Agricultural drones operate in some of the harshest environments imaginable: dusty fields, humid greenhouses, chemical-laden spray operations, and wide temperature swings from dawn to midday. XAG (formerly XAIRCRAFT) has established itself as a global leader in agricultural drone technology, with models like the P100, V40, and P40 series serving millions of hectares worldwide. Keeping these machines running reliably through an entire growing season demands a rigorous, agriculture-specific maintenance approach. This guide covers everything you need to know about maintaining XAG drones and the spare parts you should keep on hand.
Understanding the Agricultural Drone Workload
Unlike consumer or survey drones that fly for 30-40 minutes at a time, agricultural drones like the XAG P100 can perform 20 or more sorties per day during peak spraying season. Each sortie involves heavy payloads (up to 40 liters of liquid), low-altitude flight through crop canopies, and exposure to chemicals that can corrode metal and degrade plastics. This workload accelerates wear on every component, making preventive maintenance not just advisable but essential for economic viability.
Daily Maintenance Checklist
After every flying day, XAG operators should complete the following: flush the spray system with clean water for at least five minutes to remove chemical residue; inspect all propellers for edge damage, chemical staining, or balance issues; check motor bells for debris accumulation and spin each motor by hand to feel for bearing roughness; inspect the landing gear for cracks, particularly the spring-loaded struts; verify that all sensor windows are clean and unobstructed; and charge batteries to storage level if not flying the next day.
Propellers and Propulsion
XAG agricultural drones use large-diameter, foldable propellers designed for heavy-lift efficiency. These propellers endure significant stress — not just from aerodynamic loads, but also from chemical contact and UV exposure. Replace propellers every 100 to 150 flight hours or immediately if any crack, chip, or delamination is visible. XAG recommends using only genuine replacement propellers, as aftermarket alternatives may not meet the precise balance and pitch specifications required for safe heavy-lift operations.
The motors on XAG sprayers are industrial-grade brushless units rated for thousands of hours, but agricultural conditions can cut that lifespan significantly. Dust and debris ingress is the primary enemy. After each spray season, or every 500 flight hours, open the motor bells and inspect the bearings. Replace bearings proactively if they show any roughness, as a bearing failure in flight can be catastrophic for an aircraft carrying 40 kilograms of payload.
Spray System Components
The spray system is the functional heart of an agricultural drone. Key components include the liquid pump (usually a diaphragm or centrifugal pump), spray nozzles, flow sensors, liquid level sensors, and the plumbing that connects them. Nozzles are consumable items — ceramic and stainless steel nozzles wear down from the abrasive particles present in many pesticide formulations. Check spray pattern uniformity weekly and replace nozzles that produce uneven coverage. Keep at least one full set of replacement nozzles in your field kit.
The pump diaphragm should be inspected every 200 flight hours. Chemical exposure causes rubber diaphragms to harden and lose flexibility, which reduces pump pressure and spray consistency. Replacement diaphragm kits are inexpensive and quick to install — there is no reason to wait until pump failure to swap them.
Battery Management for Fleet Operations
XAG agricultural operations often involve fleets of 5 to 20 drones with 30 to 100 batteries rotating through charging stations. Fleet battery management requires a systematic approach: label every battery with a unique identifier, log charge cycles, monitor cell voltage differential (cells drifting more than 0.1V apart indicate degradation), and retire batteries at 200 cycles or when capacity drops below 80% of rated values. XAG's SuperCharge stations can charge a battery in 9 to 15 minutes, but rapid charging generates more heat and can accelerate degradation. When time permits, use standard charging to extend battery life.
Frame and Landing Gear
Agricultural drones take a beating. Repeated takeoffs and landings on uneven farmland, combined with the weight of a full spray tank, stress the landing gear and frame joints. Inspect carbon fiber arms for hairline cracks, especially around motor mounts and folding joints. Check the tank mounting brackets for looseness. The XAG P100 uses a quick-release tank system — verify that the locking mechanism engages fully and shows no signs of wear. Replace shock-absorbing landing gear components when compression travel decreases noticeably.
Sensors and RTK Systems
Precision spraying depends on accurate positioning. XAG drones use RTK (Real-Time Kinematic) GPS for centimeter-level accuracy. Keep the RTK antenna clean and free of chemical residue. The downward-facing terrain sensors that maintain spraying altitude should be cleaned daily — a buildup of chemical mist on sensor lenses will cause altitude errors and uneven application. If your drone uses a radar-based terrain following system, inspect the radar module for physical damage and verify calibration monthly.
Seasonal Overhaul
At the end of each growing season, perform a comprehensive overhaul: disassemble and deep-clean the spray system, replace all rubber seals and O-rings, inspect and relubricate all folding mechanisms, replace any propellers with more than 100 hours, send batteries with more than 150 cycles for capacity testing, update firmware, and perform full sensor calibration. This annual investment in maintenance will pay for itself many times over in reduced in-season breakdowns.
Stocking Spare Parts
For fleet operators, we recommend keeping the following XAG spare parts in inventory: a minimum of two full propeller sets per drone, one spare motor per drone, two pump diaphragm kits, a full set of spray nozzles, spare flow sensors, RTK antenna assemblies, and landing gear spring sets. At Drone-Partss, we supply the complete range of XAG agricultural drone spare parts with bulk pricing available for fleet operators. Contact us for a customized spare parts package tailored to your fleet size and operational intensity.