch at each.
  • Page 66 Obtain assistance from more experienced pilots if possible. Never leave the transmitter in a position that would allow it to be handled or upset while you not attending it...keep it cased when not in use. Starting the model: Check your battery status whenever possible. Most factory shipped batteries can only sustain three “full tank”...
  • Page 67 XVIII. TROUBLESHOOTING GUIDE Please refer to the operators guide. We wish you good luck and many happy hours of flying! If you have any further questions, feel free to call us. MINIATURE AIRCRAFT USA 31713 Long Acres Drive Sorrento, Florida 32776...
  • Page 74 Tempest Rotor Head - Section 1 - Completed...

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