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XCell Stratus
Assembly Manual
188 pgs9.46 Mb0
Assembly Manual
190 pgs9.42 Mb0

miniature aircraft XCell Stratus, X-Cell Stratus 126-100 Assembly Manual

Assembly Manual for XCell Stratus Kits #1026
Table Of Contents
R/C HELICOPTER SAFETY.......................................................................................................................................................................4
GUIDELINES FOR SAFE R/C HELICOPTER FLIGHT ...................................................................................................................................4
X-CELL LIMITED WARRANTY...............................................................................................................................................................5
WARRANTY PROCEDURES ......................................................................................................................................................................5
X-CELL STRATUS WARRANTY REGISTRATION.......................................................................................................................................5
Supplies Needed for Assembly ...........................................................................................................................................................6
Adhesives Needed...............................................................................................................................................................................6
Tools Needed for Assembly................................................................................................................................................................7
Assembly Tips ....................................................................................................................................................................................7
UNBAGGED PARTS..................................................................................................................................................................................8
Kit Box ...............................................................................................................................................................................................8
LOWER FRAME ASSEMBLY...................................................................................................................................................................10
Bag 1 – Bottom Plate Components..................................................................................................................................................10
Bag 2 – Engine Specific Components ..............................................................................................................................................17
UPPER FRAME ASSEMBLY ....................................................................................................................................................................40
Bag 3 – Left Upper Frame Components..........................................................................................................................................40
Bag 4 – Right Upper Frame Components........................................................................................................................................73
UPPER/LOWER FRAME ASSEMBLY .......................................................................................................................................................93
CONTROL SYSTEM ASSEMBLY..............................................................................................................................................................97
Bag 5 – Upper Control System Components....................................................................................................................................97
Bag 6 – Lower Control System/Canopy Components....................................................................................................................106
CANOPY ASSEMBLY ...........................................................................................................................................................................121
ROTOR HEAD ASSEMBLY ...................................................................................................................................................................127
Bag 7 – Rotor Head Components...................................................................................................................................................127
TAIL ROTOR ASSEMBLY .....................................................................................................................................................................149
Bag 8 – Tail Rotor Components.....................................................................................................................................................149
TAIL BOOM ASSEMBLY ......................................................................................................................................................................160
Bag 9 – Tail Boom Components.....................................................................................................................................................160
Bag 10 – Tail Rotor Components...................................................................................................................................................162
FINAL ASSEMBLY ...............................................................................................................................................................................178
Created: 11/1/2005 Copyright Miniature Aircraft USA Page 2 Of 188
This document may not be distributed without permission of Miniature Aircraft USA
Assembly Manual for XCell Stratus Kits #1026
Revisions to this Manual
• 10/01/05 – Version 1.2 - Revisions for final kitting modifications
• 10/08/05 – Version 1.3 – Added Canopy Cut-Out Template
• 11/01/05 - Version 1.3 – Added Canopy Cut-Out with Muffler
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
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Assembly Manual for XCell Stratus Kits #1026
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 an d 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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Assembly Manual for XCell Stratus Kits #1026
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 purch a se 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 Stratus Warranty 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
Phone (352) 383-3201
FAX (352) 383-3204
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Assembly Manual for XCell Stratus Kits #1026
Kit Assembly
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
Adhesives Needed
Slow Cyanoacrylate
JB Weld
Oil Grease
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Assembly Manual for XCell Stratus Kits #1026
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
Assembly Tips
• Follow the instructions. The methods of construction documented in this manual have been proven to work.
• Follow the order of assembly. The instructions have been organized into major sections and have been written 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 stop 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.
• 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
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Assembly Manual for XCell Stratus Kits #1026
Unbagged Parts
This section documents the parts found in the kit box which are not common to other bags
Kit Box
Kit Box Contents
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Assembly Manual for XCell Stratus Kits #1026
Box parts list
1 122-90 Canopy
1 126-100 Assembly Instructions – CD-ROM
1 126-85 Decal Set
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Assembly Manual for XCell Stratus Kits #1026
Lower Frame Assembly
This section describes the assembly of the lower frame assembly
Bag 1 – Bottom Plate Components
Bag 1
Bag 1A parts list
2 0151 Struts
1 0548-5 Fan Shroud (right & left)
2 122-39 Skids
1 126-20 Carbon Main Base Plate
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Assembly Manual for XCell Stratus Kits #1026
Bag 1B
Bag 1C
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Assembly Manual for XCell Stratus Kits #1026
Bag 1B parts list
4 0008 M3.5 washer
4 0009 M3 Washer – large
4 0021 M4 Locknut
4 0060-1 M3 x 6 Socket Head bolt
2 0063 M3 x 10 Socket Head bolt
2 0067 M3 x 14 Socket Head bolt
4 0068 M3.5 x 15 Socket Head bolt
4 0080 M4 x 14 Socket Head bolt
1 0331 Shim Washer M13x.50
1 0546-11 Y.S. Upper Collet
2 0546-16 Clutch Dampers
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Assembly Manual for XCell Stratus Kits #1026
1 0546-5 O.S. Upper Collet
1 0546-6 Brass Base Collet
1 0579-4 Fan Unit
2 126-23 Carbon Motor Side Mounts
2 126-86 Rectangular Blocks
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Assembly Manual for XCell Stratus Kits #1026
Bag 1C parts list
1 0011 M5 Washer
1 0013 M5 Hex nut
1 0397 Fuel Line – 18” – outside of tank
1 0405 Fuel Vent
1 0408 Fuel Fitting nipple
1 0409 90° Fuel Fitting
1 115-30 5/8” Velcro – 28.5” length
1 115-65 Fuel Line – 3” – inside of tank
2 126-27 Rubber Tank Bump-ons
1 4295 Fuel Magnet
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Assembly Manual for XCell Stratus Kits #1026
Bag 1D
Bag 1D content
4 0009 M3 Washer – small
4 0019 M3 Locknuts
5 0029 M2.2 x 9.5 Phillips screw
4 0058-1 M4 x 6 Socket Set Screws
6 0060-1 M3 x 6 Socket head bolt
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Assembly Manual for XCell Stratus Kits #1026
4 0063 M3 x 10 Socket head bolt
4 0065 M3 x 12 Socket head bolt
4 0073 M3 x 20 Socket Head bolt
2 0586-16 Corner Blocks
2 126-26 “A” Frame Supports
2 126-73 Lower Graphite Shroud Brackets
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Assembly Manual for XCell Stratus Kits #1026
Bag 2 – Engine Specific Components
Bag 2 - YS
Bag 2A
Bag 2B
Bag 2C
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Assembly Manual for XCell Stratus Kits #1026
Bag 2A - YS parts list
1 126-28 Main Motor Base Plate – YS
1 126-29 Adapter Plate – YS
1 126-52 Pressurized Fuel Tank
Bag 2B – YS parts list
1 0865-93 93 tooth main drive gear
Bag 2C - YS parts list
2 126-44 8.45 upper clutch plates (Right & left)
2 126-45 8.45 lower clutch plates (Right & left)
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Bag 2 - OS
Bag 2A
Assembly Manual for XCell Stratus Kits #1026
Bag 2B
Bag 2C
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Assembly Manual for XCell Stratus Kits #1026
Bag 2A - OS parts list
1 126-21 Non-Pressurized Fuel Tank
1 126-24 Main Motor Base Plate – OS
1 126-25 Adapter Plate – OS
Bag 2B – OS parts list
1 0865-90 90 tooth main drive gear
Bag 2C - OS parts list
2 126-40 8.18 upper clutch plates (Right & left)
2 126-41 8.18 lower clutch plates (Right & left)
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Assembly Manual for XCell Stratus Kits #1026
Assembly Steps
Begin by removing the crankcase rear plate bolts from your engine using an M2.5 allen wrench. You can store these in the box the engine came in as you won’t need them. This kit includes bolts that will replace them.
Do not remove the engine back plate. It must remain on the engine for now.
For this step you will need the following parts:
• One #0546-6 base collet
• One #0579-4 fan
• One #0331 washer
• One #0546-xx upper collet (motor
dependent)
• Two 0546-16 dampers
Select the 0546-6 brass base collet (it’s the one with no recess cut into its nose).
You must install the thrust washer supplied with your motor on the crankshaft first, then slip the base collet on and push it down against the washer and bearing. If you don’t install the thrust washer, the spacing between the fan and clutch driver will be wrong
Place a drop of oil (of any type) on the lower collet and use your finger to smear it on the entire collet
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Assembly Manual for XCell Stratus Kits #1026
Select the 0579-4 fan and place it over the crankshaft on the lower fan collet. Spin the fan on the collect to distribute the lubricant and to begin to seat it.
Select the upper fan collet. You will use the YS collet for a YS motor and the OS collet for an OS motor. You will not need both.
Note: The YS collet has a deeper recess and the OS collet has a recess that is less deep.
Place the upper fan collet over the engine crankshaft with the recess pointed downwards towards the fan.
Select the 0331 washer and drop it over the crankshaft
Use a toothpick to apply blue thread lock to the threads on the end of the crankshaft
Select the engine crankshaft nut that came with your motor and thread it onto the end of the crankshaft
Using the correct socket, lightly snug the engine bolt onto the washer/collet but do not tighten yet. You will need to lock the crankshaft in order to tighten this nut
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Assembly Manual for XCell Stratus Kits #1026
The best way to lock the crankshaft is to use MA optional part #0511 crank lock. To use this tool, remove the back plate from the engine and rotate the crankshaft until the rod/pin is located at the bottom of the crankshaft (or the piston is at bottom dead center). Then insert the big end of the tool into the cavity over the rod. This will prevent the crankshaft from turning but will not damage any engine parts.
With the crank locked, rotate the fan on the collets using your hand. Since you haven’t tightened the nut yet, this will turn easily.
Using the appropriate socket for your engine, start to tighten the crankshaft nut in several small increments. Continue t o turn the fan on the collets until the nut is so tight that it will no longer turn. At this point, fully tighten the crank/fan bolt.
It is very important that the fan “runout” is minimal. Runout is the amount that the fan “wobbles” on the collets. To check the runout of the fan to see how it seated on the collets, you will need a dial or test indicator. Remove the crank lock and clamp the engine so that it can’t move. Using the indicator, test the face of the fan as well as the inside of the fan hub. Place the tip of the indicator on the surface and turn the fan by hand to check total runout.
An acceptable amount of total runout is .002” or less (or +/- .001”). If you find runout greater than this, try removing the crank nut, remove the fan and spin the fan on the
collets. 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.
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Assembly Manual for XCell Stratus Kits #1026
Replace the back plate in the engine but do not reinstall the bolts that were removed earlier.
Install the 0546-16 clutch dampers in the fan as shown. Each damper has a small dimple. The dampers should be installed with this dimple facing upwards or be visible after being inserted in the fan.
The dampers fit easily into the fan and can be pushed in flush with the face of the fan with finger pressure.
For these steps you will need the following parts:
• One #126-2x main base plate
• One #126-2x adapter plate
• Four #0008 M3.5 washers
• Four #0068 M3.5 bolts
The particular plates in the photos are for the YS engine as evidenced by the letters YS engraved on the engine back plate spacer and the engine mount plate. The OS version will have the letters OS engraved on them
If you are attaching an YS.80, you will also need a #126-30 adapter plate.
Select the #126-28 (YS) or #126-24 (OS) main base plate, #126-29 (YS) or #126-25 (OS) adapter plate, four #0068 M3.5 x 15mm bolts and four #0008 M3.5 washers
Prepare the bottom engine mount for assembly. Align the plates and engine as shown. The engine initials (YS or OS) should be facing up on both plates and should be next to each other. Slide one M3.5 washers over each of the M3.5 x 15mm bolts and then insert them from the bottom of the plate such that they pass through the engine back plate spacer. The engine will be assembled on the same side as the initials, such that the cylinder covers the initials.
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Assembly Manual for XCell Stratus Kits #1026
Apply a small amount of blue Thread lock to the exposed part of the bolts and attach the combined plates onto the engine back plate as shown.
Tighten all four bolts, tightening alternate bolts one at a time in an X pattern. The purpose of this is to more evenly tighten the plate.
For these steps you will need the following parts:
• Two #126-23 motor side mounts
• Two #126-86 corner blocks
• Two #0060-1 M3 x 6mm
socket head bolts
• Four #0080 M4 x 14mm bolts
• Four #0021 M4 Locknuts
Select two #126-23 carbon motor side mounts, two #126-86 corner blocks, and two #0060-1 M3 x 6mm socket head bolts.
Assemble the two engine side mounts as shown. Assemble the flat engine mount plates to the aluminum mount blocks using 2 each M3 x 6mm bolts in each block. No washers are used. At this time only lightly tighten them. Do not fully tighten them yet or apply Thread lock. The plates and blocks are not marked left or right but must be assembled as shown.
Note how the assemblies will fit on the engine mount plate and again st the engine.
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Assembly Manual for XCell Stratus Kits #1026
Select four #0080 M4 bolts and four #0021 M4 locknuts Mount both of the assembled engine side mounts to the
engine using the M4 bolts and M4 locknuts. No washers are used At this time just snug the bolts, do not fully tighten them yet.
At this point in the assembly, the aluminum blocks are just sitting on the bottom plate. They will be attached in the next step
For these steps you will need the following parts:
• One #126-20 main base plate
• Two #0067 M3 x 14mm socket head screws
• Two #0063 M3 x 10 socket head screws
• Four #0003 M3 flat washers
Select the #126-20 main base plate, two #0067 M3 x 14 socket head screws, two #0063 M3 x 10 socket head screw and four #0003 flat washers.
Orient the main base plate so that the recessed portion faces down (or the pre-installed two sided tape faces up).
Attach the assembled engine mount to either side of the bottom frame plate oriented as shown. The engine will be facing the front part of the plate which is noted by the square opening. The X opening in the plate is the rear of the plate.
Use 2 each M3 x 14mm bolts and flat washers through the rear slotted openings into the aluminum engine mount blocks. Use 2 each M3 x 10mm bolts and flat washers through the front slotted openings into the PEM nuts on the engine mount plate. Tighten all 4 bolts but do not use Thread lock yet.
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Assembly Manual for XCell Stratus Kits #1026
First tighten each of the four M3 bolts that attach the aluminum side engine mount blocks. When complete, remove them one at a time, apply blue Thread lock and then reinstall and tighten them.
Then tighten the four M4 engine bolts and locknuts
Slightly loosen the four bolts that attach the engine mount plate to the bottom plate so that the entire engine assembly can be repositioned in the slots on the bottom plate. Leave these bolts loose until the engine alignment is done in a later step
For this step you will need the following parts:
• Two #0586-16 corner blocks
• Two #126-73 lower shroud mounts
• Six #0060-1 M3 x 6mm bolts
• Four #0063 M3 x 10mm bolts
Select two #0586-16 corner blocks, two #126-73 lower fan shroud mounts, six #0060-1 M3 x 6mm socket head bolts and four #0063 M3 x 10mm socket head bolts. The lower mounts will be assembled as shown in the photo.
Attach each of the lower fan shroud mounts to the corner blocks using two 6mm bolts as shown. Tighten only enough that the shroud mounts are flat against the corner block but can move fore and aft freely. These bolts will be tightened in a later step
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Assembly Manual for XCell Stratus Kits #1026
This step will install the fan shroud mount brackets onto the bottom plate assembly. Insert two of the 10mm bolts through the right set of slotted holes on the bottom plate from the bottom. Tighten so that the corner block is against the bottom plate, but can move freely side to side in the slots.
Repeat this procedure on the left side of the bottom plate.
For this step you will need the following parts:
• Two #126-26 A frame supports
• Four #0065 M3 x 12mm bolts
• Previously assembled bottom plate
Select two #126-26 A frame supports and four #0065 M3 x 12mm socket head bolts.
Install the frame ladder supports onto the top of the bottom plate on each end. The wide end of the ladder support installs against the bottom plate. The ladder supports can face either direction the dimensions are symmetrical. Insert the two M3 bolts to attach each frame support as shown.
At this time, lightly tighten these bolts only.
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Assembly Manual for XCell Stratus Kits #1026
For this step you will need the following parts:
• Two #115-30 velcro
• Previously assembled bottom plate
Select the #115-30 – 28” piece of Velcro. Fold it in half and cut it into two equal pieces using a pair of scissors
Insert each of the two equal pieces from the bottom of the bottom plate, through the tank support mount slots. There are two slots towards the front of the plate and four slots towards the back of the plate. For the holes at the back of the plate, use the two forward slots.
Arrange the Velcro such that equal portions are extended through all four of these slots as shown
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Assembly Manual for XCell Stratus Kits #1026
For this step you will need the following parts:
• Previously assembled bottom plate
• Four #0073 M3 x 20mm bolts
• Two #0151 Landing gear struts
• Four #0009 M3 washers
• Four #0019 M3 locknuts
Insert two #0073 M3 x 20 socket head bolts from the top of the bottom plate through the two landing gear mount holes towards the front of the bottom plate as shown. Attach one of the #0151 struts on the bottom of the plate over the two bolts and using two #0009 M3 washers and two #0019 locknuts. Do not fully tighten at this time.
Now insert the remaining M3 x 20 bolts from the top of the bottom plate, through the two landing gear mount holes towards the back of the bottom plate as shown. Attach the remaining strut over these two exposed bolts using the remaining #0009 washers and M3 locknuts. Do not fully tighten at this time.
The completed assembly with both struts installed will appear as shown
Using a marking tool, make a mark at the center of each of the bosses found on the top of the bottom part of each landing gear strut as shown.
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