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]

XCell Ion-X2Assembly Manual
Created: 8/25/2007 Copyright Miniature Aircraft USA Page 3 of 123
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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
Page 4 of 123 Copyright Miniature Aircraft USA Created: 8/25/2007
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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
Created: 8/25/2007 Copyright Miniature Aircraft USA Page 5 of 123
This document may not be distributed without permission of Miniature Aircraft USA
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
This document may not be distributed without permission of Miniature Aircraft USA
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.

XCell Ion-X2Assembly Manual
Created: 8/25/2007 Copyright Miniature Aircraft USA Page 7 of 123
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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
This document may not be distributed without permission of Miniature Aircraft USA
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

XCell Ion-X2Assembly Manual
Created: 8/25/2007 Copyright Miniature Aircraft USA Page 9 of 123
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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
Page 10 of 123 Copyright Miniature Aircraft USA Created: 8/25/2007
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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