MAINTENANCE MANUAL MBB -- BK117

NOTE Steps i. and j. apply only to actuator P/N 741 C 0000--05.

i. Inspect yaw actuator for damage, looseness of attached parts, and leakage. If there is leakage frombleed
air valve (14, figure 709--6), remove bleed air valve and replace O--ring (22). Leakage past dynamic seals
is permissible provided the oil level in the system II hydraulic reservoir drops by less than half of the spac-
ing between two graduation marks on the oil level indicator over a 20--hour flight period. If thereis agreater
loss of oil, the yaw actuator must be replaced.

j. Check play in bushing (3, figure 709--2A) of input lever (1). Input play shall be 0.4 to 1.5 mm. If input play is
exceeded, send actuator to manufacturer for repair.

A
Section A--A

1
BK117_WAH_1753_R

A
4 Input lever
5 Control rod
2 6 Bushing
Figure 709--2A Bushing -- Input lever

6A Inspection of the yaw actuator PN 741B0000--05 and PN 741C0000--05

a. Remove vertical fin fairing.

WARNING In order to avoid injured fingers or hands due to moving parts of the tail rotor con-
trols, the following check may only be accomplished after the prior agreement of
all participating persons and with the utmost caution.

NOTE Operation of the pedals is without hydraulic support.

b. Use a lint--free cloth made damp with dry cleaning solvent CM 202 to clean the tail rotor actuator assem-
bly.

c. Check the play of the yaw actuator (1, figure 709--2B). To do so, have the pedals move for several times
from the LH stop to the RH stop by a second person and while doing so, check the connection between
cardan joint (4) and bolt (3) and between cardan joint (4) and bolt (6) for excessive play by laying on a fin-
ger. Additionally, it must be checked if there is play between pin (8), cardan joint (4) and piston rod (7) by
means of a mirror and a flashlight.

d. Perform visual inspection of cardan joint (4, Figure 709--2B), bolt (3), lever (2), piston rod (7), pin (8) and
support (5) for damage, corrosion and/or cracks.

e. If neither play nor damage is detected, proceed i.a.w. point g.

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1) Replace the base support (5) if you see any demage, corrosion and/or cracks according to 709--10
and 709--11.
f. If play and/or damage is detected, contact your ECD customer service for further instructions before the
next flight.

NOTE Due to the attachment of the yaw actuator there is a slight peripheral play.

g. Check the play of the yaw actuator (1, figure 709--2B ). To do so, hold yaw actuator (1) with both hands and
move several times in peripheral direction while a second person checks the connection between cardan
joint (4) and bolt (3) as well as between cardan joint (4) and bolt (6) for excessive play by laying on a finger.
Additionally, it must be checked, if there is play between pin (8), cardan joint (4) and piston rod (7) by
means of mirror and a flash light.
h. If no peripheral play is detected, install fairing to vertical fin.
i. If excessive peripheral play is detected, contact your ECD customer service for further instructions be-
fore the next flight.
j. Check, if there a log card for the yaw actuator excisting. If no log card existing, establish log card i.a.w
SI--MBB--BK117--82

1 Yaw actuator
2 Lever
3 Bolt
4 Cardan joint 1
5 Support
6 Bolt A
7 Piston rod
8 Pin
3

7
2
8
A
4
4
BK117_WAH_1893_R

Check for play. 5

Figure 709--2B 6

7. Inspect bellcrank (1, figure 709--7) and attached yaw brake in their installed position for lateral play, me-
chanical and corrosion damage, and properly tightened attaching hardware.
If safetying device is missing, check torque on attaching hardware and, if necessary, torque--tighten and
install new safetying device (see figure 709--7).
If damage is evident, remove and repair bellcrank per paragraph 709--12.
If lateral play is evident, remove play with shims (21).
8. Inspect the rate gyro unit.

NOTE This inspection is performed in conjunction with the tail boom inspection (tail
boom removed from the helicopter).

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a. Inspect bonding jumper (6, figure 709--10) for damage and security. Replace damaged jumper and
tighten loose bonding connection.

b. Inspect rate gyro (1) for security; tighten attaching hardware as necessary.

c. Inspect electrical lead (5) for security; tighten as necessary.

9. Inspect CSAS control unit.

a. Check that CSAS control unit switches function properly. If they are faulty, replace the control unit.

b. Check electrical connector (5, figure 709--11) for security of attachment as follows:

1) Remove CSAS control unit (1) (refer to para. 709--20).

2) Inspect electrical connector for security and tighten if loose.

3) Install CSAS control unit (refer to para. 709--21).

10. Inspect torque transducer refer to Chapter 91.

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709 - 4 FUNCTIONAL TEST - YAW CSAS ELECTRICAL SYSTEM

Special tools and test equipment:

Hydraulic cart 117--45001 W1 or 105 W26

Pedal fixture 117--43001 W2
Tester 117--88444 or 117--93431 L 96.0X
Pressure regulator (0--6 bar, with an accuracty of at least 0,5%)

General
The operational check is performed after a yaw CSAS has been installed, after the yaw actuator or an
electrical component of the yaw CSAS has been replaced, and when troubleshooting.
A check shall be made to ensure that the yaw CSAS been installed and rigged as instructed (refer to para.
709--6) and that the hydraulic system has been tested (refer to para. 709--5).

1. Preparatory work

a. Remove the RH side panel in the cargo compartment to provide access for testing the yaw transducer.

b. Pull circuit breakers CSAS YAW 1A, CSAS YAW 5A.

c. Switch off the power supply.

d. Switch off the hydraulic supply.

e. Connect tester 117--88444 or 117--93431 L 96.0X to the yaw computer (see fig. 709--3).

f. Connect a 28 VDC external power supply of adequate capacity (see chapter 92) or a properly charged
battery to the helicopter electrical system (refer to chapter 92).

g. Make sure that buses FLT ESS 1 and FLT ESS 2 are supplied with power and that circuit breakers INSTR
LTS P & ENG and WARN I and II are pressed.

h. Press circuit breakers CSAS YAW 1A and CSAS YAW 5A.

i. Enter the results of the electrical system function check in a copy of table 709--2.

2. Annunciator test

a. Press and hold press--to--test switch ANN PNL TEST.

-- YAW OFF in the CSAS control unit and YAW CSAS in the annunciator panel shall continue to illuminate.
YAW STBY in the CSAS control unit shall not illuminate.

b. Release press--to--test switch ANN PNL TEST.

-- YAW OFF in the CSAS control unit and YAW CSAS in the annunciator panel shall continue to illuminate.
YAW STBY remains extinguished.

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3. Power test

a. Set AC/DC switch on the tester in DC position.

b. Turn rotary switch on tester to position 1 (indicating range ± 15V).

-- The voltage must be + 15 VDC ± 0.7 VDC.

c. Turn rotary switch on tester to position 2 (indicating range ± 15V).

-- The voltage must be -- 15 VDC ± 0.7 VDC.

d. Set AC/DC switch on the tester to AC and turn rotary switch to position 3 (indicating range ± 15V).

-- The voltage must be 9.6 VDC ± 0.6 VDC.

e. Set AC/DC switch on the tester to DC and turn rotary switch to position 5 (indicating range ± 5V).

-- The voltage must be + 5 VDC ± 0.5 VDC.

f. Turn rotary switch on tester to position 20 (indicating range ± 15V).

-- The voltage must be 0 VDC ± 0.2 VDC.

4. Valve current test

Turn rotary switch on tester to position 10 (indicating range ± 1.5V).

-- The voltage must be 0 VDC ± 0.2 VDC.

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4
BK117_WAH_0802_R

1 Yaw computer
2 Tester
3 Electrical connector
4 Power cable

Figure 709--3 Test setup for yaw CSAS

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5. Sequence switch and annunciator check

a. Turn rotary switch on tester to position 20 (indicating range ± 15V).

-- The voltage must be 0 VDC ± 0.1 VDC.

b. Press sequence switch YAW OFF/YAW STBY on the CSAS control unit.

-- YAW OFF on the CSAS control unit shall extinguish.

-- YAW STBY on the CSAS control unit shall illuminate.

-- YAW CSAS on the annunciator panel shall extinguish.

-- The voltage shall slowly increase to + 4.8 VDC ± 0.3 VDC.

6. Changeover test

a. Momentarily press sequence switch YAW OFF/YAW STBY on the CSAS control unit.

-- YAW STBY on the CSAS control unit shall extinguish and YAW OFF on the CSAS control unit and YAW
CSAS on the annunciator panel remain extinguish.

-- The voltage must be + 4.8 VDC ± 0.3 VDC.

b. Press sequence switch YAW OFF/YAW STBY.

-- YAW STBY shall illuminate.

c. Momentarily press sequence switch YAW OFF/Yaw STBY.

-- YAW STBY shall extinguish.

d. Momentarily press the STAB CUT OFF switch on the pilot’s cyclic stick.

-- YAW OFF on CSAS control unit and YAW CSAS on the annunciator panel shall illuminate.

-- The voltage must be 0 VDC ± 0.1 VDC.

e. Press sequence switch YAW OFF/YAW STBY twice.

-- YAW OFF on the CSAS control unit and YAW CSAS on the annunciator panel shall extinguish.

f. Repeat steps d. and e. for the copilot syclic stick.

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7. Error indication test

a. Pull circuit breaker CSAS YAW 1A.

-- YAW OFF on the CSAS control unit and YAW CSAS on the annunciator panel shall illuminate.

b. Press circuit breaker CSAS YAW 1A and sequence switch YAW OFF/YAW STBY twice.

-- YAW OFF on the CSAS control unit and YAW CSAS on the annunciator panel shall extinguish.

c. Set toggle switches INVERTER 1 and INVERTER 2 to OFF.

-- YAW OFF on the CSAS control unit and YAW CSAS on the annunciator panel shall illuminate.

d. Set toggle switches INVERTER 1 and INVERTER 2 to ON.

e. Press sequence switch YAW OFF/YAW STBY twice.

-- YAW OFF on the CSAS control unit and YAW CSAS on the annunciator panel shall extinguish.

-- YAW STBY on the CSAS control unit shall not illuminate.

8. Yaw transducer test

a. Set the pedals with pedal fixture 117--43001 W2 in parallel position, refer to APPENDIX B.

b. Turn rotary switch on tester to position 15 (indicating range ± 15V).

-- The voltage must be 0 VDC ± 0.2 VDC.

NOTE Repetition of the setting must yield the specified voltage. If the voltage should
deviate from this, adjust the yaw transducer in accordance with para 709--7.

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c. Remove pedal clamp assembly.

d. To determine amplitude and range, the yaw transducer is displaced as follows, by operating the
pedals. Measurement is taken from the neutral position (0 VDC).

e. Push the right pedal forward untill 10mm ± 0.1mm of travel from the neutral position is measured at the
yaw transducer.

-- The voltage must be --5.3 VDC ± 0.3 VDC.

f. Turn rotary switch on tester position 11.

-- The voltage must be --1.76 VDC ± 0.2 VDC.

g. Turn rotary switch on tester position 15 (indicating range ± 15V).

h. Push left pedalforward until 10mm ± 0.1mm of travel from the neutral position is measured at the yaw
transducer.

-- The voltage must be +5.3 VDC ± 0.3 VDC.

i. Turn rotary switch on tester position 11.

-- The voltage must be +1.76 VDC ± 0.2 VDC.

9. Rate gyro test

a. Turn rotary switch on tester to position 12 (indicating range ± 0.3V).

-- The voltage must be 0 VDC ± 0.1 VDC.

b. Jack the helicopter on the ground handling wheels.

c. Turn the helicopter right and observe the tester indication.

-- During the right turn, the pointer must deflect right.

d. Turn the helicopter left and observe the tester indication.

-- During the left turn, the pointer must deflect left.

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10. Yaw actuator test (with hydraulic pressure)

a. Pull circuit breakers CSAS YAW 1A and CSAS YAW 5A.

b. Apply 103 bar pressure to the tandem hydraulic unit. For this purpose connect hydraulic cart 117--45001
W1 or 105 W26.

c. Press circuit breakers CSAS YAW 1A and CSAS YAW 5A.

d. Press sequence switch YAW OFF/YAW STBY on the CSAS control unit.

-- YAW OFF shall extinguish and YAW STBY shall illuminate.

e. Turn rotary switch on tester to position 21 (indicating range ± 5V) (EHA zero point).

-- The voltage must be 0 VDC ± 0.1 VDC.

f. Set test switch EHA on tester to ON.

-- The voltage must rise to + 3.5V ± 0.3V.

g. Set test switch EHA on tester to OFF.

-- The voltage must drop to -- 3.5V ± 0.3V.

h. Set switch TEST on the CSAS control unit to TEST.

-- The voltage must be -- 3.5V ± 0.3V.

i. Press sequence switch YAW OFF/YAW STBY on CSAS control unit.

-- YAW OFF shall not illuminate and YAW STBY shall extinguish.

j. Move right and left pedals slowly and continously, at the same time watching the tester indication.

-- While the pedal inputs are being made, the pointer must deflect slowly and continously.

NOTE Pointer deflection need not be synchronous with the pedal inputs.

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Paragraph/ Work Test Desired value/response Actual value/ response

step/ Item
709--4

Step 2. Annunciator
Item a. Press and hold
press--to--test switch ANN
PNL TEST:

YAW OFF CSAS unit and .........................................

YAW CSAS on annunciator
.........................................
panel shall continue to
illuminate. YAW STBY on .........................................
CSAS control unit shall not
illuminate

Item b. Release press--to--test

switch ANN PNL TEST:

YAW OFF on CSAS control ..........................................

panel and YAW CSAS on
..........................................
annunciator panel shall
continue to illuminate. YAW ..........................................
STABY on CSAS control
unit shall remain off.

Step 3. Power supply

Item b. + 15 VDC 0.7 VDC + ................... VDC

Item c. -- 15 VDC 0.7 VDC -- ................... VDC
Item d. 9,6 VAC  0.6 VAC ................... VAC
Item e. + 5 VDC  0.5 VDC + ................... VDC
Item f. 0 VDC  0.2 VDC ................... VDC

Remarks:
Name Date
Performed by:
Inspected by:
Table 709-2 Test report (1 of 9)

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Paragraph/ Work Test Desired value/response Actual value/ response

step/ Item
709--4

Step 4. Valve current 0 VDC  0.2 VDC ................... VDC

Step 5. Sequence switch

and annuniator
Item a. Turn rotary switch on tester
to position 20.
0 VDC  0.1 VDC ................... VDC

Item b. Press sequence switch

YAW OFF/YAW STBY: ......................................

YAW OFF shall extinguish ..........................................

and YAW STABY shall
..........................................
illuminate.

YAW CSAS on the ..........................................

annunciator panel shall
..........................................
extinguish.

The voltage shall slowly rise + ................... VDC

to: + 4.8 VDC  0.3 VDC

Remarks:
Name Date
Performed by:
Inspected by:
Table 709-2 Test report (2 of 9)

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Paragraph/ Work Test Desired value/response Actual value/ response

step/ Item
709--4

Step 6. Changeover

Item a. Momentarily press

sequence switch YAW
OFF/YAW STBY:
YAW STBY on CSAS
control unit extinguish. YAW
OFF in CSAS control unit ..............................................
and YAW CSAS in the ..............................................
annunciator panel remain
extinguish.
+ 4.8 VDC  0.3 VDC + ................... VDC

Item b. Press sequence switch

YAW OFF/YAW STBY: ......................................

YAW STABY shall ..........................................

illuminate.
..........................................

Item c. Momentarily press ..........................................

sequence switch YAW
..........................................
OFF/YAW STBY:

YAW STABY shall extinuish. ..........................................

..........................................

Remarks:
Name Date
Performed by:
Inspected by:
Table 709-3 Test report (3 of 9)

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Paragraph/ Work Test Desired value/response Actual value/ response

step/ Item
709--4

Step 6. Changeover
(continued)

Item d. Momentarily press STAB

CUT OFF switch on the
pilot’s cyclic stick:
YAW OFF on CSAS control
and YAW CSAS on the
annunciator panel shall ..............................................
illuminate. ..............................................
0 VDC  0.1 VDC ................... VDC

Item e. Press sequence switch

YAW OFF/YAW STBY
twice:
YAW OFF on CSAS control
unit and YAW CSAS on the ..........................................
annunciator panel shall
..........................................
extinguish.

Item f. Momentarily press STAB

CUT OFF switch on the
copilot’s cyclic stick:

YAW OFF on CSAS control ..........................................

and YAW CSAS on the
..........................................
annunciator panel shall
illuminate.

0 VDC  0.1 VDC ................... VDC

Remarks:
Name Date
Performed by:
Inspected by:
Table 709-4 Test report (4 of 9)

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Paragraph/ Work Test Desired value/response Actual value/ response

step/ Item
709--4

Changeover
(continued)

Press sequence switch

YAW OFF/YAW STBY
twice:
YAW OFF on CSAS control
and YAW CSAS on the
annunciator panel ..............................................
extinguish. ..............................................

Step 7. Error indication

Item a. Pul circuit breaker CSAS
YAW 1A.

YAW OFF on CSAS control

and YAW CSAS on the ..........................................
annunciator panel shall
..........................................
illuminate.

Item b. Press circuit breaker CSAS

YAW 1A and press
sequence switch YAW
OFF/YAW STBY twice:
YAW OFF on CSAS control ..........................................
and YAW CSAS on the
..........................................
annunciator panel shall
extinguish.

Remarks:
Name Date
Performed by:
Inspected by:
Table 709-5 Test report (5 of 9)

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Paragraph/ Work Test Desired value/response Actual value/ response

step/ Item
709--4

Step 7. Error indication

(continued)
Item c. Set toggle switches
INVERTER 1 and
INVERTER 2 to OFF:
YAW OFF on CSAS control
and YAW CSAS on the ..........................................
annunciator panel shall ..........................................
illuminate. ..........................................

Item d. Set toggle switches

INVERTER 1 and
INVERTER 2 to ON:

Item e. Press sequence switch

YAW OFF/YAW STBY
twice:
YAW OFF on CSAS control
and YAW CSAS on the
annunciator panel shall ..........................................
extinguish. YAW STBY on ..........................................
the CSAS control unit shall ..........................................
not illuminate.

Remarks:
Name Date
Performed by:
Inspected by:
Table 709-6 Test report (6 of 9)

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Paragraph/ Work Test Desired value/response Actual value/ response

step/ Item
709--4

Step 8. Yaw transducer

Item b. 0 VDC  0.2 VDC ................... VDC

Item e. -- 5.3 VDC  0.3 VDC ................... VDC

Item f. -- 1.76 VDC  0.2 VDC ................... VDC

Item h. + 5.3 VDC  0.3 VDC ................... VDC

Item i. + 1.76 VDC  0.2 VDC ................... VDC

Remarks:
Name Date
Performed by:
Inspected by:
Table 709-7 Test report (7 of 9)

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Paragraph/ Work Test Desired value/response Actual value/ response

step/ Item
709--4

Step 9. Rate gyro

Item a. 0 V  0.1V ................... V

Item c. Pointer must deflect right ..........................................

Item d. Pointer must deflect left ..........................................

Remarks:
Name Date
Performed by:
Inspected by:
Table 709-8 Test report (8 of 9)

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Paragraph/ Work Test Desired value/response Actual value/ response

step/ Item
709--4

Step 10. Yaw actuator

Item d. Press sequence switch
YAW OFF/YAW STBY on
the CSAS control unit:

Annunciator YAW OFF shall ..........................................

extinguish.
Annunciator YAW STBY ..........................................
shall illuminate.
Item e. 0 V  0.1 V ................... V

Item f. + 3.5 V  0.3 V +................. V

Item g. -- 3.5 V  0.3 V ................... V

Item h. -- 3.5 V  0.3 V ................... V

Item i. Press sequence switch

YAW OFF/YAW STBY on
the CSAS control unit:

Annunciator YAW OFF shall ..........................................

not illuminate.
Annunciator YAW STBY ..........................................
shall extinguish.
Item j. Slow and continuous pointer
deflection during pedal
inputs

Remarks:
Name Date
Performed by:
Inspected by:
Table 709-9 Test report (9 of 9)

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709 - 6 RIGGING - YAW CSAS

Special tools and test equipment:

Hydraulic cart 117--45001 W1 or 105 W26

Pedal fixture 117--43001 W2
Tester 117--88444 or 117--93431 L96. 0X
Ajusting device 117--43001 W3

CAUTION IF THE LENGTH OF THE TAIL ROTOR CONTROL LINKAGE BETWEEN

THE PEDALS AND THE YAW ACTUATOR IS CHANGED, THE NEUTRAL
POSITION OF THE YAW TRANSDUCER MUST BE CHECKED AND
READJUSTED AS NECESSARY. THE YAW CSAS MUST BE IN THE
STAND--BY MODE THROUGHOUT THE ENTIRE YAW ACTUATOR
RIGGING PROCEDURE.
General
The tail rotor controls and the yaw actuator shall be rigged following the installation of a yaw CSAS and each
time the tail rotor controls are adjusted.
Make certain that the yaw CSAS has been installed as instructed, and that the yaw actuator has been checked
according to para. 709--5.

1. Preparatory work

a. Install the adjusting device 117--43001 W3 on the tail rotor according to APPENDIX B. The knurled--head
screw of the adjustment device must be removed during the adjustment procedure.

b. Connect an external source of electrical and hydraulic power (refer to Chapters 92 and 43).

c. Apply 103 bar pressure to the tandem hydraulic unit and connect hydraulic cart 117--45001 W1 or 105
W26.

d. Connect tester 117--88444 or 117--93431 L96. 0X to the yaw computer (see fig. 709--3).

e. Make certain that the FLT ESS 1 and FLT ESS 2 buses are supplied with power, INVERTERS 1 and 2 are
switched on, and circuit breakers CSAS YAW 1 A and CSAS YAW 5 A are depressed (annunciator YAW
OFF on the CSAS control unit illuminates).

f. Set the yaw CSAS to STBY (press YAW OFF/YAW STBY; YAW OFF shall extinguish and YAW STBY
shall illuminate)

2. Checking mid--position of the electrohydraulic actuator (EHA).

a. Remove control rod (17, fig. 709--7) from bellcrank (1).

b. Using the control rod (4, fig. 709--6), drive the yaw actuator to its center of strocke position (± 10 mm).

c. Measure and record EHA position X in the mid--position (see fig. 709--4).

d. Set test switch EHA to ON.

e. Measure and record position Y of the extended EHA.

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f. Set test switch EHA on the tester to OFF or change the poles of the adapter cable at the DC source.

g. Measure and record position Z of the retracted EHA.

h. Compare strokes Y--X and X--Z from the center position.

-- The difference between both strokes must not exceed 0.1 mm. Otherwise perform an electrical
check on the yaw--actuator.

NOTE The total EHA stroke is Y--Z.

i. Switch off the tester and allow the EHA to center.

j. Install the control rod (17, fig. 709--7) on bellcrank (1).

3. Setting the maximum control angle:

a. Pull the control rod (17, fig. 709--7) downward until it contacts the mechanical stop of the actuator.

b. Read the blade pitch on the scale of the adjusting device to see if it corresponds with the left pedal--full--
down value specified for the relevant model in APPENDIX B.

WARNING THE RED MARK OF THE CLEVIS THREAD MUST NOT BE VISIBLE AFTER
BOLTING OF THE COUNTER NUT.

c. Adjust the amount of clevis (3, fig. 709--4) thread engagement in the actuator ram (2), as required and
reapply safety.

d. Install the control rod (17, fig. 709--7) on bellcrank (1), but do not secure at this time.

4. Line up the pedals using the pedal fixture 117--43001 W2 according to APPENDIX B.

5. Read the blade pitch on the scale of the adjusting device. If it does not correspond with the pedals--in--line
value specified in APPENDIX B (Table B--1), obtain the required value by adjusting the amount of rod end
engagement in the lower end of control rod (17). Safety the rod end. Install and safety the control rod.

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6--6,5 Nm 10 14
3
11
12
2
22 21 13
15
20
20

21
15
21
2 15
23
6 18
19
15 3--5 Nm
17
23 18 20
21 9
8

4
1

20
9
8
3--5 Nm
BK117_WAH_0809_R

If required, remove yaw brake play

7 with item 21.

16
1 Bellcrank 9 Nylon stop nut 17 Control rod
2 Mounting plate 10 Nylon stop nut 18 Bushing
3 Flanged washer 11 Flanged washer 19 Washer
4 Bolt 12 Disk spring 20 Cotter pin
5 Washer 13 Washer 21 Shim
6 Bolt 14 Nylon stop nut 22 Intermediate gearbox
7 Bolt 15 Washer 23 Spring pin
8 Washer 16 Control rod

Figure 709--7 Removal and Installation -- yaw actuator

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