miniature aircraft X-Cell Ion-X2 User manual

Created: 8/25/2007 Copyright Miniature Aircraft US
This document may not be distributed without permission of Miniature Aircraft USA
X-Cell Ion-X2
Reference Guide
Version 1.0
Revision Date: 08/22/2007

XCell Ion-X2Reference Guide
Page 2 of 59 Copyright Miniature Aircraft USA Created: 8/25/2007
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For More Information contact:
Miniature Aircraft USA
31713 Long Acres Drive
Sorrento, FL 32776 USA
Phone [phone]
Fax [phone]
Email: [email protected]

XCell Ion-X2Reference Guide
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Table Of Contents
REVISIONS TO THIS MANUAL......................................................................................................................................................... 5
ERRATA.................................................................................................................................................................................................. 5
I. INTRODUCTION ............................................................................................................................................................................... 7
II. PARTS REFERENCES..................................................................................................................................................................... 7
2.1 MAIN CHASSIS ........................................................................................................................................................................... 7
2.1.1 - Left Frame Assembly - Parts.................................................................................................................................................. 8
2.1.2 – Landing Gear Mounts - Parts................................................................................................................................................ 9
2.1.3 Right Frame Assembly - Parts............................................................................................................................................... 10
2.1.4 Constant Drive with Single Gear - Parts................................................................................................................................ 11
2.1.5 Double Gear Constant Drive – Exploded View...................................................................................................................... 12
2.1.6 Constant Drive with Double Gear - Parts.............................................................................................................................. 13
2.1.7 Main Drive Train - Parts........................................................................................................................................................ 14
2.2 LANDING GEAR....................................................................................................................................................................... 15
2.3 MOTOR DRIVE.......................................................................................................................................................................... 16
2.3.1 Motor Mount - Parts............................................................................................................................................................... 18
2.3.2 Primary Drive - Parts............................................................................................................................................................. 19
2.4 CONTROL SYSTEM................................................................................................................................................................... 20
2.4.1 Bellcranks - Parts................................................................................................................................................................... 20
2.4.2 Swashplate/Washout Mixer - Parts ........................................................................................................................................ 22
2.4.3 Pitch Servo - Parts ................................................................................................................................................................. 24
2.4.4 Elevator Servo - Parts............................................................................................................................................................ 25
2.4.5 Aileron Servo - Parts.............................................................................................................................................................. 26
2.4.6 Rudder Servo - Parts.............................................................................................................................................................. 27
2.4.7 Control Rods - Parts............................................................................................................................................................... 28
2.5 CANOPY ................................................................................................................................................................................... 29
2.6 ROTOR HEAD ........................................................................................................................................................................... 30
2.6.1 Head Block #0844A Exploded View....................................................................................................................................... 30
2.6.2 Head Block Assembly- Parts.................................................................................................................................................. 31
2.6.3 Bell Mixer Assembly - Parts................................................................................................................................................... 32
2.6.4 Blade Arm Assembly - Parts................................................................................................................................................... 33
2.6.5 Flybar Control Assembly - Parts............................................................................................................................................ 34
2.6.6 Rotor Head Control Rods - Parts........................................................................................................................................... 35
2.7 TAIL ROTOR............................................................................................................................................................................. 36
2.7.1 Tail Rotor Hub Assembly - Parts............................................................................................................................................ 36
2.7.2 Tail Rotor Pitch Control Assembly – Parts............................................................................................................................ 37
2.7.3 Tail Rotor Gearbox #123-95 Exploded View ......................................................................................................................... 38
2.7.4 Tail Rotor Control Bellcrank - Parts...................................................................................................................................... 39
2.8 TAIL BOOM .............................................................................................................................................................................. 40
2.8.1 Tail Rotor Mount Assembly - Parts........................................................................................................................................ 40
2.8.2 Tail Boom/Boom Mount/Torque Tube.................................................................................................................................... 41
2.8.3 Horizontal Fin Mount Assembly – Parts................................................................................................................................ 42
2.8.4 Tail Rotor Control Rod Support Assembly - Parts................................................................................................................. 43
2.8.5 Tail Rotor Control Rod Assembly - Parts............................................................................................................................... 43
2.8.6 Tail Boom Supports Assembly – Parts ................................................................................................................................... 44
III. FASTENER GUIDE.................................................................................................................................................................. 45
IV. MODEL VIEWS........................................................................................................................................................................ 48
V. GEAR RATIOS......................................................................................................................................................................... 53
5.1 Available Drive Ratios – Sorted by Motor Pulley Size........................................................................................................ 53

XCell Ion-X2Reference Guide
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5.2 Available Drive Ratios – Sorted by Primary Pulley Size..................................................................................................... 56

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Revisions to this Manual
R1.0
•08/22/07 – Initial Release
For the most current version of this manual, please refer to www.miniatureaircraftusa.com, visit the Ion-
X2helicopter kit and download the Reference Guide
Errata
R1.0
•None reported

XCell Ion-X2Reference Guide
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I. Introduction
•This document contains an overview of the various parts assemblies, their assembly order and part
numbers.
•For complete assembly instructions, reference the Assembly Guide for this model.
II. Parts References
The part lists are organized by major component categories
2.1 Main Chassis

XCell Ion-X2Reference Guide
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2.1.1 - Left Frame Assembly - Parts
#0874-1
#0061 (2)
#0061 (3)
#0061 (2)
#126-55 #124-134
#115-20
#0060-1
#0169
#124-13
#124-140
#124-130
#124-138 #0019
#0009
#0019
#0061 (3)
#0062 (2)
#124-136
#0061 (2)
#120-08
#0060-1
#0061 (2)
#0063 (2)
#115-20
#124-14
#0109
#0032 (2)
#0060-1
#0061
#124-168
#127-65 #0003 (2)
#115-20
#0060-1
Left Frame Assembly Parts
#120-12
#124-142
#124-144

XCell Ion-X2Reference Guide
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Part # Description
0003 M3 Washer – Large
0009 M3 Washers – Small
0019 M3 Locknut
0032 M2.5 x 9.5 Phillips Screw
0060-1 M3 x 6 Socket Bolt
0061 M3 x 8 Socket Bolt
0062 M3 x 10 Flat Head Bolt
0063 M3 x 10 Socket Bolt
0109 M3 x 8 Threaded Ball
0169 Bellcrank Stud
0874-1 Swashplate Guide
115-20 Frame Spacer
120-8 Lower Main Shaft Bearing Block
120-12 Upper Main Shaft Bearing Block
Part # Description
124-13 Lower Canopy Stud
124-14 Upper Canopy Stud
124-130 C/F Left Main Frame
124-134 G-10 Battery Main Plate
124-136 G-10 Battery Base Plate
124-138 Vertical Rear Channel
124-140 Vertical Front Channel
124-142 Horizontal Upper Channel
124-144 Battery Base Channel
124-168 7.75:1 Left Upper Ratio Plate
126-55 Gyro Mounting Channel
127-65 Bearing Block w/M6 Bearing
2.1.2 – Landing Gear Mounts - Parts
Part # Description
0063 M3 x 10 Socket Bolt
115-40 Landing Gear Mounts
#0063 #0063
#115-40 #115-40
#0063 #0063

XCell Ion-X2Reference Guide
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2.1.3 Right Frame Assembly - Parts
Part # Description
0003 M3 Washer – Large
0032 M2.9 x 9.5 Phillips Screw
0060-1 M3 x 6 Socket Bolt
0061 M3 x 8 Socket Bolt
0063 M3 x 10 Socket Bolt
0109 M3 x 8 Threaded Ball
0169 Bellcrank Stud
124-14 Upper Canopy Stud
124-13 Lower Canopy Stud
124-132 C/F Right Main Frame
124-146 G-10 Canopy Mount Extension
124-166 7.75:1 Right Upper Ratio Plate
#0060-1 (3)
#0060-1 (4)
#0061 #0061
#0169
#0032 (2)
#0060-1#0060-1
#124-14
#124-13
#0060-1
#0061 (3)
#124-146
#0061 (2)
#0060-1 (3)
#0061
#0061
#0003 (2)
#0063 (2)
#124-132 #124-166

XCell Ion-X2Reference Guide
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2.1.4 Constant Drive with Single Gear - Parts
Part # Description
0057 M4 x 4 Socket Set Screw
0088 M3 x 8 Flat Head Bolt
0088-2 M3 x 6 Flat Head Bolt
0840-6 M3 x 20 Steel Dowel Pin
0865-93 93 tooth main gear
0866-4 Lower Autorotation Hub Assembly
0866-5 70 Tooth Crown Gear
0866-6 Crown Gear Mount
0866-10 M14 x 20 x .2 Shim
0866-11 14mm Teflon O-Ring
0866-12 Auto Retaining Ring
0866-13 M14 x 20 x .1 Shim
#0866-10
#0866-11
#0866-13
#0866-6
#0866-5
#0088-2 (Qty 8)
#0057
#0840-6
#0866-12 #0866-11
#0866-10
#0088 (Qty 4)
#0866-4
#0865-93 for 7.75

XCell Ion-X2Reference Guide
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2.1.5 Double Gear Constant Drive – Exploded View
Part # Description
0019 M3 Locknut
008x M3 x 20 Flat Head Bolt
0865-93 93 tooth main gear
0866-4 Lower Autorotation Hub Assembly
124-161 Secondary 93 tooth gear
124-174 Gear Ring Spacer
#008x
#008x
#008x
#008x
#0865-93
#124-174
#124-174
#0019
#0019
#0019
#0019
#124-161
#0866-4

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2.1.6 Constant Drive with Double Gear - Parts
Part # Description
0057 M4 x 4 Socket Set Screw
0088-2 M3 x 6 Flat Head Bolt
0840-6 M3 x 20 Steel Dowel Pin
0866-5 70 Tooth Crown Gear
0866-6 Crown Gear Mount
0866-10 M14 x 20 x .2 Shim
0866-11 14mm Teflon O-Ring
0866-12 Auto Retaining Ring
0866-13 M14 x 20 x .1 Shim
124-169 Assembled Ultimate Autorotation Unit
#0866-10
#0866-11
#0866-13
#0866-6
#0866-5
#0088-2 (Qty 8)
#0057 #0840-6 #0866-12
#0866-11
#0866-10
#124-169
Pre-Assembled

XCell Ion-X2Reference Guide
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2.1.7 Main Drive Train - Parts
Part # Description
0057 M4 x 4 Socket Set Screw
0059-1 M2.5 x 6 Socket Bolt
0232 15 tooth Spur Gear
0840-6 M3 x 20 Steel Dowel Pin
0866-12 Auto Retaining Ring
0866-15 Main Shaft
0875-1 Main Shaft Collars
Part # Description
120-8 Lower Main Shaft Bearing Block
120-9 5mm Input Shaft w/Coupler
120-12 Upper Main Shaft Bearing Block
123-87 5mm Collar
124-138 Vertical Rear Channel
#124-38
#0866-15
#120-12
#120-8
#0866-12
#0840-6
#0057
#120-9
#123-87
#0232
#0057 (2)
#0057 (2)
#0875-1
#0875-1
#0059-1
#0059-1

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2.2 Landing Gear
Part # Description
0003 M3 Washer
0019 M3 Locknuts
0058-1 M4 x 6 Socket Set Screw
0073 M3 x 20 Socket Bolt
0077 M3 x 30 Socket Bolt
0872-8 Boom Support End
115-40 Landing Gear Mounts
124-150 Control Plate G-10
124-152 C/F Reinforcement Plate
127-53 Struts
127-54 Skids
127-54A Skid Plugs (black)
#0003
#0019
#0003
#0077
#0003#0019
#0872-8
#0872-8
#127-54
#127-54
#127-53
#127-53
#127-54A
#127-54A
#127-54A
#127-54A
#0058-1
#0058-1
#0058-1
#0058-1
#0073
#124-150
#124-152
#115-40
#115-40

XCell Ion-X2Reference Guide
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2.3 Motor Drive
#0083/#0084
#124-156
#124-154
#124-157
#0075
#0075 #0075
#0075
#0073
#0073 #0073
#0073
#0063
#0063
#0061 #0061
#0032
#0032
#124-159
#124-158
#127-63 (2)
#127-63 (2)
#127-63 (2) #127-63 (2)
#0586-16 #0586-16
#0586-17 #0586-17
#0063
#0063 #0003
#0003
#0061
#124-160
#0061 #0061 #0273
#0273
#0057
#0058
#124-170
#124-172
#124-2xx
#0057
#0063
#0061
#0061
#0063
#0003
#0003 #0063
#0061
#0058
#0063

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Part # Description
0003 M3 Washer – Large
0032 M2.5 x 9.5 Phillips Screw
0057 M4 x 4 Socket Set Screw
0058 M4 x 5 Socket Set Screw
0061 M3 x 8 Socket Bolt
0063 M3 x 10 Socket Bolt
0073 M3 x 20 Socket Bolt
0075 M3 x 25 Socket Bolt
0083 M4 x 25 Socket Bolt
0084 M4 x 35 Socket Bolt
0273 M6 x .011” Shim
0586-16 Short Corner Block
0586-17 Long Corner Block
124-154 C/F Left Belt Drive Plate
124-156 C/F Right Belt Drive Plate
124-157 C/F Belt Tension Adjustment Plate
124-158 C/F Motor Mount
124-159 Belt Tension Adjustment Block
124-2xx Primary Drive Pulley
124-170 6mm shaft/double gear
124-172 12 tooth pinion gear (double gear)
124-160 Bearing Plate – 7.75
127-63 M8 x 14 Spacers

XCell Ion-X2Reference Guide
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2.3.1 Motor Mount - Parts
Part # Description
0004 M4 Washer
0009 M3 Washer – Small
0058 M4 x 5 Socket Set Screw
0063 M3 x 10 Socket Bolt
0078-5 M4 x 10 Socket Bolt
124-2xx Drive Pulley
#0078-5 (4)
#0063 (4)
#0004 (1)
#124-2xx
#0058 (2)
#0009 (4)

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2.3.2 Primary Drive - Parts
Part # Description
#124-228 Primary Drive 6mm - 28 tooth
#124-220 Primary Drive 6mm – 30 tooth
#124-232 Primary Drive 6mm – 32 tooth
#124-234 Primary Drive 6mm – 34 tooth
#124-236 Primary Drive 6mm – 36 tooth
#124-238 Primary Drive 6mm – 38 tooth
#124-240 Primary Drive 6mm – 40 tooth
#124-244 Primary Drive 6mm – 44 tooth
Part # Description
#124-216 Motor Drive - 6mm – 16 tooth
#124-216-8 Motor Drive – 8mm – 16 tooth
#124-217 Motor Drive - 6mm – 17 tooth
#124-217-8 Motor Drive – 8mm – 17 tooth
#124-218 Motor Drive - 6mm – 18 tooth
#124-218-8 Motor Drive – 8mm – 18 tooth
#124-219 Motor Drive - 6mm – 19 tooth
#124-219-8 Motor Drive – 8mm – 19 tooth
#124-220 Motor Drive - 6mm – 20 tooth
#124-220-8 Motor Drive – 8mm – 20 tooth
#124-222 Motor Drive - 6mm – 22 tooth
#124-222-8 Motor Drive – 8mm – 22 tooth
124-xxx Drive Belt
Drive Belt (ratio dependent)
#124-xxx - xxmm
#124-xxx - xxmm
1 belt
#124-2xx
Drive Pulley (ratio dependent)
1 pulley
#124-2xx
Drive Pulley (ratio dependent)
1 pulley

XCell Ion-X2Reference Guide
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2.4 Control System
2.4.1 Bellcranks - Parts
#0169
#0169
#0112
#0107
#0112
#0113
#0171
#0171
#0051
#0051
#0159
#0159
#0159
#0009 (2)
#0009
#0009
#0597-3
#122-28
#124-22
#0167
#0167
#124-148
#0019
#0099
#0105
#0105
Elevator
Aileron
Pitch
#0159
#0159
#0159