Alpha Unmanned Systems ALPHA 800 User manual

COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL
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complymayinvalidatetheUAVwarrantyandmayleadtoaccidents.Forfurtherinformationandthelatestupdatescontact
[e-mail].
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VersionRecord
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VersionDateDescription
1.009/01/2015InitialVersion
1.120/04/2015Manualupdatingandrebuild
1.210/04/2017Alpha800andfiscaladdressupdate
1.330/04/2019Section024(Switchboxbatteriesreplacement)and
025(AutopilotSWupdate)included
1.427/05/2019Alpha800partnumbersupdated
1.502/08/2019Manualupdate.Addedtorquevalues.Addedyearlyinspections
1.627/08/2019Naming&codingrulesimplementation
1.721/10/2019Partnumbering&namecorrelation.UpdatedforVisionair8
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL
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www.AlphaUnmannedSystems.com 2of143
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL

www.AlphaUnmannedSystems.com 3of143
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Sheet#000TitleINDEX
AppliestoUAVsAllAlphaUnmannedSystemsUAVs
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Sheet#Title
001GeneralNotesonUAVMaintenance
002ToolsKitsandEquipmentRequired
003Newservopreparation
004Swashplateservoreplacement
005Tailpitchservoreplacement
006Throttleservoreplacement
007Generalservocalibration
008Airfiltermaintenance
009Fuellineandfilterreplacement
010Carburetoradjustment
011Sparkplugchecks
012Camerareplacement
013Mainblademaintenance
014Silentblockmaintenance
015Maintenanceschedule
016Maintenancerecord
017Sparepartslist
018Setupinformation
019Drivebeltsreplacement
020Maingearreplacement
021Enginereplacement
022Onboardgeneratorreplacement
023GCSsparepartslist
024Switchboxbatteriesreplacement
025AutopilotSWupdate
026Joystickcalibration
027CarburetorDiaphragmsreplacement
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL
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www.AlphaUnmannedSystems.com 5of143
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AIRCRAFTMAINTENANCEMANUAL
001.GeneralNotesonUAVMaintenance
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL

www.AlphaUnmannedSystems.com 6of143
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Note:AllUAVMaintenancedocumentationisdesignedtosupplementthetraininggivenonAlphaUnmannedSystems'
comprehensiveUAVOperatorCourse.UAVMaintenancemustonlybecarriedoutbypersonsqualifiedonthatCourse;failureto
complymayinvalidatetheUAVwarrantyandmayleadtoaccidents.Forfurtherinformationandthelatestupdatescontact
[e-mail].

Sheet#001TitleGENERALNOTESONUAVMAINTENANCE
AppliestoUAVsAllAlphaUnmannedSystemsUAVs
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BACKGROUND
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1.‐ ThesenotesprovidetheintroductiontoAlpha'sseriesofUnmannedAerialVehicle(UAV)
MaintenanceSheetsCustomersaregivenaccesstotheSheetswhichcorrespondtotheUAV
system(s)purchased.
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INTRODUCTION
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2.‐ Incommonwithotheraircraft,UAVsarecomplexsystemswhichrequirethoroughand
regularmaintenanceiftheyaretoperformcorrectly.Failuretocompletethescheduled
maintenancetasksmayinvalidatetheUAVwarrantyandwillincreasetheriskofaccidents.
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LEVELSOFUAVMAINTENANCE
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3.‐ThemaintenanceofAlpha'sUAVsisdividedintotwolevels:
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UserLevelMaintenance:ThesubjectofMaintenanceSheetsandrelated
documentation.
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BaseOverhaul:CarriedoutbyAlpha'sownspecialistUAVTechnicians.
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DOCUMENTATION
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4.‐AllUAVMaintenancedocumentationisdesignedtosupplementthetraininggivenonAlpha
UnmannedSystems'comprehensiveUAVOperatorCourse.UAVMaintenancemustonlybe
carriedoutbypersonsqualifiedonthatCourse;failuretocomplymayinvalidatetheUAV
warrantyandmayleadtoaccidents.
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FLIGHTLOG
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5.‐ Inorderforthemaintenancescheduletobecompletedatthecorrectintervalsitisvital
thatalogoftheUAV'sflighthours,conditionsandperformanceismaintained.The
recommendedmethodistomaintainthisrecordbyusingUAVNavigation's'FlightLog'
software.
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL
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CUSTOMERSUPPORT
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6.‐Forfurtherinformation,andthelatestupdatescontact:
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Email:[email protected]
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SAFETY
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7.‐ Safetymustalwaysbethefirstpriority.Allnecessarysafetyprecautions,including
IndividualProtectiveEquipment,mustbeobservedwhencarryingoutmaintenance.Users
shouldbeparticularlyawareoftherisksofelectricalshort‐circuits(especiallywithLithium
Polymerbatteries).
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8.‐ Specialcaremustbetakenwheneveranenginetestisconducted.Ensurethatnobodyis
withinthedangerradiusofaspinningblade,andthattheUAVissecurelyanchoredwhenever
anengineistestedinaworkshopenvironment.
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PRIORTOMAINTENANCE
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9.‐Beforecarryingoutanymaintenancetasks,ensurethefollowing:
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TheUAVhasagasolineengine,removeallfuel.
Switchoffallelectricalsystems.
Disconnectallonboardbatteriesbeforemaintaininganyoftheelectricalsystems.
Donotchargeanyonboardbatterywhilstcarryingoutmaintenance.
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THREADLOCK
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10.‐Unlessotherwisestated,itisvitalthatengineeringthreadlock(Loctite222orblueLoctite
243,dependingontheapplication)isusedonallboltsandgrubscrewswherethereismetalto
metalcontact.ThisisparticularlyimportantingasolinepoweredhelicoptertypeUAVs,which
experiencehighlevelsofvibration.Threadlockissuppliedaspartofthestandardtoolkitwith
allAlphaUAVs.
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FASTENERSTORQUEVALUES
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11.‐ Propertorqueiscritical.Alwaysusecalibratedwrenchesandundamagedhardware.
Ensureallclampingsurfacesarecleanandnoforeignobjectsarecaughtinbetween.Improper
torqueordirtysurfacesmayresultinlossofclamp‐up,hardwareorpartdamage,and
prematurefailure.
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12.‐Fastenersshallbetorquedtostandardvalueslistedinthefollowingtableunlessotherwise
specified.Torquesealpaintisappliedtoallcriticalfastenersafterinstallation,inastripe

COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL
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www.AlphaUnmannedSystems.com 8of143
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extendingfromthefastener’sexposedthreadsacrossthenutontothecomponent.Any
subsequentrotationofthenutorboltcanbedetectedvisually.
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Nominal
Thread
Dia.mm
Class8.8Class9.8Class10.9Class12.9Class14.9
Coarse
Nm
Fine
Nm
Coarse
Nm
Fine
Nm
Coarse
Nm
Fine
Nm
Coarse
Nm
Fine
Nm
Coarse
Nm
Fine
Nm
1.60.20  0.23  0.29  0.34  0.40 
20.42  0.47  0.58  0.70  0.82 
2.50.85  0.96  1.2  1.44  1.7 
31.5  1.7  2.1  2.6  3.0 
43.5  4.0  5  6  7.0 
57.1  8.0  10  12  14 
612.1  13.6  17  20.4  23.8 
720.3  22.8  28.6  34.3  40.0 
829.431.533.135.441.344.349.653.257.962
1058.3616669828698104115121
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Table1.StandardTorqueValues.
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13.‐Engineboltsshallbetorquedtothefollowingvalues.
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ItemsScrewSizeStandard(Nm)Limit(Nm)Remarks
CarburetorM5(P=0.8)3.42.9‐3.9 
InsulatorM5(P=0.8)4.43.9‐4.9Threadlocker
ClutchM6(P=1.0)6.44.9‐7.8 
RotorM8(P=1.0)12.79.8‐14.7 
CylinderM5(P=0.8)6.84.7‐8.8 
CrankcaseM5(P=0.8)6.44.9‐7.8 
SparkPlugM10(P=1.0)10.88.8‐12.8 
MufflerM5(P=0.8)8.86.9‐9.8 
FanCoverM5(P=0.8)3.42.9‐3.9 
IgnitionCoilM4(P=0.7)3.22.5‐3.9 
StarterCaseM4(P=0.7)1.31.0‐2.5 
TappingScrewTP4.32.41.9‐2.9 

Table2.EngineTorqueValues.

CABLESANDCONNECTORS

14.‐Cablesandconnectorsareoneofthemostimportantpartofthesystem.Theyallowfor
communicationbetweendifferentcomponentsandprovideelectricalpowerwhereitis
required.Keepingtheminperfectconditionisvitalfortheperformanceoftheequipment
andthesafetyoftheoperation.MostofthecablesareaffixedtothestructureoftheUAVand
arenotmeanttoberemovedunlesssomemaintenanceisrequired.However,someother
cablesaredesignedtobeconnectedanddisconnectedineveryoperation.Theselasttypeof

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www.AlphaUnmannedSystems.com 9of143
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cablesandconnectorsrequirespecialcareandattentionfromtheoperatortobekeptin
operatingcondition.

15.‐Visualinspectionofthecablesandconnectorsmustbecarriedoutineverypreflightcheck
andattheproperintervalsindicatedintheMaintenanceSchedule(Reference:AMMSheet
015).

16.‐ Inthisinspectionoperatormustvisuallycheckthefulllengthofthecables,looking
carefullyforanysignsofwearorrippedoffsheath.Exposedorcutwiresarereasonfor
immediatesubstitution.Cablesmustbecleananddryfromoilormoisture.Sandorgritmust
becleanedoutaswell,asitcontributestoprematurewearofthecable.Operatormustpay
specialattentioninthesurroundingsofconnectorsascablesaremostlikelytobreakinthose
zones.

17.‐ Connectorsmustbecarefullyinspectedaswell.Allpinsinmaleconnectorsshouldbe
straightandleveled.Theyalsomustbecleananddry.Operatorwillavoidlettingthe
connectorsfallorlayonthegroundassandordirtcouldingressandcausemalfunctions.
Specialcontactcleaner(Suchas‘WD‐40ElectricalContactCleaner’orsimilar)shouldbeusedif
thecontactors(pinsorsockets)arefoundtobewetordirty.Connectorsonpanelsor
equipmentthataresubjecttorepeatedconnectionsarelikelytobeinspectedandcleanedas
well.Lockingringsmustmovesmoothlywithnosignsofbindingorgritting.

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www.AlphaUnmannedSystems.com 10of143
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL

www.AlphaUnmannedSystems.com 11of143
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AIRCRAFTMAINTENANCEMANUAL
002.ToolsKitsandEquipmentRequired
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL

www.AlphaUnmannedSystems.com 12of143
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Note:AllUAVMaintenancedocumentationisdesignedtosupplementthetraininggivenonAlphaUnmannedSystems'
comprehensiveUAVOperatorCourse.UAVMaintenancemustonlybecarriedoutbypersonsqualifiedonthatCourse;failureto
complymayinvalidatetheUAVwarrantyandmayleadtoaccidents.Forfurtherinformationandthelatestupdatescontact
[e-mail].

Sheet#002TitleTOOLKITSANDEQUIPMENTREQUIRED
AppliestoUAVsAllAlphaUnmannedSystemsUAVs


Introduction
ItisimportantthatthecorrecttoolsareusedwhenmaintainingAlphaUAVs.Thefollowingtoolsare
suppliedaspartofthestandardMaintenanceToolKitforallUAVs.ToolsspecifictoaparticularUAVare
indicated.
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ToolsandEquipment
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ToolBox
Spanners(metric,varioussizes)
Screwdrivers(flatandcross‐head,varioussizes)
Allenwrenches(metric,varioussizes)
Longnosepliers
Balllinkpliers
Standardpliers
Sparkplugspanner
Feelergauges
Servotester
Precisioncablecutter/scissors
Cableties(varioussizes)
Cableprotectivesheath
Heatshrinktubing(varioussizes)
Fueltubesecuringwire
Scalpel
Engineeringthreadlockcompound(Loctite222/243)
Caliber
Bladepitchgauge
Extractorscrew
Assemblyspanner
SuitableTorqueWrench

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www.AlphaUnmannedSystems.com 13of143
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AIRCRAFTMAINTENANCEMANUAL
003.NewServoPreparation
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL

www.AlphaUnmannedSystems.com 14of143

Note:AllUAVMaintenancedocumentationisdesignedtosupplementthetraininggivenonAlphaUnmannedSystems'
comprehensiveUAVOperatorCourse.UAVMaintenancemustonlybecarriedoutbypersonsqualifiedonthatCourse;failureto
complymayinvalidatetheUAVwarrantyandmayleadtoaccidents.Forfurtherinformationandthelatestupdatescontact
[e-mail].

Sheet#003TitleNEWSERVOPREPARATION
AppliestoUAVsAllAlphaUnmannedSystemsUAVs
SpecialToolsRequiredServotester
Time(approx.)15mins


Introduction
WhenreplacingaServoBLA1HH21(010124243)ononeofAlpha'sUAVsitisimportanttoensurethatthe
servoiscorrectlycenteredandcalibratedbeforeinstallation.Theservohornmustalsobecorrectly
preparedforuse.Thisensuresthatthecontrolinputsgeneratedinautomaticandmanualflightbythe
autopilot(010139269)resultinthebestperformancefromtheUAV.ThisMaintenanceSheetdescribes
howtoprepareabrandnewservo,assuppliedbyAlpha,beforeinstallingitintheUAV.

Note:itisarecommendabletotakereferencephotosofanexistingservoinstallationandorientation
beforeremovingittoaidwithnewservoinstallation.
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StepbyStepProcedure
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Step1‐InsertthefourServorubberDamper(010153318)
(suppliedwitheachnewservo).
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Step2‐TheServodamperbush(010153319)(alsosupplied
witheachnewservo)shouldbeinsertedsothattheflanged
partfitsagainstthechassiswhentheservoismounted.
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
www.AlphaUnmannedSystems.com 15of143
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Step3‐Removeretainingscrewandservohorn.
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Step4‐RefertotheappropriateMaintenanceSheet018
('SetupInformation')fortheexactdistancethattheball‐link
2.5mm(010153210)mustbemountedfromtheservooutput
shaft.
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Step5‐Usinga2mmbit,drillaholeintheservoarmtomount
theball‐linkatthecorrectdistance.
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Step6‐Fixtheball‐link(suppliedbyAlpha)totheservohorn
andsecureusingthreadlock.
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

COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL

www.AlphaUnmannedSystems.com 16of143
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Step7‐Trimdowntheendoftheservohorntoavoid
unnecessarychafing,takingcarenottodamageorfileawayany
oftheball‐link.
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Step8‐Usingtheservotester,positiontheservooutputshaft
sothatitisexactlyatitscenterposition(1500µs).
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Step9‐Maintainingtheservooutputshaftatexactlythecenter
position,mounttheservohornontotheshaft.Thisisnormally
atexactly90ºasshown,butthereareexceptions.Again,see
theappropriateMaintenanceSheetfordetailsfortheservo
beingreplaced.Donotforgettoreplacetheretainingscrew
oncethehornisinplace.Itmaybenecessarytotrimthefinal
positionoftheservohornusingtheservotester.
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Step10‐Itisimportanttoensurethattheservocableis
correctlyprotectedandsecuredtopreventdamagecausedby
chafingorvibration.Ifnecessary,protectthecableusing'snake
skin'sheathandheatshrinktubingtosecuretheendsasshown
ontheUAVOperatorTrainingCourse.
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL

www.AlphaUnmannedSystems.com 17of143
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AIRCRAFTMAINTENANCEMANUAL
004.SwashplateServoReplacement
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL

www.AlphaUnmannedSystems.com 18of143
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Note:AllUAVMaintenancedocumentationisdesignedtosupplementthetraininggivenonAlphaUnmannedSystems'
comprehensiveUAVOperatorCourse.UAVMaintenancemustonlybecarriedoutbypersonsqualifiedonthatCourse;failureto
complymayinvalidatetheUAVwarrantyandmayleadtoaccidents.Forfurtherinformationandthelatestupdatescontact
[e-mail].
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Sheet#004TitleSWASHPLATESERVOREPLACEMENT
AppliestoUAVsALPHA800
SpecialToolsRequiredBalllinkpliers
Time(approx.)60mins
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Introduction
AllAlphahelicopter‐typeUAVsarefittedwithaswashplate(010162114)whichiscontrolledbyservos,
givingtheabilitytochangecollectiveorcyclicpitch.Itisvitalthattheswashplateservosareworking
correctlyforahelicopter‐typeUAVtoflysafely.ThisMaintenanceSheetdetailsagenericprocedurefor
replacementofthistypeofservo.Notethatsomeswashplatesarefittedwith3servos,whilstothershave
4.Theremayalsobeminordifferencesinthepositioningofservosandthemethodofattachingthe
controlrodsfromtheoutputhornstothebladegripassembly.
Whenreplacingaswashplateservo,itisrecommendabletotakephotosoftheexistinginstallationtoact
asaguideforinstallationofthenewservo.
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StepbyStepProcedure
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Step1‐Disconnecttheballlinks2.5mm(010153210)usingball
linkpliers,removethecontrolrodandstoreitcarefully.
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Step2‐UndothetwoboltsISO4762A2–M3x20(000000769)
thatretaintheswashplateguide(010153287)andremoveit.
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COMMERCIALINCONFIDENCE
DEV‐M‐MMA800V1.7
MAINTENANCEMANUAL

www.AlphaUnmannedSystems.com 19of143
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Step3‐RemovetheRotorShaftSupportplate(010153284)
reatainingboltsISO4762A2‐M3x8(000000701)
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Step4‐Oncethemainshafthasbeencompletelyremoved,
undothefourISO4762A2‐M2.5x12mm(000000721)cap
headboltswhichfixtheservotothechassis(photoshowsthe
nylocnutsbeingheldsecurelywhilsttheboltisunscrew).
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Step5‐UnplugtheservofromthePowerandCommunications
Module(PCM)(010139111)byunscrewingtheconnectorand
removeanycablestiesusedtosecurethecable.
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Step6‐TheservocannowberemovedfromtheUAV.
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