ASB MBB-BK117 D-2-67A-007

Valid for Version(s): D‐2, D-2m.

ALERT SERVICE BULLETIN

CORRECTIVE MEASURE

ROTOR FLIGHT CONTROLS - Collective Controls

Inspection of the wire harness of the
collective lever copilot

Revision No. Date of issue

Revision 0 2018‐07-23
Revision 1 2021-03-23

Summary:

With this Alert Service Bulletin (ASB), Airbus Helicopters prescribes a one time inspection of the
wire harness of the collective lever copilot for condition and it gives the instruction for the
replacement of the cable support for the harness of the collective lever copilot with a divided
cable support.

Reason for last Revision:

This Revision gives the instruction for the corrective measure „Replacement of the cable
support for the harness of the collective lever copilot with a divided cable support“.

Compliance:

Compliance with this ASB is mandatory.

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 ASB MBB-BK117 D-2-67A-007
1 PLANNING INFORMATION
1.A EFFECTIVITY
1.A.1 Helicopters/installed equipment and parts
MBB‐BK117 D‐2, D-2m, all S/N up to and including S/N 20340.

Collective lever copilot

Wire harness

1.A.2 Non-installed equipment and parts

None.
1.B ASSOCIATED REQUIREMENTS
None.
1.C REASON
During an 800 Fh inspection a chafing mark was found on the wire harness of the
collective lever copilot. This chafing mark was caused by an incorrect routing of the
wire harness.
The collective lever copilot is removable via quick-release connections for single pilot
operation. After reinstallation of the collective lever copilot, the wire harness must
be installed correctly again.
This ASB prescribes a one time inspection of the wire harness of the collective lever
copilot for condition and it gives the instruction for the replacement of the cable
support for the harness of the collective lever copilot with a divided cable support.
1.D DESCRIPTION

PART 1 − Inspection of the wire harness (Protective measure)

Move the bellows up on the collective lever copilot. Inspect the wire harness of the
collective lever copilot for chafing marks and correct routing. Move the bellows in its
installation position and attach the hook-and-loop tapes.

PART 2 − Replacement of the cable support with a divided cable support

(Corrective measure)
Move the bellows up on the collective lever copilot. Remove the LH floor access
covers. Replace the cable support with a divided cable support. Install the LH floor
access covers. Move the bellows in its installation position and attach the
hook-and-loop tapes.

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 ASB MBB-BK117 D-2-67A-007
1.E COMPLIANCE

1.E.1 Compliance at H/C manufacturer level

Helicopters/installed equipment and parts:
Not affected.
Non-installed equipment and parts:
Not affected.

1.E.2 Compliance in service

Helicopters/installed equipment and parts:

PART 1 − Inspection of the wire harness (Protective measure)

EFFECTIVITY Helicopter equipped with Rescue Hoist System.
Inspect the wire harness in accordance with Section 3.B within the next 100 Fh or
within 3 months after receipt of Revision 0 of this ASB at the latest.
EFFECTIVITY Helicopter without Rescue Hoist System.
Inspect the wire harness in accordance with Section 3.B within 12 months after
receipt of Revision 0 of this ASB at the latest.

PART 2 − Replacement of the cable support with a divided cable support

(Corrective measure)
EFFECTIVITY all.
Replace the cable support for the harness of the collective lever copilot with
a divided cable support in accordance with Section 3.B.4 within the next
800 Fh (+ 80 Fh tolerance) or within 36 month (+ 3 month tolerance) after receipt
of Revision 1 of this ASB at the latest.
Non-installed equipment and parts:
Not affected.

1.F APPROVAL
Approval of modification(s):
The information or instructions contained in this document refer to change no. 6533.
The change is approved under the authority of DOA No. EASA.21J.700.

1.G MANPOWER

Qualification Mechanic Electrician Pilot Others

Estimated
approx. 4 h** approx. 0.5 h* - -
Man‐hours
* Part I (Protective measure) ** Part II (Corrective measure)

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 ASB MBB-BK117 D-2-67A-007
1.H WEIGHT AND BALANCE
Weight: 0.043 kg
Arm longitudinal: 2592 mm Moment longitudinal: 111 kgmm
Arm lateral: -668 mm Moment lateral: -29 kgmm
1.I POWER CONSUMPTION
Not affected.
1.J SOFTWARE UPGRADES/UPDATES
Not changed.
1.K REFERENCES
Aircraft Maintenance Manual
- AMM 00-10-02, 2-1 General recommendations for Working at helicopter
- AMM 24-32-00, 2-1 Energize / De-energize - Electrical System - DC Generation
System
- AMM 67-15-00, 4-3 Removal - Collective Lever (Copilot) - Collective Controls
- AMM 67-15-00, 4-4 Installation - Collective Lever (Copilot) - Collective Controls
- AMM 67-10-00, 5-2 Operational Test - Free Movement of the Main Rotor
Controls - Main Rotor Controls
Standard Practices Manual
- MTC 20-02-04-402 Installation of rivets - retrofitting and repair - Riveting
- MTC 20-80-20-401 Description of Splices for Installation on Unshielded Cables -
Standard Practices - Electrical Power
- MTC 20-80-20-423 Repair Procedure for Spiral, Heat-Shrinkable and Braided
Sheaths - Standard Practices - Electrical Power
- MTC 20-80-20-433 Crimping Splices on Unshielded Cables - Standard Practices -
Electrical Power
- MTC 20-80-20-442 Acceptable damage criteria on standard electrical
components - Standard Practices - Electrical Power
- MTC 20-80-20-603 Securing Rules for Electrical Harnesses - Standard Practices -
Electrical Power
1.L OTHER AFFECTED PUBLICATIONS
Publications to be updated:
The changes to AMM MBB-BK117 D-2 and IPC MBB-BK117 D-2 which is required as a
result of this ASB will be incorporated with one of the next revisions.
1.M INTERCHANGEABILITY OR MIXABILITY OF PARTS
Interchangeability:
Not affected.
Mixability:
Not affected.

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 ASB MBB-BK117 D-2-67A-007
2 MATERIAL INFORMATION
Information on price and availability of required material kit SB‐117D2‐67A‐007‐2C
will be provided by Airbus Helicopters, Dept. Spares Order Administration on
request.

2.A LOGISTIC INFORMATION

None.

2.B MATERIAL REQUIRED PER HELICOPTER/COMPONENT

Material kits to be ordered for one helicopter or one assembly:

Material kit SB‐117D2‐67A‐007‐2C in accordance with design document
D671M5812881.

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

ANGLE WITH
DIVIDED CABLE 1 D671M5812101 - -
1 SUPPORT
SUPPORT, ANGLE
1 - KS5239-1-9 A
TYPE
CABLE SUPPORT
2 1 D671M5823201 - -
MALE-8
CABLE SUPPORT
3 1 D671M5824201 - -
MALE-2
POSITIONER
4 2 D671M5825201 - -
SIMPLE
5 CATCHING CORD 1 L342M4094101 - -
6 BINDING CLAMP 2 E0043-4A9P - -
7 CABLE TIE 4 E0043-5A9P - -
8 BLIND RIVET 3 MBBN3012L3202 - -
9 PROTECTION 1 ECS0817B - -

Remark:
A = Airbus Helicopters does not take back parts with old part numbers.

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 ASB MBB-BK117 D-2-67A-007
Consumables to be ordered separately:

WARNING

RESPECT THE SAFETY DATA SHEET OF THE MANUFACTURER.

Qty.
No. Keyword Specification ** CM Rem.
(approx.)
1 Thinner a.n.* - 436 -
2 Hardener a.n.* - 459 -
3 Primer a.n.* - 472 -
* a.n. = as needed.
** For specification, refer to AMM 01-00-00, 2-1.

The consumables can be ordered separately from the following companies.

Aviatec global aviation BDSI

Website: https://www.aviatec.net Website: https://www.boeingdistribution.com
Telephone: +33 1.34.46.45.24 or Telephone: +1.305.925.2600
+49 4193.8803.630 Fax: +1.305.507.7191
Fax: +33 1.34.46.45.26 or AOG: +1.305.471.8888
+49 4193.8803.699 AOG email: AOGdesk@boeingdistribution.com
AOG: +49 4193.8803.660
AOG email: aog@aviatec.aero

Gaches chimie
Website: https://www.gaches.com
Telephone: +33 5.61.31.64.45
Fax: +33 5.61.40.98.63
AOG email: marketplace@gaches.com

2.C MATERIAL TO BE RETURNED

None.

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 ASB MBB-BK117 D-2-67A-007
3 ACCOMPLISHMENT INSTRUCTIONS
3.A GENERAL
Obey the “General recommendations for Working at helicopter” (AMM 00-10-02,
2-1).
3.B WORK STEPS

PART 1 − Inspection of the wire harness (Protective measure)

3.B.1 Preliminary steps

1. De-energize the helicopter electrical system (AMM 24-32-00, 2-1).
2. Pull apart the hook-and-loop tapes and move the bellows up on the collective
lever copilot (AMM 67-15-00, 4-3).
3.B.2 Inspection of the wire harness of the collective lever copilot

NOTE The inspection requires a flashlight and a mirror.

1. Inspect the wire harness (2, Fig. 1) of the collective lever copilot (1) for chafing:
1 2

Fig. 1
a. If the wire harness (2) is not chafed, continue with Section 3.B.2c.
b. If there is a chafing of the heat-shrinkable sheath, inspect the wires below for
damages:
- If there are no damaged wires:
- Repair the heat-shrinkable sheath of the wire harness
(MTC 20-80-20-423). Continue with Section 3.B.2c.
- If there are damaged wires:
- Categorize the damage (MTC 20-80-20-442).
- Repair the wires if needed (MTC 20-80-20-401, MTC 20-80-20-433).
- Repair the heat-shrinkable sheath of the wire harness
(MTC 20-80-20-423).
- If the wire harness is not repairable, replace the collective lever copilot.
(AMM 67-15-00, 4-3, AMM 67-15-00, 4-4)
c. Inspect the routing of the wire harness according Section 3.B.3 and correct
the routing if necessary.

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 ASB MBB-BK117 D-2-67A-007
3.B.3 The correct routing of the wire harness

1. Make sure the wire harness is installed in accordance with AMM 67-15-00, 4-4.

Excerpts from AMM 67-15-00, 4-4

A
1

2
A 12 3
11 13
5
10 4
9
8
7

ZONE A 14

15
21

20 16

19
7

6
18
17

2. Continue with Section 3.B.5.

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 ASB MBB-BK117 D-2-67A-007
PART 2 − Replacement of the cable support with a divided cable support
(Corrective measure)

3.B.4 Replacement of the cable support

1. Remove the LH floor access covers as needed (AMM 52-50-00, 4-3).
2. Loosen the harness (1, Fig. 2) of the collective lever copilot and the hoses (5) of
the pressure systems PT1 and PS1 by removing of the cable ties (4).
3. Remove the old cable support (3, Fig. 2) by removing of the three rivets (2), (SRM
51-00-00, 8-19).

Detail A
1 Harness
4 2 Rivet
1 23 3 Cable support
4 Cable tie
A 5 Pressure system
hoses
5

Removal of the old cable support

Figure 2

4. Transfer the positions of the boreholes for the rivets from the old cable support
to the angle with divided cable support (2, Fig.3) and drill the boreholes in the
correct diameter (MTC 20-02-04-402).
5. Install the angle with divided cable support (2, Fig. 3) with blind rivets (1), (SRM
51-00-00, 8-2).

Detail A
1 Rivet
2 Angle with divided
12 cable support
3

A
Restore surface
protection with CM 472,
CM 459 and CM 436.
Installation of the divided cable support
Figure 3

6. Restore surface protection with CM 472, CM 459 and CM 436.

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 ASB MBB-BK117 D-2-67A-007
7. Install the cable supports (1 and 3, Fig.4) on the anlge with divided cable support
and fix it with the positioners (2). See Appendix 1 how to assemble the divided
cable support.

ÁÁÁ
ÁÁÁ
1 2 3

1 Cable support male-8

2 Positioner
3 Cable support male-2
4 Angle with divided cable
support

(4)

(1) (2) (3)

Assemble of the divided cable support

Figure 4

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 ASB MBB-BK117 D-2-67A-007
8. Install the harness (1, Fig. 5) of the collective lever copilot (MTC 20-80-20-603)
on the cable support male-8 (3) and the pressure system hoses PT1 and PS1 (2),
(AMM 34-11-00, 4-1) on the cable support male-2 with cable ties (7).
9. Install the catching cord (4, Fig. 5) on the positioner (5) with a cable tie
(E0043-4A9P) and on the harness with the protection (6) and a cable tie
(E0043-4A9P).

View A

l=200+10
0 mm
1

C 5 2
a
1 1 Harness of the collective lever
A copilot
b 2 Pressure system hoses
3 Cable support male-8
Length of the Harness B 4 Catching cord
between postitions a and b
5 Positioner
6 Protection
View B 7 Cable tie P/N E0043-5A9P
Bottom view
6 4 7 3 View C
4
1
6

max. 55 mm

View with the disassebled cable support

The harness (1) of the collective lever copilot and the cable
support male-8 (3) do not have to be separated anymore for 1
removing the collective lever copilot.
The cable support male-8 remains on the harness - the angle
with divided cable support remains in the helicopter. 3
So, no cable tie has to be removed anymore for removing the
collective lever copilot.

Installation of harness and pressure system hoses

Figure 5

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 ASB MBB-BK117 D-2-67A-007
3.B.5 Final steps
1. Move the collective lever of the copilot up and down several times and check the
collective lever for free movement over the whole collective stroke.
2. Install the LH floor access covers if removed (AMM 52-50-00, 4-3).
3. Move the bellows in its installation position and attach the hook-and-loop tapes
(AMM 67-15-00, 4-4).

3.C COMPLIANCE CONFIRMATION

Compliance with this document:
Record full compliance with this ASB, with the revision number, in the helicopter
documents.
Please confirm compliance with this ASB (see IN 3643-I-00 for details):
QR-Code or hypertext link

NOTE
The recording of compliance with ASBs in the R-Tex
tool does not replace the recording in the helicopter
documents

ASB MBB-BK117 D-2‐67A‐007

Tracking of modifications in the documentation:

Record SB-Number in the section "RECORD OF SERVICE- AND ALERT SERVICE
BULLETINS" of the Flight Manual (ROIV).

3.D OPERATING AND MAINTENANCE INSTRUCTIONS

Up to the incorporation of the divided cable support in the AMM MBB-BK117 D-2,
use the Appendix of this ASB for additional guidance for installation and removal of
the collective lever copilot.

4 APPENDIX
Appendix 1: How to assemble and to disassemble the divided cable support.

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 Appendix to
ASB MBB-BK117 D-2-67A-007

Appendix 1:
How to assemble and to disassemble the divided cable support
1. Put the two pieces of the divided cable support together, slightly offset.

2. Move the cable support male until the gaps match.

3. Insert the positioner in a gap until it clicks into place.

Disassembly is carried out in reverse order.

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