Alpha Unmanned Systems ALPHA 800 Bedienungsanleitung

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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

info@AlphaUnmannedSystems.com.

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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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MAINTENANCEMANUAL

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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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AIRCRAFTMAINTENANCEMANUAL

001.GeneralNotesonUAVMaintenance

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DEV‐M‐MMA800V1.7

MAINTENANCEMANUAL

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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

info@AlphaUnmannedSystems.com.

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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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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

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MAINTENANCEMANUAL

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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 

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Table2.EngineTorqueValues.

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CABLESANDCONNECTORS

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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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MAINTENANCEMANUAL

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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.

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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).

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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.

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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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