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Alpha Unmanned Systems ALPHA 800 Aircraft Maintenance Manual Download Page 117

 

COMMERCIAL

 

IN

 

CONFIDENCE

 

DEV

‐

M

‐

MM

 

A800

 

V1.7

 

MAINTENANCE

 

MANUAL

 

 

                                      

www.AlphaUnmannedSystems.com

 

      

116

 

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

 

[email protected]

.

 

 

Sheet

 

#

 

024

 

Title

 

Switch

 

box

 

batteries

 

replacement

 

Applies

 

to

 

UAVs

 

ALPHA

 

800

 

Special

 

Tools

 

Required

 

‐ 

Time

 

(approx.)

 

60

 

min

 

 
 

Introduction

 

Batteries

 

inside

 

the

 

Switch

 

box

 

(010124110)

 

are

 

backup

 

in

 

case

 

of

 

generator

 

failure

 

or

 

during

 

the

 

preflight

 

checks.

 

Inside

 

the

 

Switch

 

Box

 

there

 

are

 

TWO

 

batteries,

 

one

 

LIFEPO4

 

5S

 

and

 

one

 

LIPO

 

3S.

  

 
 
 

Step

 

by

 

Step

 

Procedure

 

 
 
 

 

 

Step

 

1

 

–

 

Unplug

 

the

 

generator

 

and

 

power

 

supply

 

cables

 

from

 

the

 

Switch

 

Box

  

 

 

Step

 

2

 

–

 

Remove

 

the

 

Switch

 

Box

 

Base

 

Plate

 

(010153270)

 

with

 

the

 

Switch

 

Box

 

installed.

  

 
 
 
 
 
 

 
 

Summary of Contents for ALPHA 800

Page 1: ......

Page 2: ...te 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 implemen...

Page 3: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 2 of 143 PAGE INTENTIONALLY LEFT BLANK ...

Page 4: ...ement 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 O...

Page 5: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 4 of 143 PAGE INTENTIONALLY LEFT BLANK ...

Page 6: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 5 of 143 AIRCRAFT MAINTENANCE MANUAL 001 General Notes on UAV Maintenance ...

Page 7: ...omplex 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 LEVELS OF UAV MAINTENANCE 3 The maintenance of Alpha s UAVs is divided into two levels User Level Maintenance The subject of Maintenance Sheets and related documentation Base Overha...

Page 8: ... all electrical systems Disconnect all onboard batteries before maintaining any of the electrical systems Do not charge any onboard battery whilst carrying out maintenance THREAD LOCK 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 part...

Page 9: ...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 Scre...

Page 10: ...il 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 co...

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Page 12: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 11 of 143 AIRCRAFT MAINTENANCE MANUAL 002 Tools Kits and Equipment Required ...

Page 13: ...manned 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 Tools and Equipment Tool Box Spanners metric various sizes Screwdrivers flat and cross head various sizes Allen wrenches metric various sizes Long nose...

Page 14: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 13 of 143 AIRCRAFT MAINTENANCE MANUAL 003 New Servo Preparation ...

Page 15: ...4243 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 s...

Page 16: ...efer 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 Step 5 Using a 2mm bit drill a hole in the servo arm to mount the ball link at the correct distance Step 6 Fix the ball link supplied by Alpha to the servo horn and secure using thread lock ...

Page 17: ...ount 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 Step 10 It is important to ensure that the servo cable ...

Page 18: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 17 of 143 AIRCRAFT MAINTENANCE MANUAL 004 Swashplate Servo Replacement ...

Page 19: ...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...

Page 20: ... 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 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 Step 6 The servo can now be r...

Page 21: ...is required then use the information supplied in the Maintenance Sheet 003 New Servo Preparation for the UAV to prepare one Step 8 Replacement is the reverse of the above procedure taking care to orientate the servo rubber dampers 010153318 and brass eyelets correctly Ensure also that the cable routing is exactly the same as the original and that the cable does not come into contact with any movin...

Page 22: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 21 of 143 AIRCRAFT MAINTENANCE MANUAL 005 Tail Pitch Servo Replacement ...

Page 23: ...mins Introduction Yaw control in helicopter type UAVs is achieved by varying tail blade pitch controlled by the tail pitch servo It is vital that this servo is working correctly and that it is calibrated Without this the autopilot will not be able to control yaw resulting in poor flight performance or an accident Depending on the UAV the tail pitch servo may be mounted on the main chassis and conn...

Page 24: ...actly the same type as the one being replaced If a new servo horn is required then use the information supplied in the Maintenance Sheet 018 Setup Information for the UAV to prepare one Step 5 Mechanically install the new servo and connect to the electrical system Use the photos you have taken to aid correct installation Step 6 Calibrate the servo in accordance with Maintenance Sheet 007 General S...

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Page 26: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 25 of 143 AIRCRAFT MAINTENANCE MANUAL 006 Throttle Servo Replacement ...

Page 27: ...cial Tools Required Ball link pliers User Tools with Internal Pilot Time approx 60 min Introduction This generic procedure details the steps required to replace the throttle servo 010172123 for any gasoline engine UAV manufactured by Alpha It is vital that the servo is correctly calibrated see also separate Maintenance Sheet Servo Calibration Step by Step Procedure Step 1 If it is necessary to gai...

Page 28: ...ation Note the servo must be exactly the same type as the one being replaced If a new servo horn is required then use the information contained in the appropriate Maintenance Sheet 018 Setup Information to prepare one Step 5 Mechanically install the new servo and connect to the electrical system Remove the main blades Step 6 Power on electrical systems Do not start the engine yet While the servos ...

Page 29: ... left stick up trim up Important check that the direction of servo travel is correct minimum throttle commanded on Joystick must equal minimum throttle on carburetor throttle lever and vice versa Step 9 Once you are satisfied that the direction and limits of servo travel are correct and that there is no binding in the system proceed to carry out an engine test Continue with the normal pre flight c...

Page 30: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 29 of 143 AIRCRAFT MAINTENANCE MANUAL 007 General Servo Calibration ...

Page 31: ... control the servos must be correctly calibrated and centered The autopilot 010139269 must also be programmed with the limits of servo movement in either direction to avoid chafing This generic procedure details the steps required to calibrate any UAV servo with the User Tools it assumes that the new servo has been prepared in accordance with Maintenance Sheet New servo preparation Step by Step Pr...

Page 32: ...horn Step 4 Power on the UAV s autopilot and servos and then launch Visionair More windows Configuration tools Step 5 Check that the correct type of servo digital normal is chosen in the User Tools GPIO Step 6 Set the correct type of servo functionality aileron elevator throttle etc and that the servo direction of rotation is correct reverse if necessary ...

Page 33: ...N CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 32 of 143 Step 7 Set the correct minimum value in User Tools default 0 Step 8 Set the correct maximum value in User Tools default 1000 ...

Page 34: ...ll range The servo and control pushrod must not push mechanical limit If necessary conduct minor adjustments to the servo range with User Tools The servo must reach the maximum mechanical travel required without pushing it Now repeat the step this time for the maximum servo range in the opposite direction Step 12 With the Joystick lever and trim centered adjust the center and limits µs value so th...

Page 35: ...e UAV control the servos must be correctly calibrated and centered The autopilot 010139269 must also be programmed with the limits of servo movement in either direction to avoid chafing This generic procedure details the steps required to calibrate any UAV servo with the User Tools it assumes that the new servo has been prepared in accordance with Maintenance Sheet New servo preparation Step by St...

Page 36: ...and servos and then launch Visionair 8 Tools Menu Config tool Step 5 Check that the correct type of output PWM is chosen in the GPIO s tab Config Tool GPIOs Click Download If there is any change click Upload Step 6 Go to Servos tab and click Download Set the correct type of servo functionality aileron elevator throttle etc and that the servo direction of rotation is correct reverse if necessary ...

Page 37: ...ONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 36 of 143 Step 7 Set the correct minimum value in Config Tool default 1050 Step 8 Set the correct maximum value in Config Tool default 1950 ...

Page 38: ...push mechanical limit If necessary conduct minor adjustments to the servo range with Config Tool The servo must reach the maximum mechanical travel required without pushing it Now repeat the step this time for the maximum servo range in the opposite direction e g left stick Up trim Up Step 12 With the Joystick lever and trim centered adjust the center and limits µs value so that the observed servo...

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Page 40: ...9 of 143 AIRCRAFT MAINTENANCE MANUAL 008 Air Filter Maintenance 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 ...

Page 41: ...tion A clean Airfilter 010172343 is vital not only for correct engine performance but also to prevent damage to the engine caused by FOD ingress Step by Step Procedure Step 1 Visually check the Airfilter for damage or blockage caused by dirt Filters can also be damaged by excessive moisture If in any doubt the filter must be replaced with a new identical item from Alpha Step 2 To remove loosen the...

Page 42: ... Step 4 Compressed air can be used to clean the airfilter note that the direction of airflow must be from inside to outside as shown Step 5 if in any doubt replace the airfilter with a new item from Alpha Installation is the reverse procedure Name Part Number IPC Page Engine Subassembly 010172120 22 Arifilter 010172343 22 Engine 010172341 22 Airfilter Clamp 010172343 22 Carburetor WT 990 010172780...

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Page 44: ...143 AIRCRAFT MAINTENANCE MANUAL 009 Fuel Line and Filter Replacement 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 ...

Page 45: ...ed or blocked fuel line and or filter can lead to poor engine performance or at worst engine stoppage Note that dirt in the fuel system is indicative of poor refueling procedures or a lack of maintenance of the UAV s fuel tank 60 oz 010128205 Step by Step Procedure Step 1 Visually check the general condition of the fuel lines and filter for leaks and signs of blockage It may be necessary to pull o...

Page 46: ...king care to prevent fuel spillages Old filters must be discarded They must not be cleaned or reused Step 5 Use the old fuel line as a template to cut a new piece of tubing Important do not use silicon tubing with gasoline fuel systems Step 6 The fuel filter must be installed in the correct orientation The photo shows fuel flow through the filter towards the engine 010172341 from the fuel tank Nam...

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Page 48: ... 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 ...

Page 49: ... part of pre flight checks on the ground For helicopters a good test of engine performance is the vertical climb out at maximum positive pitch from hover in manual mode the helicopter must climb smoothly with adequate power to maintain tail authority After climb test is performed operator must engage hover mode and check that the GOVERNOR RPMs are reached and maintain easily without excessive vari...

Page 50: ... 010172776 see separate Maintenance Sheet Spark Plug Checks If necessary or in any doubt the spark plug s NGK CMR7H must be replaced with new items from Alpha Step 3 Once the condition of the spark plugs NGK CMR7H is confirmed the mixture can now be adjusted To adjust the mixture first identify the needles on the carb body They are normally marked H High and L Low Some carbs will have only one nee...

Page 51: ...r details Step 6 Once the selected needle has been adjusted test the result via an engine test again paying attention to engine starting performance at idle when warm performance at normal operating revs ensuring that the typical values for your configuration are reached Remember to inspect the exhaust and spark plug NGK CMR7H condition regularly in order to monitor carb adjustment Name Part Numbe...

Page 52: ... 51 of 143 AIRCRAFT MAINTENANCE MANUAL 011 Spark Plug Checks 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 ...

Page 53: ... work at optimum efficiency and reliability If in any doubt the spark plug must be replaced with a new item supplied by Alpha The procedures below shows how to check spark plug general condition and also for the correct gap Step by Step Procedure Step 1 Disconnect the high tension lead and remove the Spark Plug NGK CMR7H 010172776 using only the correct spanner Step 2 Inspect the spark plug Assumi...

Page 54: ...h an over rich mixture i e too much fuel in the mixture Typical symptoms of an over rich mixture include electrodes which have heavy carbon deposits left and or are oily right Step 5 If visual inspection shows that the spark plug is serviceable then lightly clean the electrodes using a soft wire brush to remove any small carbon deposits which may give false readings Step 6 Check the spark plug gap...

Page 55: ...0 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 54 of 143 Name Part number IPC Page Spark Plug NGK CMR7H 010172776 22 Carburetor WT 990 010172780 22 Engine 010172341 22 Step 7 Installation of the spark plug is the reverse procedure ...

Page 56: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 55 of 143 AIRCRAFT MAINTENANCE MANUAL 012 Camera Replacement ...

Page 57: ...ntroduction The camera system in any Alpha UAV is a Base Repair item The unit is not to be adjusted opened or tampered with by the user doing so will invalidate the warranty If the camera develops a fault then the entire unit must be sent to Alpha for repair or replacement This Maintenance Sheet details the generic instructions for removing and remounting cameras in Alpha UAVs When sending a camer...

Page 58: ...he retaining bolts which run around the perimeter of the cowling Having removed the cowling retaining bolts the cowling camera assembly can be lowered away from the fuselage Step 7 The camera should now be separated from its housing by removing the bolts normally 4 in total If the camera is mounted directly to the anti vibration rubber dampers take care that these are not damaged by twisting when ...

Page 59: ...ort case and arrange for it to be returned to Alpha for service When reinstalling a camera ensure that the original retaining bolts are used and that the connector is securely fastened The cable must be secured with zip ties to ensure that it does not interfere with the camera s movement or suffer from vibration Name Part Number IPC Page Canopy 010153201 1 ...

Page 60: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 59 of 143 AIRCRAFT MAINTENANCE MANUAL 013 Main Blade Maintenance ...

Page 61: ...ade balancer digital scales Time approx 20 mins Introduction The blades on Alpha s helicopter type UAVs need little maintenance but they must be in perfect condition in order to avoid vibration and to maximize flight performance Blade failure in flight will almost certainly result in the loss of the UAV If a blade is damaged during storage or transit then it must be carefully checked and replaced ...

Page 62: ...ntical items as supplied by Alpha Blades must always be replaced as pairs Step 6 When replacing blades in the blade grips ensure that they are fitted the correct way round tail blades always rotate clockwise as viewed from the right side of the UAV but main blades must rotate anti clockwise in ALPHA 800 as viewed from the top side of the UAV Step 7 The blade grip must be tightened adequately For m...

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Page 64: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 63 of 143 AIRCRAFT MAINTENANCE MANUAL 014 Rubber Dampers Maintenance ...

Page 65: ...e vibrations transmitted from the airframe to the autopilot Failure to maintain these rubber dampers will result in poor autopilot performance and may lead to total loss of control of the UAV in flight Similarly it is vital that the autopilot is not secured in any other way to the airframe e g using cable ties adhesive double sided tape etc the rubber dampers must be free to move naturally thereby...

Page 66: ... each rubber damper individually for damage as shown in the photo If in any doubt the rubber dampers must be replaced as a set of 4 with new identical items from Alpha Step 5 If it is necessary to remove the connectors for any reason be sure to make a note of which connector goes where take a photo and or mark them accordingly Step 6 When reinstalling an autopilot onto its rubber damper mounts use...

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Page 68: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 67 of 143 AIRCRAFT MAINTENANCE MANUAL 015 Maintenance Schedule ...

Page 69: ...e Flight 50 FH 100 FH 150 FH Yearly 200 FH ENGINE AND TRANSMISSION Air filter maintenance AMM 008 Carburetor Diaphragms replacement AMM 027 Every 10 FH Fuel line and filter replacement AMM 009 Spark plug checks AMM 011 Drive belts primary tail and generator AMM 019 Main gear pinion AMM 020 Engine overhaul replacement AMM 021 Carburetor adjustment AMM 010 Clutch clutch liner AVIONICS Swashplate ser...

Page 70: ...n or at the client s facilities by arrangement A certificate of maintenance and condition report will be issued by Alpha Once the 200 hour Base Overhaul has been carried out the maintenance sequence starts again from 0 hours 50 hours 100 hours etc 2 This maintenance schedule assumes that all items are found to be functioning correctly during pre flight checks if any item is found to be damaged fau...

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Page 72: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 71 of 143 AIRCRAFT MAINTENANCE MANUAL 016 Maintenance Record ...

Page 73: ...y lead to accidents For further information and the latest updates contact info AlphaUnmannedSystems com Sheet 016 Title MAINTENANCE RECORD Applies to UAVs ALPHA 800 ALPHA 800 SERIAL NUMBER Maintenance Interval 50 hours Date Completed Technician Name capitals Technician Signature Stamp Maintenance Interval 100 hours Date Completed Technician Name capitals Technician Signature Stamp Maintenance Int...

Page 74: ...hnician sig Maintenance Interval 70 hours Date Technician sig Maintenance Interval 80 hours Date Technician sig Maintenance Interval 90 hours Date Technician sig Maintenance Interval 100 hours Date Technician sig Maintenance Interval 110 hours Date Technician sig Maintenance Interval 120 hours Date Technician sig Maintenance Interval 130 hours Date Technician sig Maintenance Interval 140 hours Dat...

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Page 76: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 75 of 143 AIRCRAFT MAINTENANCE MANUAL 017 Spare Parts List ...

Page 77: ...010124397 Alpha 800 LiFe batteries 1 010124398 Alpha 800 Main Rotor Blades 1x Set of 2 matched blades 010162200 Alpha 800 Tail Rotor Blades 1x Set of 2 matched blades 010164240 Alpha 800 Spark Plug 3 010172776 Alpha 800 AirFilter 3 010172343 Alpha 800 Primary Transmission Drive Belt 3 010153282 Alpha 800 Tail Rotor Drive Belt 3 010164248 Alpha 800 Control Rod Set various sizes 3 010162102 01016413...

Page 78: ...0200 ALPHA 800 Fairing Canopy 1 010153101 Molded rubber damper ZH3 Damper 1x Set of 4 units 010153239 Silicone gel shock mount 1x Set of 4 units 010153316 Octopus shock mount 1x Set of 4 units 010153317 ALPHA 800 GPS Antenna TW2410 1 010134785 ALPHA 800 Data Link Antenna 1 010134377 ALPHA 800 Transport Case 1 020500100 ALPHA 800 Fuel tank set left and right tank 1 set 010128205 ALPHA 800 Front lan...

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Page 80: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 79 of 143 AIRCRAFT MAINTENANCE MANUAL 018 Setup Information ...

Page 81: ...cidents For further information and the latest updates contact info AlphaUnmannedSystems com Sheet 018 Title SETUP INFORMATION Applies to UAVs ALPHA 800 CONTROL PUSHRODS SERVO HORNS For control pushrods measurement is taken from center of ball link or clevis at either end of the control pushrod For servo horns the length is measured from the center of servo output shaft to center of hole in servo ...

Page 82: ...Ball link 060 7 Swashplate 3 servo 19 2 5 Ball link 060 7 Swashplate 4 servo 19 2 5 Ball link 060 7 Note To perform the following adjustments User must activate Pure Manual mode clicking the appropriate button in Visionair Config Tool Servos Tab TAIL PITCH Tail pitch for the ALPHA 800 is set using digital caliper to measure the distance from the tail rotor hub 5mm 010164238 to the tail slider 0101...

Page 83: ...ee throttle positions down center and up Step 1 Check visually that the swashplate 010162114 is leveled in all positions throttle down throttle center and throttle up Step 2 Place the blades pitch measuring tool in the last third of the blade and throttle stick at the lowest It must have between 3 and 4 degrees Important Throttle trim must be at center Step 3 Maximum tail pitch full LEFT yaw 15mm ...

Page 84: ...mannedSystems com 83 of 143 Step 3 Put the throttle stick in the center It must have between 7 and 8 degrees Important Throttle trim must be at center Step 4 Put the throttle stick in the maximum It must have between 12 and 13 degrees Important Throttle trim must be at center ...

Page 85: ...tick to reach 0 degrees Step 2 Roll degrees must be measured with the blades set to 0º and parallel to the ALPHA 800 heading Full roll left right with the joystick should be 6º Important Roll trim must be at center Step 3 Pitch elevator degrees must be measured with the blades set to 0º and perpendicular to the ALPHA 800 heading Full pitch up down with the joystick should be 6º Important Elevator ...

Page 86: ... Alpha CARBURETOR WT 990 SETUP The ALPHA 800 carburetor WT 990 010172780 has two needles with the following standard setup adjust as necessary in accordance with separate Maintenance Sheet Carburetor Adjustment Step by Step Procedure Step 1 First adjust the LOW needle by screwing all the way in CLOCKWISE Step 2 Now turn the needle ANTICLOCKWISE out 1 1 2 turns This is the standard setting for the ...

Page 87: ... V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 86 of 143 Name Part Number IPC Page Tail rotor hub 5mm 010164238 7 Tail slider 010164109 7 Main Rotor Blades 010162200 1 Carburetor WT 990 010172780 22 SPARK PLUG NGK CMR7H 010172341 22 ...

Page 88: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 87 of 143 AIRCRAFT MAINTENANCE MANUAL 019 Drive Belts Replacement ...

Page 89: ...haUnmannedSystems com Sheet 019 Title DRIVE BELTS REPLACEMENT Applies to UAVs ALPHA 800 Special Tools Required Time approx 120 min Introduction It is vital that the ALPHA 800 s drive belts are replaced at regular intervals as shown in the ALPHA 800 Maintenance Schedule Any belt which shows signs of excessive wear must also be replaced immediately There are 3 belts which require maintenance Tail ro...

Page 90: ...ep 3 Remove the tail hub Step 4 Undo the bolts 000000702 and remove the tail fin holder 010153246 Step 5 Loosen the 4 top bolts ISO 4762 A2 M3 x 8 and left bolts ISO 7040 A2 M3 000000736 from the tail boom support 010153303 Step 6 Loosen the Socket Head Cap Screw M3x55 010153278 from the tail boom support ...

Page 91: ...Loosen the screw which fix the tail strut tube 010153230 to the tail tube 010164228 Step 8 Push forward the tail tube to release tension in tail rotor belt 010164248 Step 9 Loosen the tail shaft grub screw and remove the tailrotor shaft 010164250 Step 10 Push down the tail rotor pulley 010164107 and remove it ...

Page 92: ...143 Step 11 Pull out the tail gear housing 010164245 to remove it Step 12 Loosen the grub screws from the generator and tail rotor drive pulley 010164326 Step 13 Loosen the generator base plate 010153310 bolts to release tension Step 14 Release generator belt 010153283 and tail rotor belt 010164248 ...

Page 93: ...ngthener 010153302 Step 16 Loosen the secondary gear grub screw ISO 4026 A2 M5 x 5 2 000000769 Then push up the secondary Spur gear 18T 010153297 to remove it Step 17 Loosen the bolt ISO 4762 A2 M4 x 20 000000713 from the plastic engine support 010172346 mounts on both sides Step 18 Loosen the four ISO 4762 A2 M5 x 16 000000718 bolts which secure the engine to the lower chassis ...

Page 94: ...pulley 010153281 Step 22 Now we can remove the generator and tail rotor belt Step 23 Pull out the tail belt to remove it Step 24 Tail rotor and generator belt installation is the reverse procedure Check that the vertical fin is align vertically WARNING Tail rotor belt is twisted 90º CW looking forward from the rear from the front horizontal tail rotor drive pulley to the tail rotor vertical pulley...

Page 95: ...nstall the belt correctly could lead to complete loss of the aircraft and payload Tension belts The tail rotor belt tension is set correctly when you can push the belt with your finger in the red point about 12 14mm without moving the ALPHA 800 The drive and generator belt tension is set correctly when you can push the belt with your finger in the center about 6 8mm without moving the ALPHA 800 ...

Page 96: ... M3 x 8 000000701 3 ISO 7040 A2 M3 000000736 9 bis Tail boom support 010153303 15 Socket Head Cap Screw M3x55 010153278 9 bis Tail Strut Tube 010153231 4 Tail Tube 010164228 3 Tailrotor Shaft 010164250 3 Tail Rotor Pulley 010164107 3 Tail Rotor Drive Pulley 010164326 3 Tail gear housing 010164245 3 Generator base plate 010153310 17 Frame Strengthener 010153302 15 Secondary Spur gear 18T 010153297 ...

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Page 98: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 97 of 143 AIRCRAFT MAINTENANCE MANUAL 020 Main Gear Replacement ...

Page 99: ...tact info AlphaUnmannedSystems com Sheet 020 Title MAIN GEAR REPLACEMENT Applies to UAVs ALPHA 800 Special Tools Required Ball link pliers Time approx 40 mins Introduction It is vital that the ALPHA 800 s main gear Delrin Spur Gear 90T 010153296 is replaced at regular intervals as shown in the maintenance schedule If the main gear shows signs of excessive wear it must also be replaced immediately ...

Page 100: ...ISO 4762 A2 M3 x 8 000000701 bolts in Rotor Shaft Support plate 010153284 Step 4 Remove the RPM Magnets support disc 010153299 from the main rotor shaft bottom Step 5 The main rotor shaft 010153286 can now be pulled upwards and away from the UAV Step 6 The Delrin Spur Gear 90T can now be removed sideways from the chassis ...

Page 101: ...he Freewheel this can provoke the part to not work correctly causing severe damage to the UAV Step 9 Assembly is the reverse procedure Take care to ensure that the Freewheel pin 010153288 is correctly aligned when inserting the shaft into the Freewheel bearing in the Delrin Spur Gear 90T here shown outside the UAV for clarity Important Ensure that the two separating washers 100x16x0 5mm 010153291 ...

Page 102: ...010153296 14 Swashplate 010162114 14 Swashplate guide 010153287 14 ISO 4762 A2 M3 x 20 000000706 14 ISO 4762 A2 M3 x 8 000000701 9 Rotor Shaft Support plate 010153284 14 Magnets support disc 010153299 14 Main Rotor Shaft 010153286 14 ISO 10642 A2 M3 x 20 000000727 14 Freewheel 010153285 14 Freewheel pin 010153288 14 Washers 100x16x0 5mm 010153291 14 ...

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Page 104: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 103 of 143 AIRCRAFT MAINTENANCE MANUAL 021 Engine Replacement ...

Page 105: ...The complete ALPHA 800 engine is a Base Repair item The engine can be replaced but is not to be modified dismantled or tampered with by the user doing so will invalidate the warranty If the engine develops a fault not covered by these Maintenance Sheets then the entire unit must be sent to Alpha for repair or replacement When sending the engine wrap in airtight polythene and protect from damage in...

Page 106: ... the underside of the chassis Step 6 Use the special clutch spanner to prevent the clutch pulley 010172350 from rotating and remove the clutch retaining cap head ISO 4762 A2 M6 x 40 24 000000775 bolt Step 7 Use the special clutch extractor to pull the clutch away from the engine drive shaft Step 8 Remove the two bolts ISO 4762 A2 M5 x 20 000000719 which secure the exhaust manifold 010172354 to the...

Page 107: ...s Step 10 Remove the velcro that secures each fuel tank to the chassis and then remove both fuel tanks Step 11 Disconnect the throttle pushrod 010172134 from the throttle servo 010172123 leave connected to the carburetor WT 990 Step 12 Loosen the Airfilter clamp 010172343 and remove the Airfilter 010172343 Step 13 Undo the two bolts which fix the carburetor WT 990 to the engine and remove the carb...

Page 108: ...maged by shock in transit use bubble wrap or similar Step 18 Engine installation is the reverse procedure taking care to ensure correctdrivebelt tension The drive belt tension is set correctly when you can push the belt with your finger in the center about 6 8mm without moving the ALPHA 800 Name Part Number IPC Page ISO 4762 A2 M3 x16 000000704 13 Engine Support 010172346 22 ISO 4762 A2 M4 x20 000...

Page 109: ...lphaUnmannedSystems com 108 of 143 Fuel lines 010128403 N A Fuel tanks 60 Oz 010128205 1 Carburetor WT 990 010172780 22 Throttle pushrod 010172134 26 Throttle servo 010172123 23 and 26 Airfilter clamp 010172343 22 Airfilter 010172343 22 Spark plug NGK CMR7H 010172776 22 ...

Page 110: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 109 of 143 AIRCRAFT MAINTENANCE MANUAL 022 Onboard Generator replacement ...

Page 111: ... AlphaUnmannedSystems com Sheet 022 Title Onboard Generator replacement Applies to UAVs ALPHA 800 Special Tools Required Time approx 120 min Introduction The Onboard generator 010124311 is the main source of power of the UAV and thus it is crucial for a safe operation This generator has bearings and wiring that has a useful life time In case that the generator shows unusually low voltage or high v...

Page 112: ...with the generator installed on it by unscrewing the 4 generator frame bolts Step 5 Remove the generator from the base plate by unscrewing the 4 bolts Step 6 Install a new generator The installation procedure is the reverse of the installation procedure Name Part Number IPC Page Generator 010124311 17 Fuel tanks 60 Oz 010128205 1 Generator base plate 010153310 17 Generator belt 010153283 13 Genera...

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Page 114: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 113 of 143 AIRCRAFT MAINTENANCE MANUAL 023 GCS Parts List ...

Page 115: ... latest updates contact info AlphaUnmannedSystems com Sheet 023 Title GCS PARTS LIST Applies to UAVs All UAVs using Alpha GCS consisting of GTRACK GCASE DUO Item Unit of Supply Maintenance Kit Part Number GCASE DUO 1 020100000 Visionair Dongle 1 100334011 GCS03 NR PTU D 100 1 080223023 Cables kit Payload Bay 1 020100101 Batteries 2 RRC2054 2 Data link MIMO 1 pMDDL2450 Power supply kit 1 020100100 ...

Page 116: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 115 of 143 AIRCRAFT MAINTENANCE MANUAL 024 Switch Box Batteries replacement ...

Page 117: ... accidents For further information and the latest updates contact info AlphaUnmannedSystems com Sheet 024 Title Switch box batteries replacement Applies to UAVs ALPHA 800 Special Tools Required Time approx 60 min Introduction Batteries inside the Switch box 010124110 are backup in case of generator failure or during the preflight checks Inside the Switch Box there are TWO batteries one LIFEPO4 5S ...

Page 118: ...tep 3 Remove the cover of the Switch Box by unscrewing the four star plastic bolts ISO 7040 A2 M4 000000737 Step 4 Plug in the external power connector an external power source at exactly 18 volts Step 5 Remove the protective foam Step 6 Lift the LIFE battery so there is space to access the aluminum plate ...

Page 119: ... www AlphaUnmannedSystems com 118 of 143 Step 7 Unscrew and remove the aluminum plate Step 8 Now you can remove the power supply cable of the LIFE battery Step 9 Unplug and remove the balancing circuit from the LIFE battery Step 10 Remove the external power source ...

Page 120: ... battery power supply and balancing cables Step 12 The installation procedure is the same as the removal IMPORTANT NOTE Plug in an External Power source at 18 volts before to connect the LIFE battery to the circuit Name Part Number IPC Page Switch box 010124110 8 Switch Box Base Plate 010153270 8 ISO 7040 A2 M4 000000761 8 ...

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Page 122: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 121 of 143 AIRCRAFT MAINTENANCE MANUAL 025 Autopilot SW update ...

Page 123: ...e Autopilot software update for Visionair 8 Applies to UAVs ALPHA 800 Special Tools Required PC running Visionair V8 Time approx 30 min Introduction It may be necessary to update the Vector autopilot software during its service life in this cases Alpha will provide the appropriate update files and tools to execute this procedure Step by Step Procedure First power up GCase Duo and start Visionair 8...

Page 124: ...dio Click Choose to select the new software file Click Start to install the new software The process will go through all the steps until it finishes in Finished Click back the Basic tab and click on Reset autopilot button Once the reset has finished the AP is ready Close Maintenance Tool window Visionair 8 is ready for operation ...

Page 125: ...oard RS232 to USB adapter Power source 9 to 36V DC PC running Visionair Time approx 30 min Introduction It may be necessary to update the Vector autopilot software during its service life in this cases Alpha will provide the appropriate update files and tools to execute this procedure Step by Step Procedure This procedure has two sections depending on what software is going to be updated Autopilot...

Page 126: ...ismounted from the helicopter align both Glenair rectangular connectors with its match in the Vector Evaluation Board Step 2 Carefully connect Glenair rectangular connectors Step 3 Rest the autopilot on a flat surface and push gently until there is no space between the Glenair connectors Step 4 Use the RS232 to USB cable to connect the PC to the Vector evaluation board COM_DBG port ...

Page 127: ...nch Visionair and toggle to serial port communications to do this open menu Maintenance Settings and in the Data source tab select the Serial port that should be detected apply changes and you should see COM OK in a few seconds Step 7 Launch the Software Update Tool select COM port same as used to verify connection in the previous step and click OK Step 8 Select Normal update mode this will update...

Page 128: ...the update process the user will be prompted to cycle the power Reset AP04 step this is indicated in the Tasks section of the Software Update Tool window At this point press the reset button on the Vector Development Board Step 10 Once the software update process is complete Done marker cycle power to reset the device ...

Page 129: ...oaded correctly Launch Visionair Visionair Configuration Tools Basic Tab and check that SW version installed on CPU 0 match the SW recently installed Then click on the Reset Autopilot button to force a CPU swap When the CPU is changed check again the SW version it should be the same in both CPUs In case that only Vector autopilot SW will be updated then the process is finished and autopilot should...

Page 130: ...e procedure described above Step 1 Once connected to AP in Visionair check that the IMU alarm is off and open Config Tools Step 2 Access and download the configuration of the AHRS tabs Basic Configuration and Telemetry print or save the values this is to be used later to check that no sensible configuration has been changed during the updating procedure Step 3 In Basic tab click the Program POLAR ...

Page 131: ... MAINTENANCE MANUAL www AlphaUnmannedSystems com 130 of 143 Step 5 Launch the Software Update Tool select proper COM port and click OK Step 6 Select Raw update mode and Choose the enc software file provided for this AHRS update Then click Start ...

Page 132: ... unit has been updated it is important to check that the software has loaded correctly Launch Visionair Visionair Configuration Tools Basic Tab and check that SW version installed on CPU 0 match the SW recently installed Then click on the Reset Autopilot button to force a CPU swap When the CPU is changed check again the SW version it should be the same in both CPUs Step 9 Now the autopilot can be ...

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Page 134: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 133 of 143 AIRCRAFT MAINTENANCE MANUAL 026 Joystick Calibration ...

Page 135: ...unning joystick 100FH or Yearly Calibration is also needed to comply with the Maintenance Schedule Step by Step Procedure This procedure must be accomplished every time there is a joystick change in the system It is important to run GCS0x Configuration Tool on the GCase Duo but not the Visionair software Both software are not compatibles and calibration result would not be as expected Warning Visi...

Page 136: ...four joystick panels labelled Joystick 1 to Joystick 4 is associated with this motion you will see its value field changing Step 6 Assign the corresponding joystick option to the Ailerons panel using the drop down menu Step 7 Commit this change to the GCS with the SET button Step 8 Move lever till maximum value is observed on the joystick panel and copy this value in the Max field Step 9 Move leve...

Page 137: ...d commit this change to the GCS with the SET button Step 17 On the joystick place throttle trim down Step 18 If joystick is not inverted move lever till minimum value is observed on the joystick panel and copy this value into the Min field If inverted move lever till maximum value is observed on the joystick panel and copy this value into the Max field Step 19 On the joystick place throttle trim u...

Page 138: ...nsure that the maximum throw is achieved in either direction i e max throttle min throttle Step 6 Once the autocalibrate procedure is finished remember to select SET button to save the settings Step 7 The Buttons section allows mapping of the four physical joystick user switches to user switch functions The picture shows typical mapping for a standard joystick Joystick switch 1 is mapped to usr1 j...

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Page 140: ...COMMERCIAL IN CONFIDENCE DEV M MM A800 V1 7 MAINTENANCE MANUAL www AlphaUnmannedSystems com 139 of 143 AIRCRAFT MAINTENANCE MANUAL 027 Carburetor Diaphragm Replacement ...

Page 141: ...ates contact info AlphaUnmannedSystems com Sheet 027 Title Carburetor Diaphragm Replacement Applies to UAVs ALPHA 800 Special Tools Required Diaphragm replacement kit for Alpha 800 Time approx 1h Introduction Every 10 Flight Hours is necessary to replace the carburetor Diaphragms to guarantee the reliability of the engine Step by Step Procedure Step 1 Loosen the Airfilter clamp 010172343 which sec...

Page 142: ...arburetor WT 990 from the engine and loose the Throttle Servo Pushrod Step 4 Take the carburetor apart for cleaning and to drain all the remaining fuel Step 5 Loosen the four screws of the primer Step 6 Loosen the screw of the fuel intake lid Step 7 Disassemble the carburetor Step 8 Replace the diaphragms with the new ones ...

Page 143: ... of the diaphragms they are not symmetric Carburetor Assembly Step 10 Carefully tighten the four screws that hold the primer and the single screw that hold the fuel intake lid Step 11 Install the carburetor in the engine with the adapter for the air filter by means of the two Allen bolts Step 12 Connect the Throttle Servo Pushrod to the carburetor arm Step 13 Install the air filter and tighten the...

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