ASB MBB-BK117-40A-115

Valid for Version(s): A-1, A-3, A-4,

B-1, B-2, C-1.

ALERT SERVICE BULLETIN

SUBJECT: FLIGHT CONTROL SYSTEM -- Flight Controls Main Rotor

Replacement of the clamp on the swashplate bellows

Revision No. Date of issue

Revision 0 2014-03-31
Revision 1 2014-08-04

Summary:

With this Alert Service Bulletin, Airbus Helicopters Deutschland prescribes the installation of an
improved fixation of the swashplate bellows.

Reason for last Revision:

Please replace Revision 0 of this Alert Service Bulletin with Revision 1.

With Revision 1 four more additional cable tie tools are introduced with which the Alert Service Bulletin
can be accomplished. Furthermore, the accomplishment instructions are described more detailed.

If Revision 0 of this Alert Service Bulletin has already been accomplished, the cable ties on the
swashplate must be checked for a tight fit i.a.w. Sections 3.B.1.(b)5 and 3.B.1.(c)7.

Compliance:

Airbus Helicopters Deutschland considers that compliance with this Alert Service Bulletin is essential.
See Section 1.E.

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 ASB MBB-BK117-40A-115
1. PLANNING INFORMATION
1.A. EFFECTIVITY

1.A.1. Helicopters/installed equipment

(a) MBB-BK117 A-1, A-3, A-4, B-1, B-2 and C-1, all S/N.

(b) All main transmissions without cable ties on the swashplate bellows.

1.A.2. Non-installed equipment

All main transmissions without cable ties on the swashplate bellows.

1.B. ASSOCIATED REQUIREMENTS

Not applicable.

1.C. REASON
During a postflight check on a BO105, it was detected that the lower clamp of the swashplate
bellows was missing. Prior to this, the loose clamp caused damage to the swashplate bearing ring.
A loose clamp can be caught up between the rotating and stationary parts of the swashplate. This
can cause heavy damage to the swashplate, the driving link or to the rotating control rods (see
following picture).

Damaged driving link of a MBB-BK117 A-4

As similar damage on the rotor system have been reported in the past, this Alert Service Bulletin
makes the replacement of the clamps on the swashplate bellows compulsory.

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 ASB MBB-BK117-40A-115
1.D. DESCRIPTION
Remove the clamps. Install the cable ties.

1.E. COMPLIANCE

1.E.1. Compliance at the works

Helicopters/installed equipment:
Not applicable.
Non-installed equipment:
The clamps on the swashplate bellows must be replaced i.a.w. Section 3.B. of this Alert Service
Bulletin before a main transmission is delivered as a spare part at the latest.

1.E.2. Compliance in service

Helicopters/installed equipment:

(a) The clamps on the swashplate bellows must be replaced i.a.w. Section 3.B. of this Alert
Service Bulletin within the next 12 months after receipt of Revision 0 of this Alert Service
Bulletin at the latest.

(b) After receipt of Revision 1 the cable ties on the bellows must be checked for a tight fit i.a.w.
Sections 3.B.1.(b)5 and 3.B.1.(c)7. during the next maintenance event, but by 31.03.2015
at the latest.

(c) After accomplishment of this Alert Service Bulletin the cable ties must be inspected i.a.w.
Section 3.D. every 400 FH or with every 12 months inspection, whichever occurs first.

(d) After accomplishment of this Alert Service Bulletin, the cable ties must be replaced i.a.w.
Section 3.B. with every periodical inspection.
Non-installed equipment:
The clamps on the bellows must be replaced i.a.w. Section 3.B. of this Alert Service Bulletin
before a main transmission is installed in a helicopter at the latest.

1.F. APPROVAL
Approval of modification(s):
The information or instructions contained in this document refer to change no. 3039. The
technical content of this document is approved under the authority of DOA No. EASA.21J.034.

1.G. MANPOWER

Qualification Mechanic Electrician Pilot Others

Man--hours approx. 0.8 h -- -- --

1.H. WEIGHT AND BALANCE

Not applicable.

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 ASB MBB-BK117-40A-115
1.I. EFFECT ON ELECTRICAL LOADS
Not applicable.

1.J. SOFTWARE MODIFICATION EMBODIMENT RECORD

Not applicable.

1.K. REFERENCES
Not applicable.

1.L. DOCUMENTS AFFECTED

The changes to MM MBB-BK117 / MBB-BK117 C and IPC MBB-BK117 which are required as a
result of this Alert Service Bulletin will be incorporated with one of the next revisions.

1.M. INTERCHANGEABILITY OR MIXABILITY OF PARTS

Interchangeability:
After accomplishment of this Alert Service Bulletins, clamps with P/N MBB100--W3--5 and P/N
MBB270--W3--5 must no longer be used for attachment of the swashplate bellows.
Mixability:
Not applicable.

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 ASB MBB-BK117-40A-115
2. MATERIAL INFORMATION

2.A. MATERIAL: PRICE - AVAILABILITY - PROCUREMENT

Information on price and availability of required retrofit kit SB-117-40A-115-2C will be provided
by Airbus Helicopters Deutschland, Dept. Spares Order Administration on request.
All material kits required will be provided free of cost by Airbus Helicopters Deutschland only
within the time limits specified for the compliance (Section 1.E.). Material that is ordered outside
the time limits given in the ASB will be charged according to the ruling prices.

2.B. INFORMATION CONCERNING INDUSTRIAL SUPPORT

Not applicable.

2.C. MATERIAL REQUIRED FOR EACH HELICOPTER/COMPONENT

Kits or components to be ordered for one helicopter or one assembly:

Retrofit kit SB-117-40A-115-2C.

No. Keyword Qty New P/N Old P/N Remark

Cable tie 3 E0043--6C0P -- --
1 Clamp 1 -- MBB270--W3--5 A
Clamp 1 -- MBB100--W3--5 A

Remark:
A = Parts with old P/N are not taken back by Airbus Helicopters Deutschland.

Specific tooling:

Keyword Qty Specification Remark

Thomas & Betts -- ERG120 or
Panduit -- GSH121 or
Cable tie tool 1 Panduit -- GS4EH or A
Panduit -- GS4H--120 or
Hellermann Tyton -- MK9HT

Remark:
A = Only one of the above given cable tie tools is necessary.

2.D. MATERIAL TO BE RETURNED

Not applicable.

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 ASB MBB-BK117-40A-115
3. ACCOMPLISHMENT INSTRUCTIONS

3.A. GENERAL

NOTE If a cable tie breaks during the tightening process, the next lower level of the
cable tie tool must be used. At first signs of a reduced drag force the tool must
be set back to the prescribed level i.a.w. Table 1. Generally it should be noted
that the drag force of the cable tie tool can be reduced because of wear.

NOTE Only cable tie tools given the in Table 1 are permitted for the accomplishment
of this Alert Service Bulletin. It is essential to comply with the prescribed
settings, levels and usage. If another cable tie tool than the tools i.a.w. Table
1 or a wrong setting is used the bellows can disengage from the swashplate.

Cable Tie Tool Setting Level Remarks

Thomas & Betts -- ERG120
Panduit -- GSH121
Panduit -- GS4EH
Panduit -- GS4H--120
Hellermann Tyton -- MK9HT
High 8 Tighten the cable tie (4, Figure 1 and 2) with several
full strokes of the cable tie tool until the cable tie tool
Heavy 8
cuts off the protruding end (5) of the cable tie (4)
Heavy 7 automatically.
Extra heavy 8
Heavy 8 The cutting blade must be removed i.a.w.
manufacturer’s instructions before usage. With
removed cutting blade the cable tie tool MK9HT will
not be damaged during the usage.
With removed cutting blade the cable tie tool MK9HT
will still trigger the cutting mechanism.
Tighten the cable tie (4, Figure 1 and 2) with several
full strokes of the cable tie tool until the cable tie head
touches the bellows (2) and no further clicks of the
cable tie ratchet can be achieved.
The protruding end of the cable tie must be cut off
with a suitable tool.

Table 1: Permitted cable tie tools and their settings

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 ASB MBB-BK117-40A-115
3.B. OPERATIONAL PROCEDURE

3.B.1. Procedure

(a) Remove the upper and the lower clamps (2, 4, Figure 3) from the bellows (3) of the
swashplate (5). Discard both clamps.

(b) Install one cable tie on the upper collar:

NOTE The clearance between the upper edge of the collar and the upper edge of
the rotor hub--shaft flange (1) must be approx. 80 +/-- 5 mm ( , Figure 3).

NOTE The lower end of the sectioning line (1, Figure 2, ) must not be positioned
directly over the balance weight (8) or the connecting eyes (9).

1 Position the upper collar of the bellows (3, Figure 3) on the rotor hub--shaft.

NOTE The angle between the head of the cable tie and the upper end of the
sectioning line (1, Figure 1) of the bellows (2) must be approx. 45 degree
(see ).

2 Position one cable tie (4, Figure 1) around the upper collar (3) of the bellows (2).
3 Pretighten the cable tie (4, Figure 1) by hand.
4 Tighten the cable tie (4, Figure 1) i.a.w. Table 1, Chapter 3.A.
5 Check the upper collar (3, Figure 1) for tight fit.

a If the upper collar (3, Figure 1) can slide on the rotor hub--shaft flange (1) then:
-- The preset level of the cable tie tool must be checked
-- A new cable tie must be installed i.a.w. Section 3.B.1.(b)

(c) Install two cable ties on the lower collar:

NOTE A second person is necessary for the installation of the lower cable ties. After
briefing this work can also be accomplished by a pilot.

1 Position the lower collar of the bellows (3, Figure 3) on the bearing ring of the
swashplate (5). This position must be secured by a second person during the following
worksteps.

NOTE The angle between the heads of the cable ties and the lower end of the
sectioning line (1, Figure 2) of the bellows (2) must be approx. 90 degree
(see ).

2 Fit both cable ties (4, Figure 2) into each other and position them around the lower
collar (3) of the bellows (2).
3 Pretighten both cable ties (4, Figure 2) by hand.

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 ASB MBB-BK117-40A-115
4 Remove overlap material of the bellows (2, Figure 2) with a suitable tool (see ).
5 Stretch the bellows (3, Figure 3) by hand toward the sectioning line (7) to improve the
fit on the swashplate (see ).

NOTE Make sure that the cable ties (4, Figure 2) are positioned below the flange (7)
of the swashplate (6) ( ).

6 Tighten both cable ties (4, Figure 2) i.a.w. Table 1, Chapter 3.A.
7 Check the lower collar (3, Figure 2) for a tight fit. To do so, pull on the bellows (2) but
not on the cable tie heads.

a If the lower collar (3, Figure 1) can be moved from the swashplate (6) then:
-- the preset level of the cable tie tool must be checked
-- new cable ties must be installed i.a.w. Section 3.B.1.(c)

3.C. IDENTIFICATION
Identification of this document:
Confirm accomplishment of this Alert Service Bulletin by an entry in the historical record of the
helicopter and in the log card of the main transmission.

3.D. OPERATING AND MAINTENANCE INSTRUCTIONS

Flight Manual (FLM):
Not applicable.
Aircraft Maintenance Manual (AMM):
Inspection of the cabel ties:
Check the upper and lower collar of the swashplate bellows for a proper fit. Remove loose cable
ties and install new cable ties i.a.w. Section 3.B.

4. APPENDIX
Not applicable.

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 ASB MBB-BK117-40A-115

5 6

approx. 45 degree

1 Sectioning line
2 Bellows
3 Upper collar
4 Cable tie E0043--6C0P
5 Protruding end
6 Balance weight
7 Connecting eye

Angle between the cable tie head and the upper end of sectioning line
must be approx. 45 degree.
The lower end of the sectioning line must not be positioned directly over
the balance weight or the connecting eyes.
Replacement of the Clamps
Figure 1

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 ASB MBB-BK117-40A-115
5

4x2
approx. 90 degree

A 8

SECTION A--A A
2
approx 90 degree
7
1 Sectioning line
2 Bellows
9
3 Lower collar
4 4 Cable tie E0043--6C0P
5 Protruding end
6 Swashplate
7 Flange
6 8 Balance weight
9 9 Connecting eye

Cable ties fitted into each other.

Angle between the cable tie heads and the lower end of the sectioning line must be
approx. 90 degree.
Make sure that the cable ties are positioned below the flange of the swashplate.
Overlap material must be removed with a suitable tool.
The lower end of the sectioning line must not be positioned directly over the balance
weight or the connecting eyes.
Replacement of the Clamps
Figure 2

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 ASB MBB-BK117-40A-115

+/-- 5 mm
1

80
2
3

4
4x2

6
5

1 Rotor hub--shaft flange

2 Clamp MBB100--W3--5
Cable tie E0043--6C0P
3 Bellows
4 Clamp MBB270--W3--5
Cable tie E0043--6C0P
5 Swashplate
6 Bearing ring
7 Sectioning line 7

The clearance between the upper edge of the collar and the upper edge of the rotor
hub--shaft flange must be approx. 80 +/-- 5 mm.
Before accomplishment of this Alert Service Bulletin.
After accomplishment of this Alert Service Bulletin.
Bellows streched by hand toward the sectioning line to improve the fit on the swashplate.

Replacement of the Clamps

Figure 3

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