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miniature aircraft XCell Stratus Assembly Manual

Xcell stratus 126-100
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  • Page 2: Table Of Contents

    MAINTENANCE ITEMS ................................... 183 CANOPY CUT-OUT TEMPLATE – NO MUFFLER ........................185 CANOPY CUT-OUT TEMPLATE – WITH HATORI SB16/SB17....................186 Created: 11/1/2005 Page 2 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 3: Revisions To This Manual

    For the most current version of this manual, please refer to www.miniatureaircraftusa.com, visit the Stratus helicopter kit and download the assembly manual Errata None Noted Created: 11/1/2005 Page 3 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 4: Kit Introduction

    Created: 11/1/2005 Page 4 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 5: 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. Defective components must be returned to us prior to replacement.

  • Page 6: Kit Assembly

    Supplies Needed for Assembly Blue Thread Red Thread Green Grease Lock Lock Thread Lock Adhesives Needed Slow JB Weld Cyanoacrylate Created: 11/1/2005 Page 6 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 7: Tools Needed For Assembly

    Use thread lock as indicated. Model helicopters are subject to vibration and failing to use thread • lock on any non-locking assembly may result in a part becoming loose or falling off Created: 11/1/2005 Page 7 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 8: Unbagged Parts

    This section documents the parts found in the kit box which are not common to other bags Kit Box Kit Box Contents Created: 11/1/2005 Page 8 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 9 Assembly Manual for XCell Stratus Kits #1026 Box parts list 122-90 Canopy 126-100 Assembly Instructions – CD-ROM 126-85 Decal Set Created: 11/1/2005 Page 9 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 10: Lower Frame Assembly

    Bag 1A parts list 0151 Struts 0548-5 Fan Shroud (right & left) 122-39 Skids 126-20 Carbon Main Base Plate Created: 11/1/2005 Page 10 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 11 Assembly Manual for XCell Stratus Kits #1026 Bag 1B Bag 1C Created: 11/1/2005 Page 11 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 12 0080 M4 x 14 Socket Head bolt 0331 Shim Washer M13x.50 0546-11 Y.S. Upper Collet 0546-16 Clutch Dampers Created: 11/1/2005 Page 12 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 13 O.S. Upper Collet 0546-6 Brass Base Collet 0579-4 Fan Unit 126-23 Carbon Motor Side Mounts 126-86 Rectangular Blocks Created: 11/1/2005 Page 13 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 14 5/8” Velcro – 28.5” length 115-65 Fuel Line – 3” – inside of tank 126-27 Rubber Tank Bump-ons 4295 Fuel Magnet Created: 11/1/2005 Page 14 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 15 M2.2 x 9.5 Phillips screw 0058-1 M4 x 6 Socket Set Screws 0060-1 M3 x 6 Socket head bolt Created: 11/1/2005 Page 15 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 16 M3 x 20 Socket Head bolt 0586-16 Corner Blocks 126-26 “A” Frame Supports 126-73 Lower Graphite Shroud Brackets Created: 11/1/2005 Page 16 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 17: Bag 2 - Engine Specific Components

    Assembly Manual for XCell Stratus Kits #1026 Bag 2 – Engine Specific Components Bag 2 - YS Bag 2A Bag 2B Bag 2C Created: 11/1/2005 Page 17 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 18 Bag 2C - YS parts list 126-44 8.45 upper clutch plates (Right & left) 126-45 8.45 lower clutch plates (Right & left) Created: 11/1/2005 Page 18 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 19 Assembly Manual for XCell Stratus Kits #1026 Bag 2 - OS Bag 2A Bag 2B Bag 2C Created: 11/1/2005 Page 19 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 20 Bag 2C - OS parts list 126-40 8.18 upper clutch plates (Right & left) 126-41 8.18 lower clutch plates (Right & left) Created: 11/1/2005 Page 20 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 21 Place a drop of oil (of any type) on the lower collet and use your finger to smear it on the entire collet Created: 11/1/2005 Page 21 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 22 You will need to lock the crankshaft in order to tighten this nut Created: 11/1/2005 Page 22 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 23 Then retighten and repeat the test process. You may need to do this a few times but it should eventually seat. If you have problems with this procedure, please contact MA for more details. Created: 11/1/2005 Page 23 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 24 The engine will be assembled on the same side as the initials, such that the cylinder covers the initials. Created: 11/1/2005 Page 24 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 25 Note how the assemblies will fit on the engine mount plate and against the engine. Created: 11/1/2005 Page 25 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 26 PEM nuts on the engine mount plate. Tighten all 4 bolts but do not use Thread lock yet. Created: 11/1/2005 Page 26 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 27 These bolts will be tightened in a later step Created: 11/1/2005 Page 27 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 28 Insert the two M3 bolts to attach each frame support as shown. At this time, lightly tighten these bolts only. Created: 11/1/2005 Page 28 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 29 Arrange the Velcro such that equal portions are extended through all four of these slots as shown Created: 11/1/2005 Page 29 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 30 Created: 11/1/2005 Page 30 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 31 This completes the assembly of the landing gear assembly Created: 11/1/2005 Page 31 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 32 The mount contents and sample mounting is shown. It can be assembled in several ways to provide support for many different mufflers. Created: 11/1/2005 Page 32 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 33 Position the fuel tank so that there is at 5mm-10mm of clearance between the fuel tank and the part of the muffler that it is closest to. Created: 11/1/2005 Page 33 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 34 Created: 11/1/2005 Page 34 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 35 Insert the fuel pickup and push the threaded end through the hole on the front of the tank Created: 11/1/2005 Page 35 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 36 It is possible to add an optional header tank to your fuel system if you desire, however it will need to be purchased separately and is not described further in these instructions Created: 11/1/2005 Page 36 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 37 This completes the tank attachment. Note the location of the fuel vent and pickup as shown Created: 11/1/2005 Page 37 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 38 This completes the assembly of the lower frame plate assembly. Set this assembly aside for later integration into the upper frame assembly. Created: 11/1/2005 Page 38 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 39 Be sure to include a fuel filter in the feed line for the engine and if you’re using a YS engine, the required one-way valve. Created: 11/1/2005 Page 39 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 40: Upper Frame Assembly

    This section describes the assembly of the left and right upper frames and their assembly together. Bag 3 – Left Upper Frame Components Bag 3 Bag 3B Created: 11/1/2005 Page 40 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 41 Assembly Manual for XCell Stratus Kits #1026 Bag 3C Bag 3D Created: 11/1/2005 Page 41 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 42 Bag 3A parts list 120-10 Main Shaft 126-56 Carbon Left Main Frame 126-58 Carbon Battery Plate 126-61 Carbon Rear Frame Doubler Created: 11/1/2005 Page 42 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 43 M3 x 6 Socket head bolt 0061 M3 x 8 Socket head bolt 0063 M3 x 10 Socket head bolt Created: 11/1/2005 Page 43 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 44 125-12 ½” U-Channels 126-55 Gyro Plate 126-67 9mm hex spacer 126-68 15mm hex spacer 126-69 22mm hex spacer Created: 11/1/2005 Page 44 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 45 Mainshaft/Tail Drive Bearing block 120-9 Front Input shaft 123-87 5mm collar 126-66 Front T/R Bearing block Bag 3D parts list Created: 11/1/2005 Page 45 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 46 Delrin Inner Gear 70T Upper Gear Mounting Base w/ Steel 0866-6 Sleeve 0866-10 M14.0 x 0.2 Shim Ring 0866-11 Teflon O-ring Created: 11/1/2005 Page 46 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 47 M3 x 8 Socket Head bolt 115-45 M6 Rubber O-Ring 121-11 11 tooth Clutch Bell unit 121-8 Clutch unit Created: 11/1/2005 Page 47 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 48 Assembled View of the Outside of the Left Frame Half 0061 0060-1 0061 0061 0060-1 0060-1 0061 0060-1 Created: 11/1/2005 Page 48 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 49 Assembly Manual for XCell Stratus Kits #1026 Assembled View of the Inside of the Left Frame Half 0060-1 0060-1 0064-3 Created: 11/1/2005 Page 49 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 50 (Note – if you should desire to install the switch on the left side of your model, switch sides with the #126-63 and #126-62 front doubler plate found in bag 4A.) Created: 11/1/2005 Page 50 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 51 Tighten snugly using a 5mm nut driver and a 2.5mm allen wrench or equivalent tools. Created: 11/1/2005 Page 51 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 52 Created: 11/1/2005 Page 52 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 53 Thread lock onto the threads that now extend through the frame. Thread a #115-20 round frame spacer onto the threads on the inside of the frame and using appropriate tools fully tighten. Created: 11/1/2005 Page 53 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 54 Fully tighten these parts now. This is the rear servo bridge spacer Created: 11/1/2005 Page 54 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 55 Fully tighten using appropriate tools. These are the mounts for the fan shroud plate. Created: 11/1/2005 Page 55 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 56 Install the anti-rotation guide onto the screws on the inside of the frame. Fully tighten using a Phillips head screw driver. Created: 11/1/2005 Page 56 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 57 • Select the #120-12 upper main shaft mounting block and two #0061 M3 x 8mm socket head bolts. Created: 11/1/2005 Page 57 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 58 Do not apply Thread lock at this time. The front bolt will be installed later. Created: 11/1/2005 Page 58 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 59 Lightly tighten the bolts only at this time. Created: 11/1/2005 Page 59 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 60 Do not overtighten to prevent stripping the threads in the blocks. Remove the shafts and set to the side Created: 11/1/2005 Page 60 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 61 This is to prepare the gear for proper alignment in the next step. Created: 11/1/2005 Page 61 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 62 Created: 11/1/2005 Page 62 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 63 If necessary, remove the sprag clutch from the housing and it will return to its proper configuration. Created: 11/1/2005 Page 63 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 64 You will need the #0840-6 retaining dowel pin and the #0057 M4 socket set screw from this bag in a future step Created: 11/1/2005 Page 64 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 65 Do not insert the #0059-1 M2.5 x 6 socket head bolts into the retainers at this time. Created: 11/1/2005 Page 65 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 66 Just snug the set screw. Over tightening can distort the retaining collar The t/r gear mesh will be set in the next step Created: 11/1/2005 Page 66 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 67 This will keep the gear from moving during the next instruction. Created: 11/1/2005 Page 67 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 68 PEM mounting nuts in the frame half. Tighten both bolts firmly. Make sure you install the marked left plate on the correct side. Created: 11/1/2005 Page 68 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 69 Now reassemble the clutch bell over the clutch shaft Created: 11/1/2005 Page 69 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 70 When the gears moves smoothly, remove each of the bearing block bolts individually, apply a small amount of blue Thread lock, reinsert it and tighten firmly. Created: 11/1/2005 Page 70 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 71 This completes the left frame assembly. Created: 11/1/2005 Page 71 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 72 Assembly Manual for XCell Stratus Kits #1026 Left and Right views of initial Left Frame Assembly Created: 11/1/2005 Page 72 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 73: Bag 4 - Right Upper Frame Components

    Assembly Manual for XCell Stratus Kits #1026 Bag 4 – Right Upper Frame Components Bag 4 Bag 4B Created: 11/1/2005 Page 73 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 74 Carbon Rear doubler 126-62 Carbon Front Doubler w/Switch mount 126-72 Carbon Upper Fan Shroud Bracket Bag 4B parts list Created: 11/1/2005 Page 74 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 75 M3 x 10 Socket Head bolt 0099 M3 x 30 Phillips bolt 0105 M3 x 4.5 Threaded ball Created: 11/1/2005 Page 75 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 76 Brass Spacer Ring 106-02 M3 x 7 x 3 Flanged bearing 106-41 Front Canopy stand-off 122-27 Rear Canopy stand-off Created: 11/1/2005 Page 76 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 77 122-35 Bellcrank Collar 124-22 .305” Brass spacer 126-65 Elevator bellcrank 126-68 15mm hex spacer 126-69 22mm hex spacer Created: 11/1/2005 Page 77 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 78 Assembly Manual for XCell Stratus Kits #1026 Assembled View of the Outside of the Right Frame Half Created: 11/1/2005 Page 78 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 79 Assembly Manual for XCell Stratus Kits #1026 Assembled View of the Inside of the Right Frame Half 0060-1 0060-1 Created: 11/1/2005 Page 79 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 80 15mm hex spacers on the outside of the right frame. Tighten firmly. Created: 11/1/2005 Page 80 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 81 6mm bolts and install the ratio plated on the outside of the right frame plate as shown. Tighten these bolts fully. Created: 11/1/2005 Page 81 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 82 Now take the final bearing and push it into the remaining bearing cavity. Created: 11/1/2005 Page 82 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 83 Use the rear bellcrank pivot bolt as the initial alignment key. See the photo for a guideline Created: 11/1/2005 Page 83 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 84 Tighten lightly only. Created: 11/1/2005 Page 84 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 85 PEM nut in the frame Snug all of the bolts but do not tighten fully Created: 11/1/2005 Page 85 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 86 Tighten lightly. The front bolt for the lower bearing block will be installed in a later step Created: 11/1/2005 Page 86 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 87 Finally, select the two #0032 M2.9 x 9.5 Phillips screws and screw them into the anti-rotation guide as shown and fully tighten them Created: 11/1/2005 Page 87 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 88 Apply a small amount of blue Thread lock to the threads • Insert the bolt/item and tighten firmly • Created: 11/1/2005 Page 88 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 89 Do not apply Thread lock as this will be finalized in a later step. See photo for proper orientation. Created: 11/1/2005 Page 89 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 90 The completed bellcranks will be installed in the next step Created: 11/1/2005 Page 90 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 91 Repeat this procedure for the other bellcrank on the other side of the model. Created: 11/1/2005 Page 91 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 92 Tighten the bolt firmly. Make sure the bellcrank moves freely. If it does not, check to make sure you completely seated the flanged bearings into the bellcrank. Created: 11/1/2005 Page 92 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 93: Upper/Lower Frame Assembly

    This will need to be corrected prior to proceeding. Created: 11/1/2005 Page 93 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 94 • individually Apply a small amount of blue • Thread lock Reinsert the bolt and tighten • fully Created: 11/1/2005 Page 94 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 95 This will need to be corrected prior to proceeding. Created: 11/1/2005 Page 95 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 96 Finally tighten the four bolts that attach the fan shroud to the fan shroud mounts. Be careful not to over tighten these. Created: 11/1/2005 Page 96 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 97: Control System Assembly

    This section describes the assembly of the control system of the helicopter Bag 5 – Upper Control System Components Bag 5 Bag 5A parts list Created: 11/1/2005 Page 97 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 98 M3 x 7 x 3 Ball Bearing 0217 Swashplate 0219 Wash out hub 0221 Wash out arm 0227 42mm control rod Created: 11/1/2005 Page 98 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 99 0597-3 .187” Brass Spacer 0869 Wash out links 106-07 M2 x 16 Steel pin 106-08 M2 Retainer clip Created: 11/1/2005 Page 99 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 100 120° apart from each other. Refer to the photos for correct placement. Created: 11/1/2005 Page 100 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 101 When you release the guide, it will capture the anti-rotation bearing which prevents the outer swashplate from turning. Created: 11/1/2005 Page 101 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 102 Repeat this process for the other mixing arm. Created: 11/1/2005 Page 102 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 103 Repeat this process for the remaining pin Created: 11/1/2005 Page 103 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 104 Xacto knife blade to loosen one of the clips so that the link isn’t clamped as tightly. Repeat the process for the remaining washout arm Created: 11/1/2005 Page 104 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 105 At this point the washout assembly should move smoothly on the mainshaft, although it will be somewhat stiff. After a few flights, this will loosen up and move easily on the shaft. Created: 11/1/2005 Page 105 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 106: Bag 6 - Lower Control System/Canopy Components

    Assembly Manual for XCell Stratus Kits #1026 Bag 6 – Lower Control System/Canopy Components Bag 6A Bag 6B Bag 6C Created: 11/1/2005 Page 106 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 107 Plastic Servo blocks Bag 6B parts list 122-94 M3 x 97 Control Rod 121-4 M3 x 30 Control Rod Created: 11/1/2005 Page 107 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 108 M2 x 30 Control Rod Bag 6C parts list 0053-5 M3 x 16 Socket Set screws 106-22 Rubber Grommets 122-99 Canopy Knobs Created: 11/1/2005 Page 108 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 109 Velcro to wrap these wires together to prevent them from rubbing on the frames or other components. Created: 11/1/2005 Page 109 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 110 Apply blue Thread lock to the servo bolts prior to assembly and tighten according to servo manufacturers instructions Created: 11/1/2005 Page 110 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 111 There should be one control rod for the elevator, aileron and pitch bellcranks. The ball links will snap onto the balls as shown. Created: 11/1/2005 Page 111 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 112 Created: 11/1/2005 Page 112 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 113 Tighten firmly. This servo will be connected to the elevator channel on your receiver Created: 11/1/2005 Page 113 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 114 90 degree position when the balls on the aileron and pitch servo wheels are perfectly vertical (see photos) Created: 11/1/2005 Page 114 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 115 Tighten firmly. This servo will be connected to the pitch channel on your receiver Created: 11/1/2005 Page 115 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 116 Tighten firmly. This servo will be connected to the aileron channel on your receiver Created: 11/1/2005 Page 116 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 117 Attach the control rod to the threaded balls on the servo wheel and the t/r bellcrank as shown. Created: 11/1/2005 Page 117 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 118 Snap this control rod onto the threaded balls on the servo wheel and on the throttle arm on the engine carburetor. Created: 11/1/2005 Page 118 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 119 If you are using a full length antenna, install it as you normally would. Be careful to ensure that the antenna wire cannot rub on any sharp frame corners or other components. Created: 11/1/2005 Page 119 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 120 Velcro tape routed through the frame openings to secure it. Created: 11/1/2005 Page 120 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 121: Canopy Assembly

    Using a drum sander, trim the “flashing” off the rear edges of the canopy Created: 11/1/2005 Page 121 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 122 Created: 11/1/2005 Page 122 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 123 5mm clearance between any part of the canopy and the exhaust system. When complete, you can re-install the exhaust system. Created: 11/1/2005 Page 123 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 124 Always apply a light coat first, allowing 15 to 30 minute set-up time, before final gloss coats. Created: 11/1/2005 Page 124 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 125 15 to 30 minutes. Follow this with a “wet” coat. Canopy is completed. Created: 11/1/2005 Page 125 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 126 Position each decal and remove backing paper and firm finger excess liquid with a soft rubber pressure. squeegee. Created: 11/1/2005 Page 126 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 127: Rotor Head Assembly

    This section describes the assembly of the entire rotor head Bag 7 – Rotor Head Components Bag 7 Bag 7A Bag 7B Bag 7C Created: 11/1/2005 Page 127 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 128 M2 x 8 Socket Head Bolt 0052 M3 x 6 Socket Set Screw 0053-5 M3 x 16 Socket Set screw Created: 11/1/2005 Page 128 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 129 3D Flybar Paddles Bag 7B parts list 0095 M3 x 19 Phillips bolt 0109 M3 x 8 Threaded ball Created: 11/1/2005 Page 129 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 130 M5 x 16 Flanged Socket bolt 0316 M8 Clear Silicon Tube 0319 M8 x 16 x 5 Ball Bearing Created: 11/1/2005 Page 130 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 131 Clip Tool 120-5 Head Axle 120-7 M5 x 15 Washer Bag 7D parts list 0133-1 Grey Ball Links Created: 11/1/2005 Page 131 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 132 0313 M2 x 15 Threaded Rod 121-4 M3 x 30 Threaded Rod 121-6 M3 x 75 Threaded Rod Created: 11/1/2005 Page 132 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 133 Repeat this procedure for the other flybar spacer. You will need these in the next step. Created: 11/1/2005 Page 133 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 134 Repeat for the other threaded ball Created: 11/1/2005 Page 134 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 135 Thread them in until they are just flush with the outside of the pivot extension as shown Created: 11/1/2005 Page 135 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 136 Clean any lubricant off the axle and degrease the threads in the ends Created: 11/1/2005 Page 136 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 137 Created: 11/1/2005 Page 137 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 138 The head axle installation should appear as shown. Created: 11/1/2005 Page 138 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 139 Repeat this procedure for the remaining bell mixer Created: 11/1/2005 Page 139 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 140 Now repeat this procedure for the remaining bell mixer and blade grip. Created: 11/1/2005 Page 140 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 141 “rock” the socket around, this can be easily accomplished. Now repeat this process for the remaining blade grip. Created: 11/1/2005 Page 141 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 142 Use a toothpick or other small instrument to remove any grease that is on the inside of the bearing openings. Created: 11/1/2005 Page 142 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 143 These need to be tight, however it is not necessary to overly tighten the bolts. Created: 11/1/2005 Page 143 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 144 Do not overtighten. Created: 11/1/2005 Page 144 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 145 Make sure that the flybar carrier is level and not twisted before and during tightening the flybar set screws. Created: 11/1/2005 Page 145 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 146 M2 x 15 control rod. Tighten the links until they are flush tight with each other. Do not overtighten. Created: 11/1/2005 Page 146 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 147 Tighten these bolts snug and then tighten an additional 1/8 turn to clamp the rotor head. Created: 11/1/2005 Page 147 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 148 #0082-1 M5 x 45 socket bolts and two #0023 M5 locknuts during final assembly to install the rotor blades Created: 11/1/2005 Page 148 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 149: Tail Rotor Assembly

    This section describes the assembly of the tail rotor Bag 8 – Tail Rotor Components Bag 8 Bag 8A Bag 8B Created: 11/1/2005 Page 149 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 150 M2 x 10 Socket Head bolt 0097 M3 x 22 Phillips bolt 0101 M2 x 5 Threaded Ball 0435 Brass Pitch Slider Created: 11/1/2005 Page 150 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 151 M5 x 4 x 10 Ball Bearing 122-65 T/R Hub Bag 8B parts list 0015 M2 Hex Nut 0019-1 M3 Locknut – Thin Created: 11/1/2005 Page 151 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 152 M2 x 5 Threaded ball 0159 M3 x 7 x 3 Ball Bearing 0445 Bellcrank 0597-3 .187” Brass spacer 123-75A Gear Box Created: 11/1/2005 Page 152 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 153 If you get this too tight, use an Xacto knife blade and work it between the clip and the pitch yoke to slightly loosen the clip until the assembly moves smoothly. Created: 11/1/2005 Page 153 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 154 Use the photos to ensure the correct position of these parts Created: 11/1/2005 Page 154 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 155 Select the spacing shim and set it on top of the flat side of the bearing race. Created: 11/1/2005 Page 155 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 156 Typically this can be done by adding a washer onto the back of one of the t/r mount bolts Created: 11/1/2005 Page 156 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 157 Hold the top of the bolt with a Phillips screw driver and then tighten the locknut firmly Created: 11/1/2005 Page 157 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 158 Tighten until it seats firmly in the t/r shaft and fully tighten. Now flip the hub over and fully tighten the other set screw Created: 11/1/2005 Page 158 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 159 Repeat this procedure for the remaining t/r grip. Created: 11/1/2005 Page 159 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 160: Tail Boom Assembly

    0587-14 Graphite 33” Tail Boom 0867-15 Tube Drive 0868-11 T/R Pushrod – 30.5” 0872-9 Boom Supports 0 25.5” Created: 11/1/2005 Page 160 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 161 Set this aside for now Created: 11/1/2005 Page 161 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 162: Bag 10 - Tail Rotor Components

    Assembly Manual for XCell Stratus Kits #1026 Bag 10 – Tail Rotor Components Bag 10 Bag 10A Bag 10B Created: 11/1/2005 Page 162 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 163 123-86A T/R and Vertical Fin Mount 123-86B T/R Mount – Left Side 124-84 Vertical Fin 124-85 Horizontal Fin Created: 11/1/2005 Page 163 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 164 0027 M2.2 x 9.5 Phillips screw 0032 M2.9 x 9.5 Phillips screw 0039 M2.5 x 12 Phillips bolt Created: 11/1/2005 Page 164 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 165 Guide support 0560-3 M2.5 Hex nut 0868-20 Brass sleeve 0868-4 Heat Shrinkable Teflon Tube 0868-5 Push Rod guide Created: 11/1/2005 Page 165 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 166 Created: 11/1/2005 Page 166 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 167 Rotate the t/r assembly so that the t/r grips/blades face down and set the assembly on a hard surface. Created: 11/1/2005 Page 167 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 168 Tighten fully but carefully as the transmission threads are not thick at this point Created: 11/1/2005 Page 168 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 169 The front of the triangular fin should point away from the t/r transmission. Fully tighten using a Phillips head screwdriver Created: 11/1/2005 Page 169 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 170 M2.5 hex nut onto them. Tighten using a Phillips head screw driver Created: 11/1/2005 Page 170 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 171 Created: 11/1/2005 Page 171 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 172 Tighten the four M3 x 30mm bolts and locknuts that hold the boom support clamp into the frame. Tighten these fully but don’t overtighten them Created: 11/1/2005 Page 172 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 173 Created: 11/1/2005 Page 173 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 174 Let this dry for an hour or so. Created: 11/1/2005 Page 174 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 175 Fully tighten the M3 bolt and locknut at the bottom of the rear boom support. Created: 11/1/2005 Page 175 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 176 Now use a heat gun to shrink the Teflon tube tightly onto the pushrod. Carefully shrink the entire tube so that it is evenly against the pushrod. Be careful not to melt the tube. Created: 11/1/2005 Page 176 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 177 Created: 11/1/2005 Page 177 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 178: Final Assembly

    It is recommended that a blade length of 700 to 720mm be used. A good quality rotor blade is suggested. Miniature Aircraft USA offers a variety of high quality rotor blades suitable for this model. Install the main blades as follows:...

  • Page 179: Setup Instructions

    90 degrees points, fore, aft, right and left. Miniature Aircraft USA offers an excellent tool for leveling the swashplate, order #0513. Note: Adjustments should be split at opposite sides (half turn longer on the left side and half turn shorter on the right side, for example).
  • Page 180 K) Set the throttle settings to approximately those shown on the chart or to the requirements of a governor if used. Created: 11/1/2005 Page 180 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 181: Final Inspection

    “full tank” flights on a charge. Do not take any unnecessary risks. Always turn off all components between flights. Created: 11/1/2005 Page 181 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 182: Initial Trimming Instructions

    -High blade speed >>Raise the low blade -If blades are out of track ½" or more >>Recheck original pitch settings Created: 11/1/2005 Page 182 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 183: Maintenance Items

    NOTE: Any bearing pre-load is easily observed by removing the tail rotor blades and hub and then rotating the shafts. Created: 11/1/2005 Page 183 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 184: Constant Drive

    Approximately every 100 flights, remove the constant drive assembly and lubricate the bearing by adding automatic transmission fluid or Tri-Flow oil. Created: 11/1/2005 Page 184 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 185: Canopy Cut-Out Template - No Muffler

    This cutout is for use with the standard Stratus canopy. It does not include a muffler cut-out. This end towards the front of the canopy This end towards the rear of the canopy Created: 11/1/2005 Page 185 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

  • Page 186: Canopy Cut-Out Template - With Hatori Sb16/Sb17

    This cutout is for use with the standard Stratus canopy. It includes a cut-out for the Hatori SB16/SB17 muffler. Created: 11/1/2005 Page 186 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 187 Assembly Manual for XCell Stratus Kits #1026 Created: 11/1/2005 Page 187 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...
  • Page 188 MINIATURE AIRCRAFT USA 31713 Long Acres Drive Sorrento, Florida 32776 Phone (352) 383-3201 Fax (352) 383-3204 Website: www.miniatureaircraftusa.com Email: Minair@earthlink.net Created: 11/1/2005 Page 188 Of 188 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA...

This manual is also suitable for:

X-cell stratus 126-100

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