XCell_Furion_450_Assembly_Manual_R1 Furion450manual2
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X-Cell Furion 450 Assembly Manual Version 1.1 Last Revised: 08/10/2008 Created: 8/27/2008 Copyright Miniature Aircraft US This document may not be distributed without permission of Miniature Aircraft USA X-Cell Furion 450 Assembly Manual For More Information contact: Miniature Aircraft USA 31713 Long Acres Drive Sorrento, FL 32776 USA Phone 352-383-3201 Fax 352-383-3204 Email: minair@miniatureaircraftusa.com Page 2 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 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 FURION 450 WARRANTY REGISTRATION........................................................................................................................................................... 7 II. KIT PREREQUISITES ............................................................................................................................................................................................ 8 SUPPLIES NEEDED FOR ASSEMBLY ................................................................................................................................................................................. 8 Adhesives Used ........................................................................................................................................................................................................ 8 TOOLS NEEDED FOR ASSEMBLY ..................................................................................................................................................................................... 9 ADDITIONAL COMPONENTS NEEDED (AS SHOWN OR COMPATIBLE) ................................................................................................................................. 9 DOCUMENTATION ........................................................................................................................................................................................................ 10 III. KIT ASSEMBLY PROCESS ................................................................................................................................................................................ 11 ASSEMBLY TIPS ........................................................................................................................................................................................................... 11 FASTENER GUIDE ........................................................................................................................................................................................................ 11 ASSEMBLY COMPONENTS – UNBAGGED PARTS ............................................................................................................................................................ 13 LOCATE CARBON FIBER PARTS BAG ............................................................................................................................................................................ 14 Carbon Fiber Parts - Bag #1 ................................................................................................................................................................................. 14 ASSEMBLY STEP #1 – CHASSIS............................................................................................................................................................................... 15 1A) Frame Components - Bags #2A, #2B, #2 Hardware ....................................................................................................................................... 15 1A.1 - Assemble Tail Boom Clamp/Pulleys........................................................................................................................................................................16 1B.1 - Assemble Left Frame Components .........................................................................................................................................................................18 1C.1 – Install Right Frame/Landing Gear ..........................................................................................................................................................................21 1D.1 – Install Pitch/Aileron Servos ......................................................................................................................................................................................23 ASSEMBLY STEP #2 – PRIMARY DRIVE ................................................................................................................................................................... 24 2A) Drive Train Components - Bag #3A, #3 Hardware......................................................................................................................................... 24 2A.1 - Assemble T/R Pulley .....................................................................................................................................................................................................25 2B.1 - Assemble Main Gear .....................................................................................................................................................................................................26 2C.1 – Install Drive System ....................................................................................................................................................................................................27 2D.1 – Install Motor....................................................................................................................................................................................................................28 LOCATE LONG PARTS BAG .......................................................................................................................................................................................... 29 Long Parts - Bag #4............................................................................................................................................................................................... 29 ASSEMBLY STEP #3 – TAIL ROTOR/TAIL BOOM..................................................................................................................................................... 30 3A) Tail Rotor Components - Bag #5A, 5B, 5C, #5 Hardware .............................................................................................................................. 30 3A.1 3A.2 3A.3 3A.4 3A.5 3A.6 3A.7 3A.8 3A.9 - Assemble T/R Fin ...........................................................................................................................................................................................................31 – Assemble/Install T/R Bellcrank................................................................................................................................................................................32 – Assemble/Install Tail Boom ......................................................................................................................................................................................33 – Assemble T/R Transmission......................................................................................................................................................................................34 – Set T/R Belt Tension ....................................................................................................................................................................................................35 – Assemble T/R Pitch Change Mechanism ..............................................................................................................................................................36 – Assemble T/R Hub ........................................................................................................................................................................................................38 – Install T/R Pitch Change Mechanism.....................................................................................................................................................................40 – Install Tail Rotor Assembly........................................................................................................................................................................................40 3B) Tail Rotor Control - Bag #6A, #6 Hardware................................................................................................................................................... 41 3B.1 Install T/R Servo................................................................................................................................................................................................................41 3B.2 Assemble T/R Pushrod ....................................................................................................................................................................................................43 3B.3 Assemble/Install Tail Boom Supports.......................................................................................................................................................................44 ASSEMBLY STEP #4 – CONTROL SYSTEMS ............................................................................................................................................................. 46 4A) Electronics Installation/Main Control Components - Bag #7A, #7B, #7 Hardware ....................................................................................... 46 4A.1 4A.2 4A.3 4A.4 Install Elevator Servo.............................................................................................................................................................................................47 Install Electronics.....................................................................................................................................................................................................47 Install Servo Arms...................................................................................................................................................................................................50 Assemble Cyclic Control Rods.............................................................................................................................................................................51 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 3 of 89 X-Cell Furion 450 Assembly Manual 4A.5 4A.6 4A.7 Assemble Swashplate.............................................................................................................................................................................................52 Install Swashplate/Control Rods .......................................................................................................................................................................53 Assemble Washout Mixer......................................................................................................................................................................................54 ASSEMBLY STEP #5 – ROTOR HEAD ....................................................................................................................................................................... 56 5A) Rotor Head Components - Bag #8A, #8B, #8C, #8 Hardware ........................................................................................................................ 56 5A.1 5A.2 5A.3 5A.4 5A.5 5A.6 Assemble Bell Mixers..............................................................................................................................................................................................57 Assemble Main Rotor Block..................................................................................................................................................................................58 Assemble Main Blade Grips..................................................................................................................................................................................59 Assemble Flybar Components ............................................................................................................................................................................62 Install Rotor Head....................................................................................................................................................................................................65 Assemble/Install Rotor Head Control Rods ...................................................................................................................................................67 ASSEMBLY STEP #6 – COMPLETE MODEL ASSEMBLY ............................................................................................................................................. 68 6A) Canopy Components - Bag #9A, #9 Hardware ............................................................................................................................................... 68 6A.1 6A.2 6A.3 6A.4 Assemble/Install Canopy ......................................................................................................................................................................................68 Install Decals .............................................................................................................................................................................................................70 Install Rotor Blades.................................................................................................................................................................................................71 Install Battery............................................................................................................................................................................................................71 IV. BASIC MODEL/RADIO SETUP ......................................................................................................................................................................... 72 A) B) INITIAL SETUP FOR SERVO CENTERING ............................................................................................................................................................ 72 SETUP FOR COLLECTIVE, CYCLIC AND RUDDER .............................................................................................................................................. 75 B.1 Setting Swashplate Movements................................................................................................................................................................. 75 B.1.1 B.1.2 B.1.3 B.1.3 B.2 Collective Movements.........................................................................................................................................................................................................75 Cyclic Movements ...............................................................................................................................................................................................................77 Swashplate – Center Level ..................................................................................................................................................................................................78 Swashplate – Extreme Throws Level..................................................................................................................................................................................79 Setting Blade Limits.................................................................................................................................................................................. 80 B.2.1 B.2.2 B.2.3 B.3 B.4 C) D) Install Flybar Lock/Blade Gauge.........................................................................................................................................................................................80 Pitch Curve Setup ................................................................................................................................................................................................................80 Cyclic Throw Setup .............................................................................................................................................................................................................82 Rudder Setup ............................................................................................................................................................................................ 83 Exponential............................................................................................................................................................................................... 84 SETUP FOR SPEED CONTROLLER ..................................................................................................................................................................... 84 BATTERY/MOTOR/PINION RECOMMENDATIONS .............................................................................................................................................. 85 V. MAINTENANCE/REPAIR NOTES ...................................................................................................................................................................... 86 A) B) C) TAIL BELT TENSION ....................................................................................................................................................................................... 86 T/R GRIP/BEARING/HUB REMOVAL................................................................................................................................................................ 87 MAIN BLADE GRIP/BLADE AXLE REMOVAL ................................................................................................................................................... 87 Page 4 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual Revisions to this Manual R1.0 • R1.1 • • • 07/01/08 – Initial Release 07/05/08 – 3B.1.a 4A.5.c 4A.5.g 4A.7.j-k 07/12/08 - IV.C 4A.1.d 08/10/08 - 4A.2.f-h added note changed part #130-076 to the correct #130-074 changed part #130-016 to the correct #130-070 changed part #130-150 to the correct #130-030 added warning about throttle reversing added warning about t/r belt routing renumbered part #130-450 to #130-460 For the most current version of this manual, please refer to www.miniatureaircraftusa.com, visit the Furion helicopter kit and download the assembly manual Errata R1.0 • • The finish on some metal parts and fasteners in the production kit may differ from that shown in this manual. This will not result in any change to the assembly process Some square head socket bolts shown in the manual were replaced with button head socket bolts in the production kit. The threaded dimensions are identical. Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 5 of 89 X-Cell Furion 450 Assembly Manual 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. Page 6 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 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 Furion 450 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:____________________________________ City:_______________________ State:____________ Phone:___________________ Zip:___________________ Purchased from: ________________________________________________________ Dealer’s address ________________________________________________________ Comments: ____________________________________________________________ ______________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ MINIATURE AIRCRAFT USA 31713 Long Acres Drive Sorrento, FL 32776 USA Phone (352) 383-3201 FAX (352) 383-3204 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 7 of 89 X-Cell Furion 450 Assembly Manual 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 Green Thread Lock Oil Grease Adhesives Used Slow Cyanoacrylate Page 8 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual Tools Needed for Assembly 1.5mm allen driver 2.5mm allen driver M5 Nut Driver Needle Nose Pliers Flat Screwdriver 2.5mm Phillips Screwdriver #0 Phillips Screwdriver #1 Ball Link Pliers Additional Components Needed (as shown or compatible) Gyro – Heading Hold Battery LiPo 2500 mah 3S1P Gyro Servo 1 each Created: 8/27/2008 Cyclic Servos 3 each Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 9 of 89 X-Cell Furion 450 Assembly Manual Minimum 45 amp ESC With BEC Motor Or a separate BEC is required Receiver Rotor Blades SAB 320-325mm Paddle/Pitch gauge tools Documentation The most recent version of all of the documentation can be found on the website: www.miniatureaircraftusa.com Page 10 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual III. Kit Assembly Process Assembly Tips 1. 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 the photo’s in a given step. The placement of a given part may be better understood when viewing another view of the assembly. 2. 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 3. 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. 4. 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 5. Use only the formula of thread lock as indicated. Model helicopters are subject to vibration and failing to use the correct formula of thread lock on any non-locking assembly may result in a part becoming loose or falling off. 6. Sand sharp edges on any frame plate that Velcro® or wires may rub against to prevent them from being damaged over time by vibration 7. Make sure every bearing runs smoothly after component assembly. If it does not find out why. A rough running bearing will fail prematurely. 8. 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 thick (ONLY) Cyanoacrylate adhesive applied 9. Assembly sections contain the following content: a. The contents of each bag b. An overview of part relationships c. Assembly overview 10. 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 Green Thread Lock Lubricant Grease Fastener Guide This page contains 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 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 11 of 89 X-Cell Furion 450 Assembly Manual Fasteners – Threaded Bolts, Washers, Nuts, Screws Page 12 of 89 Part # Description 130-002 m2 Washer ------------------------------------------------------- 130-004 m2 x .150" x .020" Shim Washer -------------------------- 130-006 m2.5 Washer ----------------------------------------------------- 130-008 m3 Washer ------------------------------------------------------- 130-010 m2 Hex Nut ------------------------------------------------------- 130-012 m3 Locknuts ----------------------------------------------------- 130-014 m2 x 3 Phillips Flat Head Bolt ----------------------------- 130-016 m2 x 4 Phillips Flat Head ------------------------------------ 130-019 m2 x 6 mm Phillips Tapered Head Bolt ------------- 130-020 m2 x 8.00 Phillips Tapered Head Bolt ------------------ 130-022 m2 x 8.50 Phillips Tapered Head Bolt ------------------ 130-024 m2 x 3 Phillips Self-Tapping Screw --------------------- 130-025 m2.2 x 6 Phillips Self-Tapping "Flat Head" Screw 130-028 m2 x 13 Phillips Self-Tapping Screw ----------------- 130-030 130-032 m2 x 8 Shouldered Bolt -------------------------------------m3 x 3 Socket Set Screw ------------------------------------ 130-035 m2 x 4 Socket Bolt -------------------------------------------- 130-037 m2 x 6 Socket Bolt -------------------------------------------- 130-038 m2 x 8 Socket Bolt -------------------------------------------- 130-040 m2 x 10 Socket Bolt ------------------------------------------- 130-041 m2 x 12 Socket Bolt ------------------------------------------- 130-044 m2.5 x 6 Socket Bolt ------------------------------------------ 130-046 m3 x 8 Socket Bolt -------------------------------------------- 130-049 m3 x 14 Socket Bolt ------------------------------------------- 130-153 Machined Washout Link Screw --------------------------- Actual Size Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual Assembly Components – Unbagged Parts Decals Building Notes – These parts will be found in the kit box. They are not part of a parts bag. #130-253 Furion 450 Decal Sheet 1 each Canopy #130-252 Furion 450 Windshield 1 each #130-251 Furion 450 Canopy 1 each Kit Documentation #130-405 Furion 450 Kit Documentation 1 CD Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA #130-400 Foam Blade Guard 1 each Page 13 of 89 X-Cell Furion 450 Assembly Manual Locate Carbon Fiber Parts Bag Carbon Fiber Parts - Bag #1 This Bag Should Contain: #130-122 C/F Main Blade Mounting Plates 4 each #130-163 C/F Swashplate Retaining Ring 1 each #130-360 C/F Tail Fin w/bearing 1 each #130-280 C/F Rudder Servo Plate 1 each #130-358 C/F Inner Tail Plate w/bearing 1 each #130-295 C/F Horizontal Fin 1 each #130-225 C/F Base Plate 1 each #130-242 C/F Main Frames 2 each Page 14 of 89 #130-208 C/F Gyro Plate 1 each Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA #130-239 C/F Anti-rotation Guide 1 each #130-243 Battery Plate 1 each Created: 8/27/2008 X-Cell Furion 450 Assembly Manual Assembly Step #1 – Chassis 1A) Frame Components - Bags #2A, #2B, #2 Hardware These Bags Should Contain: #130-241 Lower Mainshaft Block w/Bearing 1 each #130-052 M2 x 5 x 2.5 Ball Bearings 2 each #130-245 Plastic Landing Gear 1 each #130-205 Plastic Boom Mounts 2 each #130-215 Pulley Spacers 2 each #130-237 Upper Servo Mount 1 each #130-207 Knurled Threaded Spacers 4 each #130-210 Tail Rotor Belt Pulleys 2 each #130-236 Upper Mainshaft Block w/Bearing 1 each #130-002 M2 Washers 6 each #130-230 Frame Spacers 5 each #130-220 Canopy Mounts 2 each #130-016 M2 x 4 Phillips Flat Head Bolt 4 each #130-025 M2 x 6.5 Phillips Screw 2 each Created: 8/27/2008 #130-038 M2 x 8 Socket Bolt 6 each #130-238 Lower Servo Mount 1 each #130-037 M2 x 6 Socket Bolt 10 each Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA #130-035 M2 x 4 Socket Bolt 40 each Page 15 of 89 X-Cell Furion 450 Assembly Manual 1A.1 - Assemble Tail Boom Clamp/Pulleys Parts Relationship #130-205 #130-025 #130-035 #130-215 #130-210 #130-037 #130-207(4) #130-208 #130-052 #130-025 #130-035 #130-205 1A.1.a 1A.1.b 1A.1.c 1A.1.d #130-205 Front Knurled End #130-207(4) 1A.1.e Building Notes: Don’t push the two halves completely together, leave a small gap as the tail boom will be inserted into this later Note protrusions 1A.1.f #130-205 #130-208 Push halves together Align posts and holes 1A.1.g 1A.1.h Building Notes: Note when building the gyro plate that one side has a milled section on it. The pulleys mount on the side of the plate with the milled flat. Milled Flat Note the location of the protrusions on the blocks #130-215 #130-035 Page 16 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 1A.1.i #130-037 1A.1.j #130-210 #130-052 1A.1.k #130-052 Building Notes: Apply a thin coat of green thread lock on the bearings using a toothpick. Place a drop of thread lock on the end of the toothpick and then smear it around the bearings. Wipe away any excess and be careful not to get any in the bearing Use allen driver to seat bearing against inside flange in pulley Note Flange Inside 1A.1.m 1A.1.n 1A.1.o Building Notes: Note that each pulley has a flanged side. Building Notes: Do not over tighten bolts. Make sure pulleys spin freely Use an allen driver to push a bearing into each pulley and seat against the flange Be careful not to get any thread lock in the bearings. Set aside allow the thread lock to dry before installing the pulleys. 1A.1.q 1A.1.l 1A.1.p #130-037 1A.1.r #130-025 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 17 of 89 X-Cell Furion 450 Assembly Manual 1B.1 - Assemble Left Frame Components Parts Relationship #130-035 #130-002 #130-035 #130-035 #130-220 #130-243 #130-230 #130-016 #130-035 #130-237 #130-037 #130-242 #130-035 #130-236 #130-002 #130-037 #130-239 #130-016 #130-230 #130-241 #130-035 #130-035 #130-238 #130-037 #130-035 #130-225 Page 18 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 1B.1.a 1B.1.b #130-225 1B.1.c Building Notes: Note that the bottom plate contains 4 PEM nuts. One side of each PEM nut is wider than the other side. The side of the lower plate which shows the wide PEM is the TOP of the plate. Install the frame spacers on the BOTTOM of the plate as shown. The flat side of the spacer is against the carbon plate. #130-035 1B.1.e 1B.1.f #130-230 #130-230 1B.1.d #130-035 Wide side of PEM nuts on opposite side 1B.1.g #130-016 #130-243 1B.1.h #130-239 #130-035 #130-238 #130-242 #130-016(2) 1B.1.i 1B.1.j #130-220 #130-016 1B.1.k 1B.1.l Building Notes: The tail boom block plate installs into the left frame from the inside. The tab on the lower pulley plate slides into the left frame tab as shown Insert tab into frame slot 1B.1.m 1B.1.n #130-035 Building Notes: Install frame blocks on inside of frame using bolts seen on bolt map which follows while applying thread lock (except on the lower servo mount bolts) 1B.1.o 1B.1.p #130-236 #130-035 #130-238 #130-002 Note that the protrusions on the bearing blocks faces downwards and the upper and lower bearing flanges face each other. Slot/Tab Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA #130-241 Page 19 of 89 X-Cell Furion 450 Assembly Manual 1B.1.q 1B.1.r 1B.1.s 1B.1.t Protrusions face down #130-243 Do Not Tighten Yet #130-002 #130-035 #130-035 #130-225 Left Frame Map #130-035 #130-035 Do Not Tighten this bolt yet #130-035 Page 20 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA No Bolt Created: 8/27/2008 X-Cell Furion 450 Assembly Manual Left Frame Assembled #130-236 #130-242 #130-239 #130-238 #130-035 #130-230 #130-243 #130-241 #130-230 #130-225 1C.1 – Install Right Frame/Landing Gear Parts Relationship #130-035 #130-037 #130-220 #130-038 #130-002 #130-002 #130-245 #130-035 #130-038 #130-038 #130-038 #130-242 #130-037 #130-035 #130-280 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 21 of 89 X-Cell Furion 450 Assembly Manual Right Frame Map #130-220 #130-035 Do Not Tighten this bolt yet #130-037 #130-035 #130-035 #130-037 #130-035 No Bolts 1C.1.a 1C.1.b #130-035 1C.1.c 1C.1.d Building Notes: Install the right frame onto the assembled left frame #130-220 Begin the alignment by inserting the t/r pulley plate tab into the slot on the right frame #130-242 1C.1.e Tab into slot 1C.1.f Building Notes: Install the t/r servo mount onto the right frame as shown Don’t tighten these bolts until a later step when the tail boom is installed. 1C.1.g #130-002 1C.1.h #130-038 #130-280 #130-038 #130-037 Do not tighten these four bolts yet Page 22 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA #130-245 Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 1C.1.i 1C.1.j 1C.1.k 1C.1.l #130-237 Building Notes: The landing gear installs onto the bottom of the frame lower plate as shown. The bolts thread into the PEM nuts on the bottom of the plate The angled ends of the landing gear face forward #130-037 1D.1 – Install Pitch/Aileron Servos 1D.1.a 1D.1.b Building Notes: The servo mounts are adjustable to work with many types of servos. #130-037 The lower mount can be adjusted up and down by moving it by holding the antirotation guide. 1D.1.f 1D.1.g 1D.1.h Aileron Servo #130-037 Use anti-rotation guide to adjust lower servo mount up or down until upper servo hole aligns 1D.1.d Pitch Servo Building Notes: The servo that will become the “pitch” channel goes on the left side of the model and the servo that will be come the “aileron” channel goes on the right side of the model 1D.1.e 1D.1.c #130-037 1D.1.i 1D.1.j Building Notes: Once the servos are installed you can tighten the 4 bolts that hold the anti-rotation guide/lower servo mount into place. Use thread lock as shown 1D.1.k Tighten Both Now Tighten Both Now The servo horns will be installed in a later step. Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 23 of 89 X-Cell Furion 450 Assembly Manual Assembly Step #2 – Primary Drive 2A) Drive Train Components - Bag #3A, #3 Hardware These Bags Should Contain: #130-175 Mainshaft Collar 1 each #130-170 M5 Mainshaft 1 each #130-194 Steel Autorotation Hub 1 each #130-180 T/R Pulley Hub 1 each #130-196 Assembled Auto-rotation Hub 1 each #130-041 M2 x 12 Socket Bolt 1 each Page 24 of 89 #130-255 Tail Rotor Drive Belt 1 each #130-200 13 Tooth Pinion Gear 1 each #130-185 Plastic Drive Pulley 1 each #130-190 Plastic Main Gear 1 each #130-046 M3 x 8 Socket Bolt 2 each #130-035 M2 x 4 Socket Bolt 10 each #130-032 M3 x 3 Socket Set Screw 3 each #130-198 11 Tooth Pinion Gear 1 each #130-008 M3 Washers 2 each Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual Parts Relationship #130-175 #130-035 #130-032 #130-035 #130-035 #130-185 #130-180 #130-041 #130-196 #130-170 #130-190 #130-035 #130-194 2A.1 - Assemble T/R Pulley 2A.1.a 2A.1.b #130-185 Unthreaded Hole #130-180 Created: 8/27/2008 2A.1.c 2A.1.d Building Notes: Rotate the pulley or hub until the unthreaded mount hole aligns with the indents on the pulley as shown Align hole with an indent Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 25 of 89 X-Cell Furion 450 Assembly Manual 2A.1.e 2A.1.f Use allen driver to align holes #130-035 (5) 2B.1 - Assemble Main Gear 2B.1.a 2B.1.b #130-096 2B.1.c Building Notes: Fill the bearing cavity inside the auto hub with lubricant. 2B.1.d Shorter side #130-194 Note the orientation of the hub before inserting the main shaft sleeve. Longer side Insert this way While twisting 2B.1.e 2B.1.f 2B.1.g 2B.1.h Use allen driver to align holes Building Notes: Note that the main gear has an indented area on one side. Insert the auto hub from that side as shown until it seats on the gear Indented ring #130-190 2B.1.i #130-035 (5) Page 26 of 89 2B.1.j 2B.1.k 2B.1.l Building Notes: Install the t/r drive pulley over the main shaft sleeve as shown. Note that you need to align the holes on the pulley with those on the main shaft sleeve. This will be important when it is installed in a later step. Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Holes must align Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 2C.1 – Install Drive System 2C.1.a 2C.1.b 2C.1.c 2C.1.d Select a section of the belt and wrap with tape as shown. This will be the rear end #130-255 Lay belt flat on surface with teeth facing each other 2C.1.e With the belt in this position mark the side shown as the Top for a later step. 2C.1.f Insert other end of belt as shown 2C.1.g 2C.1.h Building Notes: Thread the belt through the pulleys and position it over the main shaft bearing as shown Building Notes: Insert the main gear assembly into the frames from the right side. Lift the belt over the tail rotor pulley being careful not to twist it or change orientation 2C.1.i 2C.1.j 2C.1.k Building Notes: Insert the main shaft from the top as shown through the top bearing, the retaining collar, the main gear and the bottom bearing as shown Note which end of main shaft 2C.1.l Insert Shaft This Way #130-175 Note which end of the main shaft to insert first. #130-032 2C.1.m 2C.1.n 2C.1.o Building Notes: Align the holes in the t/r drive collar, the main shaft sleeve and the main shaft. Insert Shaft This Way Align All holes Created: 8/27/2008 2C.1.p #130-041 Insert the bolt through the unthreaded side of the tail drive collar and tighten using thread lock Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Push bolt through holes And tighten Page 27 of 89 X-Cell Furion 450 Assembly Manual 2D.1 – Install Motor 2D.1.a 2D.1.b Building Notes: Align one of the set screws on the retaining collar with the flat on the main shaft. 2D.1.c Push shaft down Hold the assembly as shown and first tighten the set screw against the shaft flat and then tighten the other one. Apply thread lock to the set screws don’t put in the hole. Align with flat 2D.1.d Pull Collar Up against bearing and tighten There should be no vertical play in the assembly when complete. 2D.1.f 2D.1.g 2D.1.e Select pinion gear based on your motor Tighten remaining set screw 2D.1.h Gear is flush with shaft end Selected Motor #130-198 ---- or --#130-200 #130-032 2D.1.i 2D.1.j 2D.1.l 2D.1.o 2D.1.p Mount motor using holes that are Approx. 18mm apart #130-046 #130-008 2D.1.m 2D.1.n Building Notes: Motor bolts should not yet be tight. Insert paper strip between gears and push motor/gears together Page 28 of 89 2D.1.k Paper Strip Building Notes: Tighten motor bolts using thread lock and remove paper strip. Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 2D.1.q 2D.1.r Locate Long Parts Bag Long Parts - Bag #4 This Bag Should Contain: #130-142 Flybar (210mm) 1 each #130-260 C/F Boom supports and T/R Control Rod 3 each #130-270 Tail Boom 1 each Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 29 of 89 X-Cell Furion 450 Assembly Manual Assembly Step #3 – Tail Rotor/Tail Boom 3A) Tail Rotor Components - Bag #5A, 5B, 5C, #5 Hardware These Bags Should Contain: #130-337 Tail Rotor Pulley 1 each #130-305 T/R Blade Grips 2 each #130-004 M2 x .150” x .020” Shim Spacer 1 each #130-300 Tail Rotor Hub 1 each #130-336 T/R Output Shaft 1 each #130-308 T/R Blades 2 each #130-275 Plastic Rudder Servo Mount 1 each #130-290 Plastic Horizontal Fin Mount 1 each #130-040 M2 x 10 Socket Bolt 5 each Page 30 of 89 #130-345 T/R Transmission 1 each #130-350 T/R Bellcrank Mount 1 each #130-340 Plastic T/R Bellcrank 1 each #130-037 M2 x 6 Socket Bolt 4 each #130-325 T/R Brass Slider 1 each #130-330 T/R Control Ring 1 each #130-320 T/R Pitch Plate 1 each #130-035 M2 x 4 Socket Bolt 12 each #130-355 T/R Transmission Spacer 1 each #130-315 T/R Pitch Link 2 each #130-058 M4 x 7 x 2.5 Ball Bearing 2 each #130-311 M2 x 5 x 2.5 Bearing Spacer w/Bearings 2 each #130-052 M2 x 5 x 2.5 Ball Bearing 2 each #130-312 Tail Grip Sleeve 2 each #130-054 M3 x 6 x 2.5 Ball Bearing 2 each #130-010 M2 Hex Nut 1 each #130-038 M2 x 8 Socket Bolt 2 each #130-032 M3 x 3 Socket Set Screw 3 each Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual Parts Relationship #130-270 #130-040 #130-040 #130-010 #130-035 #130-052 #130-035 #130-345 #130-004 #130-052 #130-350 #130-340 #130-355 #130-032 #130-358 #130-035 #130-337 #130-336 #130-040 #130-360 #130-035 #130-032 #130-035 3A.1 - Assemble T/R Fin 3A.1.a 3A.1.b #130-360 #130-035 3A.1.c #130-040 3A.1.d Bearing Flange Inside #130-345 Split Created: 8/27/2008 Don’t tighten these now Rear View Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 31 of 89 X-Cell Furion 450 Assembly Manual 3A.1.e 3A.1.f Align slot in boom with holes 3A.1.g 3A.1.h Holes Aligned #130-355 Building Notes: Slide the boom into the transmission case as shown until the tail fin stops it at the rear and then twist as necessary to align the holes in the boom with the holes in the transmission case. Slide boom in this way #130-035 3A.2 – Assemble/Install T/R Bellcrank 3A.2.a 3A.2.b 3A.2.c 3A.2.d #130-052 #130-052 #130-340 Building Notes: Press the bearings into the bell crank as shown. Make sure you drop the spacer washer between the bearings. #130-004 3A.2.e 3A.2.f Note bellcrank orientation and extrusion on bracket 3A.2.g #130-350 #130-040 3A.2.h Note bracket orientation #130-010 3A.2.i 3A.2.j 3A.2.k 3A.2.l Building Notes: Before tightening the two bell crank bracket bolts, make sure the holes in the transmission case are aligned with those in the tail boom. When properly aligned, these will thread in with little effort. #130-035 Page 32 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Tighten snugly Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 3A.3 – Assemble/Install Tail Boom Parts Relationship #130-270 #130-290 #130-275 3A.3.a 3A.3.b Note Slot Orientation 3A.3.c 3A.3.d Building Notes: Slide the rear boom support over the front of the boom with the slot on the same side of the boom as the t/r fin. Slide it to the rear of the boom for now. #130-290 Slide towards rear of boom for now Spread the clamp at the slot to slip over the logo 3A.3.e 3A.3.f Now install the t/r servo rear mount over the front of the boom as shown. The slot and servo mount are on the opposite side of the boom from the fin. 3A.3.g Note Slot Orientation #130-275 3A.3.h Insert the end of the tail rotor belt taped earlier as shown. Don’t twist the belt at all Building Notes: Stretch the t/r drive belt out to make sure it is straight and not twisted. It should appear as shown Make sure belt is straight and not twisted 3A.3.i 3A.3.j 3A.3.k Building Notes: Slide the belt through the boom as you slide the boom into the tail boom mount previously installed on the frame. You may have to twist the boom slightly. Continue to push the boom forward until the belt extends out the back of the boom. Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 33 of 89 X-Cell Furion 450 Assembly Manual 3A.4 – Assemble T/R Transmission 3A.4.a 3A.4.b #130-032 3A.4.d Screw on flat Building Notes: Align one of the set screws with the flat on the t/r shaft as shown but only tighten enough to so that the pulley can still move but movement is limited by the shaft flat. #130-336 #130-337 3A.4.c Note flat Flush 3A.4.e 3A.4.f Building Notes: Now slide the short end of the tail shaft into the bearing in the vertical fin. Slide the shaft into the bearing as shown. When the shaft is flush with the outside of the bearing tighten the set screw on the flat 3A.4.i 3A.4.g Building Notes: Tighten the set screw that is NOT on the flat using thread lock. Now remove the remaining set screw, apply thread lock and tighten. The correct pulley position is now set. 3A.4.j 3A.4.k Building Notes: Remove the tape from the rear of the T/R belt but be careful not to change its orientation. 3A.4.l Building Notes: Insert the T/R pulley/shaft into the belt as shown and twist counter clockwise ¼ of a turn as shown. MAKE SURE YOU ONLY TWIST ¼ OF A TURN. Fit the front of the belt over the pulley as shown and slide the tail boom outward slightly to reduce the amount of belt exposed in the back. 3A.4.m 3A.4.h Insert the short end of the t/r shaft through the bearing in the t/r fin. Push the shaft in until the pulley fully seats. 3A.4.n 3A.4.o 3A.4.p Building Notes: Ease the tail boom out to take the slack out of the tail drive belt. Note – if during assembly of t/r transmission, the bearings in the graphite become loose, apply green thread lock to the bearing and push bearing back into graphite. Page 34 of 89 Position plate as shown #130-358 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Flanged side of bearing goes inside Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 3A.4.q 3A.4.r 3A.4.s 3A.4.t Building Notes: It is critical that you ensure the t/r rotates correctly. When you turn the main gear clockwise (from the top), the t/r shaft must turn counter-clockwise when looking at it from the right side of the model. If it does not, the belt is twisted in the boom. Remove and correct. #130-035 3A.5 – Set T/R Belt Tension 3A.5.a 3A.5.b Building Notes: If the tail rotor rotation is correct then pull the tail boom out slightly by grasping the t/r fin with one hand and the chassis with the other. Adjust until the belt will deflect at the point shown by only about ⅛”. Twist boom until viewed as parallel with frames Created: 8/27/2008 3A.5.d Check Tension Here: 3A.5.f Front Bolts Only Building Notes: Align the t/r vertical fin as shown so that the tail rotor is parallel with the side frames. Deflects If necessary slightly twist the 1/8” tail boom assembly for proper alignment. Grab boom as shown and pull backwards This is the correct belt tension. 3A.5.e 3A.5.c 3A.5.g Building Notes: Tighten ONLY the two front boom mount bolts at this time using thread lock Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 35 of 89 X-Cell Furion 450 Assembly Manual 3A.6 – Assemble T/R Pitch Change Mechanism Parts Relationship #130-325 #130-058 #130-330 #130-058 #130-320 #130-037 #130-037 #130-315 #130-315 #130-037 3A.6.a #130-037 3A.6.b #130-058 Building Notes: Apply a thin coat of green thread lock on the smaller bearings using a toothpick. Place a drop of thread lock on the end of the toothpick and then smear it around the bearings. Wipe away any excess and be careful not to get any in the bearing 3A.6.c 3A.6.d #130-058 Building Notes: Position the first bearing on the t/r pitch control ring as shown. Install it as follows #130-330 Page 36 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 3A.6.e 3A.6.f Building Notes: Find a metal tool with a large flat surface like shown in the example 3A.6.g Flat Surface 3A.6.h Push down until bearing seats Building Notes: Use the tool to press in the first bearing. Make sure it is square on the pitch control ring before you apply pressure. Do not drive or hammer the bearing in, simply apply pressure to the tool until the bearing slides in and bottoms in the ring. Repeat for the second bearing. 3A.6.i 3A.6.j 3A.6.k 3A.6.l Insert slider through bearings #130-058 #130-325 3A.6.m 3A.6.n Building Notes: Tighten the pitch plate onto the pitch slider only tight enough to remove all the slack. #130-320 If you over tighten it the bearings will bind up and be notchy. If this happens simply loosen the plate until it turns smoothly threads 3A.6.o Be careful not to get thread lock in the bearings 3A.6.p #130-315 Building Notes: Use a toothpick to apply thread lock around the edges of the bearing flanges on both pitch links and allow it to “wick” in. Be careful not to get any in the bearing itself Wipe off any excess thread lock. 3A.6.q 3A.6.r 3A.6.s Very carefully apply thread lock around bearing flange edges with toothpick Building Notes: Install one of the pitch links onto the pitch plate as shown. The bolt goes through the flanged side of the bearing and threads into the one of the flat ends on the pitch plate #130-037 Created: 8/27/2008 3A.6.t flange Be careful not to get thread lock into the bearings Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA #130-037 Page 37 of 89 X-Cell Furion 450 Assembly Manual 3A.7 – Assemble T/R Hub Parts Relationship #130-312 #130-300 #130-054 #130-040 #130-311 #130-054 #130-035 #130-311 #130-040 #130-312 #130-032 #130-035 #130-308 #130-308 #130-305 3A.7.b #130-040 #130-035 #130-035 #130-038 3A.7.a #130-305 3A.7.c #130-038 3A.7.d #130-054 Grip the sleeve on the bearing spacer and tighten only until the bolt is just snug #130-300 #130-311 3A.7.e 3A.7.f #130-312 3A.7.g 3A.7.h Building Notes: The sleeves simply slip over the bearing spacers. Use green thread lock on the bolts. Be careful not to get thread lock in the bearings Page 38 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 3A.7.i 3A.7.j 3A.7.k Building Notes: Install the blade grip over the bearing stack as shown. The mount holes on the blade grip must align with the holes in the bearing sleeve as shown. Use a small allen tool to align if necessary. Push the t/r grip towards the center of the hub until it bottoms out. Then install the mount bolts. #130-305 Slides over bearings 3A.7.m 3A.7.n #130-035 3A.7.l Slides over bearings Aligned Align holes 3A.7.o 3A.7.p Building Notes: If the grips and spacer are properly aligned, the mount bolts will install with little effort. If they do not thread in easily re-check the alignment and repeat. #130-035 3A.7.q 3A.7.r Building Notes: Install the t/r blades as shown. The leading edge of the blades should install as shown. Look closely at the blade arms, one side of the hole is threaded and the other is not. The bolts pass through the side that is not threaded, through the blade and then thread into the other side 3A.7.u #130-308 3A.7.s 3A.7.t Note relationship of leading edge to blade control arm Unthreaded hole #130-038 Insert This way Note relationship of leading edge to blade control arm 3A.7.v Building Notes: Partially thread the set screw into the threaded hole on the t/r hub. It should not protrude into the inside of the t/r hub. Do not use thread lock at this time. #130-032 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 39 of 89 X-Cell Furion 450 Assembly Manual 3A.8 – Install T/R Pitch Change Mechanism 3A.8.a 3A.8.b 3A.8.c 3A.8.d Building Notes: Position the t/r bell crank as shown and slip the assembled pitch change mechanism over the t/r shaft. As you slide it in, rotate the ball portion of the slider into the bell crank as shown. Slide the mechanism all the way in on the shaft. Rotate Slightly 3A.9 – Install Tail Rotor Assembly 3A.9.a 3A.9.b Note flat 3A.9.c 3A.9.d Building Notes: Install the assembled t/r hub over the t/r shaft as shown making sure that the set screw is aligned with the flat on the t/r shaft. Slide the hub onto the shaft until it is flush with the end of the shaft. Tighten the set screw using thread lock. Install this way #130-037 3A.9.e 3A.9.f Building Notes: Attach the pitch links to the t/r blade grips as shown using thread lock. Note that the bolts pass through the shouldered side of the bearing. Also note the orientation of the t/r blades to the grips and links. #130-037 Page 40 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 3B) Tail Rotor Control - Bag #6A, #6 Hardware These Bags Should Contain: #130-282 Plastic Servo Retainer 1 each #130-080 Threaded Control Rod .374” 2 each #130-285 Plastic Boom Support Ends 4 each #130-010 M2 Hex Nut 1 each #130-002 M2 Washer 4 each #130-090 Plastic Ball Link 2 each #130-028 M2 x 13 Phillips SelfTapping Screw 1 each #130-037 M2 x 6 Socket Bolt 1 each #130-072 Control Ball .118” 2 each #130-265 Rudder Pushrod Ends 2 each #130-038 M2 x 8 Socket Bolt 7 each 3B.1 Install T/R Servo Parts Relationship #130-038 #130-072 #130-010 #130-028 #130-282 NOTE: The T/R Servo can optionally be installed on the left side of the model. In order to do this, the parts orientations must be reversed from what is shown. Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 41 of 89 X-Cell Furion 450 Assembly Manual 3B.1.a 3B.1.b 3B.1.c 3B.1.d Use grommets/screws included with servo #130-282 3B.1.e 3B.1.f 3B.1.g 3B.1.h Building Notes: Tighten the bolts on the front rudder servo mount using thread lock. This mounts position can be moved to allow for changing the t/r belt tension without affecting the t/r pushrod length. The initial position of this is to center the bracket slots on the two bolts. 3B.1.i 3B.1.j 3B.1.k 3B.1.l #130-038 #130-010 8mm #130-028 #130-072 3B.1.m 3B.1.n Building Notes: Do not thread lock the t/r servo ball yet. It cannot be correctly installed until the electronics are powered up and the servo centered in a later step Use a servo wheel of the size shown 3B.1.o Don’t Tighten Yet 3B.1.p #130-038 Install the t/r bell crank onto the t/r servo but don’t tighten at this time. #130-072 Building Notes: Install t/r control ball as shown using thick adhesive only. Page 42 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 3B.2 Assemble T/R Pushrod Parts Relationship #130-090 #130-072 #130-265 #130-265 #130-090 #130-260 #130-080 #130-080 #130-038 3B.2.a 3B.2.b 3B.2.c Building Notes: Lightly sand the ends of the t/r pushrod to help the adhesive grip. #130-260 3B.2.d #130-265 #130-080 Test fit the pushrod ends to make sure they slide fully over the end. Sand as necessary Attach the two ends as shown using adhesive Thread in until it stops 3B.2.e 3B.2.f 3B.2.g #130-265 Horizontal The overall length will be approximately 312mm measured from end to end 2 mm Thread on ends as shown PRINTS ACTUAL SIZE Created: 8/27/2008 Building Notes: Repeat the process for the other end of the t/r pushrod. Align the two links so they are at right angles to each other Vertical SET THIS ASIDE FOR NOW, IT WILL BE INSTALLED IN A LATER STEP. Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 43 of 89 X-Cell Furion 450 Assembly Manual 3B.3 Assemble/Install Tail Boom Supports Parts Relationship #130-038 #130-038 #130-002 #130-002 #130-285 #130-285 #130-260 #130-038 #130-037 #130-260 #130-285 3B.3.a #130-260 (2) #130-285 #130-002 #130-002 #130-038 #130-038 3B.3.b B.3.c 3B.3.d 3B.3.g 3B.3.h Building Notes: Lightly sand the ends of the boom supports to help the adhesive grip. Test fit the support ends to make sure they slide fully over the end. Sand as necessary Attach one end to each rod as shown using adhesive 3B.3.e 3B.3.f Building Notes: Align one end of the supports using a spare 2mm bolt or other object. The other ends need to be installed parallel to these two using adhesive. You can use a bolt or other object to align the other end as shown. #130-002 Ends are parallel #130-038 Page 44 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 3B.3.i 3B.3.j Building Notes: Install one of the tail boom supports as shown. They attach to the bottom of the rear frame and to the horizontal fin mount 3B.3.k 3B.3.l #130-038 #130-002 Repeat for both supports Use adhesive and thread lock as shown #130-038 3B.3.m 3B.3.n #130-002 3B.3.o #130-037 Building Notes: (Shorter Bolt) When initially assembled, the horizontal fin mount will be spaced from the t/r transmission as shown. 3B.3.p #130-295 Depending on the belt tension this may vary slightly 77mm Dimension is approximate 3B.3.q Viewed As 90° Angle Created: 8/27/2008 Install the horizontal fin in two steps as shown 3B.3.r #130-038 (Longer Bolt) 3B.3.s Building Notes: Align the horizontal fin so that it is at a right angle to the tail fin and main shaft. Note that tightening the left horizontal fin bolt tightens the clamp and will rotate the fin slightly counter-clockwise. Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 45 of 89 X-Cell Furion 450 Assembly Manual Assembly Step #4 – Control Systems 4A) Electronics Installation/Main Control Components - Bag #7A, #7B, #7 Hardware These Bags Should Contain: #130-076 Control Ball .198” 3 each #130-074 Control Ball .157” 2 each #130-070 Control Ball .118” 7 each #130-019 M2 x 6 Phillips Tapered Head Screw 5 each Page 46 of 89 #130-155 Plastic Washout Link 2 each #130-150 Aluminum Washout Arms 2 each #130-145 Washout Hub 1 each #130-004 M2 x .150” x .020” Shim Washer 2 each #130-020 M2 x 8 Phillips Tapered Head Screw 2 each #130-022 M2 x 8.50 Phillips Tapered Head Screw 2 each #130-168 Assembled Swashplate 1 each #130-035 M2 x 4 Socket Bolt 3 each #130-090 Plastic Ball Link 6 each #130-030 M2 x 8 Shouldered Bolt 2 each #130-165 Anti-rotation Pin 1 each #130-084 Control Rod 1.013” 3 each #130-282 Plastic Servo Retainer 2 each #130-038 M2 x 8 Socket Bolt 2 each #130-040 M2 x 10 Socket Bolt 1 each Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA #130-041 M2 x 12 Socket Bolt 1 each #130-010 M2 Hex Nut 3 each #130-052 M2 x 5 x 2.5 Ball Bearings 4 each #130-153 Machined Washout Link Screw 2 each Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 4A.1 Install Elevator Servo Parts Relationship #130-282 #130-282 #130-041 #130-076 #130-010 4A.1.a 4A.1.b 4A.1.c Elevator Servo 4A.1.d #130-282 Building Notes: Install the elevator servo as shown. Use short servo screws or cut longer ones off to ensure that the servo screws do not hit the t/r belt Be careful not to disturb the routing of the t/r belt during the servo installation 4A.2 Install Electronics 4A.2.a 4A.2.b Building Notes: Install your gyro on the plate underneath the tail boom. Use the mounting method specified by the gyro manufacturer. Connect the T/R servo to the gyro. 4A.2.c 4A.2.d Building Notes: If it is not pre-wired, attach connectors to your ESC according to the manufacturer’s recommendations. Do not connect it to the motor yet as you will need to power up the receiver/servos in the next section ‘ Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 47 of 89 X-Cell Furion 450 Assembly Manual 4A.2.e 4A.2.f Building Notes: You will need connectors to connect the speed controller/BEC and the battery. Dean’s connectors have proven to be very efficient. They are available as part #130-460 4A.2.g 4A.2.h Optional Parts #130-460 Optional Parts #130-460 Red power wires connect to the marked + side of the connectors Wire the connectors as shown 4A.2.i 4A.2.j Connect male end to ESC 4A.2.k 4A.2.l 4A.2.o 4A.2.p Building Notes: You will need the Velcro and tie wraps from Bag 9 to complete the remaining steps in this section. Connect female end to Battery Mount the ESC either between the frames or on the frame side wherever it fits better. Secure the ESC with a tie wrap to prevent it from being ejected. 4A.2.m 4A.2.n Building Notes: Connect the receiver according to the manufacturer’s instructions. Make sure you at minimum connect the • Elevator • Aileron • Rudder • Pitch • Throttle • Power 4A.2.q Building Notes: Remove the front bolts from the radio tray, lift it up and install the receiver. Then reposition the radio tray and reinstall the bolts with thread lock 4A.2.r 4A.2.s 4A.2.t Building Notes: Now use Velcro to secure and organize the exposed wiring. Be careful to keep it away from turning objects and keep wires away from any sharp edges on the graphite. Page 48 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 4A.2.u 4A.2.v 4A.2.w 4A.2.x Building Notes: Secure gyro using Velcro as shown. You will need to slightly trim the Velcro width so that it fits into the slots on each side of the front boom support as shown. 4A.2.y 4A.2.z 4A.2.aa Building Notes: Refer to the Initial Setup for Servo Centering procedure found in the Model Setup section of this manual 4A.2.bb Building Notes: In the following steps you will assemble the servo arms. Select arms that will allow the control balls to be placed at distance from the servo center shown. For each servo select a servo arm and find the position that the arms are nearly perpendicular to the servo. Trim and mount the arms as shown in the following steps 4A.2.cc 4A.2.dd 4A.2.ee Ball Link Orientation Faces Inside Faces Outside Beveled Edge Building Notes: Although the plastic links can be installed on either side, one side is molded differently and will install easier with less effort. No Bevel Note the differences on the photo. The side of the link with the beveled edge should be installed first over a ball or should face inside on a ball. The side of the link with no bevel should face outside on a ball. 13mm 4A.2.ff Antenna Routing Mold Ring Created: 8/27/2008 No Ring Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 49 of 89 X-Cell Furion 450 Assembly Manual 4A.3 Install Servo Arms Parts Relationship #130-010 #130-010 Pitch Servo Arm #130-070 #130-070 #130-038 Aileron Servo Arm Prints Actual Size #130-038 #130-010 #130-041 Bolt May Protrude Less on Some Servo Arms Elevator Servo Arm #130-076 4A.3.a 4A.3.b Pitch Servo 4A.3.c Aileron Servo 4A.3.d Elevator Servo Building Notes: Shape the proper length control arms as shown, then assemble each as shown. Install in their respective positions and don’t forget the servo arm retainer screws 4A.3.e 4A.3.f Rudder Servo Building Notes: Revisit the servo previously installed for the tail rotor. Make sure it is properly centered via the radio and that the servo arm and t/r bell crank are at right angles to the tail boom. If necessary move the servo arm ball installed earlier to a new hole and apply thread lock Page 50 of 89 4A.3.g Rudder Servo Wheel 4A.3.h Building Notes: Snap the ball links over the ball on the t/r servo and on the t/r bell crank If the servo arm and the bell crank are not at right angles to the tail boom, adjust the ball links as necessary until they are. Make sure you have installed a servo arm retainer screw. Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 4A.3.i 4A.3.j 4A.3.k 90° Angle 90° Angle 4A.4 Assemble Cyclic Control Rods Parts Relationship #130-084 (3) .638” thru .734” #130-090 (6) Prints Actual Size Building Notes: Assemble three cyclic control rods as shown. These will print ACTUAL SIZE so you can lay them on the photo to determine the correct length All “actual size” rod lengths in this manual assume you are using the exact servos shown. Use of different servos may require minor adjustments to obtain the proper settings due to minor differences in servo dimensions. The final length will be within the ranges listed. Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 51 of 89 X-Cell Furion 450 Assembly Manual 4A.5 Assemble Swashplate Parts Relationship #130-040 #130-165 #130-019 #130-019 #130-020 #130-019 #130-070 #130-074 #130-070 #130-035 #130-035 #130-070 #130-168 #130-074 #130-163 #130-070 #130-019 #130-020 #130-035 #130-070 #130-019 4A.5.a 4A.5.b #130-168 #130-163 Page 52 of 89 Building Notes: Install the swashplate ring on the bottom of the swashplate as shown using thread lock #130-035 4A.5.c 4A.5.d #130-020 #130-074 Building Notes: Install the two longer balls on the inside swashplate ring. Make sure you use the slightly longer bolts #130-020 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 4A.5.e 4A.5.f #130-019 #130-019 4A.5.g Building Notes: Install the two short balls on the inside swashplate ring. Make sure you use the right length bolts. #130-070 #130-019 #130-070 4A.5.h #130-019 Building Notes: Install the balls on the outside swashplate ring. Note the positions on the ring. #130-019 4A.6 Install Swashplate/Control Rods 4A.6.a 4A.6.b 4A.6.c Building Notes: Slip the swashplate over the main shaft as shown. #130-040 Install the anti-rotation pin and bolt through the anti-rotation guide and into the remaining threaded hole on the outer swashplate ring 4A.6.e Rod 4A.6.f Rod 4A.6.g Rod 13 mm 4A.6.d #130-165 Building Notes: Install the three equal length cyclic control rods between the elevator, aileron, and pitch servo arms and the control balls on the swashplate 4A.6.h Building Notes: With the servo arms centered, if the rods are the correct lengths the distance between the bottom of the swashplate plate and the top of the upper bearing block will be as shown. If it is not, adjust the lengths of all three rods accordingly. 4A.6.i Building Notes: If the servo arms are the correct length, the rods will be parallel with the main shaft when the arms are in their centered position. This will ensure proper control authority. Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 53 of 89 X-Cell Furion 450 Assembly Manual 4A.7 Assemble Washout Mixer Parts Relationship #130-155 #130-153 #130-076 #130-022 #130-004 #130-150 #130-030 #130-145 #130-052 #130-052 #130-052 #130-052 #130-030 #130-150 #130-004 #130-022 #130-153 #130-076 #130-155 4A.7.a 4A.7.b 4A.7.c 4A.7.d Building Notes: Build the two mixer arms as shown. They are identically made. #130-052 Make sure you drop the small spacer in between the bearings before you press in the second one. #130-004 #130-150 4A.7.e 4A.7.f #130-052 4A.7.g #130-076 4A.7.h Building Notes: Install the washout links as shown using the special screws. Use thread lock sparingly Do not overtighten the bolts, the links should move smoothly. You may also slightly heat the links with a heat gun to improve their fit on the mixer arms. #130-153 #130-022 Page 54 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA #130-155 Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 4A.7.i 4A.7.j Building Notes: Install the mixer arms onto the mixer base EXACTLY as shown using thread lock. Be careful not to get any in the bearings. 4A.7.k 4A.7.l Install Links On Short Balls #130-145 The orientation of the links and balls are important The extended part of the washout base is the bottom #130-030 #130-030 4A.7.m Short Balls Created: 8/27/2008 4A.7.n 4A.7.o Building Notes: If the servos are properly centered and the swashplate rods are the correct lengths, when the collective is centered the mixer arms will be centered as shown. Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 55 of 89 X-Cell Furion 450 Assembly Manual Assembly Step #5 – Rotor Head 5A) Rotor Head Components - Bag #8A, #8B, #8C, #8 Hardware These Bags Should Contain: #130-078 Control Ball .242” 2 each #130-144 Flybar Paddles 2 each #130-115 Aluminum Blade Grip Block 2 each #130-140 Flybar Control Bar 2 each #130-032 M3 x 3 Socket Set Screw 2 each Page 56 of 89 #130-113 Brass Axle Spacer Washer 2 each #130-125 Bell Mixer 2 each #130-104 Main Rotor Head Block Assembly 1 each #130-014 M2 x 3 Phillips Flat Head Bolt 2 each #130-035 M2 x 4 Socket Bolt 26 each #130-076 Control Ball .198” 4 each #130-052 M2 x 5 x 2.5 Ball Bearing 7 each #130-120 Bell Mixer Mount 2 each #130-004 M2 x .150” x .020” Shim Washer 2 each #130-110 Head Axle 4mm 1 each #130-006 M2.5 washer 2 each #130-130 Flybar Support Tube 1 each #130-037 M2 x 6 Socket Bolt 4 each #130-044 M2.5 x 6 Socket Bolt 2 each #130-112 Brass Blade Grip Block Spacer 2 each #130-111 Bearing Damper Shims 4 each #130-068 F4-9mm Thrust Bearing 2 each #130-062 M4 x9 x 4 Ball Bearing 2 each #130-060 M4 x8 x 3 Ball Bearing 2 each #130-086 Control Rod 1.198” 2 each #130-107 Rubber Head Damper – 70D (white dot) 2 each #130-135 Flybar Control Arm 2 each #130-040 M2 x 10 Socket Bolt 4 each #130-080 Control Rod .374” 2 each #130-109 #130-012 Rubber Head Damper – 90D M3 Locknut 2 each 4 each #130-049 M3 x 14 Socket Bolt 2 each #130-030 M2 x 8 Phillips Shouldered Bolt 2 each Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA #130-090 Plastic Control Link 8 each #130-092 Plastic Flybar Control Link 2 each #130-022 M2 x 8.50 Phillips Tapered Head Bolt 4 each Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 5A.1 Assemble Bell Mixers Parts Relationship #130-030 #130-022 #130-052 #130-004 #130-076 #130-052 #130-125 #130-022 #130-022 #130-076 #130-125 #130-076 #130-076 #130-052 #130-004 #130-052 #130-022 5A.1.a 5A.1.b Building Notes: Apply a thin coat of green thread lock on the small bearings using a toothpick. Place a drop of thread lock on the end of the toothpick and then smear it around the bearings. This must be applied to all four of the bearings in this assembly #130-052 5A.1.e 5A.1.f Building Notes: Be careful to wipe away any excess thread lock and don’t get any into the bearing itself #130-004 #130-030 5A.1.c 5A.1.d #130-125 5A.1.g #130-052 5A.1.h The spacer is captured between the two bearings #130-022 #130-076 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 57 of 89 X-Cell Furion 450 Assembly Manual 5A.1.i 5A.1.j Milled “Flat” Side Use Inside hole 5A.1.k 5A.1.l Building Notes: Install the swashplate input control balls on the “flat” side of the bell mixers. Building Notes: Build the other bell mixer using the same assembly sequence. Insert the bolts to mount the mixers through the bearing/spacer stack as shown and set them aside until later. The default position is into the hole nearest the bearings. #130-076 #130-030 #130-022 5A.2 Assemble Main Rotor Block Parts Relationship #130-109 #130-109 #130-109 #130-110 Choose One but must be same on both sides #130-109 Choose One but must be same on both sides #130-104 #130-107 White Dot (Optional) #130-107 White Dot (Optional) #130-040 #130-040 5A.2.a 5A.2.b #130-109 #130-107 (Optional) #130-104 Page 58 of 89 5A.2.c 5A.2.d Building Notes: Insert one of the 90D dampers into the head damper cavity or for less aggressive response use a 70D damper here. Then put one of the 90D dampers on top of that and press them into the cavity until flush. Repeat on the opposite side of the head block #130-109 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 5A.2.e 5A.2.f 5A.2.g Building Notes: Center the axle in the head block as shown. It will slide easily in the dampers. #130-110 Insert axle through dampers 5A.3 Assemble Main Blade Grips Parts Relationship #130-049 #130-035 (2) Bevel Faces Inside 90D 70D (optional) #130-122 (top) #130-035 (2) #130-035 (2) #130-060 #130-113 90D #130-112 #130-115 #130-062 #130-006 #130-068 #130-035 (2) Bevel Faces This Way #130-044 #130-122 (bottom) #130-120 #130-035 (2) #130-035 (2) Created: 8/27/2008 #130-111 #130-012 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 59 of 89 X-Cell Furion 450 Assembly Manual 5A.3.a 5A.3.b #130-060 5A.3.e 5A.3.c Building Notes: Apply a thin coat of green thread lock on the smaller bearings using a toothpick. Place a drop of thread lock on the end of the toothpick and then smear it around the bearings. DO NOT APPLY TO THE BEARING INSIDE THE GRIP! Wipe away any excess and be careful not to get any in the bearing 5A.3.f 5A.3.d #130-060 #130-112 #130-115 5A.3.g 5A.3.h Insert Bearing Spacer goes in recess #130-111 #130-062 5A.3.i 5A.3.j 5A.3.k Second #130-111 (optional) Building Notes: Insert one of the damper shims on top of the inside bearing. OPTIONAL: If you want stiffer damping for quicker response, then put a second spacer in each grip. 5A.3.m 5A.3.n #130-068 Bearing 5A.3.l 5A.3.o #130-068 Smaller Hole #130-068 Larger hole Building Notes: Before installing thrust bearings, make sure the correct order is followed. There are two sizes of the hole in the bearing races. The race with the larger hole goes in first. Make sure the orientation of each bearing part matches the photos. 5A.3.p #130-113 Building Notes: Install the axle spacer washers so that the rounded edge faces outward Rounded edge out Page 60 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 5A.3.q 5A.3.r #130-113 5A.3.s 5A.3.t #130-006 Insert over axle #130-044 5A.3.u 5A.3.v 5A.3.w 5A.3.x Bevel Side Down Building Notes: Install the other blade grip and retain it as shown. Use two allen drivers to tighten the bolts but do not overtighten as the axle ends may distort. Building Notes: When building the blade grips, note that they are cut in pairs. The beveled edges fit around the blade grip block as shown #130-035 (2) #130-122 (top) 5A.3.y Bevel 5A.3.z 5A.3.aa 5A.3.bb Do not overtighten #130-120 Mixers must move freely when tight Bell mixer 5A.3.cc 5A.3.dd #130-035 (8) Created: 8/27/2008 5A.3.ee 5A.3.ff Bevel Side Down Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 61 of 89 X-Cell Furion 450 Assembly Manual 5A.3.gg 5A.3.hh 5A.3.ii 5A.3.jj #130-035 (6) #130-122 (bottom) 5A.4 Assemble Flybar Components Parts Relationship #130-144 #130-144 #130-142 #130-140 #130-040 #130-032 #130-035 #130-078 #130-037 #130-135 #130-078 #130-052 #130-037 #130-130 #130-135 #130-037 #130-052 #130-052 #130-040 #130-032 #130-037 #130-014 (2) #130-035 #130-140 Page 62 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 5A.4.a 5A.4.b 5A.4.c #130-052 Building Notes: Apply a thin coat of green thread lock on the smaller bearings using a toothpick. Place a drop of thread lock on the end of the toothpick and then smear it around the bearings. Be careful to not get any in the bearing and wipe off any excess #130-052 5A.4.d #130-130 5A.4.e 5A.4.f 5A.4.g 5A.4.h Building Notes: Apply a very small amount of thread lock on the bolt threads and be careful not to get any into the flybar pivot bearings. Align Holes Note head orientation 5A.4.i Allow the thread lock on the flybar pivot bolts to dry thoroughly before proceeding with the assembly. 5A.4.j #130-035 5A.4.k 5A.4.l #130-035 No Loctite On Bearing #130-014 #130-052 5A.4.m 5A.4.n #130-140 5A.4.o #130-135 5A.4.p Only Thread in half way At this time with no thread lock #130-037 #130-092 #130-032 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Flat Side Page 63 of 89 X-Cell Furion 450 Assembly Manual 5A.4.q 5A.4.r 5A.4.s 5A.4.t 5A.4.v 5A.4.w 5A.4.x Building Notes: Note that the flybar control arm posts have protrusions on each end and the correct side of the control arms has a matching recess. 5A.4.u #130-135 Insert one end as shown #130-037 #130-037 #130-078 #130-040 #130-142 5A.4.y 5A.4.z 5A.4.aa 5A.4.bb Building Notes: To center the flybar, find a drinking straw and cut it to the exact length of 78mm. Slide the straw over one end of the flybar and then adjust the flybar in or out until the threaded end of the flybar is flush with the end of the straw 78mm Install in center hole 5A.4.cc 5A.4.dd Tighten Both Set screws 5A.4.ee 5A.4.ff Building Notes: Tighten both retaining set screws using thread lock. This will center the flybar. Building Notes: Locate the decal sheet. The right hand lower corner contains two squares. These are for covering the flybar paddles. Follow the outline and cut these out with scissors Flush at one end Page 64 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 5A.4.gg 5A.4.hh 5A.4.ii 5A.4.jj 5A.4.mm 5A.4.nn Building Notes: Peel the backing off of one of the decals and apply it to a paddle. Note that the paddle has molded inlays where the decal goes. Start applying on one side of the paddle and wrap around as shown. Press out air bubbles so it seals against the paddle body. #130-144 5A.4.kk 5A.4.ll You must thread on the paddles fully Thread on flybar paddles as shown 60mm #130-144 5A.4.oo Make sure the leading edge of the paddles would be rotating this way 5A.5 Install Rotor Head 5A.5.a 5A.5.b Align Hole And Slot Building Notes: Install the main rotor on the main shaft as shown. Be careful to align the side bolt hole with the slot on the main shaft as well as the center mount hole with the center hole on the main shaft. Install the two bolts with thread lock. 5A.5.c 5A.5.d #130-040 DO NOT OVERTIGHTEN THESE BOLTS. Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 65 of 89 X-Cell Furion 450 Assembly Manual 5A.5.e 5A.5.f 5A.5.g 5A.5.h Building Notes: Snap the two flybar control links onto the balls on the ends of the mixer arms as shown. #130-040 Now you should align the flybar paddles with each other and with the centerline of the flybar control arms. Do this visually or acquire alignment tools such as these. 5A.5.i 5A.5.j 5A.5.k 5A.5.l Building Notes: Install alignment gauges on the paddles as shown and sight down the length of the flybar to align them with each other and with the flybar control arms. 5A.5.m Align both paddles with each other Page 66 of 89 5A.5.n Align a paddle with flybar control arm end bolts 5A.5.o Building Notes: When installed and properly aligned, the paddles will look like this against the head at zero degrees collective. Adjust the paddles as necessary until they align as shown with the swashplate, flybar control arm, washout arms, and blade axle center line. Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 5A.6 Assemble/Install Rotor Head Control Rods Parts Relationship #130-090 (2) 1.622 thru 1.657” #130-090 (2) #130-080 (2) Prints Actual Size #130-086 (2) .000” thru .072” #130-090 (2) #130-090 (2) Building Notes: Assemble three cyclic control rods as shown. Lay the rods on the photo to determine correct length as they print actual size 5A.6.a 5A.6.b 5A.6.c 5A.6.d #130-086 #130-086 #130-080 #130-080 #130-080 #130-086 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 67 of 89 X-Cell Furion 450 Assembly Manual Assembly Step #6 – Complete Model Assembly 6A) Canopy Components - Bag #9A, #9 Hardware These Bags Should Contain: #130-249 4” Plastic Zip Ties 4 each #130-247 Back to Back Velcro 880mm 1 each #130-248 Adhesive Back Velcro 100mm 2 each #130-250 Rubber Canopy Grommets 2 each #130-024 M2 x 3 Phillips Self Tapping Screw 6 each 6A.1 Assemble/Install Canopy 6A.1.a 6A.1.b Drill #9 #130-251 Page 68 of 89 6A.6.c 6A.1.d Building Notes: Use a #9 (.196”) drill to open the two mount holes on the side canopy. Be careful to center the drill in the relief hole. Using scissors and/or a razor knife trim the flashing from the canopy edges and then open up the top of the canopy following the molded in outline. Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 6A.1.e 6A.1.f 6A.6.g #130-250 Building Notes: Trim notches in the bottom of the canopy as shown so that it will fit flush against the front of the lower chassis. Insert the two grommets into the previously drilled mounting holes. 6A.1.i 6A.1.j #130-252 6A.1.h Notch 6A.6.k 6A.1.l Building Notes: Trim the windshield along the molded lines using scissors. The material cuts easily. The finished shape should look like the following photo. Building Notes: Using a light spray adhesive like 3M 77 or equivalent, spray the INSIDE of the windshield with the adhesive. Then apply the windshield to the canopy as shown. The windshield will cover and hide the previously installed grommets. 6A.1.m 6A.1.n 6A.6.o 6A.1.p Building Notes: Using a #55 (.052”) drill, mark and drill 6 holes through the windshield and canopy in the positions shown. (Two in the front, and then two on each side of the windshield) 6A.1.q 6A.1.r Building Notes: Screw the six self tapping mounting screws through the windshield into the canopy. Lightly tighten them to prevent “stripping” the plastic in the canopy. 6A.6.s 6A.6.t #130-024 Building Notes: Install the canopy by slipping it over the front of the chassis as shown Clean off any adhesive overspray on the windshield left from an earlier step Drill #55 Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 69 of 89 X-Cell Furion 450 Assembly Manual 6A.1.u 6A.1.v 6A.6.w 6A.6.x Building Notes: Slip the bottom of the canopy between the two landing gear canopy clamps and the bottom chassis plate. Push backwards until the chassis plates fit into the previously cut canopy notches. 6A.1.y 6A.1.z 6A.6.aa 6A.2.b 6A.2.c Building Notes: Attach the rear of the canopy by pushing the grommets at the rear of the canopy onto the canopy mounting studs on the chassis. This completes canopy installation. Make sure that the canopy clears all moving components such as the main gear, servo arms/rods or swashplate. Trim if necessary. 6A.2 Install Decals 6A.2.a 6A.2.d Building Notes: Trim the decals from the decal sheet with scissors. The standard decal layout is shown. Clean and degrease the canopy, then peel the backing off of each decal and apply into its appropriate position. Be careful not to get any air bubbles under the decals as this can cause wrinkles and collect dirt. Seal the edges of the decals with clear nail polish to further seal them. Page 70 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual 6A.3 Install Rotor Blades 6A.3.a 6A.3.b #130-049 6A.3.c Building Notes: Insert the main rotor blade into the blade grip and attach as shown. Tighten the locknut until the rotor blade is tight in the blade grip. The blade should not be able to move in the grip easily. SAB 320mm rotor blades are recommended for best overall performance. #130-012 6A.4 Install Battery 6A.4.a #130-248 Hook Side Created: 8/27/2008 6A.4.b 6A.4.c #130-248 Loop Side Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 71 of 89 X-Cell Furion 450 Assembly Manual IV. Basic Model/Radio Setup The setup shown is for a Mode II radio system however it will apply to any style radio Collective/ Throttle + Rudder A) Elevator + Aileron Initial Setup for servo centering Plug in all servos according to manufacturer’s channel assignments. It is not necessary to connect the throttle channel at this time. For Futaba FASST, the following are the default assignments (your system may vary) • Ch1 = Aileron Ch4 = Pitch • Ch2 = Elevator Ch5 = Gyro • Ch3 = Throttle Ch6 = Rudder In your radio, set the model type for helicopter and set the swash type as 120° CCPM. Check the radio manual to find the correct swashplate setting and channel arrangement (For Futaba this is SR-3/HR-3). Channel Layout Swashplate Type At this point in the setup you don’t need to power up the ESC but only the receiver and servos. If you are using a separate Rx battery, plug it into the receiver and proceed. If you are only using an ESC with a BEC for Rx power, don’t connect the ESC to the motor when you power up for this step. Page 72 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual For the pitch, aileron, and elevator servos: In your • • • • • radio ATV (servo endpoints) should be at 100% Set all trims and sub-trims to center or zero. Set an initial linear pitch curve as a straight line (sample points: 0%, 25%, 50%, 75%, 100%) Make sure there is no mixing enabled for cyclic channels at this point Center the collective stick and make sure all the cyclic channels are centered Channel ATV Trim/Sub-Trim Pitch Curve – Linear Control Sticks Centered On your model • Mount each ball into a servo arm hole approximately 13mm from the center of each arm as shown. • Slide the servo horns for each channel onto each servo exactly in the middle of its travel as shown • Failing to get them set at center will create interaction in your swash plate travel. • If possible, center the horns on the servos without using any sub trim. As a last resort, use the sub trim function to precisely center each servo. • Make sure you install hex nuts on the ball retainer bolts using threadlock • Make sure you install servo arm retainer screws Servo Arm Dimensions Aileron Pitch Aileron Servo – 90° Pitch Servo – 90° Elevator Elevator Servo - 90° 13mm Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 73 of 89 X-Cell Furion 450 Assembly Manual For the rudder servo: In your • • • radio Make sure the gyro is in non-heading hold mode. Refer to your gyro manufacturer as to how to enable this. Rudder servo endpoints (ATV) should be at 100% Make sure there is no mixing enabled for rudder channel at this point (some radios mix throttle to rudder by default). Gyro Setting Rudder ATV Rudder Mixing On your model • The ball should go into a hole approx 8mm from the center of the servo wheel as shown. • With your rudder stick centered, rotate the servo wheel until you find a spot that it aligns properly and then slide the servo wheel onto the servo exactly in the middle of its travel as shown. Do not use any sub-trim. • Now make sure that the t/r bellcrank is aligned as shown. If the servo is positioned as shown and the t/r pushrod has been built to the recommended length, this will be very close. The 90 degree pitch slider on the tail case should be in the center of its travel. Adjust the links as necessary to ensure this is correct. • Make sure you install hex nuts on the ball retainer bolts using threadlock • Make sure you install servo arm retainer screws Rudder Arm Dimension Rudder Arm Orientation Rudder Arm Alignment T/R Bellcrank Alignment 90° Angle Rudder Servo 90° Angle 8mm Use a servo wheel of the size shown Page 74 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual B) Setup for Collective, Cyclic and Rudder For the following steps you don’t need to power up the ESC, only the receiver and servos. If you are using a separate Rx battery, plug it into the receiver and proceed. If you are only using an ESC with a BEC for Rx power, don’t connect the ESC to the motor when you power up for this step. As you go through these setup procedures, make sure that none of the controls bind at full throw. If so, adjust the individual servo throws until the binding is resolved. B.1 Setting Swashplate Movements The first step is to make sure that the servo reversing and swash mix settings are correct for the controls to move properly. B.1.1 Collective Movements For a sport flying/3D setup, a linear pitch curve is appropriate (a straight line- 0%,25%,50%,75%,100%) as your pitch curve data points. Pitch Curve - Linear Check the movement of the collective commands Starting with the collective, when moving the collective stick up and down, all three servos should work in unison to equally raise and lower the swash plate. Collective Movement Collective Up Collective Down All Rods Move in the same direction Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 75 of 89 X-Cell Furion 450 Assembly Manual If the movements are not correct, first make sure that the servos are connected to the correct channel on the receiver. If the servos do not move in unison, they can be adjusted by either: • • changing the servo reverse settings for one or more of the cyclic channels changing the “sign” of individual cyclic channels on the Swashplate mix menu (Swash AFR on Futaba radios). For example if it is a +50% for a channel, make it a -50% to make it correct. You may have to change this for one channel or all channels. Servo Reversing Swash AFR For Futaba radios, the following settings are correct: Channel Aileron Elevator Pitch Page 76 of 89 Servo Reversing Normal Normal Reverse Swash AFR +50% +50% +50% Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual B.1.2 Cyclic Movements Check the movement of the cyclic commands. Cyclic – Radio Left Cyclic Swashplate Left Moving the cyclic stick left should tilt the swash plate to the left when seen from behind the model. Cyclic – Radio Right Cyclic Swashplate Right Moving the cyclic stick right should tilt the swash to the right when seen from behind the model. Cyclic – Radio Down Elevator Swashplate Forward Moving the cyclic stick forward should tilt the swash plate forward when seen from the side of the model Cyclic – Radio Up Elevator Swashplate Backward Moving the cyclic stick backwards should tilt the swash plate backwards when seen from the side of the model Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 77 of 89 X-Cell Furion 450 Assembly Manual B.1.3 Swashplate – Center Level With the collective and cyclic sticks centered, visually center the swash plate to ensure that it is straight. A swash plate leveling tool is also helpful in this case. If the swash plate is not 100% level at center collective, looking at it from the side, as well as the front, use a small amount of sub trim in the appropriate channel to make it level. Collective Centered When properly centered, the swashplate will be level from all viewed angles. Also, if the servo arms are the correct length, all rods will be parallel with the main shaft as shown Swashplate Side Swashplate Front Rods Are Parallel Level Rod Is Parallel Page 78 of 89 Level Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual B.1.3 Swashplate – Extreme Throws Level It is now time to make the swash plate level both at full positive and negative pitch. Raise the collective stick to its fullest position upwards. Visually inspect the swash plate. If the swash plate is not level, use your servo ATV’s (Endpoints) to adjust each servo to create a level swash plate. Once again, inspect the swash from the front/ back and from each side to make sure that the swash is level. Now lower your collective stick and follow the same procedure mentioned above to make your swash plate level when giving negative pitch. What this has created is a totally level swash plate during its entire travel. Collective – Radio Full Positive Collective Swashplate + collective Level Collective – Radio Full Negative Collective Swashplate - Collective Level Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 79 of 89 X-Cell Furion 450 Assembly Manual B.2 Setting Blade Limits B.2.1 Install Flybar Lock/Blade Gauge You will need to maintain the flybar at a level position in order to accurately set the blade pitch. The following shows how to install the optional flybar lock. Flybar Lock Installs Over Top of Head Lock Both Ends Under Flybar Install Pitch Gauge B.2.2 Pitch Curve Setup Now center the collective stick once again. If all links have been built per assembly manual’s instructions, a check of the main rotor blade pitch should find it close to zero degrees pitch. Adjust either the double link from the flybar cross tube to the bell mixer, or the long linkage from the swash plate to the bell mixer to get the blade angle zero degrees. Pitch Curve – Zero Degree Blade Pitch - Zero Level Level Level Page 80 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual Once this is done, there should be equal amounts of pitch in both the positive and negative directions. +- 10 degrees pitch on the collective is recommended. This can be adjusted by changing the high and low points of the pitch curve Pitch Curve – Full Positive Blade Pitch – Plus 10 Level Level Level Measure blade pitch using a pitch gauge. These typically install on a blade tip as shown and readings are determined by sighting down an edge of the gauge against the flybar/swashplate as shown. Pitch Curve – Full Negative Blade Pitch – Minus 10 Level Level Level Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 81 of 89 X-Cell Furion 450 Assembly Manual B.2.3 Cyclic Throw Setup +- 7 degrees pitch on the cyclic is recommended for elevator and aileron channels Cyclic – Full Throw Blade Pitch – Full Cyclic Level Full Cyclic Measure cyclic throw by using a pitch gauge. Install on a blade tip as shown and readings are determined by sighting down an edge of the gauge against the flybar/swashplate as shown. Turn the pitch gauge 90° from the cyclic throw being measured and read the throw on the blade gauge. The throw should be equal for forward, backward, left and right cyclic. If the throws are unequal, use a rate function in the radio to equalize them. Page 82 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual B.3 Rudder Setup Make sure that the t/r servo and gyro are connected to the Rx according to the manufacturer’s recommendations. For a typical gyro (like the Futaba 401), set the gain on the tail to roughly 45%. Set the limits for the tail servo for maximum throw to allow greater servo resolution. Use the Endpoint menu in the radio to adjust the Rudder ATV’s to adjust your pirouette rate (A recommended starting value is 100%) or follow the instructions from your gyro manufacturer. Rudder – Radio Left Rudder Rudder Servo Left T/R – Full Left Rudder – Radio Right Rudder Rudder Servo Right T/R – Full Right Now that the tail rotor slider has been adjusted for full travel, enable heading hold in the gyro using a gain of roughly 45%. Check to make sure that the heading hold is working properly. If not, refer to the gyro documentation to determine the cause. Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 83 of 89 X-Cell Furion 450 Assembly Manual B.4 Exponential If desired, add a small amount of exponential (Expo) to both aileron and elevator. For a Futaba radio, start with 20% on each. For a JR/ Spektrum radio, start with +20%. Exponential - C) Setup for Speed Controller Because of the wide variety speed controllers and the differences in their setup, refer to the manufacturer’s recommended settings for your specific speed controller. In some cases as with Futaba radios, you may need to “reverse” the throttle channel direction. Please note the manufacturers directions in regards to throttle direction settings. MAKE SURE that the speed controller is properly setup BEFORE connecting the drive motor. If the ESC is improperly setup, the motor may start unexpectedly causing injury or damage. BE CAREFUL!! Electric motors are capable of making their full power immediately! C.1 Page 84 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual D) Battery/Motor/Pinion Recommendations If using a Scorpion 2221-6 motor or similar, use the supplied 11T pinion. If using a Scorpion 2221-8 motor or similar, use the supplied 13T pinion. Available Pinion Gears #130-198 11 Tooth Pinion #130-200 13 Tooth Pinion A 3 cell battery with a capacity of 2500mah is recommended. Flight times will vary with flying style, condition of battery pack, ambient temperature, and setup, but average flight times will be roughly 4 to 6 minutes. 2500Mah Battery Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 85 of 89 X-Cell Furion 450 Assembly Manual V. Maintenance/Repair Notes The following outlines some common maintenance/repair procedures A) Tail Belt Tension The tail rotor belt requires additional adjustment to ensure that it is at the proper tension. Use the following procedure for the adjustment. A.1 A.2 A.3 A.4 Repair Notes: The correct tension for the tail rotor drive belt must be maintained and should be checked occasionally. If it can be deflected for than 1/8” at the point shown, it should be tightened. Loosen Check Tension Here Use this procedure to set the t/r belt tension. A.5 A.6 Loosen Left Fin Bolt A.7 A.8 Repair Notes: Pull the tail boom backwards to tighten the belt. Repair Notes: When the tension is correct, realign the tail boom by lining up the vertical fin with the side frame, and tighten the bolts using thread lock. The slots in the front t/r servo mounts will allow the servo to move with the boom. This eliminates the need to readjust the t/r pushrod length Check Tension Here Recheck belt tension. Tighten until it deflects 1/8” here. A.9 A.10 A.11 Tighten Viewed As 90° Angle Tighten Left Fin Bolt Page 86 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual B) T/R Grip/Bearing/Hub Removal If the t/r is damaged, the following outlines the correct procedure to remove the t/r grips. B.1 B.2 B.3 B.4 Repair Notes: To repair the t/r blade holders, bearings, bolts or hub, first remove the blade grips from the bearing stack. Then you can repair as necessary Trying to remove the center bolt with the grips still in place will result in problems. Hold hub and slide the grips off of the bearing stack Remove Bolts C) Remove Bolts, bearings, spacer, hub as necessary Main Blade Grip/Blade Axle Removal If the rotor head is damaged, it may be necessary to replace the blade axle. The following procedure outlines how to remove the blade grips/axle. C.1 C.2 C.3 Remove Links Repair Notes: To repair the main blade axle, blade grips or bearings, use the following procedure. Remove axle bolts using two allen drivers Note that it is slightly different than the original assembly procedure. C.5 C.6 C.7 C.4 Repair Notes: When you remove the axle bolts, typically only one of them will loosen up. Remove it as shown. Take care to not lose the washer inside, it can fall out however the bearing stack is captured. C.8 Repair Notes: Grasp the blade grip that the axle bolt was removed from and pull it off the axle as shown. Also remove the brass spacer from the exposed axle. Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 87 of 89 X-Cell Furion 450 Assembly Manual C.9 C.10 C.11 C.12 Repair Notes: Now Grasp the remaining grip and pull out the axle. To remove the axle from the remaining grip, grasp the axle and using an allen driver remove the remaining axle bolt from within the blade grip. C.13 Repair Notes: Replace any damaged parts as necessary. If you need to replace bearings inside the blade grip, you will need to remove both of the graphite plates from the blade holder before the bearings can be removed. Reassemble using thread lock as per assembly manual. Page 88 of 89 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Created: 8/27/2008 X-Cell Furion 450 Assembly Manual Created: 8/27/2008 Copyright Miniature Aircraft USA This document may not be distributed without permission of Miniature Aircraft USA Page 89 of 89
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