XCell 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
Assembly Manual
Version 1.0
Revision Date: 08/22/2007

XCell Ion-X2Assembly Manual
Page 2 of 123 Copyright Miniature Aircraft USA Created: 8/25/2007
This document may not be distributed without permission of Miniature Aircraft USA
For More Information contact:
Miniature Aircraft USA
31713 Long Acres Drive
Sorrento, FL 32776 USA
Phone [phone]
Fax [phone]
Email: [email protected]

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Table of Contents
REVISIONS TO THIS MANUAL......................................................................................................................................................... 5
ERRATA.................................................................................................................................................................................................. 5
I. KIT INTRODUCTION....................................................................................................................................................................... 6
R/C HELICOPTER SAFETY ...................................................................................................................................................................... 6
GUIDELINES FOR SAFE R/C HELICOPTER FLIGHT................................................................................................................................... 6
X-CELL LIMITED WARRANTY .............................................................................................................................................................. 7
WARRANTY PROCEDURES...................................................................................................................................................................... 7
X-CELL ION-X2WARRANTY REGISTRATION.......................................................................................................................................... 7
II. KIT PREREQUISITES..................................................................................................................................................................... 8
SUPPLIES NEEDED FOR ASSEMBLY......................................................................................................................................................... 8
Adhesives Used.................................................................................................................................................................................. 8
TOOLS NEEDED FOR ASSEMBLY............................................................................................................................................................. 9
ADDITIONAL COMPONENTS NEEDED ................................................................................................................................................... 10
DOCUMENTATION ................................................................................................................................................................................ 11
III. KIT ASSEMBLY PROCESS......................................................................................................................................................... 12
ASSEMBLY TIPS ................................................................................................................................................................................... 12
FASTENER GUIDE................................................................................................................................................................................. 13
ASSEMBLY COMPONENTS –UNBAGGED PARTS ................................................................................................................................... 15
ASSEMBLY COMPONENTS –LONG PARTS BAG .................................................................................................................................... 16
STEP #1 –LOCATE MAIN DRIVE COMPONENTS............................................................................................................................. 17
1A-S) Drive Train Components - Bag #1A – Single Gear............................................................................................................... 17
1A-D) Drive Train Components - Bag #1A – Double Gear............................................................................................................ 18
1B) Primary Drive - Bag #1B.......................................................................................................................................................... 19
STEP #2 –MAIN FRAME ASSEMBLY................................................................................................................................................ 20
2A) Major Frame Components - Bag #2A....................................................................................................................................... 20
2B) Chassis Components - Bag #2B................................................................................................................................................ 21
2B.1 - Assemble Left Frame...................................................................................................................................................................22
2C) Drive Train Components - Bag #2C......................................................................................................................................... 26
2C.1 Assemble Constant Drive Unit.....................................................................................................................................................27
2C.2 Install Drive Train Components.................................................................................................................................................31
2D) Drive Train Components - Bag #2D ........................................................................................................................................ 36
2D.1 Install Right Frame ........................................................................................................................................................................37
2D.2 Assemble Bellcranks......................................................................................................................................................................43
2D.3 Install Bellcranks ............................................................................................................................................................................45
STEP #3 –SKIDS/BATTERY PLATE ................................................................................................................................................. 47
3A) Landing Gear - Bag #3A........................................................................................................................................................... 47
3A.1 Assemble Landing Gear .................................................................................................................................................................48
STEP #4 –BELT DRIVE/MOTOR ASSEMBLY................................................................................................................................... 51
4A) Belt Drive - Bag #4A................................................................................................................................................................. 51
4A.1 Assemble Primary Belt Drive.......................................................................................................................................................52
4A.2 Assemble Motor Mount/Motor......................................................................................................................................................56
4A.3 Connect ESC.......................................................................................................................................................................................58
4A.4 Install Motor.......................................................................................................................................................................................59
STEP #5 –CONTROL SYSTEM/CANOPY .......................................................................................................................................... 61
5A) Washout Mixer/Swashplate Assembly – Bag #5A..................................................................................................................... 61
5A.1 - Assemble Swashplate..................................................................................................................................................................63
5A.2 – Swashplate Control Rods...........................................................................................................................................................64
5A.2 - Assemble Washout Mixer...........................................................................................................................................................64
5A.3 - Install Swashplate/Washout Mixer.........................................................................................................................................67

XCell Ion-X2Assembly Manual
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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 – Install Elevator Servo.............................................................................................................................................................73
5C.1.3 – Install Aileron Servo................................................................................................................................................................74
5C.1.4 – Install Rudder Servo...............................................................................................................................................................75
5C.1.5 – Check Servo Orientation........................................................................................................................................................76
5C.2 – Install Electronics.........................................................................................................................................................................77
5C.3 – Install Servo Control Rods........................................................................................................................................................78
5D) Install Canopy – Bag #5D........................................................................................................................................................ 80
5D.1 – Prepare Canopy............................................................................................................................................................................80
STEP #6 –ROTOR HEAD.................................................................................................................................................................. 82
6A) Assemble Rotor Head – Bag #6A.............................................................................................................................................. 82
6A.1 - Head Block Assembly ..................................................................................................................................................................83
6A.2 – Assemble Bell Mixer ....................................................................................................................................................................83
6A.3 – Install Bell Mixers.........................................................................................................................................................................85
6A.4 - Blade Arm Assembly....................................................................................................................................................................86
6A.4.1 – Assemble Blade Arms.............................................................................................................................................................86
6A.5 – Install Blade Arms........................................................................................................................................................................88
6B) Assemble Flybar – Bag #6B...................................................................................................................................................... 88
6B.1 – Assemble/Install Flybar Control System..............................................................................................................................89
6B.2 – Assemble/Install Flybar Bell Links .........................................................................................................................................91
6B.3 – Install Flybar..................................................................................................................................................................................91
6B.4 – Install Flybar Paddles..................................................................................................................................................................92
6D.5 – Install Rotor Head........................................................................................................................................................................92
STEP #7 –TAIL ROTOR.................................................................................................................................................................... 95
7A) Tail Rotor Hub – Bag #7A........................................................................................................................................................ 95
7A.1 – Assemble Tail Rotor Hub ...........................................................................................................................................................96
7A.2 – Install Tail Rotor Blades.............................................................................................................................................................98
7B) Tail Rotor Control – Bag #7B................................................................................................................................................... 99
7B.1 – Assemble TR Pitch Yoke...........................................................................................................................................................100
7B.2 – Assemble T/R Bellcrank...........................................................................................................................................................102
7B.3 – Install T/R Bellcrank..................................................................................................................................................................103
7B.3 – Install T/R Pitch Yoke................................................................................................................................................................104
STEP #8 –TAIL BOOM ................................................................................................................................................................... 105
8.1 – Install Tube Drive .........................................................................................................................................................................105
8.2 – Install T/R Transmission.............................................................................................................................................................105
8A) Tail Boom – Bag #8A.............................................................................................................................................................. 106
8A.1 – Install Vertical Fin Mount/Fin.................................................................................................................................................107
8A.2 – Install Horizontal Fin Mount/Fin............................................................................................................................................109
8A.3 – Install Tail Rotor.........................................................................................................................................................................111
8A.4 – Assemble/Install T/R Pushrod ...............................................................................................................................................112
8A.5 – Assemble/Install T/R Pushrod Guide...................................................................................................................................113
8A.6 – Install Tailboom ..........................................................................................................................................................................113
8A.7 – Assemble T/R Pushrod .............................................................................................................................................................114
8A.8 – Install T/R Pushrod....................................................................................................................................................................115
8A.9 – Assemble Tail Boom Supports...............................................................................................................................................116
8A.10 – Install Tail Boom Supports...................................................................................................................................................118
8A.11 – Install Vertical Fin....................................................................................................................................................................119
8A.12 – Balance Model...........................................................................................................................................................................119
8A.13 – Install Main Rotor Blades......................................................................................................................................................120

XCell Ion-X2Assembly Manual
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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
helicopter kit and download the assembly manual
Errata
R1.0
•Some views of #124-166/168 show G-10 material. A production change was made replace this
with graphite material.

XCell Ion-X2Assembly Manual
Page 6 of 123 Copyright Miniature Aircraft USA Created: 8/25/2007
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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.
A model helicopter must be built exactly in accordance with the building instructions. The kit manufacturer
has spent much time and effort refining his product to make it reliable in operation and easy to build. The
essentially bolt together construction can proceed quite rapidly, giving the builder a strong sense of
accomplishment that encourages hasty progress from one construction phase to the next, so that the
completed model can be more quickly seen and enjoyed. It is essential to recognize and guard against this
tendency. Follow building instructions exactly. Vibration and stress levels are high and all fasteners and
attachments must be secure for safe operation.
Note that this is the first use of the word SAFETY in these comments. Previously the kit manufacturer’s
efforts to ensure reliable operation were mentioned. That is ALL that he can do. Safe operation is the
responsibility of the builder/flyer and starts with careful construction and continues with selection and
installation of reliable radio equipment and engine.
The need for safety is nowhere greater than at the flying field. A number of guidelines for safe flight have
been developed by experienced flyers and are set down here. It is urged that they be read, understood
and followed.
Guidelines for Safe R/C Helicopter Flight
•Fly only at approved flying fields and obey field regulations.
•Follow frequency control procedures. Interference can be dangerous to all.
•Know your radio. Check all transmitter functions before each flight.
•Be aware that rotating blades are very dangerous and can cause serious injury.
•Never fly near or above spectators or other modelers.
•If a beginner, get help trimming the model first and flight training later.
•Don’t “track” the main blades by holding the tail boom. This is a temptation to builders who cannot
hover yet and is very dangerous.
•Follow all recommended maintenance procedures for model, radio and engine.
WARNING!
This helicopter is not a toy, but a complex flying machine that must be assembled with care by a
responsible individual. Failure to exert care in assembly, or radio or accessory installation, may result in a
model incapable of safe flight or ground operation. Rotating components are an ever present danger and
source of injury to operators and spectators. Since the manufacturer and his agents have no control over
the proper assembly and operation of his products, no responsibility or liability can be assumed for their
use.

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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.
Any part, which has been improperly installed, abused, crash damaged or altered by unauthorized
agencies, is not covered. Under no circumstances will the buyer be entitled to consequential or incidental
damages. The components used in this kit are made form special materials designed for special
applications and design strengths. We recommend that all replacement parts be original parts
manufactured by Miniature Aircraft, USA, to ensure proper and safe operation of your model. Any part
used which was manufactured by any firm other than Miniature Aircraft, USA, VOIDS all warrantees of this
product by Miniature Aircraft, USA.
Warranty Procedures
Mail all warranty information within 15 days of original purchase date. If service is required, send the
component in question (if not missing) together with a photocopy of your bill of sale and an accurate
description of the problem and part. Ship components fully insured and prepaid. Miniature Aircraft, USA is
not responsible for any shipping damages. We will, at our discretion, notify you of any costs involved, or
ship it COD. You are required to pay all postage, shipping and insurance charges.
X-Cell Ion-X2Warranty Registration
Please print or type, filling in the information listed below and mail immediately
Model No:____________ Serial No:____________ Price paid:___________________
Owners name:______________________________ Age_______________________
Address:____________________________________ Phone:___________________
City:_______________________ State:____________ Zip:___________________
Purchased from: ________________________________________________________
Dealer’s address ________________________________________________________
Comments: ____________________________________________________________
______________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
MINIATURE AIRCRAFT USA
31713 Long Acres Drive
Sorrento, FL 32776 USA
Phone [phone]
FAX [phone]

XCell Ion-X2Assembly Manual
Page 8 of 123 Copyright Miniature Aircraft USA Created: 8/25/2007
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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
Lock Red Thread Lock Green Thread Lock Oil Grease
Adhesives Used
Slow
Cyanoacrylate JB Weld

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Tools Needed for Assembly
M5 Nut Driver
M5.5 Nut Driver
M7 Nut Driver
M4 Nut Driver
1.5mm allen driver
2.0mm allen driver
2.5mm allen driver
3.0mm allen driver
Needle Nose Pliers
Phillips Screwdriver #1
Flat Screwdriver 2.5mm
Razor Knife (Xacto)
8.0mm wrench
5.5mm wrench
4.0mm wrench

XCell Ion-X2Assembly Manual
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Additional Components Needed
Electronics
Rotor Blades
Main Rotor Blades
700-720mm
5mm blade bolt
14mm blade root
Tail Rotor Blades
95-105mm
Gyro
Servo
1 each
Cyclic
Servos
3 each Gyro –
Heading Hold
Battery – NiCad
NiMH/LiPo
800mah
A or AA cells
Switch
Receiver

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

XCell Ion-X2Assembly Manual
Page 12 of 123 Copyright Miniature Aircraft USA Created: 8/25/2007
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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"
and other details noted in the pictures and to carefully review all of the photo’s in a given step. The
placement of a given part may be better understood when viewing another view of the assembly.
•Follow the order of assembly. The instructions have been organized into major sections and have
been developed in such a way that each step builds upon the work done in the previous step.
Changing the order of assembly may result in unnecessary steps
•The photos in this manual are organized within each step to correspond with the order of assembly.
The sequence of the photos within a step is from top to bottom and from left to right and is
indexed accordingly.
•Clean all metal parts: All of the steel parts in this kit are coated with a lubricant to prevent them
from rusting. This coating can interfere with the adhesives and thread locks needed for assembly.
Use a solvent such as alcohol or acetone to clean the various metal parts, especially threads
•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
•Sand sharp edges on any frame plate that Velcro® or wires may rub against to prevent them from
being damaged over time by vibration
•Make sure every bearing runs smoothly after component assembly. If it does not find out why. A
rough running bearing will fail prematurely.
•As a general rule any bolt that threads into a metal part should have thread lock applied
and any screw or bolt that threads into a plastic part should have adhesive applied
•Assembly sections contain the following content:
oThe contents of each bag
oAn overview of part relationships
oAssembly overview
•Photographs will contain assembly icons that indicate use of thread lock, adhesive or lubricant as
needed. If an assembly has more than one of the same part number, application of thread lock,
adhesive or lubricant will apply to all of the same numbered parts in that photograph Examples of
the icons are as follows:
Thick
Adhesive
Blue
Thread
Lock
Red
Thread
Lock
Green
Thread
Lock
Lubricant Grease

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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 – Washers, Nuts, Small Bolts, Set Screws
Part # Description Actual Size
0003 M3 Washer (Large) ---------------------
0004 M4 Washer (Small)---------------------
0009 M3 Washer (Small) ---------------------
0015 M2 Hex Nut -----------------------------
0016 M3 Serrated Lockwasher ---------------
0017 M3 Hex Nut -----------------------------
0019 M3 Locknut -----------------------------
0019-1 M3 Locknut – Thin ----------------------
0020 M2.5 Locknut ---------------------------
0021 M4 Locknut -----------------------------
0023 M5 Locknut -----------------------------
0027 M2.2 x 9.5 Phillips Screw --------------
0032 M2.5 x 9.5 Phillips Screw---------------
0038 M2 x 8 Phillips Bolt ---------------------
0039 M2 x 10 Phillips Bolt -------------------
0039-1 M2.5 x 14 Phillips Bolt -----------------
0043 M2 x 10 Slotted Bolt -------------------
0048 M3.5 x 25 Socket Set Screw -----------
0049-3 M2 x 8 Socket Bolt ---------------------
0049 M2 x 10 Socket Bolt --------------------
0051 M3 x 3 Socket Set Screw --------------
0052 M3 x 6 Socket Set Screw --------------
0053-5 M3 x 16 Socket Set Screw -------------
0056 M3 x 5 Dog Point Set Screw -----------
0057 M4 x 4 Socket Set Screw --------------
0058 M4 x 5 Socket Set Screw --------------
0058-1 M4 x 6 Socket Set Screw --------------

XCell Ion-X2Assembly Manual
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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 ---------------------
0062 M3 x 10 Flat Head Socket Bolt --------
0063 M3 x 10 Socket Bolt --------------------
0065 M3 x 12 Socket Bolt --------------------
0073 M3 x 20 Socket Bolt --------------------
0075 M3 x 25 Socket Bolt --------------------
0077 M3 x 30 Socket Bolt --------------------
0078-5 M4 x 10 Socket Bolt --------------------
0081 M4 x 16 Socket Head Bolt -------------
0082-1 M5 x 45 Socket Head Bolt -------------
0083 M4 x 25 Socket Head Bolt -------------
0084 M4 x 35 Socket Bolt --------------------
0086 M5 x 12 Flanged Socket Bolt ----------
0088-2 M3 x 6 Flat Head Socket Bolt ----------
0093 M3 x 18 Phillips Bolt -------------------
0097 M3 x 22 Phillips Bolt -------------------
0099 M3 x 30 Phillips Bolt -------------------

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Assembly Components – Unbagged Parts
Decals
Building Notes – These parts will be found in the kit
box. They are not part of a parts bag.
Canopy
Kit Documentation
#124-100
Ion-X2 Kit
Documentation
1 CD
#124-98
Ion-X
Canopy
1 each
#124-99
Ion-X
Decal Sheet
1 each

XCell Ion-X2Assembly Manual
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Assembly Components – Long Parts Bag
Building Notes – These parts are bagged together due to their size and will be used in later steps.
#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”
1
Each

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Step #1 – Locate Main Drive Components
1A-S) Drive Train Components - Bag #1A – Single Gear
Building Notes: If you have ordered the standard kit, this will be the Bag 1A contents. If you have ordered an optional gear ratio,
the part number for the ratio plates and main gear may be different. If you ordered the optional “ultimate 3d kit” this bag will be
replaced with the one on the following page.
These parts will be used in Steps 2 and 4
#124-166
7.75:1 Right Upper
Ratio Plate G-10
1 each
#0865-93
93 tooth
main gear
1 each
#124-168
7.75:1 Left Upper
Ratio Plate G-10
1 each
#124-160
7.75:1 Bearing Plate
1 each
#124-170
6mm shaft
double gear
1 each
#124-172
12 tooth
pinion gear
1 each
#0088
M3 x 8
Flat Head Bolt
4
each
#0866-4
Lower
Autorotation
Hub Assembly
1 each

XCell Ion-X2Assembly Manual
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1A-D) Drive Train Components - Bag #1A – Double Gear
Building Notes: If you have ordered the optional “Ultimate 3D kit”, this will be the Bag 1A contents. If you have ordered an
optional gear ratio, the part number for the ratio plates and main gear may be different. In this version of the kit the autorotation
unit comes fully assembled.
These parts will be used in Steps 2 and 4
#124-166
7.75:1 Right Upper
Ratio Plate
1 each
#124-168
7.75:1 Left Upper
Ratio Plate
1 each
#124-160
7.75:1 Bearing Plate
1 each
#124-170
6mm shaft
double gear
1 each
#124-172
12 tooth
pinion gear
1 each
#124-169
Assembled
Ultimate 3D
Autorotation
Unit
1 each

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1B) Primary Drive - Bag #1B
Building Notes: The part numbers for these will vary depending on the drive ratio chosen for the kit.
These parts will be used in Step 4
Drive Belt
#124-xxx - xxmm
#124-xxx - xxmm
1 belt
Drive Pulley (ratio dependent)
#124-216 – 6mm – 16 tooth
#124-216-8 – 8mm – 16 tooth
#124-217 – 6mm – 17 tooth
#124-217-8 – 8mm – 17 tooth
#124-218 – 6mm – 18 tooth
#124-218-8 – 8mm – 18 tooth
#124-219 – 6mm – 19 tooth
#124-219-8 – 8mm – 19 tooth
#124-220 – 6mm – 20 tooth
#124-220-8 – 8mm – 20 tooth
#124-222 – 6mm – 22 tooth
#124-222-8 – 8mm – 22 tooth
1 pulley
Drive Pulley (ratio dependent)
#124-228 – 6mm – 28 tooth
#124-220 – 6mm – 30 tooth
#124-232 – 6mm – 32 tooth
#124-234 – 6mm – 34 tooth
#124-236 – 6mm – 36 tooth
#124-238 – 6mm – 38 tooth
#124-240 – 6mm – 40 tooth
#124-244 – 6mm – 44 tooth
1 pulley

XCell Ion-X2Assembly Manual
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Step #2 – Main Frame Assembly
2A) Major Frame Components - Bag #2A
#124-130
CF Left
Main Frame
1 each
#124-132
CF Right
Main Frame
1 each
#124-134
G-10 Battery
Main Plate
1 each
#124-136
G-10 Battery
Base Plate
1 each
#124-142
Horizontal Upper
Channel
1 each
#124-138
Vertical Rear
Channel
1 each
#124-140
Vertical
Front
Channel
1 each